2010 KIA Picanto SM

General Information
General Information
General Information
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2010 > G 1.0 SOHC >
Identification Number Locations
Identification Number Description

Vehicle Identification Number
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1. World Manufacturer Identifier (WMI)
- KNA : Passenger vehicle, MPV(Multipurpose Passenger Vehicle)/SUV(Sports Utility Vehicle)/RV(Recreational
Vehicle)
- KNC : Commercial vehicle (Van)
- KND: MPV/SUV/RV (For U.S.A, Canada, Mexico)
- KNH: Van
2. Vehicle line
- B : PICANTO
3. Model & Series
- F : Low grade (L)
- J : Middle-Low grade (GL)
- K : Middle grade (GLS, JSL, TAX)
- L : Middle-High grade (HGS)
- M : High grade (TOP)
4. Body/Cabin type, Gross Vehicle Weight Rating
KNA
- 1 : Limousine
- 2 : Sedan - 2 door
- 6 : Coupe
- 7 : Convertible
- 8 : Wagon
- 9 : Commercial Van
- 0 : Pick-Up
KNC (Commercial vehicle / Van)
Except U.S.A, Canada, Mexico, Gulf Cooperation Council, China
- X : Standard Cabin / Semi-Bonnet
- Y : Double Cabin / Bonnet
- Z : Super Cabin / Box
For U.S.A, Canada, Mexico, Gulf Cooperation Council, China
- 2 : Standard Cabin Class-H 4!2
- 3 : Standard Cabin Class-E 4!2 / Semi-Bonnet Class-E 4!2
- 4 : Standard Cabin Class-E 4!4 / Semi-Bonnet Class-E 4!4
- 5 : Standard Cabin Class-F 4!2 / Semi-Bonnet Class-F 4!2
- 6 : Standard Cabin Class-F 4!4 / Semi-Bonnet Class-F 4!4
- 7 : Double Cabin Class-E 4!2 / Bonnet Class-E 4!2
- 8 : Double Cabin Class-E 4!4 / Bonnet Class-E 4!4
- 9 : Double Cabin Class-F 4!2 / Bonnet Class-F 4!2
- 0 : Double Cabin Class-F 4!4 / Bonnet Class-F 4!4
- A : Super Cabin Class-E 4!2 / Box Class-E 4!2
- B : Super Cabin Class-E 4!4 / Box Class-E 4!4
- C : Super Cabin Class-F 4!2 / Box Class-F 4!2
- D : Super Cabin Class-F 4!4 / Box Class-F 4!4
KND
- 1 : Wagon 4!2 Class-A
- 2 : Wagon 4!2 Class-B
- 3 : Wagon 4!2 Class-C
- 4 : Wagon 4!2 Class-D
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- 5 : Wagon 4!2 Class-E
- 6 : Wagon 4!2 Class-F
- 7 : Wagon 4!2 Class-G
- A : Wagon 4!4 Class-A
- B : Wagon 4!4 Class-B
- C : Wagon 4!4 Class-C
- D : Wagon 4!4 Class-D
- E : Wagon 4!4 Class-E
- F : Wagon 4!4 Class-F
- G : Wagon 4!4 Class-G
KNH
- 1 : Box
- 2 : Bonnet
- 3 : Semi-Bonnet
5. Restraint system, Brake system
KNA, KND
Except U.S.A, Canada, Mexico
- 0 : Both side - None
- 1 : Both side - Active belt
- 2 : Both side - Passive belt
For U.S.A, Canada, Mexico
Front air bag Knee air bag Side air bag Curtain air bag
Seat
Code 3rd
belt Driver's Passenger's Driver's Passenger's 1st row 2nd row 1st row 2nd row 3rd row
row
A " " " ! ! " ! ! " " !
B " " " ! ! ! ! ! ! ! !
C " " " ! ! " ! ! " " "
D " " " ! ! " " ! " " !
E " " ! ! ! ! ! ! ! ! !
F " " " ! ! " ! ! ! ! !
N " ! ! ! ! ! ! ! ! ! !
H " " " " ! " ! ! " " "
KNC, KNH
Except U.S.A, Canada, Mexico
- 7 : Hydraulic brake system
- 8 : Pneumatic brake system
- 9 : Mixed brake system
For U.S.A, Canada, Mexico
- X : Hydraulic brake system
- Y : Pneumatic brake system
- Z : Mixed brake system
6. Engine type
- 3 : Gasoline engine 1.1
- 4 : Gasoline engine 1.0
- 5 : Diesel engine 1.1
7. Check digit or Driver’s side & Transmission
Except U.S.A, Canada, Mexico, Gulf Cooperation Council, China, Yemen
- A : LHD & MT
- B : LHD & AT
- C : LHD & MT+Transfer
- D : LHD & AT+Transfer
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- E : LHD & CVT
- L : RHD & MT
- M : RHD & AT
- N : RHD & MT+Transfer
- S : RHD & AT+Transfer
- T : RHD & CVT
For U.S.A, Canada, Mexico, Gulf Cooperation Council, China, Yemen
- Check digit : 0 ~ 9, !
8. Production year
- A : 2010, B : 2011, C : 2012, D : 2013...
9. Plant of production
- 6 : Sohari (Korea)
- 5 : Hwasung (Korea)
- 7 : Kwangju (Korea)
- T : Seosan (Korea)
10. Vehicle production sequence number
- 000001 ~ 999999
Paint Code
Code Color
3D Bright Silver
IZ Soda Orange
II Fresh Yellow
C0 Cool Blue
IM Titanium Silver
UD Clear White
Z1 Galaxy Black
P9 Scarlet Red
L6 Blue Diamond
Engine Number
1. Engine fuel
- G : Gasoline
- D : Diesel
2. Engine range
- 4 : 4 cycle 4 cylinder
- 6 : 4 cycle 6 cylinder
3 - 4. Engine development order and capacity
- HE : # engine, 999cc (Gasoline)
- HG : # engine, 1086cc (Gasoline)
- FA : U engine, 1120cc (Diesel)
5. Production year
- 9 : 2009, A : 2010, B : 2011, C : 2012, D : 2013...
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Engine production sequence number
- 000001 ~ 999999
Transaxle Number
Manual
1. Model
- M : M5EF2
- R : M5CF1
2. Production year
- 9 : 2009, A : 2010, B : 2011, C : 2012, D : 2013...
3. Gear ratio
- 1671 : 4.437
- 2073 : 3.650
4. Transaxle production sequence number
- 000001 ~ 999999
Automatic
1. Model
- E : A4CF0
2. Production year
- 9 : 2009, A : 2010, B : 2011, C : 2012, D : 2013...
3. Gear ratio
- 5 = 4.587
4. Detailed chassification
- BD : # - 1.1
5. Spare
6. Transaxle production sequence number
- 000001 ~ 999999
Warning / Caution Label Locations
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1. Coolant level caution 4. Battery caution
2. Fan caution 5. Air cleaner caution
3. Radiator cap caution
Battery Caution Label Describtion
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Warning / Caution Label (Cont'd)
A.
Keep lighted cigarettes and all other flames or sparks away from the battery.
B.
Wear eye protection when charging or working near a battery. Always provide ventilation when working in an
enclosed space.
• When lifting a plastic-cased battery, excesive pressure on acid to leak resulting in personal injury. Lift with a
battery carrier or with your hands on opposite corners.
• Never attempt to change the battery when the battery cables are connected.
• The electrical ignition system works with high voltage.
Never touch these components with the engine running or the ignition switched on.
C.
Keep batteries out of the reach of children because batteries contain highly corrosive SULFURIC ACID. Do not allow
battery acid to contact your skin, eyes, clothing or paint finish.
D.
If any electrolyte gets into your eyes, flush your eyes with clean water for at least 15 minutes and get immediate
medical attention. If possible, continue to apply water with a sponge or cloth until medical attention is received.
If electrolyte gets on your skin, throughly wash the contacted area. If you feel a pain or a burning sensation, get
medical attention immediately.
E.
Always read the following instructions carefully when handing a battery.
F.
Hydrogen, which is a highly combustible gas, is always presents in battery cells and may explode if ignited.
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G.
An improperly disposed battery can be harmful to the environment and human health.
Always confirm local regurations for battery disposal.
Handling And Storage The Battery

Battery Itself • Batteries should be stored in cool, dry (27 degrees Celsius) places and out of
direct sunlight.
• MF batteries are tightly sealed to prevent acid leakage.
However, tilting the battery to an angle of 45 degrees can cause acid to leak
through the vents on the sides. Therefore, batteries should always be stored
in their upright positions. Prevent placing any aqueous or solid (i.e.
conductors) bodies on top of the battery.
• It is extremely dangerous to use tools, such as hammers, on the battery
terminals when connecting cables to the mounted battery.
Battery on Vehicle • When storing the vehicle for long periods of time, make sure to remove the
memory fuse at junction box to prevent natural discharging.
• Also, run the engine for battery charging within 1 month if the memory fuse
wasn't removed from the start of vehicle storing.
If the memory fuse was removed, run the engine for battery charging within 3
months from the start of vehicle storing.
After reconnecting or recharging a discharged battery, the ESP OFF indicator may illuminate.
In this case, turn the handle half way to the left and right whilst the ignition switch is in the ON position.
Then, restart the engine after the ignition is OFF.
The ESP OFF indicator may turn OFF.
If the ESP OFF indicator does not turn OFF, have the system checked refering to DTC. (Refer to the BR group.)
Lift And Support Points
When heavy rear components such as suspension, fuel tank, spare tire, tailgate and trunk lid are to be removed,
place additional weight in the luggage area before hoisting. When substatial weight is removed from the rear of
the vehicle, the center of gravity may change and can cause the vehicle to tip forward on the hoist.
• Since each tire/wheel assembly weights approximately 30lbs (14kg), placing the front wheels in the luggage
area can assist with the weight distribution.
• Use the same support points to support the vehicle on safety stands.
1. Place the lift blocks under the support points as shown in the illustration.
2. Raise the hoist a few inches (centimeters) and rock the vehicle to be sure it is firmly supported.
3. Raise the hoist to full height to inspect the lift points for secure support.
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Towing
If the vehicle needs to be towed, call a professional towing service. Never tow vehicle with just a rope or chain. It is
very dangerous.
Emergency Towing
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There are three popular methods of towing a vehicle :
- The operator loads the vehicle on the back of truck. This is best way of transporting the vehicle.
- The tow truck uses two pivoting arms that go under the tires of the driving axle and lift them off the ground. The
other two wheels remain on the ground.
- The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or
suspension, and the cables lift that end of the vehicle off the ground. The vehicle's suspension and body can be
seriously damaged if this method of towing is attempted.
If the vehicle cannot be transported by flat-bed, should be towed with the wheels of the drivig axle off the ground
and do the following :
Manual Transaxle
• Release the parking brake.
• Shift the Transaxle to neutral
Automatic Transaxle
• Release the parking brake.
• Start the engine.
• Shift to [D] position, then [N] position.
• Turn off the engine.
• The vehicle equipped with full-time 4WD should be only transported on a flat-bed.
• Improper towing preparation will damage the transaxle. follow the above procedure exactly. If you cannot shift
the transaxle or start the engine(automatic transaxle), your vehicle must be transported on a flatbed.
• It is the best to tow vehicle no farther than 30km (19miles), and keep the speed below 50km/h (30mph). (For
the full-time 4WD vehicle, limit the towing to 1.5km (1mile) and 15km/h (10mph)
• Trying to lift or tow your vehicle by the bumpers will cause serious damage. The bumpers are not designed to
support the vehicle's weight.
Tightening Torque Table Of Standartd Parts

Bolt niminal diameter Torque Nm (kg.cm, lb.ft)
Pich (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 ~ 50, 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 (300 ~ 500, 22 ~ 36)
M12 1.25 35 ~ 45 (350 ~ 450, 25 ~ 33) 60 ~ 80 (600 ~ 800, 43 ~ 58)
120 ~ 140 (1,200 ~ 1,400, 85
M14 1.5 75 ~ 85 (750 ~ 850, 54 ~ 61)
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M14 1.5 75 ~ 85 (750 ~ 850, 54 ~ 61)
~ 100)
110 ~ 130 (1,100 ~ 1,300, 80 180 ~ 210 (1,800 ~ 2,100, 130
M16 1.5
~ 94) ~ 150)
160 ~ 180 (1,600 ~ 1,800, 116 260 ~ 300 (2,600 ~ 3,000, 190
M18 1.5
~ 130) ~ 215)
220 ~ 250 (2,200 ~ 2,500, 160 360 ~ 420 (3,600 ~ 4,200, 260
M20 1.5
~ 180) ~ 300)
290 ~ 330 (2,900 ~ 3,300, 210 480 ~ 550 (4,800 ~ 5,500, 350
M22 1.5
~ 240) ~ 400)
360 ~ 420 (3,600 ~ 4,200, 260 610 ~ 700 (6,100 ~ 7,000, 440
M24 1.5
~ 300) ~ 505)
1. The torques shown in the table are standard values under the following conditions.
• Nuts and bolts are made of galvanized steel bar.
• Galvanized plain steel washers are inserted.
• All nuts, bolts and plain washers are dry.
2. The torques shown in the table are not applicable.
• When spring washers, toothed washers and the like are inserted.
• If plastic parts are fastened.
• If self-tapping screws or self-locking nuts are used.
• If threads and surfaces are coated with oil.
3. Reduce the torque values to the indicated percentage of the standard value under the following conditions.
• If spring washers are used : 85%
• If threads and bearing surfaces are stained with oil : 85%
General Service Information

Protection Of The Vehicle
Always be sure to cover fenders, seats, and floor areas before starting work.
The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine
compartment to prevent the hood from falling and causing possible injury.
Make sure that the support rod has been released prior to closing the hood. Always check to be sure the hood is
firmly latched before driving the vehicle.
Preparation Of Tools And Mesuring Equipment

Be sure that all necessary tools and measuring equipment are available starting work.
Special Tools
Use special tools when they are required.
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Removal Of Parts
First find the cause of the problem and then determine whether removal or disassembly before starting the job.
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 on suspected for malfunction, deformation, damage, and other
problems.
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2. Arrangement of parts
All disassembled parts should be carefully arranged for effective reassembly.
Be sure to separate and correctly identify the parts to be replaced from those that will be used again.
3. Cleaning parts for reuse

All parts to be used again should be carefully and thoroughly cleaned by an appropriate method.
Parts
When replacing parts, use KIA genuine parts.
Replacement
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Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
If removed, the following parts should always be replaced with new ones.
1. Oil seals
2. Gaskets
3. O-rings
4. Lock washers
5. Cotter pins (split pins)
6. Plastic nuts
Depending on their location.

7. Sealant should be applied to gaskets.
8. Oil should be applied to the moving components of parts.
9. Specified oil or grease should be applied to the prescribed locations (oil seals, etc) before assembly.
Adjustment
Use gauges and testers to adjust correctly the parts to standard values correctly.
Electrical System
1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery.
2. Never pull on the wires 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 against other parts.
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Ruber Parts And Tubes
Always prevent gasoline or from touching rubber parts or tubing.
Measuring Body Dimensiongs

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 dimensions and actual - measurement dimensions are used in this
manual.
Dimensions Projected
1. These are the dimensions measured when the measurement points are projected from the vehicle's surface, and
are the reference dimensions used for used for body alterations.
2. If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long as the
different value in height of the two surface.
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Measuring Actual Dimensions
1. These dimensions indicate the actual linear distance between mesaurement points, and are used as the reference
dimensions when a tracking gauge is used for measurement.
2. First adjust both probes to the same length (A=A') before measurement.
Check the probes and gauge itself to make sure there is no free play.
Measurement Point
Measurements should be taken at the center of the hole.
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Checking Cables And Wires
1. Check the terminal for tightness.
2. Check terminals and wires for corrosion from battery electrolyte, etc.
3. Check terminals and wires for open circuits.
4. Check wire insulation and coating for damage, cracks and degrading.
5. Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).
6. Check grounded parts to verify that there is complete continuity between their attaching bolt(s) and the vehicle's
body.
7. Check for incorrect wiring.
8. Check that the wiring is so clamped to the prevent contact with sharp corners of the vehicle body, etc. or hot parts
(exhaust manifold, etc.)
9. Check that the wiring is clamped firmly to provide enough clearance from the fan pulley, fan belt and other rotating
or moving parts.
10. Check that the wiring has a little space so that it can vibrate between fixed and moving parts such as the vehicle
body and the engine.
Check Fuses
A blade type fuse test taps provided to allow checking the fuse itself without removing if from the fuse box. The fuse is
good if the test lamp lights up when one lead is connected to the test taps (one at a time) and the other lead is
grounded. (Turn the ignition switch so that the fuse circuit becomes operative)
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Serivicing 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 trouble code
retained by the computer will be cleared. There fore, if necessary, record the diagnostic data before removing
the battery cable.
2. Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the
engine or other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine
vibrations to cause the harness to come into contact with any of the surrounding parts and then secure the harness
by using a clamp.
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3. If any section of a wiring harness interferes with the edge of a parts, or a corner, wrap the section of the harness
with tape or something similar in order to protect if from damage.
4. When installing any parts, be careful not to pinch or damage any of the wiring harness.
5. Never throw relays, sensors or electrical parts, or expose them to strong shock.
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6. The electronic parts used in the computer, relays, etc. are readily 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 before hand.
7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.
8. When disconnecting a connector, be sure to grip only the connector, not the wires.
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9. Disconnect connector which have catches by pressing in the direction of the arrows shown the illustration.
10. Connect connectors which have catches by inserting the connectors until they make a clicking sound.
11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the
harness side. If the connector is a sealed connector, insert the test probe through the hole in the rubber cap until
contacts the terminal, being careful not to damage the insulation of the wires.
12. To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and
determine the appropriate wire size.
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Permissible current
Noeminal size SAE gauge No.
In engine compartment Other areas
0.3mm$ AWG 22 - 5A
0.5mm$ AWG 20 7A 13A
0.85mm$ AWG 18 9A 17A
1.25mm$ AWG 16 12A 22A
2.0mm$ AWG 14 16A 30A
3.0mm$ AWG 12 21A 40A
5.0mm$ AWG 10 31A 54A
Precautions For Catalytic Converter
If a large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To
prevent this observe the following precations and explain them to your customer.
1. Use only unleaded gasoline.

2. Do not run the engine while the car is at rest for a long time. Avoid running the engine at fast idle for more than
10minutes and idle speed for more than 20 minutes.
3. Do not measure engine compression for an extended time. Engine compression tests must be made as rapidly as
possible. Remove the fuel pump relay before performing a compression test.
4. Do not dispose of used catalytic converter together with parts contaminated with gasoline or oil.
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Engine Mechanical System
General Information
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2010 > G 1.0 SOHC >
SPECIFICATION
SPECIFICATION
DESCRIPTION LIMIT
EPSILON 1.0 EPSILON 1.1
General
Type In-line, SOHC
Number of cylinders 4
Bore 66mm (2.5984in) 67mm (2.6378in)
Stroke 73mm (2.8740in) 77mm (3.0315in)
Total displacement 999cc (60.9 cu.in) 1,086cc (66.3 cu.in)
Compression ratio 9.7 : 1 10.1 : 1
Firing order 1-3-4-2
Valve timing
Opens (BTDC) 5°
Intake valve
Closes (ABDC) 35°
Opens (BBDC) 43°
Exhaust valve
Closes (ATDC) 5°
Cylinder head
Flatness of gasket surface Less than 0.03mm (0.0012in) 0.10mm (0.0039in)
Flatness of manifold Intake Less than 0.15mm (0.0059in) 0.30mm (0.0118in)

mounting surface Exhaust Less than 0.15mm (0.0059in) 0.30mm (0.0118in)
STD 10.000 ~ 10.015mm (0.3937 ~ 0.3943in)
Valve guide hole 0.05 OS 10.050 ~ 10.068mm (0.3957 ~ 0.3964in)

diameter 0.25 OS 10.250 ~ 10.268mm (0.4035 ~ 0.4043in)
0.50 OS 10.500 ~ 10.518mm (0.4134 ~ 0.4141in)
STD 24.000 ~ 24.021mm (0.9449 ~ 0.9457in)
Intake valve seat ring
0.3 OS 24.300 ~ 24.321mm (0.9567 ~ 0.9575in)
hole diameter
0.6 OS 24.600 ~ 24.621mm (0.9685 ~ 0.9693in)
STD 29.000 ~ 29.021mm (1.1417 ~ 1.1426in)
Exhaust valve seat
ring 0.3 OS 29.300 ~ 29.321mm (1.1535 ~ 1.1544in)
hole diameter
0.6 OS 29.600 ~ 29.621mm (1.1654 ~ 1.1662in)
Camshaft
Intake 33.941 ~ 34.141mm (1.3363 ~ 1.3441in)
Cam height
Exhaust 34.055 ~ 34.255mm (1.3407 ~ 1.3486in)
Journal outer Diameter 40.940 ~ 40.955mm (1.6118 ~ 1.6124in)
Bearing oil clearance 0.045 ~ 0.085mm (0.0018 ~ 0.0033in)
End play 0.07 ~ 0.24mm (0.0028 ~ 0.0094in)
Rocker arm
Rocker arm inner diameter 17.010 ~ 17.028mm (0.6697 ~ 0.6704in)
Rocker arm shaft outer diameter 16.985 ~ 16.998mm (0.6687 ~ 0.6692in)
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Valve
Intake 99.55mm (3.9193in)
Valve length
Exhaust 99.05mm (3.8996in)
Intake 5.465 ~ 5.480mm (0.2152 ~ 0.2157in)
Stem outer diameter
Exhaust 5.430 ~ 5.450mm (0.2138 ~ 0.2146in)
Face angle 45° ~ 45°30'
Thickness of Intake 0.8mm (0.0315in) 0.50mm (0.019in)

valve head (margin) Exhaust 1.2mm (0.0472in) 0.90mm (0.035in)
Valve stem to Intake 0.020 ~ 0.047mm (0.0008 ~ 0.0019in)

valve guide clearance Exhaust 0.050 ~ 0.082mm (0.0020 ~ 0.0032in)
Valve guide
Intake 46.0mm (1.8110in)
Length
Exhaust 48.0mm (1.8898in)
Valve seat
Intake 0.9 ~ 1.3mm (0.0354 ~ 0.0512in)
Width of seat contact
Exhaust 0.9 ~ 1.3mm (0.0354 ~ 0.0512in)
Intake 43°30' ~ 44°
Seat angle
Valve spring 43°30' ~ 44°
Valve spring
Free length 40.50mm (1.5945in)
15.6±0.9kg/32.0mm (34.4±2.0lb/1.2598in)
Load
33.3±1.8kg/24.5mm (73.4±4.0 lb/0.9646in)
Out of squareness Less than 1.5°
Valve clearance
Cold (20°C) [68°F] Intake 0.15 ~ 0.21mm (0.0059 ~ 0.0083in)

Only for reference Exhaust 0.19 ~ 0.25mm (0.0075 ~ 0.0098in)
Hot (80 ~ 95°C) Intake 0.22 ~ 0.28mm (0.0087 ~ 0.0110in)

[176 ~ 203°F] Exhaust 0.27 ~ 0.33mm (0.0106 ~ 0.0130in)
Cylinder block
1.0 66.000 ~ 66.030mm (2.5984 ~ 2.5996in)
Cylinder bore
1.1 67.000 ~ 67.030mm (2.6378 ~ 2.6390in)
Flatness of gasket surface Less than 0.05mm (0.002in)
Piston
Piston outer diameter 1.0 65.970 ~ 66.000mm (2.5972 ~ 2.5984in)
1.1 66.970 ~ 67.000mm (2.6366 ~ 2.6378in)
Piston to cylinder clearance 0.020 ~ 0.040mm (0.0008-0.0016in)
No. 1 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in)
Ring groove width No. 2 ring groove 1.21 ~ 1.23mm (0.0476 ~ 0.0484in)
Oil ring groove 2.01 ~ 2.03mm (0.0791 ~ 0.0799in)
Piston ring
No. 1 ring 0.03 ~ 0.07mm (0.0012 ~ 0.0028in) 0.10mm (0.0039in)
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Side clearance No. 2 ring 0.02 ~ 0.06mm (0.0008 ~ 0.0024in) 0.10mm (0.0039in)
Oil ring 0.06 ~ 0.15mm (0.0024 ~ 0.0059in)
No. 1 ring 0.15 ~ 0.30mm (0.0059 ~ 0.0118in)
End gap No. 2 ring 0.30 ~ 0.50mm (0.0098 ~ 0.0157in)
Oil ring 0.20 ~ 0.70mm (0.0079 ~ 0.0276in)
Piston pin
Piston pin outer diameter 17.000 ~ 17.003mm (0.6693 ~ 0.6694in)
Piston pin hole inner diameter 17.011 ~ 17.015mm (0.6697 ~ 0.6699in)
Piston pin hole clearance 0.008 ~ 0.014mm (0.0003 ~ 0.0006in)
Connecting rod small end hole inner diameter 16.974 ~ 16.985mm (0.6683 ~ 0.6687in)
Connecting rod small end hole clearance -0.026 ~ -0.015mm (-0.0010 ~ -0.0006in)
Piston pin press-in load 500 ~ 1100kg (1102.3 ~ 2425.1lb)
Connecting rod
Connecting rod big end inner diameter 41.000 ~ 41.015mm (1.6142 ~ 1.6148in)
Connecting rod bearing oil clearance 0.012 ~ 0.041mm (0.0005 ~ 0.0016in)
Side clearance 0.10 ~ 0.25mm (0.0039 ~ 0.0098in) 0.40mm (0.0157in)
Crankshaft
Main journal outer diameter 41.982 ~ 42.000mm (1.6528 ~ 1.6535in)
Pin journal outer diameter 37.980 ~ 38.000mm (1.4953 ~ 1.4961in)
Main bearing oil clearance 0.020 ~ 0.038mm (0.0008 ~ 0.0015in)
End play 0.05 ~ 0.25mm (0.0020 ~ 0.0098in)
Flywheel
Run out 0.13mm (0.0051in)
Oil pump
Inner rotor 0.040 ~ 0.095mm (0.0016 ~ 0.0037in)
Side clearance
Outer rotor 0.040 ~ 0.095mm (0.0016 ~ 0.0037in)
Body clearance 0.100 ~ 0.181mm (0.0039 ~ 0.0071in)
490.33±49.03kpa (5±0.5kg/cm!,
Relief valve opening pressure
71.12±7.11psi)
Free length 38.6mm (1.5197in)
Relief spring
Load 3.65±0.4kg/33mm (8.0±0.85 lb/1.2992in)
Engine oil
When replacing a
Total 3.0 L (3.17 US qt, 2.63 lmp qt) short engine or a
block assembly
Oil quantity
Oil pan 2.8 L (2.95 US qt, 2.46 lmp qt)
Drain and refill 3.0 L (3.17 US qt, 2.64 lmp qt) Including oil filter
If not available, refer
to the recommended
Recommendation
5W-20/GF4&SM API or ILSAC
(except Middle East)
classification and SAE
viscosity number.
Oil grade Satisfy the
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API SL, SM or above requirement of the
Classification
ILSAC GF3, GF4 or above API or ILSAC
classification.
Refer to the
SAE viscosity grade Recommended SAE viscosity number
"Lubrication System"
Oil temperature in oil
Oil pressure (at 800rpm) 50kPa (0.5kg/cm!, 7.1psi) or above pan : 95±5°C (203±
41°F)
Cooling method
Cooling system Forced circulation with cooling fan
Type Wax pellet type
Opening temperature 82 ± 1.5 °C (180 ± 34.7°F)
Thermostat
Full opening
95°C (203°F)
temperature
Main valve opening 93.16 ~ 122.58kpa
pressure (0.95 ~ 1.25kg/cm!, 13.51 ~ 17.78psi)
Radiator cap
Vacuum valve 0.98 ~ 4.90 kpa
opening pressure (0.01 ~ 0.05kg/cm!, 0.14 ~ 0.71 psi)
Water temperature sensor
Type Thermistor type
20°C (68°F) 2.45±0.14 k"
Resistance
80°C 176°F) 0.3222 k"
TIGHTENING TORQUES
Tightening torque
Item Quentity
N-m kg-m lb-ft
Cylinder block
Engine support bracket bolt 3 44.1 ~ 53.9 4.5 ~ 5.5 32.5 ~ 39.8
Engine mounting
Engine mounting bracket and body fixing blot 2 49.0 ~ 63.7 5.0 ~ 6.5 36.1 ~ 47.0
Engine mounting bracket and body fixing nut 1 49.0 ~ 63.7 5.0 ~ 6.5 36.1 ~ 47.0
Engine mounting bracket and engine support
1 49.0 ~ 63.7 5.0 ~ 6.5 36.1 ~ 47.0
bracket fixing bolt
Engine mounting bracket and engine support
2 49.0 ~ 63.7 5.0 ~ 6.5 36.1 ~ 47.0
bracket fixing nut
Transaxle mounting bracket and body fixing bolt 3 49.0 ~ 63.7 5.0 ~ 6.5 36.1 ~ 47.0
Transaxle mounting insulator and transaxle support
2 49.0 ~ 63.7 5.0 ~ 6.5 36.1 ~ 47.0
bracket fixing bolt
Rear roll stopper bracket and sub frame fixing bolt 1 49.0 ~ 63.7 5.0 ~ 6.5 36.1 ~ 47.0
Rear roll stopper bracket and rear roll stopper
1 49.0 ~ 63.7 5.0 ~ 6.5 36.1 ~ 47.0
support bracket bolt
Main moving system
Connecting rod bearing cap nut 8 19.6 ~ 22.6 2.0 ~ 2.3 14.5 ~ 16.6
Crankshaft main bearing cap bolt 10 49.0 ~ 53.9 5.0 ~ 5.5 36.2 ~ 39.8
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Fly wheel bolt (M/T) 5 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9
Drive plate bolt (A/T) 5 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9
Timing belt
Timing belt upper cover bolt (6#20) 3 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing belt upper cover bolt (6#10) 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing belt lower cover bolt (6#20) 3 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Crankshaft pulley bolt 1 147.1 15.0 108.5
Camshaft sprocket bolt 1 78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3
Timing belt tensioner bolt 1 21.6 ~ 29.4 2.2 ~ 3.0 15.9 ~ 21.7
Cylinder head
Rocker cover bolt 6 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Rocker arm shaft bolt 5 26.5 ~ 31.4 2.7 ~ 3.2 19.5 ~ 23.1
Camshaft thrust cap bolt 2 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Cylinder head bolt 10 58.8 ~ 68.6 6.0 ~ 7.0 43.4 ~ 50.6
Cooling system
Water pump pulley bolt 4 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Water pump bolt (6#18) 3 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Water pump bolt (6#35) 1 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Water pump and alternator brace fixing bolt (6#55) 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump and alternator brace fixing bolt (8#22) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Water inlet pipe fixing bolt (8#25) 2 16.7 ~ 19.6 1.7 ~ 2.0 12.3 ~ 14.5
Water inlet pipe fixing bolt (6#22) 2 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Thermostat housing bolt (Water inlet fitting) 3 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Water outlet fitting assembly bolt (8X25) 3 16.7 ~ 19.6 1.7 ~ 2.0 12.3 ~ 14.5
Lubrication system
Oil filter 1 11.8 ~ 15.7 1.2 ~ 1.6 8.7 ~ 11.6
Front case bolt (6#35) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Front case bolt (6#18) 5 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan bolt 16 5.9 ~ 7.8 0.6 ~ 0.8 4.3 ~ 5.8
Oil pan drain plug 1 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Oil screen bolt 2 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Oil pressure switch 1 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Intake and exhaust system
Intake manifold and cylinder head fixing nut 2 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Intake manifold and cylinder head fixing bolt 2 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Intake manifold stay bolt 2 17.7 ~ 24.5 1.8 ~ 2.5 14.5 ~ 19.5
Intake manifold bracket bolt and nut 2 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Exhaust manifold and cylinder head fixing nut 9 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
Oxygen sensor to exhaust manifold (FR) 1 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
Oxygen sensor to exhaust manifold (RR) 1 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
Exhaust manifold heat protector and exhaust
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Exhaust manifold heat protector and exhaust
3 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
manifold fixing bolt
Throttle body and surge tank fixing bolt and nut 4 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Exhaust manifold and front muffler fixing nut 2 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9
Front muffler pipe and main muffler pipe clamp nut 1 17.7 ~ 27.5 1.8 ~ 2.8 13.0 ~ 20.3
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2010 > G 1.0 SOHC >
COMPRESSION PRESSURE INSPECTION
If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression
pressure.
1. Start the engine and allow to warm up to operating temperature (about five minutes).
Stop the engine.
2. Disconnect the ignition coil connector(A) and the spark plug cables(B).
3. Remove the four spark plugs using a 16mm spark plug wrench.
4. Check the cylinder compression pressure.
(1) Insert a compression gauge into the spark plug hole.
(2) Fully open throttle.

(3) While cranking the engine, measure the compression pressure.
Always use a fully charged battery to obtain engine speed of 250rpm or more.
(4) Repeat step (1) through (3) for each cylinder.
This measurement must be done in as short a time as possible.
Compression pressure:
1,520kPa (15.5kg/cm!, 220psi) / 370rpm
Minimum pressure:
1,373kPa (14.0kg/cm!, 199psi)
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Difference between each cylinder :
98kPa (1.0kg/cm!, 14psi) or less
(5) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder
through the spark plug hole and repeat step (1) through (3) for cylinders with low compression.
A. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or
damaged.
B. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the
gasket.
5. Reinstall the spark plugs.

6. Connect the ignition coil connector and the spark plug cables.
TIMING BELT TESION ADJUSTMENT

1. Remove the RH front wheel.
2. Remove the bolts and the RH under cover (A).
3. Temporarily loosen the water pump pulley (A) bolts.
4. Remove the air conditioner compressor drive belt. (Refer to Air conditioner compressor in HA group)
5. Remove the alternator drive belt. (Refer to Alternator in EE group)
6. Remove the water pump pulley.
7. Remove the bolts (B) and timing belt upper cover (A).
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8. Turn the crankshaft pulley and align its groove with timing mark "T" of the timing belt cover.
9. Remove the drive belt pulley (B) and washer (A).
10. After loosen the crankshaft pulley bolt (A), remove the crankshaft pulley(C) and washer (B).
11. Remove the bolts (B) and the timing belt lower cover (A).
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12. Apply spring tension to the timing belt by temporarily loosening the bolt (A) of the tensioner pulley.
13. Adjust the timing belt tension.

(1) Rotate crankshaft clock wise (view from the front) through angle equivalent to two teeth ( 15°) of camshaft
sprocket (A).
It is procedure to give uniformly tension in the tension side of timing belt by setting exhaust rocker arm of
the No. 2 cylinder on the cam.
(2) Push the timing belt in the arrow direction and check the installation condition, and then apply spring tension
to the timing belt.
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(3) Tightening the tensioner bolt.
Tightening torque:
21.6 ~ 29.4Nm (2.2 ~ 3.0kgf.m, 15.9 ~ 21.7lb-ft)
14. Use a SONIC TENSION GAUGE, measure the timing belt tension.
(1) Inspect and adjust the valve clearance. (Refer to Valve clearance inspection and adjustment)
(2) Rotate the crankshaft in clockwise direction to set no.1 piston on top dead center, and rotate crankshaft in
counter-clockwise (38 teeth of camshaft sprocket), then calculate the nature frequency of belt by free vibration
at a center of tension side span (A).
When rotating the crankshaft counter-clockwise, be sure to rotate the crankshaft at a time.
(3) Method of translating measurement frequency; f(Hz) to tension; T (kgf) follows below equation.
A. Measuring belt length L : 24.9288 cm

B. Belt density r : 0.00090 (kg/cm)
Target value of timing belt tension (In cool condition) :

T = 12.7 ~ 13.3 kgf
15. Turn the crankshaft two turns in the operating direction (clockwise) and realign the crankshaft sprocket and
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camshaft sprocket timing marks.
16. Install the timing belt lower cover (A) with bolts (B).
Tightening torque:
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
17. Install the crankshaft pulley (C) and washer (B) with the bolt (A).
Tightening torque:
83.4 ~ 93.2Nm (8.5 ~ 9.5kgf.m, 61.5 ~ 68.7lb-ft)
18. Install the drive belt pulley (B) and washer (A) with bolts.
Tightening torque:
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
19. Install the timing belt upper cover (A) with bolts (B).
Tightening torque:
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
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20. Install the water pump pulley.
21. Install the alternator drive belt. (Refer to Alternator in EE group)
22. Install the air conditioner compressor drive belt. (Refer to Air conditioner compressor in HA group)
23. Tighten the water pump pulley bolts.
Tightening torque:
7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
24. Install the RH under cover (A).
Tightening torque:
6.8 ~ 107Nm (0.7 ~ 1.1kgf.m, 5.1 ~ 7.9lb-ft)
25. Install the RH front wheel.
Tightening torque:
88.3 ~ 107.9Nm (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
VALVE CLEARANCE INSPECTION AND ADJUSTMENT
Warm up the engine (80 ~ 95°C [176 ~ 203°F]), and then inspect and adjust the valve clearance with the cylinder
head installed on the cylinder block.
1. Remove the bolts (B) and timing belt upper cover (A).
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2. Remove the cylinder head cover. (Refer to Cylinder head in this group)
(1) Disconnect the spark plug cables and do not pull on the cable by force.
Pulling or bending the cables may damage the conductor inside.
(2) Remove the P.C.V (Positive Crankcase Ventilation) hose (A) and the breather hose (B) from the cylinder head
cover.
(3) Remove the cylinder head cover bolts (B), and then remove the cover (A) and gasket.
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3. Set No. 1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing belt cover.
(2) Check that timing mark of the camshaft sprocket (A) is aligned with the timing mark of the cylinder head.
If not, turn the crankshaft one revolution (360°).
4. Inspection the valve clearance.

(1) Check only the valve indicator as shown. [No. 1 cylinder: TDC/Compression]. Measure the valve clearance.
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(2) Using a thickness gauge, measure the clearance between the adjusting screw and the valve stem end.
Valve clearance
[Specification]
Engine coolant temperature : 80 ~ 95°C[176 ~ 203°F]
Intake: 0.22 ~ 0.28 mm (0.0087 ~ 0.0110in)
Exhaust: 0.27 ~ 0.33mm (0.0106 ~ 0.0130in)
[Reference data]
Engine coolant temperature : 20°C[68°F]
Intake: 0.15 ~ 21mm (0.0059 ~ 0.0083in)
Exhaust: 0.19 ~ 0.25mm (0.0075 ~ 0.0098in)
(3) Using the adjusting screw, adjust valve clearance by the specification value after loosen lock nut.
(4) If the adjustment is completed, tighten the lock nut.
(5) Turn the crankshaft pulley one revolution (360°) and align the groove with timing mark "T" of the lower timing
belt cover.
(6) Check only valves indicator as shown. [No. 4 cylinder: TDC/compression]. Measure the valve clearance. (Refer
to procedure step (1))
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2010 > G 1.0 SOHC >
TROUBLESHOOTING
Symptom Suspect area Remedy
Engine misfire with Repair or replace the flywheel as
Loose or improperly installed engine flywheel.
abnormal internal required.
lower engine noises.
Worn piston rings. Inspection the cylinder for a loss of
(Oil consumption may or may not cause the engine compression.
to misfire.) Repair or replace as required.
Replace the crankshaft and bearings as
Worn crankshaft thrust bearings.
required.
Engine misfire with Stuck valves. Repair or replace as required.
abnormal valve train (Carbon buildup on the valve stem can cause the
noise. valve not to close properly.)
Replace the timing belt and sprocket as
Excessive worn or mis-aligned timing belt.
required.
Worn camshaft lobes. Replace the camshaft and valve lifters.
Engine misfire with • Faulty cylinder head gasket and/or cranking or • Inspect the cylinder head and
coolant consumption other damage to the cylinder head and engine engine block for damage to the
block cooling system . coolant passages and/or a faulty
• Coolant consumption may or may not cause the head gasket.
engine to overheat. • Repair or replace as required.
Engine misfire with Worn valves, valve guides and/or valve stem oil
Repair or replace as required.
excessive oil seals.
consumption
Worn piston rings. Inspection the cylinder for a loss of
(Oil consumption may or may not cause the engine compression
to misfire) Repair or replace as required.
Engine noise on start- Drain the oil.
Incorrect oil viscosity.
up, but only lasting a Refill with the correct viscosity oil.
few seconds.
Worn crankshaft thrust bearing. Inspect the thrust bearing and
crankshaft.
Upper engine noise, Low oil pressure. Repair or replace as required.
regardless of engine
Broken valve spring. Replace the valve spring.
speed.
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing belt and/or damage Replace the timing belt and sprockets.
sprocket teeth.
Replace the timing belt tensioner as
Worn timing belt tensioner, if applicable.
required.
Worn camshaft lobes. Inspect the camshaft lobes.
Replace the camshaft and valve lifters
as required.
Worn valve guides or valve stems. Inspect the valves and valve guides,
then repair as required.
Stuck valves. (Carbon on the valve stem or valve Inspect the valves and valve guides,
seat may cause the valve to stay open.) and then repair as required.
Lower engine noise, Repair or replace damaged components
Low oil pressure.
regardless of engine as required.
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speed.
Loose or damaged flywheel. Repair or replace the flywheel.
Damaged oil pan, contacting the oil pump screen. Inspect the oil pan.
Inspect the oil pump screen.
Oil pump screen loose, damaged or restricted. Inspect the oil pump screen .
Excessive piston-to-cylinder bore clearance. Inspect the piston and cylinder bore.
Repair as required.
Excessive piston pin-to bore clearance. Inspect the piston, piston pin and the
connecting rod.
Excessive connecting rod bearing clearance. Inspect the following components and
repair as required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
• The crankshaft journal.
Excessive crankshaft bearing clearance. Inspect the following components and
repair as required.
• The crankshaft bearings.
• The crankshaft journals.
Incorrect piston, piston pin and connecting rod Verify the piston pins and connecting
installation. rods are installed correctly.
Repair as required.
Engine noise under Low oil pressure. Repair or replace as required.
load.
Excessive connecting rod bearing clearance. Inspect the following components and
repair as required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
Excessive crankshaft bearing clearance. Inspect the following components and
repair as required.
• The crankshaft bearings.
• The crankshaft journal.
• The cylinder block crankshaft
bearing bore.
Engine will not crank Hydraulically locked cylinder. Remove spark plugs and check for
(crankshaft will not • Coolant/antifreeze in cylinder. fluid.
rotate) • Oil in cylinder. Inspect for broken head gasket.
• Fuel in cylinder. Inspect for cracked engine block or
cylinder head.
Inspect for a sticking fuel injector and/or
leaking fuel regulator.
Broken timing belt and/or timing belt sporckets. Inspect timing belt and sprockets.
Repair as required.
Foreign material in cylinder. Inspect cylinder for damaged
• Broken valve. components and/or foreign materials.
• Piston material. Repair or replace as required.
• Foreign material.
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Seized crankshaft or connecting rod bearings. Inspect crankshaft and connecting rod
bearing.
Bent or broken connecting rod. Inspect connecting rods
Broken crankshaft. Inspect crankshaft.
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2010 > G 1.0 SOHC >
SPECIAL SERVICE TOOLS

Tool (Number and name) Illustration Use
Crankshaft front oil seal Installation of the front oil seal
installer (With 09231-22100)
(09231-22000)
Crankshaft front oil seal Installation of the front oil seal

guide (With 09231-22000)
(09231-22100)
Camshaft oil seal installer Installation of the camshaft oil seal

(09221-21000) (With 09221-21100)
Camshaft oil seal guide Installation of the camshaft oil seal

(09221-21100) (With 09221-21000)
Valve guide remover and Removal and installation of the valve guide
installer
(09222-02100)
Valve stem oil seal installer Installation of the valve stem oil seal
(09222-02000)
Valve spring lifer arm Removal and installation of the intake or
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Valve spring lifer arm Removal and installation of the intake or
(0K993 120 001) exhaust valve
Valve spring lifter pivot Removal and installation of the intake or

(0K993 120 004) exhaust valve
Crankshaft rear oil seal Installation of the crankshaft rear oil seal
installer
(09231-21000)
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Timing System
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2010 > G 1.0 SOHC >
COMPONENT
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2010 > G 1.0 SOHC >
REMOVAL
Engine removal is not required for this procedure.
1. Remove the cowl grill and the wiper motor. (Refer to Wiper motor in BE group.)
2. Remove the cowl panel (A).
3. Remove the RH front wheel.

4. Remove the bolts and RH under cover (A).
5. Remove the engine mounting bracket.

(1) Install the engine hanger.
(2) Remove engine mounting bracket (A).
6. Temporarily loosen the water pump pulley (A) bolts.
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7. Remove air conditioner compressor drive belt. (Refer to Air conditioner compressor in HA group.)
8. Remove alternator drive belt. (Refer to Alternator in EE group.)
9. Remove the water pump pulley.
10. Remove the bolts (B) and the timing belt upper cover (A).
11. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover.
12. Remove the drive belt pulley (B) and washer (A).
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13. Loosen the crankshaft pulley bolt (A), and then remove the crankshaft pulley(C) and washer (B).
14. Remove the bolts (B) and the timing belt lower cover (A).
15. Remove the crankshaft position sensor target wheel (A).
16. Temporarily loosen the tensioner bolt (A).

Release tension from the timing belt by pulling the tensioner (B) in the arrow direction, and then temporarily
tighten the tensioner bolt (A).
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17. Remove the timing belt (A).
If the timing belt is going reused, make an arrow indicating the turning direction to make sure that the belt is
reinstalled in the same direction as before.
18. Remove the crankshaft sprocket (A).
19. Remove the crankshaft position sensor (A), tensioner spring (B) and tensioner (C).
INSPECTION
SPROCKET, TENSIONER
1. Check the camshaft sprocket, crankshaft sprocket and tensioner pulley for abnormal wear, cracks, or damage.
Replace as necessary.
2. Inspect the tensioner pulley for easy and smooth rotation and check for play or noise. Replace as necessary.
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3. Replace the pulley if there is grease leak from its bearing.
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 carefully. If any damage is found, replace the
belt.
Do not bend, twist or turn the timing belt inside out.

Do not allow timing belt to come into contact with oil, water and steam.
INSTALLATION
1. Install the crankshaft sprocket (A).
2. Align the timing marks of the camshaft sprocket (A) and crankshaft sprocket (B) with the No. 1 piston placed at top
dead center and its compression stroke.
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3. Install the crankshaft position sensor (A), tensioner spring (B) and tensioner (C).
Tightening torque:
A : 7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
(1) Pull the timing belt tensioner (A) in the arrow direcion (to the water pump) until it stops, and then temporarily
tighten the tensioner bolt.
(2) Hang oneside of the tensioner spring (B) on the tensioner bracket first and using a driver, install otherside to
the frontcase.
4. Install the belt so as not give slack at each center of shaft. Do as following procedures when installing timing belt.
Crankshaft sprocket (A) !camshaft sprocket (B) !timing belt tensioner (C).
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5. Apply the spring tension to the timing belt by loosening the tensioner bolt (A).
6. Adjust the timing belt tension.

(1) Rotate crankshaft clock wise (view from the front) through angle equivalent to two teeth ( 15°) of camshaft
sprocket (A).
It is procedure to give uniformly tension in the tension side of timing belt by setting exhaust rocker arm of
the No. 2 cylinder on the cam.
(2) Push the timing belt in the arrow direction and check the installation condition, and then apply spring tension to
the timing belt.
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(3) Tightening the tensioner bolt.
Tightening torque
21.6 ~ 29.4Nm (2.2 ~ 3.0kgf.m, 15.9 ~ 21.7lb-ft)
7. Use a SONIC TENSION GAUGE, measure the timing belt tension.

(1) Inspect and adjust the valve clearance. (Refer to Valve clearance inspection and adjustment)
(2) Rotate the crankshaft in clockwise direction to set no.1 piston on top dead center, and rotate crankshaft in
counter-clockwise (38 teeth of camshaft sprocket), then calculate the nature frequency of belt by free vibration
at a center of tension side span (A).
When rotating the crankshaft counter-clockwise, be sure to rotate the crankshaft at a time.
(3) Method of translating measurement frequency; f(Hz) to tension; T (kgf) follows below equation.
A. Measuring belt length L : 24.9288 cm

B. Belt density r : 0.00090 (kg/cm)
Target value of timing belt tension (In cool condition) :

T = 12.7 ~ 13.3 kgf
8. Turn the crankshaft two turns in the operating direction (clockwise) and realign the crankshaft sprocket and
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camshaft sprocket timing marks.
9. Install the crankshaft position sensor target wheel (A).
10. Install the timing belt lower cover (A) with bolts (B).
Tightening torque:
9.8 ~ 11.8 Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
11. Install the crankshaft pulley (C) and washer (B) with bolt (A).
Tightening torque:
147.1Nm (15.0kgf.m, 108.5lb -ft)
12. Install the drive belt pulley (B) and washer (A).
Tightening torque:
11.8 ~ 14.7 Nm (1.2 ~ 1.5kgf.m, 8.7 ~ 10.8lb-ft)
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13. Install the timing belt upper cover (A) with bolts (B).
Tightening torque:
9.8 ~ 11.8 Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

15. Install air conditioner compressor dirve belt. (Refer to Air conditioner compressor in HA group.)
16. Install alternator dirve belt. (Refer to Alternator in EE group.)
Tightening torque:
7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.7 ~ 7.2lb-ft)
18. Install the engine mounting bracket.

(1) Install the engine mounting bracket (A) with bolts and nut.
Tightening torque:
Nut and bolt :
49.0 ~ 63.7Nm (5.0 ~ 6.5kgf.m, 36.1 ~ 47.0lb-ft)
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(2) Remove the engine hanger.
19. Install the RH under cover (A).
Tightening torque:
6.8 ~ 10.7Nm (0.7 ~ 1.1kgf.m, 5.1 ~ 7.9lb-ft)
20. Install the RH front wheel.
Tightening torque:
88.8 ~ 107.9Nm (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
21. Install the cowl panel (A).
22. Install the cowl grill and the wiper motor. (Refer to Wiper motor in BE group.)
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Cylinder Head Assembly
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2010 > G 1.0 SOHC >
COMPONENT
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2010 > G 1.0 SOHC >
REMOVAL
Engine removal is not required for this procedure.
• Use Fender cover to avoid damaging painted surfaces.

• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal
temperature before removing it.
• When handing a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
• Mark all wiring and hoses to avoid misconnection.

• Inspect the timing belt before removing the cylinder head.
• Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1. Disconnect the terminals (A) from battery.
2. Drain the engine coolant. (Refer to Cooling system in this group.)

Remove the radiator cap to speed draining.
3. Remove the cowl grill and the wiper motor. (Refer to Wiper motor BE group.)
5. Remove the resonator and air cleaner assembly.

(1) Remove the air hose clamp (A) and the vacuum hose (B).
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(2) Remove the resonator (A).
(3) Remove the air cleaner bolts, nut and air duct mounting clips then remove the air cleaner assembly.
6. Remove the radiator upper hose(A) and lower hose(B).
7. Remove the heater hose (A).
8. Remove the engine wire harness connectors and wire harness clamp from cylinder head and the intake manifold.
(1) Disconnect the ISA (Idle Speed Actuator) connector (A).
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(2) Disconnect the TPS (Throttle Position Sensor) connector (B).
(3) Remove the accelerator cable(C).
(4) Disconnect the rear oxygen sensor connector (A).

(5) Disconnect the ignition coil connector (B).
(6) Disconnect the CMP (Camshaft position sensor) connector (C).
(7) Disconnect the ECT (Engine Coolant Temperature) sensor connector (D).
(8) Disconnect the MAP (Manifold Absolute Pressure) sensor connector (A).
(9) Disconnect the brake oil level switch connector (B).
(10) Disconnect the injector combination connector (A).

(11) Disconnect the CKP (Crankshaft position sensor) connector (B).
(12) Disconnect the knock sensor connector (C).
(13) Disconnect the front oxygen sensor connector (D).
(14) Disconnect the oil pressure switch connector (E).
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9. Remove the fuel inlet hose (A) from the delivery pipe.
10. Remove the PCSV (Purge Control Solenoid Valve) hose (B).
11. Disconnect the PCSV (Purge Control Solenoid Valve) connector (C).
12. Remove the brake booster vacuum hose (A).
13. Remove the spark plug cables and disconnect the ignition coil assembly. (Refer to Ignition system in EE group.)
14. Remove the intake and exhaust manifold. (Refer to Intake and exhaust system in this group.)
15. Remove the timing belt. (Refer to Timing system in this group.)
16. Remove the bolts (B) and the cylinder head cover (A).
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17. Remove the rocker arm shaft assembly (A).
18. Remove the camshaft sprocket (A).
19. Remove the CMP (Camshaft position sensor)(A) and the thrust cap (B).
20. Remove the camshaft (A).
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21. Remove the cylinder head bolts, and then remove the cylinder head.
(1) Using hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the
sequence shown.
Head warpage or cracking could result from removing bolts in an incorrect order.
(2) Lift the cylinder head from the cylinder block, and then place the cylinder head on wooden blocks on a bench.
Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
REPLACEMENT
VALVE GUIDE
1. Using the SST (09222 - 02100), withdraw the old valve guide toward the bottom of cylinder head.
2. Recondition the valve guide hole of cylinder head so that it can match the newly press-fitted oversize valve guide.
3. Using SST (09222 - 02100), press-fit the valve guide. The valve guide must be press-fitted from the upper side of
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the cylinder head. Keep in mind that the intake and exhaust valve guides are different in length.
Valve guide length

Intake: 46.0mm (1.8110 in)
Exhaust: 48.0mm (1.8898 in)
4. After the valve guide is press-fitted, insert a new valve and check for proper stem-to-guide clearance.
5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as
necessary.
VALVE GUIDE OVERSIZE
Valve guide
Oversize Size Valve guide hole inner Valve guide outer
Item protrusion height
[mm (in)] mark diameter [mm (in)] diameter [mm (in)]
[mm (in)]
10.000 ~ 10.015 10.050 ~ 10.060
STD -
(0.3937 ~ 0.3943) (0.3957 ~ 0.3961)
10.050 ~ 10.068 10.100 ~ 10.110 Intake: 15.5 ~ 16.1
0.05 (0.002) OS 5
Valve (0.3957 ~ 0.3964) (0.3976 ~ 0.3980) (0.6102 ~ 0.6339)
guide 10.250 ~ 10.268 10.300 ~ 10.310 Exhaust: 14.5 ~ 15.1
0.25 (0.010) OS 25 (0.5709 ~ 0.5945)
(0.4035 ~ 0.4043) (0.4055 ~ 0.4059)
10.500 ~ 10.518 10.550 ~ 10.560
0.50 (0.020) OS 50
(0.4134 ~ 0.4141) (0.4154 ~ 0.4157)
VALVE SEAT RING

1. Cut away the inner face of the valve seat to reduce the wall thickness.
2. Enlarge the seat ring hole of cylinder head so that matches the specified cylinder head hole inner diameter of new
valve seat ring.
3. Heat the cylinder head to about 250°C(480°F) and press-fit an oversize seat ring for the bore in the cylinder head.
4. Using lapping compound, lap the valve to the new seat.
VALVE SEAT RING OVERSIZE
Over size Size Seat ring hole inner Seat ring outer diameter Seat ring height
Item
[mm(in.)] mark diameter [mm (in.)] [mm (in.)] [mm (in.)]
24.000 ~ 24.021 24.125 ~ 24.145 5.900 ~ 6.100
STD -
(0.9449 ~ 0.9457) (0.9498 ~ 0.9506) (0.2323 ~ 0.2402)
Intake
valve 24.300 ~ 24.321 24.425 ~ 24.445 6.200 ~ 6.400
0.3 (0.012) OS 30
seat (0.9567 ~ 0.9575) (0.9616 ~ 0.9624) (0.2441 ~ 0.2520)
ring
24.600 ~ 24.621 24.725 ~ 24.745 6.500 ~ 6.700
0.6 (0.024) OS 60
(0.9685 ~ 0.9693) (0.9734 ~ 0.9742) (0.2559 ~ 0.2638)
29.000 ~ 29.021 29.125 ~ 29.145 5.900 ~ 6.100
STD -
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STD -
(1.1417 ~ 1.1426) (1.1467 ~ 1.1474) (0.2323 ~ 0.2402)
Exhaust
valve 29.300 ~ 29.321 29.425 ~ 29.445 6.200 ~ 6.400
0.3 (0.012) OS 30
seat (1.1535 ~ 1.1544) (1.1585 ~ 1.1592) (0.2441 ~ 0.2520)
ring
29.600 ~ 29.621 29.725 ~ 29.745 6.500 ~ 6.700
0.6 (0.024) OS 60
(1.1654 ~ 1.1662) (1.1703 ~ 1.1711) (0.2559 ~ 0.2638)
DISSASSEMBLY
Identify rocker arm, valves, valve springs as they are removed so that each item can be reinstalled in its original
position.
1. Remove the valves.

(1) Using the SST (0K993 120 001, 0K993 120 004), compress the valve spring and remove the retainer lock.
(2) Remove the spring retainer.

(3) Remove the valve spring.
(4) Remove the valve.
(5) Using needle-nose pliers, remove the oil seal.
(6) Using a magnetic finger, remove the spring seat.
INSPECTION
CYLINDER HEAD
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure flatness in contacting surface of the cylinder block and
the manifolds.
Flatness of cylinder head gasket surface

Standard: Less than 0.03mm (0.0012in)
Limit: 0.10mm (0.0039in)
Flatness of manifold mating surface
Limit: 0.30mm (0.0118in)
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2. Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked,
replace the cylinder head.
VALVE AND VALVE SPRING

1. Inspect the valve stems and valve guides.
(1) Using the caliper gauge, measure the inner diameter of the valve guide.
Valve guide inner diameter:

5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
(2) Using a micrometer, measure the outer diameter of valve stem.
Valve stem outer diameter

Intake: 5.465 ~ 5.480mm (0.2152 ~ 0.2157in)
Exhaust: 5.430 ~ 5.450mm (0.2138 ~ 0.2146in)
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(3) Subtract the valve stem outer diameter measurement from the valve guide inner diameter measurement.
Valve stem- to-guide clearance

Standard :
Intake: 0.020 ~ 0.047mm (0.0008 ~ 0.0019in)
Exhaust: 0.050 ~ 0.082mm (0.0014 ~ 0.0026in)
If the clearance is greater than maximum, replace the valve and valve guide.
2. Inspect the valves.

(1) Check the valve is ground to the correct valve face angle.
(2) Check the surface of the valve face for damage or wear.
If the valve face is damaged or worn, replace the valve.
(3) Check the valve head margin thickness.
If the margin thickness is less then minimum, replace the valve.
Margin
Standard
Intake: 0.8mm (0.0315in)
Exhaust: 1.2mm (0.0472in)
Limit
Intake: 0.5mm (0.0197in)
Exhaust: 0.9mm (0.0354in)
(4) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect the valve seats.

(1) Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
(2) Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, and then
recondition the seat.
(3) Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within
specifications and centered on the valve face.
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4. Inspect the valve springs.
(1) Using a steel square, measure the out-of-square of the valve spring.
(2) Using a vernier calipers, measure the free length of the valve spring.
Valve spring
Standard
Free height: 40.50mm (1.5945in)
Load : 15.6±0.9kg/32.0mm (34.4±2.0lb/1.2598in)
33.3±1.8kg/24.5mm (73.4±4.0lb/0.9646in)
Out of square : Less than 1.5 °
Limit
Out of square : 3°
If the loads is not as specified, replace the valve spring.
CAMSHAFT
1. Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
Intake: 33.941 ~ 34.141mm (1.3363 ~ 1.3441in)
Exhaust: 34.055 ~ 34.255mm (1.3407 ~ 1.3486in)
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If the cam lobe height is less than minimum, replace the camshaft.
2. Inspect the camshaft journal.
Using a micrometer, measure outer diameter of the camshaft journal.
Camshaft journal outer diameter

Standard: 40.940 ~ 40.955mm (1.6118 ~ 1.6124in)
3. Inspect the camshaft end play.

(1) Install the camshaft.
(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play

Standard: 0.07 ~ 0.24mm (0.0028 ~ 0.0094in)
If the end play is greater than maximum, replace the camshaft. If necessary, replace the cylinder head.
ROCKER ARM AND ROCKER ARM SHAFT

1. Inspect the rocker arm.
(1) Check the rocker arm face.
Replace it if damaged or pressed.
(2) Check the contacting surface on the cam and valve stem.
If badly worn or damaged, replace it.
2. Inspect the rocker arm shaft.

(1) Check the rocker arm shafts for damaged. Replace as necessary.
(2) Check the oil hole (A) whether clogged or not.
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3. Measure the rocker arm-to-rocker arm shaft clearance.
(1) Measure the rocker arm inner diameter.
Rocker arm inner diameter:

17.010 ~ 17.028mm (0.6697 ~ 0.6704in)
(2) Measure the rocker arm shaft outer diameter.
Rocker arm shaft outer diameter:

16.985 ~ 16.998mm (0.6687 ~ 0.6692in)
(3) Calculate the difference between the rocker arm inner diameter and the rocker arm shaft outer diameter.
Oil clearance:
0.012 ~ 0.043mm (0.00047 ~ 0.00169in)
REASSEMBLY
• Thoroughly clean all parts to be assembled.

• Before installing the parts, apply fresh engine oil to all sliding and rotating surface.
• Replace the oil seals with new ones.
1. Install the valves.

(1) Install the spring seats.
(2) Using the SST (09222 - 02000), push in a new oil seal.
Do not reuse old valve stem seals.

Incorrect installation of the seal could result in oil leakage past the valve guides.
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(3) Install the valve, valve spring and spring retainer.
Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then
installs the retainer.
(4) Using SST (0K993 120 001, 0K993 120 004), compress the spring and install the retainer locks. After installing
the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor.
(5) Lightly tap the end of each valve stem two or three times the wooden handle of a hammer to ensure proper
seating of the valve and retainer lock.
INSTALLATION
• Thoroughly clean all parts to be assembled.

• Always use a new head and manifold gasket.
• The cylinder head gasket is a metal gasket. Take care not to bend it.
• Rotate the crankshaft, set No. 1 piston at TDC.
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1. Install the cylinder head gasket on the cylinder block.
Be careful of the installation direction.
2. Place the cylinder head onto the block carefully in order to prevent damaging the gasket. If the gasket is damaged,
fluid leakage could occur.
3. Install the cylinder head bolts.
(1) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
(2) Using hexagon wrench, install and tighten the 10 cylinder head bolts, in several passes, in the sequence
shown.
Tightening torque:
58.8 ~ 68.6Nm (6.0 ~ 7.0kgf.m, 43.4 ~ 50.6lb-ft)
4. Install the camshaft (A).
5. Install the thrust cap (B) and CMP (Camshaft position sensor) (A).
Tightening torque:
A : 9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
B : 7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
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6. Using the SST (09221 - 21000), install the camshaft bearing oil seal.
7. Install the camshaft sprocket (A).
Tightening torque:
78.5 ~ 98.1Nm (8.0 ~ 10.0kgf.m, 57.9 ~ 72.3lb-ft)
8. Install the rocker arm shaft assembly (A).
Tightening torque:
26.5 ~ 31.4Nm (2.7 ~ 3.2kgf.m, 19.5 ~ 23.1lb-ft)
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• When installing the rocker arm shaft, set the chamfer side of shaft in front of engine (timing belt side).
• At this time, the oil hole of shaft should face downward (cylinder head side).
9. Inspect and adjust the valve clearance. (Refer to Valve clearance inspection and adjustment in GI group.)
10. Install the cylinder head cover.
(1) Install the cylinder head cover gasket (A) in the groove of the cylinder head cover (B).
• Before installing the cylinder head cover gasket, thoroughly clean the cylinder head cover and the
groove.
• When installing, make sure the cylinder head cover gasket is seated securely in the corners of the
recesses with no gap.
(2) Install the cylinder head cover (A) with the bolts (B). Uniformly tighten the bolts in several passes.
Tightening torque:
7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
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11. Install the timing belt. (Refer to Timing system in this group.)
12. Install the intake manifold. (Refer to Intake and exhaust system in this group.)
13. Install the exhaust manifold. (Refer to Intake and exhaust system in this group.)
14. Install the ignition coil assembly and connect the spark plug cables. (Refer to Ignition in EE group.)
15. Install the brake booster vacuum hose (A).
16. Connect the PCSV (Purge Control Solenoid Valve) connector (C).
17. Connect the PCSV (Purge Control Solenoid Valve) hose (B).
18. Install the fuel inlet hose (A) from the delivery pipe.
19. Connect the engine wire harness connectors and wire harness clamp from cylinder head and the intake manifold.
(1) Connect the ISA (Idle Speed Actuator) connector (A).
(2) Connect the TPS (Throttle Position Sensor) connector (B).
(3) Install the accelerator cable(C).
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(4) Connect the rear oxygen sensor connector (A).
(5) Connect the ignition coil connector (B).
(6) Connect the CMP (Camshaft position sensor) connector (C).
(7) Connect the ECT (Engine Coolant Temperature) sensor connector (D).
(8) Connect the MAP (Manifold Absolute Pressure) sensor connector (A).
(9) Connect the brake oil level switch connector (B).
(10) Connect the injector combination connector (A).

(11) Connect the CKP (Crankshaft position sensor) connector (B).
(12) Connect the knock sensor connector (C).
(13) Connect the front oxygen sensor connector (D).
(14) Connect the oil pressure switch connector (E).
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20. Install the resonator and air cleaner assembly.
(1) Install the air duct and air cleaner assembly (B).
(2) Install the resonator (A).
Tightening torque:
7.8 ~ 11.7Nm (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
(3) Install the air hose clamp(A) and the vacuum hose(B).
Tightening torque:
2.9 ~ 4.9Nm (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
21. Install the cowl panel (A).
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22. Install the cowl grill and wiper motor (Refer to Wiper motor in BD group.)
23. Connect the battery terminals (A).
24. Fill with engine coolant.

25. Start the engine and check for leaks.
26. Recheck the engine coolant level and oil level.
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Engine & Transaxle Assembly
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL
• Use fender covers to avoid damaging painted surfaces.

1. Disconnect the battery terminals (A).
2. Remove the battery (A) and battery tray (B).
Tightening torque:
9.8 ~ 11.7Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
3. Loosen the drain plug (A), and drain the coolant.
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4. Recover refrigerant and remove the high & low pressure pipe. (Refer to Air conditioning in HA group)
5. Remove the cowl grill and wiper motor. (Refer to Wiper motor in BD group)
7. Remove the resonator and air cleaner assembly.

(1) Remove the air hose clamp (A) and the vacuum hose (B).
Tightening torque:
2.9 ~ 4.9Nm (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
(2) Remove the resonator (A).
Tightening torque:
7.8 ~ 11.7Nm (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
(3) Remove the air cleaner bolts, nut and air duct mounting clips then remove the air cleaner assembly(B).
Tightening torque:
7.8 ~ 11.7Nm (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
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8. Remove the radiator upper hose(A) and lower hose(B).
9. Remove the reservoir tank(A).
Tightening torque:
6.9 ~ 10.8Nm (0.7 ~ 1.1kgf.m, 5.1 ~ 7.9lb-ft)
10. Remove the heater hoses (A).
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11. Remove the cooling fan. (Refer to Cooling system in this group.)
(4) Disconnect the rear oxygen sensor connector (A).

(5) Disconnect the ignition coil connector (B).
(6) Disconnect the CMP (Camshaft position sensor) connector (C).
(7) Disconnect the ECT (Engine Coolant Temperature) sensor connector (D).
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(10) Disconnect the injector combination connector (A).
(11) Disconnect the CKP (Crankshaft position sensor) connector (B).
(12) Disconnect the knock sensor connector (C).
(13) Disconnect the front oxygen sensor connector (D).
(14) Disconnect the oil pressure switch connector (E).
13. Remove the transaxle wire harness connectors and control cable from the transaxle (A/T).
17. Remove the brake booster vacuum hose (A).
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18. Remove the front wheel. (LH, RH)
Tightening torque:
88.8~107.9Nm (9.0 ~11.0kgf.m, 65.1~79.6lb-ft)
19. Remove under covers.
Tightening torque:
6.9 ~ 10.8Nm (0.7 ~ 1.1kgf.m, 5.1 ~ 7.9lb-ft)
20. Remove the front muffler (A).
Tightening torque:
39.2 ~ 53.9Nm (4.0~ 5.5kgf.m, 28.9 ~ 39.8lb-ft)
21. Remove the air conditioner compressor drive belt and alternator drive belt.
22. Remove the alternator (A) and brace (B). (Refer to Alternator in EE group.)
Tightening torque:
C: 9.8 ~ 11.7Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
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D: 19.6~26.5 Nm (2.0~2.7kgf.m, 14.4~ 19.5lb-ft)
E: 11.7 ~14.7 Nm (1.2~1.5kgf.m, 8.7 ~ 10.4lb-ft)
F: 19.6~24.5 Nm (2.0~2.5kgf.m, 14.4~ 18.1lb-ft)
23. Disconnect the starter connector (B), "B" terminal (C), and remove the ground cable (A).
Tightening torque:
A :16.6~25.5Nm (1.7 ~ 2.6kgf.m, 12.3 ~ 18.8lb-ft)
C : 6.9 ~ 10.8Nm (0.7 ~ 1.1kgf.m, 5.1 ~ 7.9lb-ft)
24. Remove the cables and tubes related to the transaxle. (Refer to MT or AT group)
25. Remove the drive shafts and stabilizer bar link. (Refer to DS and SS group)
26. Remove the rear roll stopper (A).
Tightening torque:
49.0 ~ 63.7Nm (5.0 ~ 6.5kgf.m, 36.1 ~ 47.0lb-ft)
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Mark the rear roll stopper direction for proper installation.
27. Using a floor jack, support the engine and transaxle assembly.
After removing the mounting bolt (engine and transaxle), the engine and transaxle assembly may fall
downward, and so support them securely with floor jack.
Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
28. Remove the engine-mounting bracket (A).
Tightening torque:
bolts and nuts :
49.0 ~ 63.7Nm (5.0 ~ 6.5kgf.m, 36.1 ~ 47.0lb-ft)
29. Remove the transaxle-mounting bracket.
Tightening torque:
49.0 ~ 63.7Nm (5.0 ~ 6.5kgf.m, 36.1 ~ 47.0lb-ft)
30. Remove the engine and transaxle assembly by lifting vehicle.
When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body
components.
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INSTALLATION
Installation is in the reverse order of removal.
Perform the following:
• Adjust the shift cable.
• Adjust the throttle cable.
• Refill the engine with engine oil.
• Refill the transaxle with fluid.
• Refill the radiator and reservior tank with engine coolant.
• Place the heater control knob on "HOT" position
• Bleed air from the cooling system.
- Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be
removed from the cooling system.
- Put the radiator cap on tightly, then run the engine again and check for leaks.
• Clean the battery posts and cable terminals with sandpaper assemble them, and then apply grease to prevent
corrosion.
• Inspect for fuel leakage.
- After assemble the fuel line, turn on the ignition switch (do not operate starter) so that the fuel pump runs for
approximately two seconds and fuel line pressurizes.
- Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
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Cylinder Block
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2010 > G 1.0 SOHC >
COMPONENT
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2010 > G 1.0 SOHC >
DISASSEMBLY
1. M/T: Remove the fly wheel.
2. A/T: Remove the drive plate.
3. Install the engine block onto an engine stand for disassembly.
4. Remove the intake manifold and exhaust manifold. (Refer to Intake and exhaust system in this group.)
6. Remove the cylinder head. (Refer to Cylinder head assembly in this group.)
7. Remove the oil pressure switch.
8. Remove the water pump. (Refer to Cooling system in this group.)
9. Remove the oil fan (A).
10. Remove the oil screen.

Remove the 2bolts(C), oil screen (A) and gasket (B).
11. Check the connecting rod end play.

12. Remove the connecting rod caps and check oil clearance.
13. Remove the piston and connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
• Keep the bearings, connecting rod and cap together.

• Arrange the piston and connecting rod assemblies in the correct order.
14. Remove the front case. (Refer to Lubrication system in this group.)
15. Remove the rear oil seal case.
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Remove the 4 bolts (B) and rear oil seal case (A).
16. Remove the crankshaft bearing cap and check oil clearance.
17. Check the crankshaft end play.
18. Lift the crankshaft (A) out of the engine, being careful not to damage journals.
Arrange the main bearings and thrust bearings in the correct order.
19. Check fit between piston and piston pin.

Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a
set.
20. Remove the piston rings.
(1) Using a piston ring expender, remove the 2 compression rings.
(2) Remove the 2 side rails and oil ring by hand.
• Arrange the piston rings in the correct order only.
21. Remove the connecting rod from the piston.

Using a press, remove the piston pin from the piston.
[Press-in load: 500 ~ 1100kg (1102 ~ 2425lb)]
INSPECTION
CONNECTING ROD AND CRANKSHAFT
1. Check the connecting rod end play.
Using feeler gauge, measure the end play while moving the connecting rod back and forth.
End play
Standard : 0.1 ~ 0.25mm (0.004 ~ 0.010in)
Maximum : 0.4mm (0.016in)
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A. If out-of-tolerance, install a new connecting rod.
B. If still out of tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
(1) Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove the 2 connecting rod cap nuts.
(3) Remove the connecting rod cap and lower bearing.
(4) Clean the crank pin journal and bearing.
(5) Place a plastigage across the crankshaft pin journal.
(6) Reinstall the lower bearing and cap, and tighten the nuts.
Tightening torque:
19.6 ~ 22.6Nm (2.0 ~ 2.3kgf.m, 14.5 ~ 16.6lb-ft)
Do not turn the crankshaft.
(7) Remove the 2 nuts, connecting rod cap and lower bearing.
(8) Measure the plastigage at its widest point.
Standard oil clearance

0.012 ~ 0.041mm (0.0005 ~ 0.0016in)
(9) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new
bearings with the same color mark (Refer to connecting rod bearing selection table)
Recheck the oil clearance.
Do not file, shim, of scrape the bearings or the caps to adjust clearance.
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(10) If the plastigage shows the clearance is still incorrect, try the next lager or smaller bearing.
(Refer to connecting rod bearing selection table)
If the proper clearance cannot be obtained by using the appropriate lager or smaller bearings, replace the
crankshaft and start over.
If the alignment marks are unreadable because of an accumulation of grease or grime, don't clean with a
wire or abrasive cleaner. Clean only with correct cleaning solvent or detergent.
Discrimination of connecting rod

Mark Connecting rod big-end Inner diameter
NONE 41.000 ~ 41.015mm (1.6142 ~ 1.6148in)
Crankshaft pin journal mark location
Discrimination of crankshaft pin journal

Crankshaft pin journal
Mark Color
Outer diameter
37.994 ~ 38.000mm
I Yellow
(1.4958 ~ 1.4961in)
37.986 ~ 37.994mm
II None
(1.4955 ~ 1.4958in)
37.980 ~ 37.986mm
III White
(1.4953 ~ 1.4955in)
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Connecting rod bearing mark location
Discrimination of connecting rod bearing

Connecting rod
Mark Color
bearing thickness
1.498 ~ 1.501mm
A Blue
(0.0590 ~ 0.0591in)
1.494 ~ 1.497mm
B None
(0.0588 ~ 0.0589in)
1.490 ~ 1.493mm
C Yellow
(0.0587 ~ 0.0588in)
(11) Select the bearing by using the selection table.

Connecting rod bearing selection table
Crankshaft pin journal Connecting rod bearing
Oil clearance
mark mark
0.014 ~ 0.041mm
I(Yellow) C(Yellow)
(0.0006 ~ 0.0016in)
0.012 ~ 0.041mm
II(None) B(None)
(0.0005 ~ 0.0016in)
0.012~ 0.039mm
III(White) A(Blue)
(0.0005 ~ 0.0015in)
3. Check the connecting rods.

(1) When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match.
When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the
same side.
(2) Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely
rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well.
(3) Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the
repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be
replaced.
Allowable bend of connecting rod:

0.05mm / 100mm (0.0020in / 3.94in) or less
Allowable twist of connecting rod:
0.1mm / 100mm (0.0039in / 3.94in) or less
4. Check the crankshaft bearing oil clearance.

(1) To check main bearing-to-journal oil clearance, remove the main bearing caps and lower bearings.
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(2) Clean each main journal and lower bearing with a clean shop towel.
(3) Place one strip of plastigage across each main journal.
(4) Reinstall the lower bearings and caps, then tighten the bolts.
Tightening torque:
49.0 ~ 53.9Nm(5.0 ~ 5.5kgf.m, 36.2 ~ 39.8lb-ft)
Do not turn the crankshaft.
(5) Remove the cap and bearing again, and measure the widest part of the plastigage.
Standard oil clearance:

0.020 ~ 0.038mm (0.0008 ~ 0.0015in)
(6) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new
bearings with the same color mark.
(Refer to crankshaft main bearing selection table)
Do not file, shim, or scrape the bearings or the cap to adjust clearance.
(7) If the plastigage shows the clearance is still incorrect, try the next lager or smaller bearing. (Refer to crankshaft
main bearing selection table) Recheck the oil clearance.
If the proper clearance cannot be obtained by using the appropriate lager or smaller bearings, replace the
crankshaft and start over.
If the alignment marks are unreadable because of accumulation of grease or grime, don't clean with a wire
or abrasive cleaner. Clean only with correct cleaning solvent or detergent.
Cylinder block crankshaft journal bore mark location

Letters have been stamped on the end of the block as a mark for the size of each the 5 main journal bores.
Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct
bearings.
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Discrimination of cylinder block crankshaft journal bore
Mark Cylinder block crankshaft journal bore inner diameter
46.000 ~ 46.006mm
A
(1.8110 ~ 1.8113in)
46.006 ~ 46.012mm
B
(1.8113 ~ 1.8115in)
46.012 ~ 46.018mm
C
(1.8115 ~ 1.8117in)
Crankshaft main journal mark location
Discrimination of crankshaft main journal

Mark Color Crankshaft main journal outer diameter
41.994 ~ 42.000mm
I YELLOW
(1.6533 ~ 1.6535in)
41.998 ~ 41.994mm
II NONE
(1.6531 ~ 1.6533in)
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41.982 ~ 41.988mm
III WHITE
(1.6528 ~ 1.6531in)
Crankshaft main bearing mark location
Discrimination of crankshaft main bearing

Mark Color Crankshaft main bearing thickness
1.999~ 2.002mm
A Blue
(0.0787 ~ 0.0788in)
1.996 ~ 1.999mm
B None
(0.0786 ~ 0.0787in)
1.993 ~ 1.996mm
C Yellow
(0.0785 ~ 0.0786in)
1.990 ~ 1.993mm
D Green
(0.0783 ~ 0.0785in)
1.987 ~ 1.990mm
E Pink
(0.0782 ~ 0.0783in)
(8) Select the bearing by using selection table.

Crankshaft main bearing selection table
Cylinder block crankshaft journal bore mark
A B C
E D C
I(Yellow)
(Pink) (Green) (Yellow)
Crank shaft main D C B
II(None)
journal mark (Green) (Yellow) (None)
C B A
III(White)
(Yellow) (None) (Blue)

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Crankshaft end play:

0.05 ~ 0.25mm (0.0020 ~ 0.0098in)
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If the end play is greater than maximum, replace the thrust bearings as a set.
Thrust bearing thickness:

2.470 ~ 2.475mm (0.0972 ~ 0.0974in)
Crankshaft end play:
0.05 ~ 0.25mm (0.0020 ~ 0.0098in)
6. Inspect the crankshaft main journals and pin journals. Using a micrometer, measure the diameter of each main
journal and pin journal.
Main journal diameter:

41.982 ~ 42.000mm (1.6528 ~ 1.6535in)
Pin journal diameter:
37.980 ~ 38.000mm (1.4953 ~ 1.4961in)
CYLINDER BLOCK
1. Remove the gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean the cylinder block.
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for
warpage.
Flatness of cylinder block gasket surface:

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4. Inspect the cylinder bore.
Visually check the cylinder for vertical scratchs.
If deep scratchs are present, replace the cylinder block.
5. Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.
Standard diameter:
1.0 : 66.000 ~ 66.030mm (2.5984 ~ 2.5996in)
1.1 : 67.000 ~ 67.030mm (2.6378 ~ 2.6390in)
6. Check the cylinder bore size code on the cylinder block bottom face.
Discrimination of cylinder bore size

Mark Cylinder bore inner diameter
1.0 66.00 ~ 66.01mm (2.5984 ~ 2.5988in)
A
1.1 67.00 ~ 67.01mm (2.6378 ~ 2.6457in)
1.0 66.01 ~ 66.02mm (2.5988 ~ 2.5992in)
B
1.1 67.01 ~ 67.02mm (2.6382 ~ 2.6457in)
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1.0 66.02 ~ 66.03mm (2.5992 ~ 2.5996in)
C
1.1 67.02 ~ 67.03mm (2.6457 ~ 2.6390in)
7. Check the piston size mark (A) on the piston top face.
Discrimination of piston outer diameter

Mark Piston outer diameter
1.0 65.97 ~ 65.98mm (2.5972 ~ 2.5976in)
A
1.1 66.97 ~ 66.98mm (2.6366 ~ 2.6370in)
1.0 65.98 ~ 65.99mm (2.5976 ~ 2.5980in)
None
1.1 66.98 ~ 66.99mm (2.6370 ~ 2.6374in)
1.0 65.99 ~ 66.00mm (2.5980 ~ 2.5984in)
C
1.1 66.99 ~ 67.00mm (2.6374 ~ 2.6378in)
8. Select the piston related to cylinder bore class.
Clearance:
0.02 ~ 0.04mm (0.00078 ~ 0.00157in)
BORING CYLINDER
1. Oversize pistons should be selected according to the largest bore cylinder.
The size of piston is stamped on top of the piston.
2. Measure the outside diameter of the piston to be used.

3. According to the measured O.D (Outer Diameter) calculate the new bore size.
New bore size = piston O.D + 0.02 to 0.04mm (0.0008 to 0.0016in) (clearance between piston and
cylinder) - 0.01mm (0.0004in) (honing margin.)
4. Bore each of the cylinders to the calculated size.
To prevent distortion that result from temperature rise during honing, bore the cylinder holes in the firing order.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
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Standard: 0.02 ~ 0.04mm (0.0008 ~ 0.0016in)
When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to the
oversize.
PISTON AND PISTON RINGS

1. Clean the piston
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.
Do not use a wire brush.
2. The standard measurement of the piston outside diameter is taken 37.6mm (1.48in) from top land of the piston.
Standard diameter:
1.0 : 65.97 ~ 66.00mm (2.5972 ~ 2.5984in)
1.1 : 66.97 ~ 67.00mm (2.6366 ~ 2.6378in)
3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.
Piston -to-cylinder clearance:

0.02 ~ 0.04mm (0.0008 ~ 0.0016in)
4. Inspect the piston ring side clearance.

Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove.
Piston ring side clearance:

No.1 : 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
No. 2 : 0.02 ~ 0.06mm (0.0008 ~ 0.0024in)
Oil ring : 0.06 ~ 0.15mm (0.0024 ~ 0.0059)
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If the clearance is greater than maximum, replace the piston.
5. Inspect the piston ring end gap.
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 rings. If the gap is too large, recheck the cylinder bore inner diameter. If the
bore is over the service limit, the cylinder block must be rebored.
Piston ring end gap

No.1 : 0.15 ~ 0.30mm (0.0059 ~ 0.0118in)
No.2 : 0.30 ~ 0.50mm (0.0118 ~ 0.0197in)
Oil ring : 0.20 ~ 0.70mm (0.0079 ~ 0.0276in)
PISTON PINS
1. Measure the outer diameter of piston pin.
Piston pin diameter:

17.000 ~ 17.003mm (0.6693 ~ 0.6694in)
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2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance:

0.008 ~ 0.014mm (0.0003 ~ 0.0006in)
3. Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter.
Piston pin-to-connecting rod interference:

-0.026 ~ -0.015mm (-0.0010 ~ -0.0006in)
OIL PRESSURE SWITCH

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 the switch.
3. If there is no continuity when a 49.0kpa (0.5kg/cm!, 7.1psi) is applied through the oil hole, the switch is operating
properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.
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REASSEMBLY
• Thoroughly clean all parts to assembled.

• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
• Replace all gaskets, O-rings and oil seals with new parts.
1. Assemble the piston and connecting rod.

(1) Use a hydraulic press for installation.
(2) The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
2. Install the piston rings.

(1) Install the oil ring expender and 2 side rails by hand.
(2) Using a piston ring expender, install the 2 compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.
3. Install the connecting rod bearings.

(1) Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2) Install the bearings (A) in the connecting rod and connecting rod cap (B).
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4. Install the crankshaft main bearings.
Upper bearings have an oil groove of oil holes; Lower bearings do not.
(1) Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings (A).
(2) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
5. Install the thrust bearings.

Install the 2 thrust bearings (A) under the No.3 journal position of the cylinder block with the oil grooves facing
outward.
6. Place the crankshaft on the cylinder block.

7. Place the main bearing caps on the cylinder block.
8. Install the main bearing cap bolts.
The main bearing cap bolts are tightened in 2 progressive steps.

If any of the bearing cap bolts in broken or deformed, replace it.
(1) Apply a light coat of engine oil on the threads and under the bearing cap bolts.
(2) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Tightening torque:
49.0 ~ 53.9Nm (5.0 ~ 5.5kgf.m, 36.2 ~ 39.8lb-ft)
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(3) Check that the crankshaft turn smoothly.

10. Install the piston and connecting rod assemblies.
Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.
(1) Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the
connecting rod bolts.
(2) Install the ring compressor, check that the rings are securely in place, then position the piston in the cylinder,
and tap it in using the wooden handle of a hammer.
(3) Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before
pushing the piston into place.
(4) Apply engine oil to the bolt threads. Install the rod caps with bearings, and tighten the nuts.
Tightening torque:
19.6 ~ 22.6Nm (2.0 ~ 2.3kgf.m, 14.5 ~ 16.6lb-ft)
Maintain downward force on the ring compressor to prevent the rings from expending before entering the
cylinder bore.
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11. Install a new gasket and rear oil seal case (A) with 4 bolts (B).
Tightening torque:
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Check that the mating surfaces are clean and dry.
12. Install the rear oil seal.

(1) Apply engine oil to a new oil seal lip.
(2) Using SST (09231-21000) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal
retainer edge.
13. Install the front case. (Refer to Lubrication system in this group.)
14. Install the oil screen.
Install a new gasket (B) and oil screen (A) with 2 bolts (C).
Tightening torque:
14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)
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15. Install the oil pan.
(1) Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces.
Check that the mating surfaces are clean and dry before applying liquid gasket.
(2) Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Liquid gasket: MS 721-40A or equivalent
• To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
• Do not install the parts if five minutes of more have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the residue.
• After assembly, wait at least 30 minutes before filling the engine with oil.
(3) Install the oil pan (A) with the bolts.

Uniformly tighten the bolts in several passes.
Tightening torque:
5.9 ~ 7.8Nm (0.6 ~ 0.8kgf.m, 4.3 ~ 5.8lb-ft)
16. Install the water pump. (Refer to Cooling system in this group.)
17. Install the oil pressure switch.
(1) Apply adhesive to 2 or 3 threads.
Adhesive: MS 721-39(B) or equivalent.
(2) Install the oil pressure switch .
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Tightening torque:
14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)
18. Install the cylinder head. (Refer to Cylinder head in this group.)
20. Install the intake manifold and exhaust manifold. (Refer to Intake and exhaust system in this group.)
21. Remove the engine stand.
22. A/T: install the drive plate (A) and adaptor (B) with bolts (C).
Tightening torque:
68.6 ~ 78.5Nm (7.0 ~ 8.0kgf.m, 50.6 ~ 57.9lb-ft)
23. M/T: install the flywheel (A) with bolts (B).
Tightening torque:
68.6 ~ 78.5Nm (7.0 ~ 8.0kgf.m, 50.6 ~ 57.9lb-ft)
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Cooling System
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2010 > G 1.0 SOHC >
ENGINE COOLANT REFILLING AND BLEEDING
When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts of
the paint. If any coolant spills, rinse it off immediately.
1. Slide the heater temperature control lever to maximum heat. Make sure engine and radiator are cool to the touch.
2. Loosen the drain plug (A), and drain the coolant.
Remove the radiator cap to speed draining.
3. Tighten the radiator drain plug (A) securely.

4. Remove the coolant reservoir tank. Drain the coolant and reinstall the coolant reservoir tank. Fill the coolant
reservoir tank to the MAX mark with the coolant.
Tightening torque:
6.9 ~ 10.8Nm (0.7 ~ 1.1kgf.m, 5.1 ~ 7.9lb-ft)
5. Mix the recommended antifreeze with an equal amount of water in a clean container.
• Use only genuine antifreeze/coolant.

• For best corrosion protection, the coolant concentration must be maintained year-round at 50% minimum.
Coolant concentrations less than 50% may not provide sufficient protection against corrosion of freezing.
• Coolant concentrations greater then 60% will impair cooling efficiency and are not recommended.
• Do not mix different brands of antifreeze/coolants.

• Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.
6. Pour the coolant into the radiator to the base of the filler neck, and install the radiator cap loosely.
7. Start the engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
8. Turn off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed
from the cooling system.
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9. Put the radiator cap on tightly, then run the engine again and check for leaks.
Recheck the coolant level in the reservoir tank for 2~3 days after replacing coolant.
Coolant capacity : 4.7 liters(4.96US qt, 4.13lmp qt)
RADIATOR CAP TESTING

1. Remove the radiator cap, wet its seal with engine coolant, then install it on the pressure tester.
2. Apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm! , 13.51 ~ 17.78psi)

3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.
RADIATOR LEAKGE TEST

1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant.
2. Install a pressure tester to the radiator and apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm! , 13.51 ~
17.78psi).
3. Inspect for engine coolant leaks and a drop in pressure.

4. Remove the tester and reinstall the radiator cap.
Check for engine oil in the coolant and/or coolant in the engine oil.
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2010 > G 1.0 SOHC >
COMPONENT
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2010 > G 1.0 SOHC >
TROUBLESHOOTING
WATER PUMP
SYMPTOMS POSSIBLE CAUSES REMEDY

▷If coolant still leaks, replace a
▷ From the bleed water pump.
▷Check leaks after about ten-
hole of the water
minute warming up. ▷If leakage stops, reuse the
pump water pump(Do not replace the
pump with a new one).
Coolant Naked eye ▷Check the tightening of the
▷Retighten the mounting bolts.
leakage ▷ From gaskets or observation water pump mounting bolts.
bolts ▷Check damage of gaskets or ▷Replace the gasket and clean
inflow of dust. dust off.
▷ From outer
▷Check the material or any ▷Poor material. If any crack
surface of water
cracks of the water pump. found, replace the water pump.
pump
▷If there is no noise, reuse the
Inspection water pump(do not replace it).
▷After starting the engine, check
with a
noise with a stethoscope. ▷If there is any noise from the
stethoscope water pump, remove the drive
▷ From bearings belt and recheck.
▷If there is noise, reuse the
▷ From mechanical Inspection
Noise seals ▷After removing a water pump water pump. Check other drive
after line parts.
and a drive belt, check noise
removing a
▷ Impeller again. If there is no noise, replace the
drive belt
interference water pump with a new one.
Inspection
▷After removing a water pump ▷If there is any interference
after
and a drive belt, check noise between them, replace the water
removing a
again. pump with a new one.
water pump
▷Check engine coolant.
- Poor coolant quality /
Maintenance check
▷Corrosion of the impeller wing - Poor coolant quality /
▷ Damaged impeller Loosened Maintenance check
Overheating
▷ Loosened impeller impeller
▷Poor coolant quality /
Maintenance check
▷Impeller seperation from the
▷Replace the water pump.
shaft
THERMOSTAT
SYMPTOMS POSSIBLE CAUSES REMEDY
Check the
▷Check the torque of the ▷Retighten the bolts and check
mounting
mounting bolts leakage again.
Coolant ▷ From the bolts
leakage thermostat gasket Check the
▷Check gasket or seal for ▷Replace gaskets and reuse the
gasket for
damage thermostat.
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damage thermostat.
damage
Naked
eyes
observation
after ▷Insufficient coolant or leakage. ▷After refilling coolant, recheck.
removing
the radiator
cap.
▷ Low hearer
▷Check DTCs
performance (cool air
Cooled HI-scan ▷Check connection of the fan
blowed-out) ▷Check the enging coolant
excessively check& clutch or the fan motor.
▷ Thermogauge sensor, wiring and connectors.
Starting ※ If the fan clutch is always
indicates 'LOW' ▷Replace the componants.
engine connected, there will be a noise
at idle.
Remove
▷Check if there are dusts or ▷Clean the thermostat valve and
the
chips in the thermostat valve. reuse the thermostat.
thermostat
▷Check adherence of the ▷Replace the thermostat, if it
and
thermostat. doesn't work properly.
inspection
Naked
eyes ▷Insufficient coolant or leakage. ▷After refilling coolant, recheck.
observation ※Be careful when removing a ▷Check the cylinder head
after radiator cap of the overheated gaskets for damage and the
removing vehicle.※ tightening torque of the mounting
the radiator ▷Check air in cooling system. bolts.
cap.
▷Check the enging coolant
▷Check DTCs
sensor, wiring and connectors.
▷Check the fan motor
▷Engine overheated HI-scan ▷Check the fan motor, the relay
Heated performance as temperature
▷Thermogauge check& and the connector.
excessively varies.
indicates 'HI' Starting ▷Replace the fan clutch, if it
▷Check if the fan clutch slips.
engine doesn't work properly.
▷Check the water pump
▷Replace the water pump, if it
adherence or impeller damaged.
doesn't work properly.
Immerse
the ▷After removing the thermostat,
thermostat check it works properly. ▷Replace the thermostat, if it
in boiling ※ Check the thermostat opens at doesn't work properly.
water and the valve opening temperature.
inspection.
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2010 > G 1.0 SOHC >
REMOVAL
WATER PUMP
1. Drain the engine coolalnt.
System is under high pressure when the engine is hot.

To avoid danger of releasing scalding engine coolant, remove the cap only when the engine is cool.
2. Remove the drive belts.

4. Remove the alternator (Refer to Alternator in EE group.)
5. Remove the water pump.
(1) Remove the bolts (D, E), and alternator brace (A).
(2) Remove the bolts (C), and remove the water pump (B) and gasket.
THERMOSTAT
Disassembly of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.
1. Drain the engine coolant so its level is below thermostat.

2. Remove the water inlet fitting (A), O-ring (C) and the thermostat (B).
RADIATOR
1. Drain the engine coolant.
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2. Remove the battery terminals (A).
3. Remove the upper radiator hose (A) and lower radiator hose (B).
4. Remove the radiator from the vehicle.

(1) Disconnect the fan motor connector (A).
(2) Remove the cooling fan (B) from the radiator.
(3) Remove the radiator mounting bracket (C) after loosen the screw then full up the radiator.
INSTALLATION
WATER PUMP
1. Install the water pump.
(1) Install the water pump (B) and a new gasket with the 3 bolts (C).
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Tightening torque:
7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
(2) Install the alternator brace (A) with the 2 bolts (D, E).
Tightening torque:
Bolt (E): 19.6 ~ 26.5Nm (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
Bolt (D): 9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
2. Install the alternator. (Refer to Alternator in EE group.)

5. Install the drive belts.
Tightening torque:
7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

9. Recheck the engine coolant level.
THERMOSTAT
1. Place the thermostat in the thermostat housing.
(1) Install the thermostat (B) with the jiggle valve upward.
(2) Install a new O-ring (C) to the thermostat (B).
2. Install the water inlet fitting (A).
Tightening torque:
7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

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RADIATOR
1. Install the radiator.
(1) Install the radiator to the vehicle with the mounting bracket (C).
(2) Install the cooling fan (B) to the radiator.
Tightening torque:
bolts : 6.8~10.8Nm (0.7 ~1.1kgf.m. 5.1~7.9lb-ft)
(3) Connect the fan motor connector (A).
2. Install the upper radiator hose (A) and lower radiator hose (B).
3. Install the battery terminals.

5. Start engine and check for leaks.
6. Recheck engine coolant level.
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Lubrication System
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2010 > G 1.0 SOHC >
OIL AND FILTER REPLACEMENT
• Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading
to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants
which may cause skin cancer.
• Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear
protective clothing and gloves. Wash your skin thoroughly with soap and water, or use waterless hand
cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.
• In order to preserve the environment, used oil and used oil filter must be disposed of only at designated
disposal sites.
1. Drain the engine oil.

(1) Remove the oil filler cap.
(2) Remove the oil drain plug (A), and drain the oil into a container.
2. Replace the oil filter.

(1) Remove the oil filter.
(2) Check and clean the oil filter installation surface.
(3) Check the part number of the new oil filter is as same as old one.
(4) Apply clean engine oil to the gasket of a new oil filter.
(5) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(6) Tighten it an additional 3/4 turn.
3. Refill with engine oil

(1) Clean and install the oil drain plug with a new gasket.
Tightening torque:
34.3 ~ 44.1Nm (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb-ft)
(2) Fill with fresh engine oil.
capacity
Total : 3.0 L (3.17 US qt, 2.63 lmp qt)
Oil pan : 2.8 L (2.95 US qt, 2.46 lmp qt)
Drain and refill including oil filter : 3.0 L (3.17 US qt, 2.63 lmp qt)
(3) Install the oil filler cap.
4. Start engine and check for oil leaks.

5. Recheck the engine oil level.
INSPECTION
1. Check the engine oil quality.
Check for oil deterioration, entry of water, discoloring of thinning.
If the quality is visibly poor, replace the oil.
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2. Check the engine oil level.
After warming up the engine for five minutes, stop the engine and check the oil level. The level should be between
the "L" and "F" marks on the dipstick.
If low, check for oil leakage and add oil up to the "F" mark on the dipstick.
Do not fill with engine oil above the "F" mark.
SELECTION OF ENGINE OIL

Recommendation (except Middle East) : 5W-20/GF4&SM (If not available, refer to the recommended API or ILSAC
classification and SAE viscosity number.)
API classification : SL, SM or above
ILSAC classification : GF3, GF4 or above
SAE viscosity grade : Refer to the recommended SAE viscosity number.
For best performance and maximum protection of all types of operation, select only those lubricants which :
1. Satisfy the requirement of the API or ILSAC classification.
2. Have proper SAE grade number for expected ambient temperature range.
3. Lubricants that do not have both an SAE grade number and API or ILSAC service classification on the
container should not be used.
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2010 > G 1.0 SOHC >
COMPONENT
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2010 > G 1.0 SOHC >
REMOVAL
OIL PAN
1. Remove the drain plug (A) and drain engine oil.
3. Remove the oil pan.
OIL PUMP
1. Drain the engine oil.
2. Remove the drive belts.
3. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover.
5. Remove the timing belt auto tensioner. (Refer to Timing system in this group.)
6. Remove the oil pan and oil screen.
7. Remove the alternator. (Refer to Alternator in EE group.)
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8. Remove the air conditioner compressor. (Refer to Air conditioner compressor in HA group.)
9. Remove the air conditioner compressor bracket (A).
10. Remove the bolts (A, B) and front case (C).
(1) Remove the screws (B) from the pump housing, then separate the housing and cover (A).
(2) Remove the inner rotor (A) and outer rotor (B).
DISASSEMBLY
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RELIEF PLUNGER
1. Remove the relief plunger.
Remove the snap ring (A), spring (B) and relief plunger (C).
INSPECTION
OIL PUMP
1. Inspect the relief plunger.
Coat the plunger with engine oil and check that it falls smoothly into the plunger hole by its own weight.
If it does not, replace the relief plunger. If necessary, replace the front case.
2. Inspect the relief valve spring.
Inspect for distorted or broken relief valve spring.
Standard value
Free height: 38.6mm (1.5197in)
Load : 3.65±0.4kg/33mm (8.00±0.9 lb /1.2992in)
3. Inspect the rotor side clearance.

Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight
edge.
0.040 ~ 0.095mm
Outer rotor
(0.0016 ~ 0.0037in)
Side clearance
0.040 ~ 0.095mm
Inner rotor
(0.0016 ~ 0.0037in)
If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front case.
4. Inspect the rotor tip clearance.
Using a feeler gauge, measure the tip clearance between the inner and outer rotor tips.
Tip clearance
0.06 ~ 0.18mm (0.0024 ~ 0.0071in)
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If the tip clearance is greater than maximum, replace the rotors as a set.
5. Inspect the rotor body clearance.
Using a feeler gauge, measure the clearance between the outer rotor and body.
Body clearance
0.100 ~ 0.181mm (0.0039 ~ 0.0071in)
If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front case.
REASSEMBLY
RELIEF PLUNGER
1. Install the relief plunger.
Install the relief plunger (C) and spring (B) into the front case hole, and install the snap ring (A).
INSTALLATION
OIL PUMP
1. Install the oil pump.
(1) Place the inner and outer rotors into front case with the marks facing the oil pump cover side.
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(2) Install the oil pump cover (A) to front case with the screws (B).
Tightening torque:
7.8 ~ 11.8Nm (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
2. Check that the oil pump turns freely.

3. Install the oil pump on the cylinder block
(1) Place a new front case gasket on the cylinder block.
(2) Apply engine oil to the lip of the oil pump seal. Then, install the oil pump onto the crankshaft.
(3) When the pump is in place, clean any excess grease off the crankshaft and check that the oil seal lip is not
distorted.
Bolt length
(A) : 18mm (0.7087in), (B) : 35mm (1.1811in)
Tightening torque:
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
4. Apply a light coat of oil to the front case oil seal lip.
5. Using the SST (09231-22000), install the front case oil seal.
6. Install the air conditioner compressor bracket (A).
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7. Install the air conditioner compressor (Refer to Air conditioner compressor in HA group)
8. Install the alternator. (Refer to Alternator in EE group.)
9. Install the oil screen.
Tightening torque:
14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)
Tightening torque:
5.9 ~ 7.8Nm (0.6 ~ 0.8kgf.m, 4.3 ~ 5.8lb-ft)
Clean the oil pan gasket mating surfaces.
11. Install the timing belt tensioner. (Refer to Timing system in this group)
12. Install the timing belt (Refer to Timing system in this group)
13. Install the drive belts.
14. Fill with engine oil.
OIL PAN
(1) Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces.
Check that the mating surfaces are clean and dry before applying liquid gasket.
(2) Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Liquid gasket: MS 721 - 40A or equivalent
• To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
• Do not install the parts if five minutes of more have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the residue.
• After assembly, wait at least 30 minutes before filling the engine with oil.
(3) Install the oil pan (A) with the bolts.

Uniformly tighten the bolts in several passes.
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Tightening torque:
5.9 ~ 7.8Nm (0.6 ~ 0.8kgf.m, 4.3 ~ 5.8lb-ft)
2. Install the front muffler (A).
Tightening torque:
39.2 ~ 53.9Nm (4.0 ~ 5.5kgf.m, 28.9 ~ 39.8lb-ft)
3. Fill with engine oil.
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Intake & Exhaust System
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Intake And Exhaust System - Intake Manifold
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2010 > G 1.0 SOHC >
COMPONENT
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2010 > G 1.0 SOHC >
REPLACEMENT
1. Remove the battery terminals (A).
2. Remove the cowl grill and wiper motor. (Refer to Wiper motor in BE group.)
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8. Remove the brake oil tank (A) with the hoses connected.
9. Remove the surge tank stay (A) and surge tank assembly (B).
Tightening torque
Bolt (C), nut (D):
17.7 ~ 24.5Nm (1.8 ~ 2.5kgf.m, 14.5 ~ 19.5lb-ft)
Bolt (E), nut (F):
14.7 ~ 19.6Nm (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft)
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10. Remove the delivery pipe assembly (A).
Tightening torque:
14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)
11. Remove the intake manifold stay (A).
Tightening torque:
17.7 ~ 24.5Nm (1.8 ~ 2.5kgf.m, 14.5 ~ 19.5lb-ft)
12. Remove the intake manifold (A).
Tightening torque:
14.7 ~ 19.6Nm (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft)
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13. Installation is in the reverse order of removal with new gasket.
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Intake And Exhaust System - Exhaust

Manifold
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2010 > G 1.0 SOHC >
COMPONENT
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2010 > G 1.0 SOHC >
REPLACEMENT
1. Disconnect the front and rear oxygen sensor connector.
Tightening torque:
39.2 ~ 53.9Nm (4.0 ~ 5.5kgf.m, 28.9 ~ 39.8lb-ft)
3. Remove the catalytic converter stay (A).
Tightening torque:
42.2 ~ 53.9Nm (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)
4. Remove the heat protector (A).
Tightening torque:
8.8 ~ 10.8Nm (0.9 ~ 1.1kgf.m, 6.5 ~ 7.6lb-ft)
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5. Remove the exhaust manifold and catalytic converter assembly (A).
Tightening torque:
29.4 ~ 34.3Nm (3.0 ~ 3.5kgf.m, 21.7 ~ 25.3lb-ft)
6. Remove the exhaust manifold gasket(A).
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Intake And Exhaust System - Front Exhaust

Pipe
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2010 > G 1.0 SOHC >
COMPONENT
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2010 > G 1.0 SOHC >
REPLACEMENT
Tightening torque:
39.2 ~ 53.9Nm (4.0 ~ 5.5kgf.m, 28.9 ~ 39.8lb-ft)
2. Remove the main muffler.
Tightening torque:
39.2 ~ 53.9Nm (4.0 ~ 5.5kgf.m, 28.9 ~ 39.8lb-ft)
3. Install the clamp in between the front muffler pipe and main muffler pipe.
(1) Align the marks on the front muffler pipe and main muffler pipe as shown illustration.
(2) The clamp installing position (A) must be upper than the line virtually made by the two marks.
Tightening torque:
17.7~ 27.5Nm (1.8 ~ 2.8kgf.m, 13.0 ~ 20.3lb-ft)
• Do not reuse the clamp.
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Engine Electrical System
General Information
Engine ,SLJ[YPcal System
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2010 > G 1.0 SOHC >
SPECIFICATIONL
IGNITION SYSTEM
Items Specification
Primary resistance 0.87 ± 10 % (!)
Ignition coil
Secondary resistance 13.0 ± 15 % (k!)
NGK BKR5ES-11
Spark plugs CHAMPION RC10YC4
Gap 1.0 ~ 1.1 mm (0.0394 ~ 0.0433 in.)
STARTING SYSTEM
Items Specification
Rated voltage 12 V, 0.9 kW
No. of pinion teeth 8
Voltage 11.5 V
No-load
Ampere 60A MAX
characteristics
Starter Speed 5,500 rpm Min
Commutator Standard 33.0 mm (1.2992in.)

diameter Limit 32.4 mm (1.2756in.)
Standard 0.5 mm (0.0197in.)
Under cut depth
Limit 0.2 mm (0.0079in.)
CHARGING SYSTEM
Items Specification
Type Battery voltage sensing
Rate voltage 13.5 V , 70A
Speed in use 1,000 ~ 18,000 rpm
Alternator
Voltage regulator IC Regulator built-in type
Regulator setting voltage 14.7± 0.3 V (AMS : 14.4 ± 0.1V)
Temperature compensation -7 ± 3 mV / °C (AMS : -3.5 ± 2mV / °C)
Type 30-20DL
Cold cranking amperage [at
354 A
-18°C(-0.4°F)]
Battery
Reserve capacity 55 min
Specific gravity
1.280 ± 0.01
[at 20°C(68°F)]
• COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminal
voltage of 7.2V or greater at a specified temperature.
• RESERVE CAPACITY RATING is amount of time a battery can deliver 25A and maintain a minimum terminal
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voltage of 10.5V at 26.7°C(80.1°F).
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2010 > G 1.0 SOHC >
TROUBLE SHOOTING
IGNITION SYSTEM
Engine will not start or is Ignition lock switch Inspect ignition lock switch, or replace as
hard to start (Cranks OK) Ignition coil required
Spark plugs Inspect ignition coil, or replace as required
Ignition wiring disconnected or broken Inspect spark plugs, or replace as required
Spark plugs cable Repair wiring, or replace as required
Inspect cable, or replace as required
Rough idle or stalls Ignition wiring Repair wiring, or replace as required
Ignition coil Inspect ignition coil, or replace as required
Spark plugs cable Inspect cable, or replace as required
Engine hesitates/poor Spark plugs and spark plug cables Inspect spark plugs / cable, or replace as
acceleration Ignition wiring required
Repair wiring, or replace as required
Poor mileage Spark plugs and spark plug cables Inspect spark plugs / cable, or replace as
required
CHARGING SYSTEM
Charging warning indicator Fuse blown Check fuses
does not light with ignition Light burned out Replace light
switch "ON" and engine off. Wiring connection loose Tighten loose connection
Electronic voltage regulator Replace voltage regulator
Charging warning indicator Drive belt loose or worn Adjust belt tension or replace belt
does not go out with engine Battery cable loose, corroded or worn Inspect cable connection, repair or replace
running. Electronic voltage regulator or alternator cable
(Battery requires frequent Wiring Replace voltage regulator or alternator
recharging) Repair or replace wiring
Overcharge Electronic voltage regulator Replace voltage regulator
Voltage sensing wire Repair or replace wiring
Discharge Adjust belt tension or replace belt
Drive belt loose or worn
Inspect wiring connection, repair or replace
Wiring connection loose or short circuit
wiring
Electronic voltage regulator or alternator
Replace voltage regulator or alternator
Poor grounding
Inspect ground or repair
Worn battery
Replace battery
STARTING SYSTEM
Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded or worn Repair or replace cables
out Refer to A/T Group
Transaxle range switch (Vehicle with
automatic transaxle only) Replace fuse
Fuse blown Replace
Starter faulty Replace
Ignition switch faulty
Engine cranks slowly Battery charge low
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Engine cranks slowly Battery charge low
Charge or replace battery
Battery cables loose, corroded or worn
Repair or replace cables
out
Replace
Starter faulty
Starter keeps running Starter Replace
Ignition switch Replace
Starter spins but engine will Short in wiring
Repair wiring
not crank Pinion gear teeth broken or starter
Replace
motor
Replace fly wheel or torque converter
Ring gear teeth broken
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2010 > G 1.0 SOHC >
The Micro 570 Analyzer

The Micro 570 Analyzer provides the ability to test the charging and starting systems, including the battery, starter and
alternator.
Because of the possibility of personal injury, always use extreme caution and appropriate eye protection when
working with batteries.
Keypad
The Micro 570 button on the key pad provide the following functions :
Battery Test Procedure

1. Connect the tester to the battery.
A. Red clamp to battery positive (+) terminal.
B. Black clamp to battery negative (-) terminal.
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Connect clamps securely. If "CHECK CONNECTION" message is displayed on the screen, reconnect clamps
securely.
2. The tester will ask if the battery is connected "IN-VEHICLE" or "OUT-OF-VEHICLE". Make your selection by
pressing the arrow buttons; then press ENTER.
3. Select CCA and press the ENTER button.
CCA : Cold cranking amps, is an SAE specification for cranking batteried at -0.4°F (-18°C).
4. Set the CCA value displayed on the screen to the CCA value marked on the battery label by pressing up and
down buttons and press ENTER.
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The battery ratings(CCA) displayed on the tester must be identical to the ratings marked on battery label.
5. The tester will conduct battery test.
6. The tester displays battery test results including voltage and battery ratings.
Refer to the following table and take the appropriate action as recommended by the Micro 570.
Battery Test Results

Result On Printer Remedy
GOOD BATTERY No action is required.
GOOD RECHARGE Battery is in a good state.
Recharge the battery and use.
CHARGE & RETEST Battery is not charged properly.
- Charge and test the battery again. (Failure to charge the battery fully may read
incorrect measurement value.)
REPLACE BATTERY Replace battery and recheck the charging system.
- Improper connection between battery and vehicle cables may cause
"REPLACE BATTERY", retest the battery after removing cables and connecting
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the tester to the battery terminal directly prior to replacing the battery.
BAD CELL-REPLACE Charge and retest the battery.
- If the Micro 570 recommends "REPLACE BATTERY", replace the battery and
recheck the charging system.
Whenever filing a claim for battery, the print out of the battery test results must be attached.
Starter Test Procedure

7. After the battery test, press ENTER immediately for the starter test.
8. Start the engine.
9. Cranking voltage and starter test results will be displayed on the screen.
Refer to the following table and take the appropriate action as recommended by the Micro 570.
Starter Test Results

CRANKING VOLTAGE System shows a normal starter draw.
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NORMAL
CRANKING VOLTAGE LOW Cranking voltage is lower than normal level.
- Check starter.
CHARGE BATTERY The state of battery charge is too low to test.
- Charge the battery and retest.
REPLACE BATTERY Replace battery.
- If the vehicle is not started though the battery condition of "GOOD BATTERY"
is displayed, check wiring for open circuit, battery cable connection, starter and
repair or replace as necessary.
- If the engine does crank, check fuel system.
When testing the vehicle with old diesel engines, the test result will not be favorable if the glow plug is not
heated. Conduct the test after warming up the engine for 5 minutes.
Charging System Test Procedure

10. Press ENTER to begin charging system test.
11. The tester displays the actual voltage of alternator.

Press ENTER to continue.
12. Turn off all electrical load and rev engine for 5 seconds with pressing the accelerator pedal. (Follow the
instructions on the screen)
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13. The message that engine RPM is detected will be displayed on the screen. Press ENTER to continue.
14. If the engine RPM is not detected, press ENTER after revving engine.
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15. The tester will conduct charging system test during loads off.
16. Turn on electrical loads (air conditioner, lamps, audio and etc). Press ENTER to continue.
17. The tester will conduct charging system test during loads on.
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18. Rev engine for 5 seconds with pressing the accelerator pedal. (Follow the instructions on the screen)
19. The message that engine RPM is detected will be displayed on the screen. Press ENTER to continue.
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20. If the engine RPM is not detected, press ENTER after revving engine.
21. Turn off electrical loads (air conditioner, lamps, audio and etc). Turn the engine off.
22. Charging voltage and charging system test results will be displayed on the screen.
Shut off engine end disconnect the tester clamps from the battery. Refer to the following table and take the
appropriate action as recommended by the Micro 570.
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Charging System Test Results
CHARGING SYSTEM Charging system is normal.
NORMAL / DIODE RIPPLE
NORMAL
NO CHARGING VOLTAGE Alternator does not supply charging current to battery.
- Check belts, connection between alternator and battery and replace belts or
cable or alternator as necessary.
LOW CHARGING Alternator does not supply charging current to battery and electrical load to system
VOLTAGE fully.
- Check belts and alternator and replace as necessary.
HIGH CHARGING The voltage from alternator to battery is higher than normal limit during voltage
VOLTAGE regulating.
- Check connection and ground and replace regulator as necessary.
- Check electrolyte level in the battery
EXCESS RIPPLE One or more diodes in the alternator is not functioning properly.
DETECTED - Check alternator mounting and belts and replace as necessary.
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Ignition System
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2010 > G 1.0 SOHC >
DESCRITION
Ignition timing is controlled by the electronic control ignition timing system. The standard reference ignition timing data
for the engine operating conditions are pre-programmed in the memory of the ECM (Engine Control Module).
The engine operating conditions (speed, load, warm-up condition, etc.) are detected by the various sensors. Based on
these sensor signals and the ignition timing data, signals to interrupt the primary current are sent to the ECM. The
ignition coil is activated, and timing is controlled.
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2010 > G 1.0 SOHC >
ON-VEHICLE INSPECTION
SPARK TEST
1. Disconnect the spark plug cable(A) from the spark plug.
2. Using a spark plug socket, remove the spark plug.

3. Install the spark plug to the spark plug cable.
4. Ground the spark plug to the engine.
5. Check that spark occurs while engine is being cranked.
To prevent fuel being injected from injectors while the engine is being cranked, remove the fuel pump relay (A)
from the fuse box.
Crank the engine for no more than 5 ~ 10 seconds.
6. Inspect all the spark plugs.

7. Using a spark plug socket, install the spark plugs.
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8. Install the spark plug cables.
INSPECT SPARK PLUG

1. Remove the spark plug cables (A).
When removing the spark plug cable, pull on the spark plug cable boot (not the cable), as it may be damaged.
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2. Using a spark plug socket, remove the spark plug.
Be careful that no contaminates enter through the spark plug holes.
3. Inspect the electrodes (A) and ceramic insulator (B).
INSPECTION OF ELECTRODES
Dark White
Condition
deposits deposits
- Fuel mixture too rich - Fuel mixture too lean
Description - Low air intake - Advanced ignition timing
- Insufficient plug tightening torque
4. Check the electrode gap (A).
Standard (New): 1.0 ~ 1.1 mm (0.0394 ~ 0.0433 in.)
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INSPECT SPARK PLUG CABLE
1. Carefully remove the spark plug cable by pulling on the rubber boots (A).
Check the condition of the spark plug cable terminals (B), if any terminal has surface corrosion, clean it off, and if it
broken or distorted, replace the spark plug cable.
2. Connect the ohmmeter probes and measure resistance.
Resistance: 5.6k!/m ± 20 %
3. Resistance should not be higher than 10k!/m.

If resistance is higher, replace the cable.
INSPECT IGNITION COIL

1. Measure the primary coil resistance between terminals 1, 2 and 1, 3
Standard value: 0.58!±10%
2. Measure the secondary coil resistance between the high-voltage terminals for the No.1 and No. 4 cylinders, and
between the high voltage terminals for the No. 2 and No. 3 cylinders.
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Standard value: 8.8k!/m ±15%
Be sure, when measuring the resistance of the secondary coil, to disconnect the connector of the ignition coil.
REPLACEMENT
IGNITION COIL
1. Disconnect the spark plug cables (A) and ignition coil connector (B).
2. Remove the ignition coil (A).
Tightening torque: 11.8 ~ 14.7 N.m (1.2 ~ 1.5 kgf.m, 8.7 ~ 10.8 lbf.ft)
3. Installation is the reverse of removal.
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Charging System
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2010 > G 1.0 SOHC >
DESCRIPTION
The charging system consists a battery, an alternator with a built-in regulator, and the charging indicator light and wire.
The Alternator has built-in diodes, each rectifying AC current to DC current.
Therefore, DC current is present at the alternator "B" terminal.
Additionally, the alternator and charging voltage is regulated by the battery voltage detection system.
The alternators is regulated by the battery voltage detection system. The main components of the alternator are the
rotor, stator, rectifier, capacitor, brushes, bearings and V-ribbed belt pulley. The brush holder contains a built-in
electronic voltage regulator.
Alternator Management System

Alternator management system controls the charging voltage set point in order to improve fuel economy, manage
alternator load under various operating conditions, keep the battery charged, and protect the battery from over-
charging. ECM controls generating voltage by duty cycle (charging control, discharging control, normal control) based
on the battery conditions and vehicle operating conditions.
The system conducts discharging control when accelerating a vehicle. Vehicle reduces an alternator load and
consumes an electric power form a battery.
The system conducts charging control when decelerating a vehicle. Vehicle increases an alternator load and charges
a battery.
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2010 > G 1.0 SOHC >
ON-VEHICLE INSPECTION
• Check that the battery cables are connected to the correct terminals.
• Disconnect the battery cables when the battery is given a quick charge.
• Never disconnect the battery while the engine is running.
CHECK BATTERY VOLTAGE

1. If 20 minutes have not passed since the engine was stopped, turn the ignition switch ON and turn on the electrical
system (headlamp, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge.
2. Turn the ignition switch OFF and turn off the electrical systems.
3. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.
Standard voltage: 12.5 ~ 12.9V at 20°C(68°F)
If the voltage is less than specification, charge the battery.
CHECK THE BATTERY TERMINALS AND FUSES

1. Check that the battery terminals are not loose or corroded.
2. Check the fuses for continuity.
INSPECT DRIVE BELT

1. Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.
Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it
should be replaced.
2. Measure the drive belt tension and adjust it.
VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES

1. Check that the wiring is in good condition.
2. Check that there is no abnormal noise from the alternator while the engine is running.
CHECK DISCHARGE WARNING LIGHT CIRCUIT

1. Warm up the engine, and then turn it off.
2. Turn off all accessories.
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3. Turn the ignition switch "ON". Check that the discharge warning light is lit.
4. Start the engine. Check that the light is lit.
If the light does not go off as specified, troubleshoot the discharge light circuit.
INSPECT CHARGING SYSTEM

VOLTAGE DROP TEST OF ALTERNATOR OUTPUT WIRE
This test determines whether or not the wiring between the alternator "B" terminal and the battery (+) terminal is good
by the voltage drop method.
PREPARATION
1. Turn the ignition switch to "OFF".
2. Disconnect the output wire from the alternator "B" terminal. Connect the (+) lead wire of ammeter to the "B"
terminal of alternator and the (-) lead wire of ammeter to the output wire. Connect the (+) lead wire of voltmeter to
the "B" terminal of alternator and the (-) lead wire of voltmeter to the (+) terminal of battery.
TEST
2. Turn on the headlamps and blower motor, and set the engine speed until the ammeter indicates 20A. And then,
read the voltmeter at this time.
RESULT
1. The voltmeter may indicate the standard value.
Standard value: 0.2V max
2. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case
check the wiring from the alternator "B" terminal to the battery (+) terminal. Check for loose connections, color
change due to an over-heated harness, etc. Correct them before testing again.
3. Upon completion of the test, set the engine speed at idle. Turn off the headlamps, blower motor and the ignition
switch.
OUTPUT CURRENT TEST

This test determines whether or not the alternator gives an output current that is equivalent to the normal output.
PREPARATION
1. Prior to the test, check the following items and correct as necessary.
Check the battery installed in the vehicle to ensure that it is good condition. The battery checking method is
described in the section "Battery".
The battery that is used to test the output current should be one that has been partially discharged. With a fully
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charged battery, the test may not be conducted correctly due to an insufficient load.
Check the tension of the alternator drive belt. The belt tension check method is described in the section "Inspect
drive belt".
2. Turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Disconnect the alternator output wire from the alternator "B" terminal.
5. Connect a DC ammeter (0 to 150A) 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 alternator "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.
TEST
1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the
open circuit in the wire between alternator "B" terminal and battery (+) terminal or poor grounding is suspected.
2. Start the engine and turn on the headlamps.
3. Set the headlamps 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.
RESULT
1. The ammeter reading must be higher than the limit value. If it is lower but the alternator output wire is in good
condition, remove the alternator from the vehicle and test it.
Limit value (70A alternator): 49A min.
• The nominal output current value is shown on the nameplate affixed to the alternator body.
• The output current value changes with the electrical load and the temperature of the alternator itself.
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Therefore, the nominal output current may not be obtained. If such is the case, keep the headlamps on the
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 alternator 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.
4. Remove the ammeter and voltmeter and the engine tachometer.
5. Connect the alternator output wire to the alternator "B" terminal.
6. Connect the battery ground cable.
REGULATED VOLTAGE TEST

The purpose of this test is to check that the electronic voltage regulator controls voltage correctly.
PREPARATION
1. Prior to the test, check the following items and correct if necessary.
Check that the battery installed on the vehicle is fully charged. The battery checking method is described in the
section "Battery".
Check the alternator drive belt tension. The belt tension check method is described in the section "Inspect drive
belt".
2. Turn ignition switch to "OFF".
4. Connect a digital voltmeter between the "B" terminal of the alternator and ground. Connect the (+) lead of the
voltmeter to the "B" terminal of the alternator. Connect the (-) lead to good ground or the battery (-) terminal.
5. Disconnect the alternator output wire from the alternator "B" terminal.
6. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire. Connect
the (-) lead wire of the ammeter to the disconnected output wire.
7. Attach the engine tachometer and connect the battery ground cable.
TEST
1. Turn on the ignition switch and check to see that the voltmeter indicates the following value.
Voltage: Battery voltage
If it reads 0V, there is an open circuit in the wire between the alternator "B" terminal and the battery and the battery
(-) terminal.
2. Start the engine. Keep all lights and accessories off.
3. Run the engine at a speed of about 2,500 rpm and read the voltmeter when the alternator output current drops to
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10A or less.
RESULT
1. If the voltmeter reading agrees with the value listed in the regulating voltage table below, the voltage regulator is
functioning correctly. If the reading is other than the standard value, the voltage regulator or the alternator is faulty.
REGULATING VOLTAGE TABLE
Voltage regulator ambient temperature °C (°F) Regulating voltage (V)
-20 (-4) 14.2 ~ 15.4
20 (68) 14.0 ~ 15.0
60 (140) 13.7 ~ 14.9
80 (176) 13.5 ~ 14.7
2. Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.
4. Remove the voltmeter and ammeter and the engine tachometer.
5. Connect the alternator output wire to the alternator "B" terminal.
6. Connect the battery ground cable.
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Charging System - Alternator
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COMPONENT
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2010 > G 1.0 SOHC >
REPLACEMENT
1. Disconnect the battery negative terminal first, then the positive terminal.
2. Disconnect the alternator connector (A), and remove the cable (B) from the alternator "B" terminal.
3. Remove the adjusting bolt (A) and mounting bolt (B), then remove the alternator drive belt.
4. Pull out the through bolt (C) and then remove the alternator (D).
Tightening torque
B : 11.7 ~ 14.7 N.m (1.2 ~ 1.5 kgf.m, 8.7 ~ 10.4 lb.ft)
C : 17.6 ~ 24.5 N.m (2.0 ~ 2.5 kgf.m, 14.4 ~ 18.1 lb.ft)
5. Installation is the reverse order of removal.

6. Adjust the alternator belt tension after installation.
DISASSEMBLY
1. Remove the 2 bolts (B) and rear cover (A).
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2. Remove the slip ring guide (A) from the regulator.
When removing the slip ring guide, be careful that other parts are not damaged.
3. Remove the 3 bolts (A) and regulator.
When removing the regulator, be careful that slip ring is not damaged.
4. Remove the 4 through bolts (A).
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5. Insert a flat screwdriver between the front bracket and stator core, and pry downward.
Do not insert the screwdriver too deeply, as there is a danger of damaging the stator coil.
6. Remove the nut and pulley (A).
7. Remove the rotor (A) and front bracket (B).
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8. Reassembly is the reverse order of disassembly.
INSPECTION
INSPECT ROTOR
1. Check that there is continuity between the slip rings (A).
2. Check that there is no continuity between the slip rings and the rotor (B) or rotor shaft (C).
3. If the rotor fails either continuity check, replace the alternator.
INSPECT STATOR
1. Check that there is continuity between each pair of leads (A).
2. Check that there is no continuity between each lead and the coil core.
3. If the coil fails either continuity check, replace the alternator.
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ALTERNATOR BELT INSPECTION AND ADJUSTMENT
When using a new belt, first adjust the deflection or tension to the values for the new belt, then readjust the
deflection or tension to the value for the used belt after running engine for five minutes.
Deflection method:
Apply a force of 98N (10kg, 22lb), and measure the deflection between the alternator and water pump pulley.
Deflection
New belt: 8.5 ~ 9.5mm (0.3346 ~ 0.3740.in)
Used belt: 9.5 ~ 11.0mm (0.3740 ~ 0.4330.in)
If the belt is worn or damaged, replace it.
TENSION GAUGE METHOD :

Follow the gauge monufacturer's imstructions, install the belt tension gauge. (Measurement may be done at any spans
of pulleys.)
Tension
New belt: 490 ± 49N (50 ± 5 kgf, 361 ± 36 lbf)
Used belt: 392 ± 49N (40 ± 5 kgf, 289 ± 36 lbf)
• "New belt" refers to a belt which has been used less than 5 minutes on a running engine.
• "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more.
• After installing a belt, check that it fits properly in the ribbed grooves.
• Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.
• After installing a new belt, run the engine for about 5 minutes and recheck the belt tension.
If adjustment is necessary:
1. Loosen the adjusting bolt (A) and the lock bolt (B, C).
2. Move the alternator to obtain the proper belt tension, then retighten the nuts.
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3. Recheck the deflection or tension of the belt.
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Charging System - Battery
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2010 > G 1.0 SOHC >
DESCRIPTION
1. The maintenance-free battery is, as the name implies, totally maintenance free and has no removable battery cell
caps.
2. Water never needs to be added to the maintenance-free battery.
3. The battery is completely sealed, except for small vent holes in the cover.
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2010 > G 1.0 SOHC >
Inspection
Battery Diagnostic Flow
Vehicle parasitic current inspection

1. Turn the all electric devices OFF, and then turn the ignition switch OFF.
2. Close all doors except the engine hood, and then lock all doors.
(1) Disconnect the hood switch connector.
(2) Close the trunk lid.
(3) Close the doors or remove the door switches.
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3. Wait a few minutes until the vehicle’s electrical systems go to sleep mode.
For an accurate measurement of a vehicle parasitic current, all electriacl systems should go to sleep mode. (It
takes at least one hour or at most one day.) However, an approximate vehicle parasitic current can be
measured after 10~20 minutes.
4. Connect an ammeter in series between the battery (-) terminal and the ground cable, and then disconnect the
clamp from the battery (-) terminal slowly.
Be careful that the lead wires of an ammeter do not come off from the battery (-) terminal and the ground
cable to prevent the battery from being reset. In case the battery is reset, connect the battery cable again, and
then start the engine or turn the ignition switch ON for more than 10 sec. Repeat the procedure from No. 1.
To prevent the battery from being reset during the inspection,
1) Connect a jump cable between the battery (-) terminal and the ground cable.
2) Disconnect the ground cable from the battery (-) terminal.
3) Connect an ammeter between the battery (-) terminal and the ground cable.
4) After disconnecting the jump cable, read the current value of the ammeter.
5. Read the current value of the ammeter.

A. If the parasitic current is over the limit value, search for abnormal circuit by removing a fuse one by one and
checking the parasitic current.
B. Check the parasitic current again, and search for suspected unit by removing a unit connected with the
abnormal circuit one by one.
Limit value (after 10~20 min.) : Below 50mA
Cleaning
1. Make sure the ignition switch and all accessories are in the OFF position.
2. Disconnect the battery cables (negative first).
3. Remove the battery from the vehicle.
Care should be taken in the event the battery case is cracked or leaking, to protect your skin from the
electrolyte.
Heavy rubber gloves (not the household type) should be wore when removing the battery.
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4. Inspect the battery tray for damage caused by the loss of electrolyte. If acid damage is present, it will be necessary
to clean the area with a solution of clean warm water and baking soda. Scrub the area with a stiff brush and wipe
off with a cloth moistened with baking soda and water.
5. Clean the top of the battery with the same solution as described above.
6. Inspect the battery case and cover for cracks. If cracks are present, the battery must be replaced.
7. Clean the battery posts with a suitable battery post tool.
8. Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged or frayed
cables and broken terminal clamps.
9. Install the battery in the vehicle.
10. Connect the cable terminals to the battery post, making sure tops of the terminals are flush with the tops of the
posts.
11. Tighten the terminal nuts securely.
12. Coat all connections with light mineral grease after tightening.
When batteries are being charged, an explosive gas forms beneath the cover of each cell. Do not smoke
near batteries being charged or which have recently been charged. Do not break live circuit at the terminals
of batteries being charged.
A spark will occur when the circuit is broken. Keep open flames away from battery.
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Starting System
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2010 > G 1.0 SOHC >
DESCRIPTION
The starting system includes the battery, starter, solenoid switch, ignition switch, inhibitor switch (A/T), ignition lock
switch , connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter motor's solenoid coil.
The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.
The contacts close and the starter motor cranks. In order to prevent damage caused by excessive rotation of the
starter armature when the engine starts, the clutch pinion gear overruns.
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2010 > G 1.0 SOHC >
STARTER CIRCUIT TROUBLE SHOOTING
The battery must be in good condition and fully charged.
1. Remove the fuel pump relay (A) from the fuse box.
2. With the shift lever in N or P (A/T) or clutch pedal pressed (M/T), turn the ignition switch to START.
If the starter cranks the engine normally, starting system is OK. If the starter will not crank the engine at all, go to
next step.
If it won't disengage from the ring gear when you release key, check for the following until you find the cause.
A. Solenoid plunger and switch malfunction.
B. Dirty pinion gear or damaged overrunning clutch.
3. Check the battery condition. Check electrical connections at the battery, battery negative cable connected to the
body, engine ground cables, and the starter for looseness and corrosion. Then try starting the engine again.
If the starter cranks the engine normally, repairing the loose connection repaired the problem. The starting system
is now OK.
If the starter still does not crank the engine, go to next step.
4. Disconnect the connector from the S-terminal of solenoid. Connect a jump wire from the B-terminal of solenoid to
the S-terminal of solenoid.
If the starter cranks the engine, go to next step.
If the starter still does not crank the engine, remove the starter, and repair or replace as necessary.
5. Check the following items in the order listed until you find the open circuit.
A. Check the wire and connectors between the driver's under-dash fuse/relay box and the ignition switch, and
between the driver's under-dash fuse/relay box and the starter.
B. Check the ignition switch (Refer to Ignition system in BE group)
C. Check the transaxle range switch connector or ignition lock switch connector.
D. Inspect the starter relay.
STATER SOLENOID TEST

1. Disconnect the field coil wire from the M-terminal of solenoid switch.
2. Connect a 12V battery between S-terminal and the starter body.
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3. Connect the field coil wire to the M-terminal.
This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
4. If the pinion moves out, the pull-in coil of solenoid is working properly.
If the pinion does not move, replace the solenoid.
5. Disconnect the field coil wire from the M-terminal.
6. If the pinion has moved out, the hold-in coil of the solenoid is working properly.
If the pinion moves in, replace the solenoid.
FREE RUNNING TEST

1. Place the starter in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter as follows:
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostats shown is the illustration.
3. Connect a voltmeter (15-volt scale) across starter.
4. Rotate carbon pile to the off position.

5. Connect the battery cable from battery's negative post to the starter body.
6. Adjust until battery voltage shown on the voltmeter reads 11volts.
7. Confirm that the maximum amperage is within the specifications and that the starter turns smoothly and freely.
Current: 60A MAX

Speed: 5500 RPM
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Starting System - Starter
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COMPONENT
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REPLACEMENT
1. Disconnect the battery negative cable.
2. Disconnect the connector (A) from the S terminal ,and remove the cable (B) from the B terminal.
Tightening torque
B : 6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 7.9 lb.ft)
3. Remove the 2 bolts holding the starter, and then remove the starter.
Tightening torque
26.5 ~ 33.3 N.m (2.7 ~ 3.4 kgf.m, 19.5 ~ 24.6 lb.ft)

5. Connect the battery negative cable to the battery.
DISASSEMBLY
1. Disconnect the M-terminal (A) on the magnet switch assembly (B).
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2. After loosening the 2 screws (A), detach the magnet switch assembly (B).
3. Loosen the brush holder mounting screw (A) and through bolts (B).
4. Remove the rear bracket (A) and brush holder assembly (B).
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5. Remove the yoke (A) and armature (B).
6. Remove the lever plate (A) and packing (B).
7. Remove the overrunning clutch (A) and lever (B).
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8. Press the stop ring (A) using a socket (B).
9. After removing the stopper (A) using stopper pliers (B).
10. Remove the stopper (A), stop ring (B), overrunning clutch (C) and armature (D).
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11. Reassembly is the reverse of disassembly.
Using a suitable pulling tool (A), pull the overrunning clutch stop ring (B) over the stopper (C).
INSPECTION
ARMATURE INSPECTION AND TEST
1. Remove the starter.
2. Disassemble the starter as shown at the beginning of this procedure.
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage,
replace the armature.
4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the
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following specifications, or recondition with #500 or #600 sandpaper (B).
5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.
Commutator diameter
Standard (New) : 33.0mm (1.2992in.)
Service limit : 32.4mm (1.2756in.)
6. Measure the commutator (A) runout.

A. If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips
between the segments.
B. If the commutator run out is not within the service limit, replace the armature.
Commutator runout
Standard (New): 0.02mm (0.0008in.), max
Service limit: 0.05mm (0.002in.)
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7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth.
Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow,
or v-shaped (D).
Commutator mica depth

Standard (New) : 0.5mm (0.0197in.)
Limit : 0.2mm (0.0079in.)
8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments,
replace the armature.
9. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and
between the commutator and armature shaft (C). If continuity exists, replace the armature.
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INSPECT STARTER BRUSH
Brushes that are worn out, or oil-soaked, should be replaced.
The seat new brushes, slip a strip of #500 or #600 sandpaper, with the grit side up, between the commutator and
each brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same
contour as the commutator.
STARTER BRUSH HOLDER TEST

1. Check that there is no continuity between the (+) brush holder (A) and (-) brush holder (B). If there is no continuity,
replace the brush holder assembly.
Use a pipe (C) of suitable size for the brushes not to get removed from the brush holder.
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INSPECT OVERRUNNING CLUTCH
1. Slide the overrunning clutch along the shaft.
Replace it if does not slide smoothly.
2. Rotate the overrunning clutch both ways.
Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction of it locks in both
directions, replace it.
3. If the starter drive gear is worn or damage, replace the overrunning clutch assembly. (the gear is not available
separately)
Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.
CLEANING
1. Do not immerse parts in cleaning solvent. Immersing the yoke assembly and/or armature will damage the
insulation. Wipe these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent. The overrunning clutch is pre-lubricated at the factory and
solvent will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.
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Starting System - Starter Relay
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2010 > G 1.0 SOHC >
INSPECTION
1. Remove the fuse box cover.
2. Remove the starter relay (A).
3. Using an ohmmeter, check that there is continuity between each terminal.

Terminal Continuity
30 - 87 NO
85 - 86 YES
4. Apply 12V to terminal 85 and ground to terminal 86. Check for continuity between terminal 30 and 87.
5. If there is no continuity, replace the starter relay.

6. Install the starter relay.
7. Install the fuse box cover.
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Emission Control System
General Information
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SCHEMATIC DIAGRAM
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DESCRIPTION
Components Function Remarks
Crankcase Emission System
- Positive Crankcase Ventilation (PCV) HC reduction Variable flow rate type
valve
Evaporative Emission System
- Evaporative emission canister HC reduction
- Purge Control Solenoid Valve (PCSV) HC reduction Duty control solenoid valve
Exhaust Emission System

- MFI system (air-fuel mixture control CO, HC, NOx reduction Heated oxygen sensor feedback type
device) CO, HC, NOx reduction Monolithic type
- Three-way catalytic converter
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2010 > G 1.0 SOHC >
COMPONENT LOCATION
1 Purge Control Solenoid Valve (PCSV) 2 Positive Crankcase Ventilation (PCV) Valve
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3 Canister
4 Catalytic Converter
5 Two-Way Valve
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2010 > G 1.0 SOHC >
TROUBLESHOOTING
Vacuum hose disconnected or damaged Repair or replace
Engine will not start or hard to
start Malfunction of the Purge Control Solenoid
Repair or replace
Valve
Vacuum hose disconnected or damaged Repair or replace
Malfunction of the PCV valve Replace
Rough idle or engine stalls
Check the system; if there is a
Malfunction of the evaporative emission
problem, check related
canister purge system
components parts
Check positive crankcase
Excessive oil consumption Positive crankcase ventilation line clogged
ventilation system
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2010 > G 1.0 SOHC >
SPECIFICATIONS
▷ Specification
Item Specification
Coil Resistance (!) 32.0! [20°C (68°F)]
TIGHTENING TORQUES
Item N!m kgf!m lbf!ft
Positive Crankcase Ventilation Valve 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
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Crankcase Emission Control System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
INSPECTION
1. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve. Remove the PCV valve from
the rocker cover and reconnect it to the ventilation hose.
2. Run the engine at idle and put a finger on the open end of the PCV valve and make sure that intake manifold
vacuum can be felt.
The plunger inside the PCV valve will move back and forth.
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Crankcase Emission Control System -

Positive Crankcase Ventilation (PCV) Valve
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2010 > G 1.0 SOHC >
OPERATION
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2010 > G 1.0 SOHC >
REMOVAL
1. Disconnect the vacuum hose (A) and remove the PCV valve.
INSTALLATION
Install the PCV valve and tighten to the specified torque.
PCV Valve installation : 7.8 ~ 11.8 N·m (0.8 ~ 1.2 kgf·m, 5.8 ~ 8.7lbf·ft)
INSPECTION
1. Remove the PCV valve.
2. Insert a thin(A) into the PCV valve(B) from the theaded side to check that the pluger moves.
3. If the pluger dose not move, the PCV valve is clogged. Clean it or replace.
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Evaporative Emission Control System
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2010 > G 1.0 SOHC >
DESCRIPTION
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2010 > G 1.0 SOHC >
INSPECTION
1. Disconnect the vacuum hose from the throttle body, and connect a vacuum pump to the vacuum hose.
2. Check the following points when the engine is cold [engine coolant temperature 60°C(140°F) or below] and when it
is warm [engine coolant temperature 80°C(176°F) or higher].
WHEN ENGINE IS COLD
Engine operating condition Applied vacuum Result

Idling 50 kPa
Vacuum is held
3,000 rpm (7.3 psi)
WHEN ENGINE IS WARM
Engine operating condition Applied vacuum Result

50 kPa
Idling Vacuum is held
(7.3 psi)
Within 3 minutes after engine start at 3,000
Try to apply vacuum Vacuum is released
rpm
After 3 minutes have passed after engine 50 kPa Vacuum will be held momentarily,
start at 3,000 rpm (7.3 psi) after which, it will be released
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Evaporative Emission Control System -

Canister
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2010 > G 1.0 SOHC >
INSPECTION
1. Look for loose connections, sharp bends or damage to the fuel vapor lines.
2. Look for distortion, cracks or fuel damage.
3. After removing the canister, inspect for cracks, damage or saturated canister.
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Evaporative Emission Control System -

Purge Control Solenoid (PCS) Valve
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2010 > G 1.0 SOHC >
INSPECTION
Purge Control Solenoid Valve (PCSV) is installed on the surge tank and controls the passage between the canister
and the intake manifold. It is a solenoid valve and is open when the PCM grounds the valve control line. When the
passage is open (PCSV ON), fuel vapors stored in the canister is transferred to the intake manifold.
SPECIFICATION
Item Specification
Coil Resistance (!) 32.0! at 20°C (68°F)
CIRCUIT DIAGRAM
(A/T)
(M/T)
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COMPONENT INSPECTION
1. Turn ignition switch OFF.
2. Disconnect PCSV connector.
3. Measure resistance between PCSV terminals 1 and 2.
4. Check that the resistance is within the specification.
Specification: Refer to SPECIFICATION.
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Evaporative Emission Control System - Fuel

Filler Cap
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2010 > G 1.0 SOHC >
DESCRIPTION
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Exhaust Emission Control System
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2010 > G 1.0 SOHC >
DESCRIPTION
Modifications to the combustion chamber, intake manifold, camshaft and ignition system form the basic control system.
These items have been integrated into a highly effective system which controls exhaust emissions while maintaining
good driveability and fuel economy.
AIR/FUEL MIXTURE CONTROL SYSTEM [MULTIPORT FUEL INJECTION (MFI) SYSTEM]

This in turn allows the engine to produce exhaust gases of the proper composition to permit the use of a three way
catalyst. The three way catalyst is designed to convert the three pollutants (1) hydrocarbons (HC), (2) carbon
monoxide (CO), and (3) oxides of nitrogen (NOx) into harmless substances. There are two operating modes in the MFI
system.
1. Open Loop air/fuel ratio is controlled by information programmed into the ECM.
2. Closed Loop air/fuel ratio is adjusted by the ECM based on information supplied by the oxygen sensor.
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Fuel System
General Information
Fuel System
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2010 > G 1.0 SOHC >
SPECIFICATIONS
FUEL DELIVERY SYSTEM
Items Specification
Fuel Tank Capacity 35lit. (37 US qt., 30.8 Imp qt)
Fuel Filter
Type High pressure type
(built in Fuel Pump Assembly)
Fuel Pressure Regulator Regulated
338 ~ 348kpa (3.45 ~ 3.55kgf/cm!, 49.0 ~ 50.5psi)
(built in Fuel Pump assembly) Fuel Pressure
Type Electrical, in-tank type
Fuel Pump
Driven by Electric motor
Fuel Retrun System Type Returnless
SENSORS
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS)
▷ Type: Piezo-resistive pressure sensor type
▷ Specification
Pressure (kPa) Output Voltage (V)

20.0 0.79
46.7 1.84
101.32 4.0
INTAKE AIR TEMPERATURE SENSOR (IATS)

▷ Type: Thermistor type
▷ Specification
Temperature [°C(°F)] Resistance (k!)
-40(-40) 40.93 ~ 48.35
-30(-22) 23.43 ~ 27.34
-20(-4) 13.89 ~ 16.03
-10(14) 8.50 ~ 9.71
0(32) 5.38 ~ 6.09
10(50) 3.48 ~ 3.90
20(68) 2.31 ~ 2.57
25(77) 1.90 ~ 2.10
30(86) 1.56 ~ 1.74
40(104) 1.08 ~ 1.21
60(140) 0.54 ~ 0.62
80(176) 0.29 ~ 0.34
ENGINE COOLANT TEMPERATURE SENSOR (ECTS)

▷ Type: Thermistor type
▷ Specification
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-40(-40) 48.14
-20(-4) 14.13 ~ 16.83
0(32) 5.79
20(68) 2.31 ~ 2.59
40(104) 1.15
60(140) 0.59
80(176) 0.32
THROTTLE POSITION SENSOR (TPS)

▷ Type: Variable resistor type
▷ Specification
Throttle Angle Output Voltage (V)

C.T 0.25 ~ 0.9
W.O.T Min. 4.0V
Items Specification
Sensor Resistance (k") 1.6 ~ 2.4
HEATED OXYGEN SENSOR (HO2S)

▷ Type: Zirconia (ZrO2) type
▷ Specification
A/F Ratio Output Voltage (V)
Rich 0.6 ~ 1.0
Lean 0 ~ 0.4
Item Resistance (!)

Heater Resistance (") Approx. 9.0 (20°C)
CAMSHAFT POSITION SENSOR (CMPS)

▷ Type: Hall effect type
CRANKSHAFT POSITION SENSOR (CKPS)
▷ Type: Magnetic field sensitive Type
KNOCK SENSOR (KS)
▷ Type: Piezo-electricity type
▷ Specification
Item Specification
Capacitance (pF) 800 ~ 1,600
ACTUATORS
INJECTOR
▷ Number: 4
▷ Specification
Item Specification
Coil Resistance (") 13.8 ~ 15.2 [20°C (68°F)]
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IDLE SPEED CONTROL ACTUATOR (ISCA)
▷ Type: Double coil type
▷ Specification
Item Specification
Closing Coil Resistance (") 16.6 ~ 18.6 [20°C (68°F)]
Opening Coil Resistance (") 14.5 ~ 16.5 [20°C (68°F)]
PURGE CONTROL SOLENOID VALVE (PCSV)

▷ Specification
Item Specification
Coil Resistance (") 32.0 [20°C (68°F)]
IGNITION COIL
▷ Type: Stick type
▷ Specification
Item Specification
Primary Coil Resistance (") 0.87" ± 10％ [20°C (68°F)]
Secondary Coil Resistance (k") 13.0k" ± 15% [20°C (68°F)]]
SERVICE STANDARD
Ignition Timing BTDC 7° ± 5°
Neutral,N,P-range
A/CON OFF 750 ± 100 rpm
D-range
Idle Speed
Neutral,N,P-range
A/CON ON 800 ± 100 rpm
D-range
TIGHTENING TORQUES
ENGINE CONTROL SYSTEM
Item Kgf"m N"m lbf"ft
PCM/ECM installation bolts 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
PCM/ECM bracket installation bolts 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
Manifold absolute pressure sensor installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Engine coolant temperature sensor installation 3.0 ~ 4.0 29.4 ~ 39.2 21.7 ~ 28.9
Throttle position sensor installation bolts 0.15 ~ 0.25 1.5 ~ 2.5 1.1 ~ 1.8
Crankshaft position sensor installation bolt 0.9 ~ 1.0 8.8 ~ 9.8 6.5 ~ 7.2
Camshaft position sensor installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Knock sensor installation bolt 1.7 ~ 2.6 16.7 ~ 25.5 12.3 ~ 18.8
Heated oxygen sensor (Bank 1 / Sensor 1) installation 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
Heated oxygen sensor (Bank 1 / Sensor 2) installation 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
Idle speed control actuator installation screws 0.6 ~ 0.8 5.9 ~ 7.8 4.3 ~ 5.8
Ignition coil installation bolt 1.2 ~ 1.5 11.8 ~ 14.7 8.7 ~ 10.9
Purge control solenoid valve bracket installation bolts 1.9 ~ 2.4 18.6 ~ 23.5 13.7 ~ 17.4
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Throttle body installation bolts/nuts 1.9 ~ 2.4 18.6 ~ 23.5 13.7 ~ 17.4
FUEL DELIVERY SYSTEM

Item Kgf"m N"m lbf"ft
Fuel pump plate cover tightening 6.1 ~ 7.1 60.0 ~ 70.0 44.3 ~ 51.6
Delivery pipe installation bolts 1.9 ~ 2.4 18.6 ~ 23.5 13.7 ~ 17.3
Fuel tank mounting nuts 4.0 ~ 5.5 39.2 ~ 54.0 28.9 ~ 39.8
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2010 > G 1.0 SOHC >

Tool
Illustration Application
(Number and name)
09353-24100 Measuring the fuel line pressure
Fuel Pressure Gauge
09353-38000 Connection between the delivery pipe and

Fuel Pressure Gauge Adapter fuel feed line
09353-24000 Connection between Fuel Pressure

Fuel Pressure Gauge Connector Gauge (09353-24100) and Fuel Pressure
Gauge Adapter (09353-38000)
09310-2B100 Removing and installing the fuel sender

Fuel Pump Plate Cover Wrensh plate cover
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2010 > G 1.0 SOHC >
BASIC TROUBLESHOOTING
BASIC TROUBLESHOOTING GUIDE
CUSTOMER PROBLEM ANALYSIS SHEET
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BASIC INSPECTION PROCEDURE
The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be
measured at ambient temperature (20°C, 68°F), unless stated otherwise.
The measured resistance in except for ambient temperature (20°C, 68°F) is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again
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during testing. An example would be if a problem appears only when the vehicle is cold but has not appeared when
warm. In this case, the technician should thoroughly make out a "CUSTOMER PROBLEM ANALYSIS SHEET" and
recreate (simulate) the environment and condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent, broken or corroded pins,
and then verify that the connectors are always securely fastened.
3. Slightly shake the connector and wiring harness vertically and horizontally.
4. Repair or replace the component that has a problem.
5. Verify that the problem has disappeared with the road test.
! SIMULATING VIBRATION
1) Sensors and Actuators
: Slightly vibrate sensors, actuators or relays with finger.
Strong vibration may break sensors, actuators or relays
2) Connectors and Harness

: Lightly shake the connector and wiring harness vertically and then horizontally.
! SIMULATING HEAT
1) Heat components suspected of causing the malfunction with a hair dryer or other heat source.
• DO NOT heat components to the point where they may be damaged.

• DO NOT heat the ECM directly.
! SIMULATING WATER SPRINKLING

1) Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
DO NOT sprinkle water directly into the engine compartment or electronic components.
! SIMULATING ELECTRICAL LOAD

1) Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, rear window defogger,
etc.).
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CONNECTOR INSPECTION PROCEDURE
1. Handling of Connector
A. Never pull on the wiring harness when disconnecting connectors.
B. When removing the connector with a lock, press or pull locking lever.
C. Listen for a click when locking connectors. This sound indicates that they are securely locked.
D. When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire
harness side.
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E. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from
harness side.
• Use a fine wire to prevent damage to the terminal.

• Do not damage the terminal when inserting the tester lead.
2. Checking Point for Connector

A. While the connector is connected:
Hold the connector, check connecting condition and locking efficiency.
B. When the connector is disconnected:
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
C. Check terminal tightening condition:
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
D. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
3. Repair Method of Connector Terminal

A. Clean the contact points using air gun and/or shop rag.
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Never use sand paper when polishing the contact points, otherwise the contact point may be damaged.
B. In case of abnormal contact pressure, replace the female terminal.
WIRE HARNESS INSPECTION PROCEDURE

1. Before removing the wire harness, check the wire harness position and crimping in order to restore it correctly.
2. Check whether the wire harness is twisted, pulled or loosened.
3. Check whether the temperature of the wire harness is abnormally high.
4. Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part.
5. Check the connection between the wire harness and any installed part.
6. If the covering of wire harness is damaged; secure, repair or replace the harness.
ELECTRICAL CIRCUIT INSPECTION PROCEDURE

1. Procedures for Open Circuit
A. Continuity Check
B. Voltage Check
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity Check Method) or
Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
When measuring for resistance, lightly shake the wire harness above and below or from side to side.
Specification (Resistance)
1" or less # Normal Circuit
1M" or Higher # Open Circuit
A. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1M" and below 1 " respectively. Specifically
the open circuit is line 1 (Line 2 is normal). To find exact break point, check sub line of line 1 as described in
next step.
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B. Disconnect connector (B), and measure for resistance between connector (C) and (B1) and between (B2) and
(A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1M" and the open circuit
is between terminal 1 of connector (C) and terminal 1 of connector (B1).
3. Voltage Check Method

A. With each connector still connected, measure the voltage between the chassis ground and terminal 1 of each
connectors (A), (B) and (C) as shown in [FIG. 4].
The measured voltage of each connector is 5V, 5V and 0V respectively. So the open circuit is between
connector (C) and (B).
! CHECK SHORT CIRCUIT

1. Test Method for Short to Ground Circuit
A. Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing Step 2
(Continuity Check Method with Chassis Ground) as shown below.
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2. Continuity Check Method (with Chassis Ground)
Lightly shake the wire harness above and below, or from side to side when measuring the resistance.
Specification (Resistance)
1" or less # Short to Ground Circuit
1M" or Higher # Normal Circuit
A. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis Ground as
shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 " and higher than 1M" respectively.
Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken point, check the sub line
of line 1 as described in the following step.
B. Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and
between (B1) and chassis ground as shown in [FIG. 7].
The measured resistance between connector (B1) and chassis ground is 1" or less. The short to ground circuit
is between terminal 1 of connector (C) and terminal 1 of connector (B1).
SYMPTOM TROUBLESHOOTING GUIDE CHART
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MAIN SYMPTOM DIAGNOSTIC PROCEDURE ALSO CHECK FOR
Unable to start 1. Test the battery

(Engine does not turn 2. Test the starter
over) 3. Inhibitor switch (A/T) or clutch start switch (M/T)
1. Test the battery • DTC

Unable to start 2. Check the fuel pressure • Low compression
(Incomplete 3. Check the ignition circuit • Intake air leaks
combustion) 4. Troubleshooting the immobilizer system (In case of • Slipped or broken timing belt
immobilizer lamp flashing) • Contaminated fuel
• DTC
1. Test the battery
• Low compression
2. Check the fuel pressure
Difficult to start • Intake air leaks
3. Check the ECT sensor and circuit (Check DTC)
• Contaminated fuel
4. Check the ignition circuit
• Weak ignition spark

2. Check the Injector • DTC
Poor idling 3. Check the long term fuel trim and short term fuel trim • Low compression
(Rough, unstable or (Refer to CUSTOMER DATASTREAM) • Intake air leaks
incorrect Idle) 4. Check the idle speed control circuit (Check DTC) • Contaminated fuel
5. Inspect and test the Throttle Body • Weak ignition spark
6. Check the ECT sensor and circuit (Check DTC)
1. Test the Battery

• DTC
• Intake air leaks
Engine stall 3. Check the idle speed control circuit (Check DTC)
• Contaminated fuel
4. Check the ignition circuit
• Weak ignition spark
5. Check the CKPS Circuit (Check DTC)

2. Inspect and test Throttle Body • DTC
3. Check the ignition circuit • Low compression
Poor driving
4. Check the ECT Sensor and Circuit (Check DTC) • Intake air leaks
(Surge)
5. Test the exhaust system for a possible restriction • Contaminated fuel
6. Check the long term fuel trim and short term fuel trim • Weak ignition spark
(Refer to CUSTOMER DATASTREAM)

2. Inspect the engine coolant • DTC
Knocking
3. Inspect the radiator and the electric cooling fan • Contaminated fuel
4. Check the spark plugs
1. Check customer's driving habits

• Is A/C on full time or the defroster mode on?
• Are tires at correct pressure? • DTC
• Is excessively heavy load being carried? • Low compression
Poor fuel economy • Is acceleration too much, too often? • Intake air leaks
2. Check the fuel pressure • Contaminated fuel
3. Check the injector • Weak ignition spark
4. Test the exhaust system for a possible restriction
5. Check the ECT sensor and circuit
1. Test the canister close valve

2. Inspect the fuel filler hose/pipe
• Malfunctioning gas station
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• Malfunctioning gas station
Hard to refuel • Pinched, kinked or blocked?
filling nozzle (If this problem
(Overflow during • Filler hose is torn
occurs at a specific gas
refueling) 3. Inspect the fuel tank vapor vent hose between the station during refueling)
EVAP. canister and air filter
4. Check the EVAP. canister
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Fuel System
Engine Control System
Fuel System
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2010 > G 1.0 SOHC >
DESCRIPTION
1. Engine is hard to start or does not start at all.
2. Unstable idle.
3. Poor driveability
If any of the above conditions are noted, first perform a routine diagnosis that includes basic engine checks (ignition
system malfunction, incorrect engine adjustment, etc.). Then, inspect the Gasoline Engine Control system components
with the HI-SCAN (Pro).
• Before removing or installing any part, read the diagnostic trouble codes and then disconnect the battery
negative (-) terminal.
• Before disconnecting the cable from battery terminal, turn the ignition switch to OFF. Removal or connection
of the battery cable during engine operation or while the ignition switch is ON could cause damage to the
ECM.
• The control harnesses between the ECM and heated oxygen sensor are shielded with the shielded ground
wires to the body in order to prevent the influence of ignition noises and radio interference. When the shielded
wire is faulty, the control harness must be replaced.
• When checking the generator for the charging state, do not disconnect the battery '+' terminal to prevent the
ECM from damage due to the voltage.
• When charging the battery with the external charger, disconnect the vehicle side battery terminals to prevent
damage to the ECM.
Malfunction Indicator Lamp (MIL)

Faults with the following items will illuminate the MIL.
• Catalyst
• Fuel system
• Mass Air Flow Sensor (MAFS)
• Intake Air Temperature Sensor (IATS)
• Engine Coolant Temperature Sensor (ECTS)
• Throttle Position Sensor (TPS)
• Upstream Oxygen Sensor
• Upstream Oxygen Sensor Heater
• Downstream Oxygen Sensor
• Downstream Oxygen Sensor Heater
• Injector
• Misfire
• Crankshaft Position Sensor (CKPS)
• Camshaft Position Sensor (CMPS)
• Evaporative Emission Control System
• Vehicle Speed Sensor (VSS)
• Idle Speed Control Actuator (ISCA)
• Power Supply
• ECM/ PCM
• MT/AT Encoding
• Acceleration Sensor
• MIL-on Request Signal
• Power Stage
Refer to "INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES (DTC)" for more information.
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Faults with the following items will illuminate the MIL
• Heated oxygen sensor (HO2S)
• Mass Air Flow sensor (MAFS)
• Throttle position sensor (TPS)
• Engine coolant temperature sensor (ECTS)
• Idle speed control actuator (ISCA)
• Injectors
• ECM
Refer to "INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES (DTC)" for more information.
1. After turning ON the ignition key, ensure that the light illuminates for about 5 seconds and then goes out.
2. If the light does not illuminate, check for an open circuit in the harness, a blown fuse or a blown bulb.
Self-Diagnosis
If a sensor connector is disconnected with the ignition switch turned on, the diagnostic trouble code (DTC) is
recorded. In this case, disconnect the battery negative terminal (-) for 15 seconds or more, and the diagnosis
memory will be erased.
THE RELATION BETWEEN DTC AND DRIVING PATTERN IN EOBD SYSTEM
1. When the same malfunction is detected and maintained during two sequential driving cycles, the MIL will
automatically illuminate.
2. The MIL will go off automatically if no fault is detected after 3 sequential driving cycles.
3. A Diagnostic Trouble Code(DTC) is recorded in ECM memory when a malfunction is detected after two sequential
driving cycles. The MIL will illuminate when the malfunction is detected on the second driving cycle.
If a misfire is detected, a DTC will be recorded, and the MIL will illuminate, immediately after a fault is first
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detected.
4. A Diagnostic Trouble Code(DTC) will automatically erase from ECM memory if the same malfunction is not detected
for 40 driving cycles.
• A "warm-up cycle" means sufficient vehicle operation such that the coolant temperature has risen by at least
40 degrees Fahrenheit from engine starting and reaches a minimum temperature of 160 degress Fahrenheit.
• A "driving cycle" consists of engine startup, vehicle operation beyond the beginning of closed loop operation.
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2010 > G 1.0 SOHC >
COMPONENTS LOCATION
1. ECM/PCM 2. Manifold Absolute Pressure Sensor (MAPS)

16. Main Relay 3. Intake Air Temperature Sensor (IATS)
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4. Engine Coolant Temperature Sensor (ECTS) 5. Throttle Position Sensor (TPS)
6. Crankshaft Position Sensor (CKPS) 7. Camshaft Position Sensor (CMPS)
9. Heated Oxygen Sensor (HO2S) [Bank1/Sensor1]

8. Knock Sensor
10. Heated Oxygen Sensor (HO2S) [Bank2/Sensor2]
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12. Injector 13. Idle Speed Control Actuator (ISCA)
14. Purge Control Solenoid Valve (PCSV) 15. Ignition Coil
17. Fuel Pump Relay
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Fuel System
Engine Control System - Powertrain Control

Module
Fuel System
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2010 > G 1.0 SOHC >
POWERTRAIN CONTROL MODULE (PCM)

1. HARNESS CONNECTOR (A/T)
2. TERMINAL FUNCTION (A/T)

CONNECTOR [C02-2]
Pin
Description Connected to
No.
1 Power Ground Chassis Ground
4 For Autotransaxle Control
6 Battery voltage supply after main relay Main Relay
7 -
8 Sensor ground Manifold Absolute Pressure Sensor (MAPS)
9 Sensor ground Heated Oxygen Sensor (Sensor 2)
10 Manifold Absolute Pressure Sensor signal input Manifold Absolute Pressure Sensor (MAPS)
11 -
12 -
13 Heated Oxygen Sensor (Sensor 2) signal input Heated Oxygen Sensor (Sensor 2)
14 -
15 -
16 -
17 Alternator load signal input Alternator
18 -
19 -
20 Vehicle speed signal input ABS/ESP Control Module [With ABS/ESP]
21
22 Electric Load signal input (Defrost)
23 A/C switch "ON" signal input A/C Switch
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29
30 Sensor ground A/C Pressure Transducer (APT)
32 Intake Air Temperature Sensor signal input Intake Air Temperature Sensor (IATS)
33 -
34 -
36 -
37 -
38 Sensor ground Camshaft Position Sensor (CMPS)
39 -
40 -
41 Camshaft Position Sensor signal input Camshaft Position Sensor (CMPS)
42 -
43 -
44 Power steering switch signal input
45 -
46 A/C thermal switch signal input A/C Thermal Switch
51 Sensor ground Throttle Position Sensor (TPS)
52 -
53 -
54 -
55 -
56 -
58 -
59 -
63 -
69 -
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73 Sensor ground Engine Coolant Temperature Sensor (ECTS)
74 -
75 Throttle Position Sensor signal input Throttle Position Sensor (TPS)
76 -
77 Engine Coolant Temperature Sensor signal input Engine Coolant Temperature Sensor (ECTS)
78 -
79 A/C Pressure Transducer signal input A/C Pressure Transducer (APT)
85 -
CONNECTOR [C02-1]
Pin
Description Connected to
No.
1 Ignition Coil (Cylinder #2, #3) control output Ignition Coil (Cylinder #2, #3)
2 -
3 -
4 -
5 -
6 Idle Speed Control Actuator [OPEN] control output Idle Speed Control Actuator (ISCA)
7 -
8 Purge Control Solenoid Valve control output Purge Control Solenoid Valve (PCSV)
9 Main Relay control output Main Relay
10 -
11 Battery voltage supply after ignition switch Ignition Switch
12 CAN [HIGH] Other control module
13 -
14 -
GETtheMANUALS.org
15 Knock Sensor signal input Knock Sensor (KS)
16 -
18 -
19 -
20 -
21 Cooling Fan Relay [Low] control output Cooling Fan Relay [Low]
Idle Speed Control Actuator [CLOSE] control
22 Idle Speed Control Actuator (ISCA)
output
23 Cooling Fan Relay [High] control output Cooling Fan Relay [High]
24 Fuel consumption signal output Trip Computer
25 Engine speed signal output Cluster (Tachometer)
26 -
27 CAN [LOW] Other control module
28 -
29 -
30 Sensor ground Knock Sensor (KS)
31 -
32 Immobilizer lamp control output Immobilizer Lamp
Heated Oxygen Sensor (Sensor 2) Heater control
33 Heated Oxygen Sensor (Sensor 2)
output
output
35 -
36 Injector (Cylinder #3) control output Injector (Cylinder #3)
37 Fuel Pump Relay control output Fuel Pump Relay
38 A/C Compressor Relay control output A/C Compressor Relay
39 -
40 Crankshaft Position Sensor [A] signal input Crankshaft Position Sensor (CKPS)
41 -
42 -
43 Sensor power (+5V) Manifold Absolute Pressure Sensor (MAPS)
44 Immobilizer communication line Immobilizer Control Module
45 Wheel Speed Sensor [A] signal input Wheel Speed Sensor (WSS) [Without ABS/ESP]
46 -
47 -
49 -
51 Malfunction Indicator Lamp (MIL) control output Cluster (Malfunction Indicator Lamp)
53 -
54 -
GETtheMANUALS.org
55 Crankshaft Position Sensor [B] signal input Crankshaft Position Sensor (CKPS)
56 Battery Power Battery
57 Sensor power (+5V) A/C Pressure Transducer (APT)
58 Sensor power (+5V) Throttle Position Sensor (TPS)
59 -
60 Wheel Speed Sensor [B] signal input Wheel Speed Sensor (WSS)[Without ABS/ESP]
3. TERMINAL INPUT/OUTPUT SIGNAL (A/T)

CONNECTOR [C02-2]
PinNo Description Condition Type Level Test Result
1 Power Ground Idle DC Max. 50mV 0mV
2 Power Ground Idle DC Max. 50mV 3.6mV
Battery voltage supply after IG OFF Max. 1.0V 200mV

6 DC
main relay IG ON Battery Voltage 12.9V
7 -
8 Sensor ground Idle DC Max. 50mV 16mV
9 Sensor ground Idle DC Max. 50mV 6.2mV
Manifold Absolute Pressure IG ON 3.9 ~ 4.1V 4.09V

10 DC
Sensor signal input Idle 0.8 ~ 1.6V 1.44V
11 -
12 -
Heated Oxygen Sensor Rich: 0.6 ~ 1.0V 860mV

13 Racing Analog
(Sensor 2) signal input Lean: Max. 0.4V 10mV
14 -
15 -
16 -
Hi: Battery Voltage 13.2V
17 Alternator load signal input Idle Pulse
Lo: Max. 1.5V 1.34V
18 -
19 -
Hi: Min. 4.5V 12.2V
Idle Lo: Max. 1.0V 0V
Freq.: 72.2Hz
20 Vehicle speed signal input Pulse
Hi: Min. 4.5V 12.2V
Vehicle Run
Lo: Max. 1.0V 0V
(30km/h)
Freq.: 212Hz
21 -
Electric Load signal input
22
(Defrost)
A/C S/W OFF Max. 1.0V 20mV
GETtheMANUALS.org
A/C switch "ON" signal A/C S/W OFF Max. 1.0V 20mV
23 DC
input A/C S/W ON Battery Voltage 12.48V
29 -
Intake Air Temperature
32 Idle DC 0.2 ~ 4.8V 1.89V
Sensor signal input
33 -
34 -

35 Racing Analog
36 -
37 -
39 -
40 -
Camshaft Position Sensor Hi: Battery Voltage 13.72V

41 Idle Pulse
signal input Lo: Max. 0.5V 200mV
42 -
43 -
Power steering switch
44
signal input
45 -
A/C thermal switch signal A/C S/W OFF Max.0.5V 200mV

46 DC
52 -
53 -
54 -
55 -
56 -
58 -
59 -
GETtheMANUALS.org
63 -
69 -
74 -
Throttle Position Sensor C.T 0.25 ~ 0.9V 0.34V

75 Analog
signal input W.O.T Min. 4.0V 4.43V
76 -
Engine Coolant
77 Temperature Sensor signal Idle Analog 0.5 ~ 4.5V 1.43V
input
78 -
A/C Pressure Transducer
79 A/C ON Analog Max. 4.8V 1.88V
signal input
85 -
CONNECTOR [C02-1]
Pin
Description Condition Type Level Test Result
No.
GETtheMANUALS.org
1st Voltage: 300 ~
372V
Ignition Coil (Cylinder #2, 400V
1 Idle Pulse
#3) control output ON Voltage: Max.
1.1V
2.0V
2 -
3 -
4 -
5 -
Idle Speed Control Actuator Hi: Battery Voltage 13.8V

6 Idle Pulse
[OPEN] control output Lo: Max. 1.0V 20mV
7 -
Purge Control Solenoid Active Hi: Battery Voltage 14.2V

8 Pulse
Valve control output Inactive Lo: Max. 1.0V 120mV
Relay OFF Battery Voltage 12.78V
9 Main Relay control output DC
Relay ON Max. 1.0V 860mV
10 -
Battery voltage supply after IG OFF Max. 1.0V 3.2mV

11 DC
ignition switch IG ON Battery Voltage 12.68V
RECESSIVE 2.0 ~ 3.0V 2.5V
12 CAN [HIGH] Pulse
DOMINANT 2.75 ~ 4.5V 3.58V
13 -
14 -
Knocking Variable
15 Knock Sensor signal input
Normal Frequency
16 -
1st Voltage: 300 ~
352V
17 Idle Pulse
1.1V
2.0V
18 -
19 -
20 -
Cooling Fan Relay [Low] Relay OFF Battery Voltage 14.12V

21 DC
control output Relay ON Max. 1.0V 61.6mV

22 Idle Pulse
[CLOSE] control output Lo: Max. 1.0V 200mV
Cooling Fan Relay [High] Relay OFF Battery Voltage 14.01V

23 DC
Fuel consumption signal Hi: Battery Voltage 13.8V

24 Idle Pulse
output Lo: Max. 0.5V 20mV
25 Engine speed signal output Idle Pulse Lo: Max. 0.5V 20mV
Freq.: 20 ~ 26Hz 22Hz
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26 -
27 CAN [LOW] Pulse
DOMINANT 0.5 ~ 2.25V 1.5V
28 -
29 -
30 Sensor ground Idle DC Max. 50mV
31 -
Immobilizer lamp control Lamp OFF Battery Voltage 12.6V

32 DC
output Lamp ON Max. 1.0V 20mV
Heated Oxygen Sensor Hi: Battery Voltage 14.2V
33 (Sensor 2) Heater control Engine Run Pulse

35 -
Injector (Cylinder #3)
36 Idle Pulse Lo: Max. 1.0V 40mV
control output
Vpeak: Max. 80V 73.6V
Fuel Pump Relay control Relay OFF Battery Voltage 12.8V

37 DC
output Relay ON Max. 1.0V 400mV
A/C Compressor Relay Relay OFF Battery Voltage 14.1V

38 DC
control output Relay ON Max. 1.0V 400mV
39 -
Crankshaft Position Sensor
40 Idle Vp_p: Min. 1.0V 6.48V
[A] signal input
41 -
42 -
IG OFF Max. 0.5V 3.6mV
43 Sensor power (+5V) DC
IG ON 4.8 ~ 5.2V 5.02V
When Hi: Min. 8.5V 12.51V
Immobilizer communication
44 communicating Pulse
line Lo: Max. 3.5V 1.17V
after IG ON
Wheel Speed Sensor [A] SINE
45 Vehicle Run Vp_p: Min. 0.2V
signal input Wave
46 -
47 -
control output
49 -
control output
Lamp OFF Battery Voltage 11.51V
GETtheMANUALS.org
Malfunction Indicator Lamp Lamp OFF Battery Voltage 11.51V
51 DC
(MIL) control output Lamp ON Max. 1.0V 663mV
control output
53 -
54 -
Crankshaft Position Sensor SINE
[B] signal input Wave
56 Battery Power Always DC Battery Voltage 12.23V
IG ON 4.9 ~ 5.1V 5.02V
IG ON 4.9 ~ 5.1V 5.02V
59 -
Wheel Speed Sensor [B] SINE
signal input Wave
ENGINE CONTROL MODULE (ECM)

1. HARNESS CONNECTOR (M/T)
2. TERMINAL FUNCTION (M/T)

CONNECTOR [C01]
PinNo. Description Connectedto
4 -
5 -
6 Battery voltage supply after main relay Main Relay
7 -
8 A/C thermal switch signal input A/C Thermal Switch
9 -
10 Power steering switch signal input Power steering switch
11 Knock Sensor signal input Knock Sensor (KS)
12 Sensor ground Throttle Position Sensor (TPS)
13 -
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14 -
15 Sensor ground Manifold Absolute Pressure Sensor (MAPS)
17 Sensor ground Camshaft Position Sensor (CMPS)
18 Immobilizer communication line Immobilizer Control Module
19 Manifold Absolute Pressure Sensor signal input Manifold Absolute Pressure Sensor (MAPS)
20 -
21 Head Lamp signal input Head Lamp relay
22 Main Relay control output Main Relay
23 Cooling Fan Relay [High] control output Cooling Fan Relay [High]
Idle Speed Control Actuator [CLOSE] control
25 Idle Speed Control Actuator (ISCA)
output
26 -
27 -
28 Cooling Fan Relay [Low] control output Cooling Fan Relay [Low]
29 -
30 A/C switch "ON" signal input A/C Switch
31 Electric Load signal input (Defrost)
32 Sensor ground Knock Sensor (KS)
33 Sensor ground A/C Pressure Transducer (APT)
34 -
35 Sensor ground Engine Coolant Temperature Sensor (ECTS)
37 -
39 Throttle Position Sensor signal input Throttle Position Sensor (TPS)
40 A/C Pressure Transducer signal input A/C Pressure Transducer (APT)
41 -
42 -
43 Intake Air Temperature Sensor signal input Intake Air Temperature Sensor (IATS)
44 -
45 A/C Compressor Relay control output A/C Compressor Relay
46 Fuel Pump Relay control output Fuel Pump Relay
48 Immobilizer lamp control output Immobilizer Lamp
49 -
50 -
52 -
53 -
GETtheMANUALS.org
55 -
56 -
57 -
58 Wheel Speed Sensor [A] signal input Wheel Speed Sensor (WSS)[Without ABS/ESP]
59 Sensor power (+5V) A/C Pressure Transducer (APT)
60 Sensor power (+5V) Throttle Position Sensor (TPS)
61 -
62 CAN [LOW] Other control module
63 Camshaft Position Sensor signal input Camshaft Position Sensor (CMPS)
64 Vehicle speed signal input ABS/ESP Control Module [With ABS/ESP]
65 -
66 Alternator load signal input Alternator
67 Engine speed signal output Cluster (Tachometer)
69 Purge Control Solenoid Valve control output Purge Control Solenoid Valve (PCSV)
70 Malfunction Indicator Lamp (MIL) control output Cluster (Malfunction Indicator Lamp)
output
output
74 -
75 -
76 -
77 Engine Coolant Temperature Sensor signal input Engine Coolant Temperature Sensor (ECTS)
78 -
79 Wheel Speed Sensor [B] signal input Wheel Speed Sensor (WSS)[Without ABS/ESP]
80 -
81 Sensor power (+5V) Manifold Absolute Pressure Sensor (MAPS)
82 Battery Power Battery
83 Battery voltage supply after ignition switch Ignition Switch
84 CAN [HIGH] Other control module
85 -
86 Crankshaft Position Sensor [B] signal input Crankshaft Position Sensor (CKPS)
87 Crankshaft Position Sensor [A] signal input Crankshaft Position Sensor (CKPS)
88 Fuel consumption signal output Trip Computer
89 -
90 Idle Speed Control Actuator [OPEN] control output Idle Speed Control Actuator (ISCA)
92 -
93 -
94 Alternator [PWM] control output Alternator
GETtheMANUALS.org
3. TERMINAL INPUT/OUTPUT SIGNAL (M/T)
CONNECTOR [C01]
Pin No. Description Condition Type Level Test Result
1st Voltage: 300 ~
352V
1 Idle Pulse
1.1V
2.0V
2 Power Ground Idle DC Max. 50mV 0mV
1st Voltage: 300 ~
366V
3 Idle Pulse
1.1V
2.0V
4 -
5 -
Battery voltage supply after IG OFF Max. 1.0V 200mV

6 DC
main relay IG ON Battery Voltage 12.9V
1st Voltage: 300 ~
372V
Ignition Coil (Cylinder #4) 400V
7 Idle Pulse
control output ON Voltage: Max.
1.1V
2.0V
A/C thermal switch signal A/C S/W OFF Max.0.5V 200mV

8 DC
9 -
Power steering switch in
10
put
Knocking Variable
11 Knock Sensor signal input
Normal Frequency

13 -
14 -
When Hi: Min. 8.5V 12.51V
Immobilizer communication
18 communicating Pulse
line Lo: Max. 3.5V 1.17V
after IG ON
Manifold Absolute Pressure IG ON 3.9 ~ 4.1V 4.09V

19 DC
Sensor signal input Idle 0.8 ~ 1.6V 1.44V
20 -
21 Head Lamp signal input
Relay OFF Battery Voltage 12.78V
22 Main Relay control output DC
Relay ON Max. 1.0V 860mV
Cooling Fan Relay [High] Relay OFF Battery Voltage 14.01V

23 DC
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control output

25 Idle Pulse
[CLOSE] control output Lo: Max. 1.0V 200mV
26 -
27 -
Cooling Fan Relay [Low] Relay OFF Battery Voltage 14.12V

28 DC
29 -
A/C switch "ON" signal A/C S/W OFF Max. 1.0V 20mV
30 DC
Electric Load signal input
31
(Defrost)
32 Sensor ground Idle DC Max. 50mV
34 -

36 Racing Analog
37 -
Throttle Position Sensor C.T 0.25 ~ 0.9V 0.34V

39 Analog
signal input W.O.T Min. 4.0V 4.43V
A/C Pressure Transducer
40 A/C ON Analog Max. 4.8V 1.88V
signal input
41 -
42 -
Intake Air Temperature
43 Idle DC 0.2 ~ 4.8V 1.89V
Sensor signal input
44 -
A/C Compressor Relay Relay OFF Battery Voltage 14.1V

45 DC
control output Relay ON Max. 1.0V 400mV
Fuel Pump Relay control Relay OFF Battery Voltage 12.8V

46 DC
output Relay ON Max. 1.0V 400mV
control output
Immobilizer lamp control Lamp OFF Battery Voltage 12.6V

48 DC
output Lamp ON Max. 1.0V 20mV
49 -
50 -
GETtheMANUALS.org
52 -
53 -

54 Racing Analog
55 -
56 -
57 -
Wheel Speed Sensor [A] SINE
signal input Wave
IG ON 4.9 ~ 5.1V 5.02V
IG ON 4.9 ~ 5.1V 5.02V
61 -
62 CAN [LOW] Pulse
DOMINANT 0.5 ~ 2.25V 1.5V
Camshaft Position Sensor Hi: Battery Voltage 13.72V

63 Idle Pulse
signal input Lo: Max. 0.5V 200mV
Hi: Min. 4.5V 12.2V
Idle Lo: Max. 1.0V 0V
Freq.: 72.2Hz
64 Vehicle speed signal input Pulse
Hi: Min. 4.5V 12.2V
Vehicle Run
Lo: Max. 1.0V 0V
(30km)
Freq.: 212Hz
65 -
66 Alternator load signal input Idle Pulse
Lo: Max. 1.5V 1.34V
67 Engine speed signal output Idle Pulse Lo: Max. 0.5V 20mV
Freq.: 20 ~ 26Hz 22Hz
control output
Purge Control Solenoid Active Hi: Battery Voltage 14.2V

69 Pulse
Valve control output Inactive Lo: Max. 1.0V 120mV
Malfunction Indicator Lamp Lamp OFF Battery Voltage 11.51V

70 DC
(MIL) control output Lamp ON Max. 1.0V 663mV

GETtheMANUALS.org
74 -
75 -
76 -
Engine Coolant
77 Temperature Sensor signal Idle Analog 0.5 ~ 4.5V 1.43V
input
78 -
Wheel Speed Sensor [B]
79 Vehicle Run SINEWave Vp_p: Min. 0.2V
signal input
80 -
IG ON 4.8 ~ 5.2V 5.02V
82 Battery Power Always DC Battery Voltage 12.23V
Battery voltage supply after IG OFF Max. 1.0V 3.2mV

83 DC
ignition switch IG ON Battery Voltage 12.68V
84 CAN [HIGH] Pulse
DOMINANT 2.75 ~ 4.5V 3.58V
85 -
[B] signal input Wave
[A] signal input Wave
Fuel consumption signal Hi: Battery Voltage 13.8V

88 Idle Pulse
89 -

90 Idle Pulse
[OPEN] control output Lo: Max. 1.0V 20mV
control output
92 -
93 -
Alternator [PWM] control
94
output
GETtheMANUALS.org
2010 > G 1.0 SOHC >
CIRCUIT DIAGRAM
[A/T]
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
[M/T]
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
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GETtheMANUALS.org
2010 > G 1.0 SOHC >
PCM PROBLEM INSPECTION PROCEDURE

1. TEST PCM GROUND CIRCUIT: Measure resistance between PCM and chassis ground using the backside of PCM
harness connector as PCM side check point. If the problem is found, repair it.
Specification (Resistance): 1! or less
2. TEST PCM CONNECTOR: Disconnect the PCM connector and visually check the ground terminals on PCM side
and harness side for bent pins or poor contact pressure. If the problem is found, repair it.
3. If problem is not found in Step 1 and 2, the PCM could be faulty. If so, replace the PCM with a new one, and then
check the vehicle again. If the vehicle operates normally then the problem was likely with the PCM.
4. RE-TEST THE ORIGINAL PCM : Install the original PCM (may be broken) into a known-good vehicle and check
the vehicle. If the problem occurs again, replace the original PCM with a new one. If problem does not occur, this
is intermittent problem (Refer to INTERMITTENT PROBLEM PROCEDURE in BASIC INSPECTION
PROCEDURE).
REPLACEMENT
1. Turn ignition switch off.
2. Disconnect the battery (-) cable from the battery.
3. Disconnect the PCM connectors (A).
4. Unscrew the PCM mounting bolts (B) and remove the PCM.
5. Install a new PCM.
PCM mounting bolts: 7.8 ~ 9.8 N·m (0.8 ~ 1.0 kgf·m, 5.8 ~ 7.2 lbf·ft)
GETtheMANUALS.org
Fuel System
Engine Control System - Manifold Absolute

Pressure Sensor (MAPS)
Fuel System
GETtheMANUALS.org
2010 > G 1.0 SOHC >
INSPECTION
Manifold Absolute Pressure Sensor (MAPS) is speed-density type sensor and is installed on the surge tank. This
MAPS senses absolute pressure in surge tank and transfers this analog signal proportional to the pressure to the
PCM. The PCM calculates the intake air quantity and engine speed based on this signal. This MAPS consists of
piezo-electric element and hybrid IC that amplifies the element output signal. The element is silicon diaphragm type
and adapts pressure sensitive variable resistor effect of semi-conductor. 100% vacuum and the manifold pressure
applies to both sides of it respectively. That is, this sensor outputs the silicon variation proportional to pressure change
by voltage.
SPECIFICATION
Pressure(kPa) Output Voltage (V)

20.0 0.79
46.66 1.84
101.32 4.0
CIRCUIT DIAGRAM
(A/T)
GETtheMANUALS.org
(M/T)
GETtheMANUALS.org
1. Connect a scantool on Diagnisis Link Connector (DLC).
2. Check MAPS output voltage at idle and IG ON.
Condition Output Voltage (V)
Idle 0.8V ~ 1.6V
IG ON 3.9V ~ 4.1V
GETtheMANUALS.org
Fuel System
Engine Control System - Intake Air

Temperature Sensor (IATS)
Fuel System
GETtheMANUALS.org
2010 > G 1.0 SOHC >
INSPECTION
Intake Air Temperature Sensor (IATS) is installed inside the Manifold Absolute Pressure Sensor (MAPS) and detects
the intake air temperature. To calculate precise air quantity, correction of the air temperature is needed because air
density varies according to the temperature. So the PCM uses not only MAPS signal but also IATS signal. This sensor
has a Negative Temperature Coefficient (NTC) and its resistance is in inverse proportion to the temperature.
SPECIFICATION
Temperature [°C (°F)] Resistance (k!)

-40 (-40) 40.93 ~ 48.35
-30 (-22) 23.43 ~ 27.34
-20 (-4) 13.89 ~ 16.03
-10 (14) 8.50 ~ 9.71
0 (32) 5.38 ~ 6.09
10 (50) 3.48 ~ 3.90
20 (68) 2.31 ~ 2.57
25 (77) 1.90 ~ 2.10
30 (86) 1.56 ~ 1.74
40 (104) 1.08 ~ 1.21
60 (140) 0.54 ~ 0.62
80 (176) 0.29 ~ 0.34
CIRCUIT DIAGRAM
(A/T)
GETtheMANUALS.org
(M/T)
GETtheMANUALS.org
2. Disconnect IATS connector.
3. Measure resistance between IATS terminals 3 and 4.
GETtheMANUALS.org
Fuel System
Engine Control System - Engine Coolant

Temperature Sensor (ECTS)
Fuel System
GETtheMANUALS.org
2010 > G 1.0 SOHC >
INSPECTION
Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the cylinder head for
detecting the engine coolant temperature. The ECTS uses a thermistor whose resistance changes with the
temperature. The electrical resistance of the ECTS decreases as the temperature increases, and increases as the
temperature decreases. The reference 5 V in the PCM is supplied to the ECTS via a resistor in the PCM.That is, the
resistor in the PCM and the thermistor in the ECTS are connected in series. When the resistance value of the
thermistor in the ECTS changes according to the engine coolant temperature, the output voltage also changes. During
cold engine operation the PCM increases the fuel injection duration and controls the ignition timing using the
information of engine coolant temperature to avoid engine stalling and improve drivability.
SPECIFICATION
-40(-40) 48.14
-20(-4) 14.13 ~ 16.83
0(32) 5.79
20(68) 2.31 ~ 2.59
40(104) 1.15
60(140) 0.59
80(176) 0.32
CIRCUIT DIAGRAM
(A/T)
GETtheMANUALS.org
(M/T)
GETtheMANUALS.org
2. Disconnect ECTS connector.
3. Remove the ECTS.
4. After immersing the thermistor of the sensor into engine coolant, measure resistance between ECTS terminals 3
and 4.
GETtheMANUALS.org
Fuel System
Engine Control System - Throttle Position

Sensor (TPS)
Fuel System
GETtheMANUALS.org
2010 > G 1.0 SOHC >
INSPECTION
The Throttle Position Sensor (TPS) is mounted on the throttle body and detects the opening angle of the throttle plate.
The TPS has a variable resistor (potentiometer) whose characteristic is the resistance changing according to the
throttle angle. During acceleration, the TPS resistance between the reference 5V and the signal terminal decreases
and output voltage increases; during deceleration, the TPS resistance increases and TPS output voltage decreases.
The PCM supplies a reference 5V to the TPS and the output voltage increases directly with the opening of the throttle
valve. The TPS output voltage will vary from 0.25~0.9V at closed throttle to minimum 4.0V at wide-open throttle. The
PCM determines operating conditions such as idle (closed throttle), part load, acceleration/deceleration, and wide-open
throttle from the TPS. Also The PCM uses the Manifold Absolute Pressure Sensor (MAPS) signal along with the TPS
signal to adjust fuel injection duration and ignition timing.
SPECIFICATION
Throttle Angle Output Voltage (V)

C.T 0.25 ~ 0.9
W.O.T Min. 4.0V
Items Specification
Sensor Resistance (k!) 1.6 ~ 2.4
CIRCUIT DIAGRAM
(A/T)
GETtheMANUALS.org
(M/T)
GETtheMANUALS.org
1. Connect a scantool on the Data Link Connector (DLC).
2. Start engine and check output voltages of TPS at C.T and W.O.T.
3. Turn ignition switch OFF and disconnect the scantool from the DLC.
4. Disconnect TPS connector and measure resistance between TPS terminals 2 and 3
GETtheMANUALS.org
Fuel System
Engine Control System - Heated Oxygen

Sensor (HO2S)
Fuel System
GETtheMANUALS.org
2010 > G 1.0 SOHC >
INSPECTION
Heated Oxygen Sensor (HO2S) consists of zirconium and alumina and is installed on upstream and downstream of the
Manifold Catalyst Converter (MCC). After it compares oxygen consistency of the atmosphere with the exhaust gas, it
transfers the oxygen consistency of the exhaust gas to the PCM. When A/F ratio is rich or lean, it generates
approximately 1V or 0V respectively. In order that this sensor normally operates, the temperature of the sensor tip is
higher than 370°C (698°F). So it has a heater which is controlled by the PCM duty signal. When the exhaust gas
temperature is lower than the specified value, the heater warms the sensor tip.
SPECIFICATION
A/F Ratio Output Voltage (V)

RICH 0.6 ~ 1.0
LEAN 0 ~ 0.4
Item Specification
Heater Resistance (!) Approx. 9.0! at 20°C (68°F)
GETtheMANUALS.org
WAVEFORM
CIRCUIT DIAGRAM
(A/T)
GETtheMANUALS.org
(M/T)
GETtheMANUALS.org
1. Check signal waveform of HO2S using a scantool.
Specification: Refer to "waveform".
2. Disconnet the HO2S connector.

3. Measure resistance between HO2S heater terminals 3 and 4.
GETtheMANUALS.org
Fuel System
Engine Control System - Knock Sensor (KS)
Fuel System
GETtheMANUALS.org
2010 > G 1.0 SOHC >
INSPECTION
Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine damage. Knock
Sensor (KS) senses engine knocking and is installed on the cylinder block. When knocking occurs, the vibration from
the cylinder block is applied as pressure to the piezoelectric element. At this time, this sensor transfers the voltage
signal higher than the specified value to the PCM and the PCM retards the ignition timing. If the knocking disappears
after retarding the ignition timing, the PCM will advance the ignition timing. This sequential control can improve engine
power, torque and fuel economy.
SPECIFICATION
Item Specification
Capacitance (pF) 800 ~ 1,600
WAVEFORM
GETtheMANUALS.org
CIRCUIT DIAGRAM
(A/T)
(M/T)
GETtheMANUALS.org
GETtheMANUALS.org
Fuel System
Engine Control System - Crankshaft Position

Sensor (CPKS)
Fuel System
GETtheMANUALS.org
2010 > G 1.0 SOHC >
INSPECTION
Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one of the most important sensors of the
engine control system. If there is no CKPS signal input, the engine may stop because of CKPS signal missing. This
sensor is installed on transaxle housing and generates alternating current by magnetic flux field which is made by the
sensor and the target wheel when engine runs. The target wheel consists of 58 slots and 2 missing slots on 360 CA
(Crank Angle).
WAVEFORM
CIRCUIT DIAGRAM
(A/T)
GETtheMANUALS.org
(M/T)
1. Check signal waveform of CKPS and CMPS using a scantool.
Specification : Refer to "WAVE FORM"
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Fuel System
Engine Control System - Camshaft Position

Sensor (CMKS)
Fuel System
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2010 > G 1.0 SOHC >
INSPECTION
Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft position by using a hall element. It is
related with Crankshaft Position Sensor (CKPS) and detects the piston position of each cylinder which the CKPS can't
detect. The CMPS are installed on engine head cover and uses a target wheel installed on the camshaft. This sensor
has a hall-effect IC which output voltage changes when magnetic field is made on the IC with current flow.
WAVEFORM
CIRCUIT DIAGRAM
(A/T)
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(M/T)
1. Check signal waveform of CMPS and CKPS using a scantool.
Specification : Refer to "WAVE FORM"
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Fuel System
Engine Control System - Injector
Fuel System
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2010 > G 1.0 SOHC >
INSPECTION
Based on information from various sensors, the PCM measures the fuel injection amount. The fuel injector is a
solenoid-operated valve and the fuel injection amount is controlled by length of time that the fuel injector is held open.
The PCM controls each injector by grounding the control circuit. When the PCM energizes the injector by grounding
the control circuit, the circuit voltage should be low (theoretically 0V) and the fuel is injected. When the PCM de-
energizes the injector by opening control circuit, the fuel injector is closed and circuit voltage should momentarily peak.
SPECIFICATION
Item Specification
Coil Resistance (!) 13.8 ~ 15.2! at 20°C (68°F)
CIRCUIT DIAGRAM
(A/T)
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(M/T)
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2. Disconnect injector connector.
3. Measure resistance between injector terminals 1 and 2.
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Fuel System
Engine Control System - Idle Speed Control

Actuator (ISCA)
Fuel System
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2010 > G 1.0 SOHC >
INSPECTION
The Idle Speed Control Actuator (ISCA) is installed on the throttle body and controls the intake airflow that is bypassed
around the throttle plate to keep constant engine speed when the throttle valve is closed. The function of the ISCA is
to maintain idle speed according to various engine loads and conditions, and also to provide additional air during
starting. The ISCA consists of an opening coil, a closing coil, and a permanent magnet. Based on information from
various sensors, the PCM controls both coils by grounding their control circuits. According to the control signals from
the PCM, the valve rotor rotates to control the by pass airflow into the engine.
SPECIFICATION
Items Specification
Closing Coil Resistance (!) 16.6 ~ 18.6 [20°C (68°F)]
Opening Coil Resistance (!) 14.5 ~ 16.5 [20°C (68°F)]
CIRCUIT DIAGRAM
(A/T)
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(M/T)
2. Disconnect ISCA connector.
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3. Measure resistance between ISCA terminals 2 and 1 [Opening Coil].
4. Measure resistance between ISCA terminals 2 and 3 [Closing Coil].
Check that the resistance is within the specification.
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Fuel System
Engine Control System - Purge Control

Solenoid Valve (PCSV)
Fuel System
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2010 > G 1.0 SOHC >
INSPECTION
Purge Control Solenoid Valve (PCSV) is installed on the surge tank and controls the passage between the canister
and the intake manifold. It is a solenoid valve and is open when the PCM grounds the valve control line. When the
passage is open (PCSV ON), fuel vapors stored in the canister is transferred to the intake manifold.
SPECIFICATION
Item Specification
Coil Resistance (!) 32.0! at 20°C (68°F)
CIRCUIT DIAGRAM
(A/T)
(M/T)
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2. Disconnect PCSV connector.
3. Measure resistance between PCSV terminals 1 and 2.
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Fuel System
Fuel Delivery System
Fuel System
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2010 > G 1.0 SOHC >
COMPONENT LOCATION
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2010 > G 1.0 SOHC >
FUEL PRESSURE TEST
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Fuel System
Fuel Delivery System - Fuel Tank
Fuel System
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2010 > G 1.0 SOHC >
REMOVAL (INCLUDING FUEL FILTER AND FUEL PRESSURE REGULATOR)

1. Preparation
(1) Fold the rear seat cushion (Refer to "SEAT" in BD group).
(2) Open the service cover (A).
(3) Disconnect the fuel pump connector (A).
(4) Start the engine and wait until fuel in fuel line is exhausted.
(5) After engine stalls, turn the ignition switch to OFF position.
2. Disconnect the fuel feed quick-connector (A).
3. Lift the vehicle and remove the mufflers passing under the fuel tank. (Iatake and exhaust system in EM group)
4. Disconnect the fuel filler hose (A), the leveling hose (B).
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5. Ungasten the torsion axle assembly mounting bolts (A) to make working space.
Support the tortion axle assembly with a jack in order not to seperate it completely.
6. Unfasten 4 fuel tank mounting nuts (A) and remove the fuel tank with a jack.
INSTALLATION
Installation is reverse of removal.
Fuel Pump installation bolts : 39.2 ~ 54.0 N·m (4.0 ~ 5.5 kgf·m, 28.9 ~ 39.8 lbf·ft)
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Fuel System
Fuel Delivery System - Fuel Pump
Fuel System
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2010 > G 1.0 SOHC >
REMOVAL (INCLUDING FUEL FILTER AND FUEL PRESSURE REGULATOR)

1. Preparation
(1) Fold the rear seat cushion (Refer to "SEAT" in BD group).
(2) Open the service cover (A).
(3) Disconnect the fuel pump connector (A).
(4) Start the engine and wait until fuel in fuel line is exhausted.
(5) After engine stalls, turn the ignition switch to OFF position.
2. Disconnect the fuel feed tube quick-connector (A) and the canister purge line hose (B).
3. Unfasten the fuel pump plate cover (C) and remove the fuel pump assembly.
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INSTALLATION
Installation is reverse of removal.
Fuel Pump installation : 60.0 ~ 70.0 N·m (6.1 ~ 7.1 kgf·m, 44.3 ~ 51.6 lbf·ft)
When installing a pump module, be careful not to get the seal-ring entangled.
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Fuel System
Fuel Delivery System - Fuel Filter
Fuel System
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2010 > G 1.0 SOHC >
REPLACEMENT
1. Remove the fuel pump (Refer to “FUEL PUMP” in this group).
2. Disconnect the fuel pump& sender wiring connector (A) and seperate the flange assembly (B) from the fuel pump &
filter assembly after disengaging three fixing hooks (C).
3. Seperate the fuel filter& pump (A) from the reservoir cup (B) and disconnect the electric pump wiring connector (C).
4. Separate the fuel filter assembly (A) from the fuel pump assembly (B) after disengaging three hooks (C).
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Fuel System
Fuel Delivery System - Filler-Neck Assembly
Fuel System
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2010 > G 1.0 SOHC >
REMOVAL
1. Disconnect the fuel filler hose (A), the leveling hose (B).
2. Open the fuel filler door and unfasten the filler-neck assembly mounting screws (A).
3. Remove the rear-LH wheel, tire, and the inner wheel house.
4. Remove the bracket mounting bolt (A) and remove the filler-neck assembly.
If the filler neck assembly can't be removed easily, remove it again after loosening the rear cross member
mounting bolt partly (Refer to "REAR LOWER ARM" in SS group).
INSTALLATION
1. Installation is reverse of removal.
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Driveshaft and Axle
General Information
Driveshaft and Axle
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2010 > G 1.0 SOHC >
SPECIAL TOOLS
Tool (Number and Name) Illustration Use
09495-33000 Removal of wheel bearing inner race from a
Puller hub.
09495-33100 1. Removal of a wheel bearing from a

Center bearing remover and knuckle. (use with 09517-29000)
installer 2. Installation of a hub to a knuckle.
09517-21500 1. Removal of a front hub from a knuckle.

Front hub remover and (use with 09517-29000)
installer 2. Measurement of a front wheel bearing
pre-load. (use with 09532-11600)
09517-29000 1. Removal of a front hub from a knuckle.

Knuckle arm bridge (use with 09517-21500)
2. Removal of a wheel bearing outer race
from a knuckle. (use with 09495-33100)
09532-11600 Measurement of a front wheel bearing pre-

Preload socket load. (use with 09517-21500)
09532-11500 Installation of a wheel bearing to knuckle.

Bearing outer race installer
0K 130 283 021 Separation of a lower arm and a tie rod end
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0K 130 283 021 Separation of a lower arm and a tie rod end
Ball joint puller ball joint.
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2010 > G 1.0 SOHC >
TROUBLESHOOTING
GENERAL DIAGNOSTICS AND TESTS
To assist the service adviser and the technician, check the drive shaft condition with the questions listed below by
filling them.
It serves as a place to record information reported as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the questions.
Once the concern is narrowed down to a symptom/condition, proceed to condition and Symptom Categories below.
Condition and Symptom Categories.
Operation Condition Vehicle is moving.
Depends more one how the vehicle is operated.
1. Speed related
(1) Related to vehicle speed
A. Noise occurs at specific vehicle speed. A high pitch noise (whine).
Go to troubleshooting.
B. Loudness proportional to vehicle speed. Low frequency noise at high speeds, noise and loudness increase
with speed. Go to Troubleshooting.
2. Acceleration
(1) Light/moderate acceleration
A. Driveline shudder. Go to Troubleshooting.
3. Cruising speeds
(1) Driveline vibration. Go to Troubleshooting.
Symptom Possible cause Remedy

Vehicle pulls to one side Galling of drive shaft ball joint Replace
Wear, rattle or galling of wheel bearing Replace
Defective front suspension and steering Adjust or replace
Vibration Wear, damage or bending of drive shaft Replace
Drive shaft rattle and hub serration Replace
Wear, rattle or scratching of wheel bearing Replace
Shimmy Improper wheel balance Adjust or replace
Excessive noise Wear, damage or bending of drive shaft Replace
Drive shaft rattle and hub serration Replace
Drive shaft rattle and side gear serration Replace
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Wear, rattle or galling of wheel bearing Replace
Loose hub nut Adjust or replace
Quire-noise from the rear hub, Cap separation from the hub bearing Remove the rear hub check the
occurs when driving on rugged hub bearing cap.
roads Install a new cap if necessary.
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2010 > G 1.0 SOHC >
SPECIFICATIONS
Item M/T A/T
Outer BJ BJ
Joint type
Inner TJ TJ
Drive shaft
Outer 46° or more 46° or more
Maximum permissible
Inner 23° or more 23° or more
Hub end play mm (in.) 0.08 (0.003) or less
Wheel bearing starting torque 1.3 N·m (13 kg·cm, 0.95 lb·ft) or less
BJ : Birfield Joint
TJ : Tripod Joint
TIGHTENING TORQUE
Item N!m kg!cm lb!ft
Drive shaft lock nut 100 ~ 240 1000 ~ 2400 72 ~ 177
Knuckle to strut assembly nut 100 ~ 120 1000 ~ 1200 72 ~ 87
Lower arm ball joint to knuckle nut 60 ~ 72 600 ~ 720 43 ~ 52
Tie rod end to knuckle 16 ~ 34 160 ~ 340 12 ~ 25
Brake caliper to knuckle 69 ~ 75 690 ~ 750 50 ~ 55
Wheel nut 90 ~ 110 900 ~ 1100 65 ~ 80
Rear hub bearing flange bolt 100 ~ 120 1000 ~ 1200 72 ~ 87
Replace self-locking nuts with new ones after removal.
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Driveshaft and Axle
Driveshaft Assembly - Front Driveshaft
Driveshaft and Axle
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2010 > G 1.0 SOHC >
COMPONENTS
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL
1. Remove the front wheel and tire.
2. Drain the transaxle oil.
3. Remove the drive shaft nut(A) while applying brake.
4. Remove the tie rod end(A) from the knuckle(B) using the special tool (0K130 283 021) after removing the split pin.
5. Remove the wheel speed sensor(A) from the knuckle(B).
6. Remove the strut upper mounting bolts(A).
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7. Using a plastic hammer(A), remove the drive shaft(B) from the axle hub(C).
8. Insert a pry bar(A) between the transaxle case(B) and the joint case(C), and separate the drive shaft(D) from the
transaxle case(B).
9. Remove the drive shaft from the transaxle on the opposite side by repeating 1~8 procedures.
• Use a pry bar being careful not to damage the transaxle and joint.
Do not insert the pry bar too deep, as this may cause damage to the oil seal. [max. depth : 7mm (0.28 in.)]
• Do not pull the drive shaft by excessive force it may cause components inside the BJ or TJ joint kit to
dislodge resulting in a torn boot or a damaged bearing.
• Plug the hole of the transaxle case with the oil seal cap to prevent contamination.
• Support the drive shaft properly.
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• Replace the retainer ring whenever the drive shaft is removed from the transaxle case.
Tone Wheel Replacement

1. Remove the driveshaft.
2. Matchmark (A) the driveshaft and remove the tone wheel from the driveshaft.
3. Clean the portion where new tone wheel is installed.

4. Heat a new tone wheel to 280 ~ 300°C for 10minutes and below using a hot plate or a heat gun. Do not heat it
excessively over 350°C.
5. Put on the gloves and slide the heated tone wheel (A) to the machmark on the driveshaft.
6. Wait for the new tone wheel cools down and then reinstall the driveshaft.
INSTALLATION
1. Apply gear oil on the drive shaft splines(A) and the contacting surface of differential case oil seal(B).
2. After installation, check that the drive shaft cannot be removed by hand.
3. Install the drive shaft into the knuckle.
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Be careful not to damage the boot.
4. Install the knuckle in the strut assembly with the tightening torque, 100~120 Nm (1000~1200 kg·cm, 72~87 lb·ft)
5. Install the wheel speed sensor in the knuckle.
6. Install the tie rod end ball joint in the knuckle with the tightening torque 16~34 Nm (160~340 kg·cm, 12~25 lb·ft)
7. Install the drive shaft nut.
8. Install the front wheel and tire.
INSPECTION
1. Check the drive shaft boots for damage and deterioration.
2. Check the ball joints for wear and damage.
3. Check the splines for wear and damage.
4. Check the dynamic damper for cracks and wear.
DISASSEMBLY
• Do not disassemble the BJ assembly.

• Special grease must be applied to the drive shaft joint. Do not substitute with another type of grease.
• The boot band should be replaced with a new one.
1. Remove the clip(B) from drive shaft splines(A).
2. Remove both boot bands from the transaxle side TJ case.
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3. Pull out the boot from the transaxle side joint(TJ).
4. When separating the joint and boot(A), remove the grease from the TJ case(B).
• Be careful not to damage the boot.

• Make alignment marks on spider roller assembly(A), TJ case(B), and shaft splines(C) to aid reassembly.
5. Using a plier or flat-tipped (-) screwdriver, remove the snap ring(A).
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6. Remove the spider assembly(B) from drive shaft(A) by using the special tool(09495-33000).
7. Clean the spider assembly.

8. Remove the boot(A), of the transaxle side joint(TJ).
Wrap tape(B) around the drive shaft splines(C) to protect the boot(A).
9. Remove both side of bands(B,C) of the dynamic damper(A).
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10. Fix the drive shaft(A) with a vice(B) as illustrated.
11. Apply soap powder on the shaft to prevent being damaged between the shaft spline and the dynamic damper
when the dynamic damper is removed.
12. Separate dynamic damper(A) from the shaft(B) carefully.
13. Remove both bands on the side of wheel.
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14. Pull out the joint(BJ) boot on the side of wheel into the transaxle direction.
Be careful not to damage the boot.
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Driveshaft and Axle
Front Axle Assembly - Front Hub/Axle
Driveshaft and Axle
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL
1. Remove the front wheel and tire.
2. Remove the drive shaft nut(A) while applying brake.
3. Remove the brake caliper and disc after loosening the two mounting bolts.
Hang the separated brake caliper with wire.
4. Remove the tie rod end ball joint(A) from the knuckle(B) using the special tool(0K130 283 021).
Be sure to secure the ball joint so that it doesn't fall when the ball joint is removed.
5. Remove the wheel speed sensor(A) from the knuckle(B).
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6. Remove the strut assembly from the knuckle.
(1) Remove the mounting bolts(A) from the lower portion of the strut assembly.
7. Remove the lower arm ball joint(C) from the knuckle(B) after loosening the nut(A).
8. Remove the hub and knuckle as an assembly.
Be careful not to damage the boot and tone wheel.
INSTALLATION
1. Installation is the reverse of the removal procedures.
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Tighten the components below to the specified torque as follows :
Items Torque Nm (kg!cm, bl!ft)

60~72
Lower arm ball joint to knuckle nut
(600~720, 43~52)
100~120
Knuckle to strut assembly nut
(1000~1200, 72~87)
2. Install the strut assembly and the drive shaft in the knuckle.
3. Tighten the lower arm ball joint nut.
4. Connect the wheel speed sensor.
5. Install the caliper assembly in the hub and knuckle assembly which the brake disc is already installed.
6. Tighten the tie rod end ball joint nut and insert the split pin.
7. Insert the washer(B) and tighten the lock nut(A).
8. Insert the split pin(C).
9. Install the wheel and tire and tighten the wheel nuts.
DISASSEMBLY
1. Remove the snap ring(A).
2. Install the special tools(09517-29000, 09517-21500) as shown in illustration below.
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3. Separate the hub from the knuckle by turning nut(A) of the special tool(09517-21500).
4. Using a plastic hammer, remove the dust cover from the knuckle.
5. Remove the bearing inner race(B) from the hub(A) using the special tool.
6. Using the special tools (09495-33100, 09517-29000), remove the wheel bearing outer race(A)from the knuckle(B).
INSPECTION
WHEEL BEARING CHECK
1. Raise the vehicle until the front tires are off the floor.
Make sure the wheels are in a straight forward position.
Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of
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the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
2. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the
tire off the front wheel bearings.
3. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry
out one of the following.
On vehicles with inner and outer bearings, inspect the bearings and races for wear or damage. Adjust or install new
bearing and races as necessary.
4. Check the hub for cracks and the splines for wear.
5. Check the brake disc for scoring and damage.
6. Check the knuckle for cracks.
7. Check the bearing for cracks or damage.
REASSEMBLY
1. Apply multi-purpose grease to the contacting surface of the knuckle hub and bearing thinly.
2. Using the special tool (09532-11500), press-in the bearing to the knuckle.
(1) Install the snap ring.
• Press-in the outer race of the wheel bearing to prevent damage to the bearing assembly.
• When installing a bearing assembly, always use a new one.
• The right and the left bearings must be replaced as a matched set.
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3. Using a plastic hammer, install the dust cover.
4. Press-in the hub to the knuckle.
Press-in the inner race of the wheel bearing to prevent damage to the bearing assembly.
5. Tighten the hub and the knuckle to the specified torque using the special tool (09517-21500).
Specified torque : N·m (kg·cm, lb·ft)

200~240 (2000~2400, 147~177)
6. Measure the hub bearing starting torque.
Hub bearing starting torque [Limit]

1.3 N·m (13 kg·cm, 0.95 lb·ft) or less
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7. If the starting torque is 0 Nm (0 kg·cm, 0 lb·ft), measure the hub bearing axial play.
8. If the hub axial play exceeds the limit while the nut is tightened to 200~240 Nm (2000~2400kg·cm, 145~177 lb·ft),
the bearing, hub and knuckle are not installed correctly. Repeat the disassembly and assembly procedure.
Hub bearing axial play [Limit]

0.08 mm (0.003 in.) or less
9. Remove the special tool.

10. Fix the brake disc with the mounting screws.
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Driveshaft and Axle
Rear Axle Assembly - Rear Hub/Carrier
Driveshaft and Axle
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL
1. Remove the rear wheel and tire.
2. Remove the brake hose mounting bolt(A) after disconnecting the wheel speed sensor connector.
3. Remove the rear brake caliper mounting bolt with brake released.
4. Remove the caliper assembly from the carrier and suspend it with wire.
5. Remove the fixed screw (A) and brake disc (B).
6. Remove the rear axle(B) after removing the rear axle mounting bolts(A).
INSTALLATION
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INSPECTION
1. Check the rear hub bearing for wear or damage.
2. Check the rear rotor for chipped teeth.
3. Check the rear carrier for cracks.
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Clutch System
General Information
Clutch System
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2010 > G 1.0 SOHC >
SPECIFICATIONS
Item Specification
Gasoline : Cable type
Clutch operation method
Diesel : Hydraulic type
Clutch disc
Type Single dry with diaphragm
Facing diameter (outside x inside)mm (in) • Gasoline : Ø181.5 ! Ø122 (Ø7.1 ! Ø4.8)
• Diesel : Ø215 ! Ø148 (Ø8.5 ! Ø5.8)
Clutch cover assembly
Type Diaphragm spring strap
Clutch release cylinder [Diesel only]
* I.D. mm (in) 20.64 (0.81)
Clutch master cylinder [Diesel only]
* I.D. mm(in) 15.87 (0.62)
* I.D: Inside diameter

SERVICE STANDARD
Standard value
Clutch disc thickness [When free] Gasoline : 7.9 ± 0.3 mm (0.311 ±0.012 in)
Diesel : 8.55 ± 0.3 mm (0.337 ± 0.012 in)
Clutch pedal height [Without carpet] Gasoline : 180.3 mm (7.09 in)
Diesel : 209.6 mm (8.25 in)
Clutch pedal free play 6 ~ 13 mm (0.24 ~ 0.51 in)
Clutch pedal stroke Gasoline : 145 ± 3mm (5.7 ± 0.12 in)
Diesel : 145 ± 3mm (5.7 ± 0.12 in)
Limit
Clutch disc rivet depth Gasoline : 1.1 mm (0.043 in)
Diesel : 1.4 mm (0.055 in)
TIGHTENING TORQUE
Item Nm kgf.m lb-ft
Clutch pedal to pedal support member
17 ~ 26 1.7 ~ 2.6 12.3~ 18.8
(Clutch pedal bracket)
Clutch pedal support member to master
9 ~ 14 0.9 ~ 1.4 6.5 ~ 10.1
cylinder (Diesel)
Clutch tube flare nut (Diesel) 13 ~ 17 1.3 ~ 1.7 9.4 ~ 12.4
Clutch tube bracket (Diesel) 9 ~ 14 0.9 ~ 1.4 6.5 ~ 10.1
Clutch release cylinder (Diesel) 15 ~ 22 1.5 ~ 2.2 10.9 ~ 16.0
Clutch release cylinder union bolt (Diesel) 25 ~ 35 2.5 ~ 3.5 18.1 ~ 25.5
Clutch cover assembly (6ea) 15 ~ 22 1.5 ~ 2.2 10.9 ~ 16.0
Ignition lock switch nut (Diesel) 8 ~ 10 0.8 ~ 1.0 5.8 ~ 7.3
LUBRICANTS
Items Specified lubricants Quantity
Contact surface of release bearing and fulcrum of clutch
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Contact surface of release bearing and fulcrum of clutch
CASMOLY L9508 As required
release fork
Inner surface of clutch release bearing CASMOLY L9508 As required
Inner surface of clutch release cylinder and outer
Brake fluid DOT 3 or DOT 4 As required
circumference of piston and cup
Inner surface of clutch disc spline CASMOLY L9508 As required
Inner surface of clutch master cylinder and outer
Brake fluid DOT 3 or DOT 4 As required
circumference of piston assembly
Wheel bearing grease SAE J310,
Clutch master cylinder push rod, clevis pin and washer As required
NLGI No.2V
Chassis grease SAE J310a, NLGI
Clutch pedal shaft and bushings As required
No.1
Contact portion of release fork to release cylinder push
CASMOLY L9508 As required
rod
Input shaft spline CASMOLY L9508 As required
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2010 > G 1.0 SOHC >

09411-11000 Installation of the clutch disc.
Clutch disc guide
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2010 > G 1.0 SOHC >
TROUBLESHOOTING
Trouble symptom Suspect area Remedy (See page)
Clutch slipping Insufficient pedal free play Adjust
• Car will not respond to engine Clogged hydraulic system Correct or replace parts
speed during acceleration
• Insufficient vehicle speed Excessive wear of clutch disc facing Replace
• Lack of power during uphill Hardened clutch disc facing, or oil on surface Replace
driving Damaged pressure plate or flywheel Replace
Weak or broken pressure spring Replace
Difficult gear shifting (gear noise Excessive pedal free play Adjust
during shifting)
Hydraulic system fluid leaks, air trapping or Repair or replace parts
clogging
Unusual wear or corrosion of the clutch disc Replace
spline
Excessive vibration (distortion) of the clutch
Replace
disc
Clutch When the clutch is not Insufficient play of the clutch pedal Adjust
noisy used
Excessive wear of the clutch disc facing Replace
A noise is heard after Unusual wear and/ or damage of the release Replace
the clutch is bearing
disengaged
A noise is heard when Insufficient grease on the sliding surface of Repair
the clutch is the bearing sleeve
disengaged
Improperly installed clutch assembly or Repair
bearing
A noise is heard when Damaged pilot bushing Replace
the car suddenly
rolled up with the
clutch partially
engaged
Hard pedal effort Insufficient lubrication of the clutch pedal Repair
Insufficient lubrication of the spline part of Repair
clutch disc
Insufficient lubrication of the clutch release Repair
lever shaft
Hard to shift or will not shift Excessive clutch pedal free play Adjust the pedal free play
Faulty of the clutch release cylinder Repair the release cylinder
Clutch disc out of place, runout is excessive Inspect the clutch disc
or lining broken
Spline on the input shaft or clutch disc dirty Repair as necessary
or burned
Faulty of the clutch pressure plate Replace the clutch cover
Clutch slips Insufficient clutch pedal free play Adjust the pedal free play
Clogged of the hydraulic system Repair or replace parts
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Clutch disc lining oily or worn out Inspect the clutch disc
Faulty pressure plate Replace the clutch cover
Binding of the release fork Inspect the release fork
Clutch grabs/chatters Clutch disc lining oily or worn out Inspect the clutch disc
Faulty the pressure plate Replace the clutch cover
Bent clutch diaphragm spring Replace the clutch cover
Worn or broken torsion spring Replace the clutch disc
Engine mounts loose Repair as necessary
Clutch noisy Damaged the clutch pedal bushing Replace the clutch pedal bushing
Loose part inside housing Repair as necessary
Worn or dirty release bearing Replace the replease bearing
Sticking release fork or linkage Repair as necessary
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Clutch System
Clutch System
Clutch System
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2010 > G 1.0 SOHC >
SERVICE ADJUSTMENT PROCEDURE

CLUTCH PEDAL INSPECTION AND ADJUSTMENT
[GASOLINE]
1. Measure the clutch pedal height.
Standard value (A) : 180.3mm ( 7.10in)
2. Measure the clutch pedal free play.
Standard value (B) : 15~20mm (0.5 8~ 0.78in)
3. If the clutch pedal free play is not within the standard value range, turn and adjust the nut.
Clutch cable free play (C) : 3~4mm (0.12~0.16in)
4. After completing the adjustments, check that the distance between the clutch pedal (the face of the pedal pad) and
the toe board when the clutch is disengaged, are within the standard value ranges.
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Standard value (D) : 33mm (1.30in)
[DIESEL]
1. Measure the clutch pedal height (from the face of the pedal pad to the floorboard) and the clutch pedal clevis pin
play (measured at the face of the pedal pad.)
Standard value
(A) : 6~13mm (0.24~0.51in)
(B) : 209.6mm (8.25in)
2. If the clutch pedal freeplay and height is not within the standard value range, adjust as follows:
(1) Turn and adjust the bolt within the standard value, then secure by tightening the lock nut.
If the clutch pedal height is lower than the standard value, loosen the bolt and adjust the push rod.
After adjustment, tighten the bolt so that the clearance with pedal stopper is within the standard value
(A)(0.8~1.0mm, 0.031~0.039in) and secure with lock nut.
(2) Turn the push rod to agree with the standard value and then secure the push rod with the lock nut.
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When adjusting the clutch pedal height or the clutch pedal play, be careful not to push the push rod toward
the master cylinder.
3. 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 clutch master cylinder. Bleed the air or disassemble and inspect the master cylinder or clutch.
BLEEDING (Diesel only)
Use the specified fluid. Avoid mixing different brands of fluid.
Specified fluid: SAE J1703 (DOT 3 or DOT 4)
1. Loosen the bleeder screw(A) at the clutch release cylinder.
2. Depress the clutch pedal slowly until all air is expelled.

3. Hold the clutch pedal down until the bleeder is retightened.
4. Refill the clutch master cylinder with the specified fluid.
The rapidly-repeated operation of the clutch pedal in B-C range may disrupt the release cylinder's position.
During the bleeding operation, press the clutch pedal to the floor after it returns to the "A" point.
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Clutch System
Clutch System - Clutch Cover and Dinode
Clutch System
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2010 > G 1.0 SOHC >
COMPONENTS (1)
COMPONENTS (2)
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2010 > G 1.0 SOHC >
REMOVAL
[GASOLINE]
1. Remove the transaxle assembly. (Refer to Manual transaxle's removal in MT group)
2. Insert the special tool (09411-11000) in the clutch disc to prevent the disc from falling.
3. Loosen the bolts in succession, one or two turns at a time in a star pattern, to avoid bending the cover flange.
Do not clean the clutch disc or release bearing with cleaning solvent.
4. Remove the reamer bolt (A) from the clutch release fork.
5. Remove the return clip and the clutch release assembly.

6. Remove the clutch release fork after removing the return clip.
7. Remove the clutch release shaft and return spring.
[DIESEL]
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1. Remove the transaxle assembly. (Refer to Manual transaxle's removal in MT group)
2. Insert the special tool (09411-11000) in the clutch disc to prevent the disc from shifting.
3. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover.
Do not clean the clutch disc or the release bearing with cleaning solvent.
INSTALLATION
[GASOLINE]
1. Apply multipurpose grease to release fork assembly.
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. Apply multipurpose grease into the groove of the release bearing.
Grease : CASMOLY L9508
3. Install the release bearing and release fork to clutch housing.
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4. Install the return clip to the release bearing and tighten the reamer bolt (A).
5. Apply multipurpose grease to clutch release bearing contact surface of the clutch release fork assembly.
6. Clean the surfaces of the flywheel and pressure plate throughly with fine sandpaper or crocus cloth, and make
certain that all oil or grease has been removed.
7. Apply a small amount of multipurpose grease to the clutch disc splines and input shaft splines.
Do not apply more grease than necessary. Too much grease could cause clutch slip or judder.
8. Install the clutch disc to flywheel using special tool (09411-11000).
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9. Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at a time in a
star pattern.
10. Remove the special tool(09411-11000)
11. Install the transaxle assembly to the engine
12. Adjust the clutch pedal free play.
[DIESEL]
1. Apply multipurpose grease to the spline of the disc.
Grease: CASMOLY L 9508
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease.
It can cause clutch slippage and vibration (shudder).
2. Temporarily install the clutch disc assembly to the flywheel using the special tool (09411-11000).
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3. Tighten the bolts one or two steps at a time in a star pattern.
TORQUE :
15~22Nm (1.5~2.2 kgf.m, 10.9~16.0 lb-ft)
4. Remove the clutch disc guide (09411-11000).

5. Install the transaxle assembly to the engine. (Refer to Manual transaxle's installation in MT group)
INSPECTION
Clutch cover assembly
1. Check the diaphragm spring end for wear and uneven height.
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.
Clutch disc
1. Check the clutch facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil, or grease, and
replace the clutch disc if defective.
2. Measure the thickness of the disc when free.
Standard value
Clutch disc thickness(A)[when free]
Clutch disc rivet depth(B)
: refer to 'SERVICE STANDARD' in GENERAL section.
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3. Check for the torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.
Clutch release bearing
The release bearing is packed with grease. Do not use cleaning solvent or oil.
Standard grease : CASMOLY L9508
1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for
wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.
Clutch release fork

If there is abnormal wear at the point of contact with the bearing, replace the release fork assembly.
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Clutch System
Clutch System - Clutch Master Cylinder
Clutch System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
COMPONENTS
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Clutch System
Clutch System - Clutch Pedal
Clutch System
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2010 > G 1.0 SOHC >
COMPONENTS (1)
COMPONENTS (2)
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2010 > G 1.0 SOHC >
REMOVAL
[GASOLINE]
1. Remove the clutch cable bracket (A) from the transaxle assembly.
2. Seperate the clutch cable (B) from the clutch lever.

3. Remove the mounting nuts.
4. Remove the clutch pedal assembly.
[DIESEL]
1. Disconnect the push rod from the master cylinder by removing the snap pin (A) and washer-bolt (B).
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2. Remove the screws or nut mounting the master cylinder to the clutch pedal assembly.
INSTALLATION
[GASOLINE]
1. Installation is reverse of removal.
2. Apply multi-purpose grease to the bushings.
Standard grease :
Multi-purpose grease SAE J310, NLGI No.3
3. Adjust the clutch pedal height and pedal free play after installing.
Clutch pedal height : 180.3mm (7.10in)

Clutch pedal free play :15 ~ 20mm (0.58 ~ 0.78in)
[DIESEL]
1. Apply the specified grease to the clutch pedal and bushings.
Chassis grease: SAE J310a, NLGI No.1
2. Install the screws or nut mounting the master cylinder to the clutch pedal assembly.
3. Apply the specified grease to the snap pin(A) and washer.
Wheel bearing grease: SAE J310, NLGI No.2
4. Connect the push rod to the clutch pedal by installing the snap pin (A) and washer-bolt (B).
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INSPECTION
1. Check the pedal shaft and bushing for wear.
2. Check the clutch pedal for bending or torsion.
3. Check the return spring for damage or deterioration.
4. Check the pedal pad for damage or wear.
Ignition lock switch (DIESEL ONLY)

Remove the ignition lock switch and check for continuity between the terminals. If the continuity is not as specified,
replace the switch.
Standard value
Full stroke(A) : 12.0 ± 0.3mm (0.472 ± 0.012 in.)
ON-OFF point (B) : 2.0 ± 0.3mm (0.078 ± 0.012 in)
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Clutch System
Clutch System - Clutch Release Cylinder
Clutch System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL
1. Drain the brake fluid through the bleed plug (A).
2. Disconnect the clutch tube (A).
3. Remove the two clutch release cylinder mounting nuts (B-2ea).
INSTALLATION
1. Coat the clutch clevis push rod specified grease.
Specified grease: CASMOLY L9508
2. Install the release cylinder mounting nuts (B-2ea).
TORQUE :
15~22Nm (1.5~2.2kgf.m, 11~16lb-ft)
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3. Install the clutch tube (A).
4. Refill the brake fluid.
5. Bleed the air in the clutch system.
(refer to Bleeding in Service Adjustment Procedure)
INSPECTION
1. Check the release cylinder bore for rust and damage.
2. Check the clutch release cylinder for fluid leakage.
3. Check the clutch release cylinder boots for damage.
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Steering System
General Information
Steering System
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2010 > G 1.0 SOHC >

Tool (Number and Name) Illustration Use
09561-11001 Removal of the steering wheel
Steering wheel puller
09568-34000 Removal of the tie rod end ball joint

Ball joint puller
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2010 > G 1.0 SOHC >
GENERAL
SPECIFICATIONS
Item Specification
Manual Steering System
Type
Electric Power Steering System
Manual 4.3 turns
Steering wheel turns
GSL 3.0 turns
(Lock to lock) EPS
DSL 3.1 turns
Steering gear Type Rack & Pinion
TIGHTENING TORQUES
Tightening torque
Items
Nm kgf.m lb-ft
Hub nuts 90 ~ 110 9.0 ~ 11.0 65 ~ 80
Steering wheel lock nut 40 ~ 50 4.0 ~ 5.0 29 ~ 36
Steering column mounting bolts and nuts 13 ~ 18 1.3 ~ 1.8 9.4 ~ 13.0
Manual 13 ~ 18 1.3 ~ 1.8 9.4 ~ 13.0
Bolt connecting universal joint to pinion
EPS 30 ~ 35 3.0 ~ 3.5 22 ~ 25
Manual 13 ~ 18 1.3 ~ 1.8 9.4 ~ 13.0
Bolt connecting steering column to universal joint
EPS 30 ~ 35 3.0 ~ 3.5 22 ~ 25
Steering gear to sub-frame 60 ~ 80 6.0 ~ 8.0 43 ~ 58
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Steering System
Electric Power Steering
Steering System
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2010 > G 1.0 SOHC >
DESCRIPTION
EPS (Electric power steering, Column assist type) system uses an electric motor to assist the steering force and it is
an engine operation independent steering system.
EPS control module controls the motor operation according to information received from the each sensor and resulting
in a more precise and timely control of steering assist than conventional engine-driven hydraulic systems.
Components (Torque Sensor, Fail-safe relay, etc.) of the EPS system are located inside the steering column & EPS
unit assembly and the steering column & EPS unit assembly must not be disassemble to inspect or replace them.
NOTES WITH REGARD TO DIAGNOSIS

Trouble Check
Trouble symtom Explanation Note
factor item
Drop, Motor Abnormal noise - Visable or unvisable damage - Do not use the impacted
impact, and can occur. EPS.
ECU Circuit damage
overload The steering wheel could pull - Do not overload each parts.
- Wrong welding
to one side by using the
point
dropped parts.
- Broken PCB
- Precise parts of motor/ECU
- Damaged precise
are sensitive to vibration and
parts
impact.
- Overload can cause
unexpected damage
Torque - Do not impact the connecting
sensor parts (When inserting and
Overload to INPUT shaft can torquing)
Insufficient steering
cause malfunction of the torque - Use the specified tool to
effort
sensor remove the steering wheel.
(Do not hammer on it)
- Do not use the impacted EPS
Shaft Insufficient steering Do not use the impacted EPS
effort (Uneven
between LH and RH)
Pull/Dent Harness - Malfunction- Disconnection between harness Do not overload the harness
impossible power connecting portion and harness
operation
- Malfunction of
EPS
Abnormal Motor/ECU Abnormal steering - Waterproof at the normal - Keep the normal temperature
storage effort by improper condition and proper moisture, while
temperature operation of the - Even a little moisture can storaging
motor/ECU cause malfunction of the - Avoid drowning
precise parts of the
motor/ECU
1. Do not impact the electronic parts, if they are dropped or impacted, replace them with new ones.
2. Avoid heat and moisture to the electronic parts.
3. Do not contact the connect terminal to avoid deformation and static electricity.
4. Do not impact the motor and torque sensor parts, if they are dropped or impacted, replace them with new ones.
5. The connector should be disconnected or connected with IG OFF.
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2010 > G 1.0 SOHC >
COMPONENTS
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Steering System
Electric Power Steering - Steering Column

And Shaft
Steering System
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2010 > G 1.0 SOHC >
REPLACEMENT
1. Disconnect the battery negative cable from the battery and then wait for at least 30 seconds.
2. Turn the steering wheel so that the front wheels can face straight ahead.
3. Loosen the torx bolts which are located on the both side of the steering wheel.
4. Disconnect the connector from the airbag module and then remove the airbag module (or Horn pad) (A) from the
steering wheel.
5. Loosen the lock nut and then remove the steering wheel (A) from the steering column shaft by using a SST
(09561-11001).
Tightening torque Nm (kgf.m, lb-ft):

40 ~ 50 (4.0 ~ 5.0, 29 ~ 36)
Do not hammer on the steering wheel to remove it; it may damage the steering column.
6. Remove the steering column upper (A) and lower (B) shroud.
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7. Remove the clock spring (A) and the multifunction switches (B) from the steering column shaft.
8. Remove the lower crash pad (A).
9. Loosen the bolt and then disconnect the universal joint assembly (A) from the pinion of the steering gear box.
Tightening torque Nm (kgf.m, lb-ft)

Manual: 13 ~ 18 (1.3 ~ 1.8, 9.4 ~ 13.0)
EPS: 30 ~ 35 (3.0 ~ 3.5, 22 ~ 25)
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Keep the neutral-range to prevent the damage of the clock spring inner cable when you handlethe steering
wheel.
10. Disconnect all connectors connected the steering column & EPS unit assembly.
11. Remove the steering column & EPS unit assembly by loosening the mounting bolts and nuts.

13 ~ 18 (1.3 ~ 1.8, 9.4 ~ 13.0)
12. Installation is the reverse of the removal.
Apply the multipurpose grease to sliding surface of the each part before the installation.
When installing the clock spring, refer the RT group to prevent the damage of clock spring inner cable.
DISASSEMBLY AND REASSEMBLY
Do not disassemble the steering column & EPS unit assembly.
1. Loosen the bolt and then disconnect the universal joint assembly (A) from the steering column assembly.

MNL : 13 ~ 18 (1.3 ~ 1.8, 9.4 ~ 13)
EPS : 30 ~ 35 (3.0 ~ 3.5, 22 ~ 25)
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2. Make a groove on the head of special bolts (A) by a punch.
3. Loosen the special bolts by using screw driver and than remove the key lock assembly (B) from the steering
column assembly.
4. Reassembly is the reverse of the disassembly. When reassembling the key lock assembly, install the key lock
assembly to the steering column and then tighten new special bolts until its head (A) is cut off.
INSPECTION
1. Check the steering column for damage and deformation.
2. Check the connection for play, damage and smooth operation.
3. Check the join bearing for damage and wear.
4. Check the tilt bracket for damage and cracks.
5. Check the key lock assembly for proper operation and replace it if necessary.
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Steering System
Electric Power Steering - Steering Gear Box
Steering System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REPLACEMENT
1. Remove the front wheel & tire.

90 ~ 110 (9.0 ~ 11.0, 65 ~ 80)
2. Loosen the bolt and then disconnect the universal joint assembly (A) from the pinion of the steering gear box.

Manual: 13 ~ 18 (1.3 ~ 1.8, 9.4 ~ 12.3)
EPS: 30 ~ 35 (3.0 ~ 3.5, 22 ~ 36)
Keep the neutral-range to prevent the damage of the clock spring inner cable when you handlethe steering
wheel.
3. Disconnect the stabilizer link (A) with the front strut assembly.

35 ~ 45 (3.5 ~ 4.5, 25 ~ 33)
4. Remove the sprit pin and castle nut and then disconnect the tie-rod end from the front knuckle by using SST
(09568-34000).

16 ~ 34 (1.6 ~ 3.4, 12 ~ 25)
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5. Remove the bolt (A) and then disconnect the lower arm with the knuckle.

60 ~ 72 (6.0 ~ 7.2, 43 ~ 52)

40 ~ 55 (4.0 ~ 5.5, 29 ~ 40)
7. Remove the rear roll stopper through bolt & nut (A).

50 ~ 65 (5.0 ~ 6.5, 36 ~ 47)
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8. Remove the cross member (A) from the body by loosening the mounting bolts and nuts.

140 ~ 160 (14.0 ~ 16.0, 101 ~ 116)
9. Remove the steering gear box (A) from the cross member by loosening the mounting bolts.

60 ~ 80 (6.0 ~ 8.0, 43 ~ 58)
DISASSEMBLY
1. Remove the dust packing & cap (A) from the pinion housing.
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2. Loosen the lock nut and then remove the tie rod end (B) and lock nut (A) from the tie rod.
3. Remove the bellows clip (A) and band (B) and then pull the bellows (C) away from the end of the tie rod.
4. Remove the tie rod (B) from the rack bar (A) by unscrewing the tie rod inner ball joint.
5. Remove the plug (A) from the pinion housing.
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6. Remove the oil seal (B) from the plug (A).
7. Remove the lock nut (A), yoke plug (B), spring (C) and support yoke (D).
8. Remove the O-rings (B) from the support yoke assembly (A).
9. Pull the pinion assembly (A) out of the pinion housing.
10. Pull the rack bar (A) out of the rack housing.
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INSPECTION
1. Rack bar
A. Check the rack gear for damage.
B. Check the rack bar for bend and deformation.
2. Pinion assembly
A. Check the pinion gear for damage.
B. Check the surface contacting the oil seal for damage.
C. Check the oil seal for damage.
3. Check the inside of rack housing for damage.
4. Check the bellows for being torn.
REASSEMBLY
1. Apply the grease to rack gear teeth and then insert the rack bar (A) into the rack hosing.
2. Insert the pinion assembly (A) into the pinion housing.
3. Tap the top of the pinion assembly with a plastic hammer to seat the pinion assembly thoroughly.
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4. Assemble new O-rings (B) to support yoke (A).
5. Insert the support yoke assembly (D) into the housing.

6. Apply the sealant to the thread of the yoke plug and then assemble the yoke plug (B) and the yoke spring (C)
together. Tighten the lock nut (A).

4.9 ~ 6.8 (0.5 ~ 0.7, 0.3 ~ 0.5)
7. Apply the grease to the edge of the new oil seal (B) and then assemble it to the pinion plug (A).
8. Apply the sealant to the thread of the plug and then assemble the pinion plug (A) to the housing.

51 ~ 71 (5.1 ~ 7.1, 37 ~ 51)
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9. Assemble the tie rod (A) to the rack bar (B).

80 ~ 100 (8.0 ~ 10.0, 58 ~ 72)
10. Assemble new bellows band (A) to the bellows.
11. Apply the grease to the portion (C) of the tie-rod.

12. Apply the sealant to the bellows mating surface of the rack housing.
13. Assemble the bellows (B) to rack housing and then tighten the bellows clip (A) and band.
14. Assemble the lock nut (A) and tie rod end (B) to tie rod.
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Manual Transaxle System
General Information
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2010 > G 1.0 SOHC >
SPECIFICATIONS
Engine type Gasoline 1.1
Transaxle type M5EF2
Gear ratio 1st 3.545
2nd 1.894
3rd 1.192
4th 0.853
5th 0.719
Reverse 3.636
Final gear ratio 4.437
TIGHTENING TORQUES
Standard value Nm kgf.m lb-ft
Oil drain plug 60-80 6.0-8.0 43.4-57.8
Oil filler plug 60-80 6.0-8.0 43.4-57.8
Shift control cable bracket 20-27 2.0-2.7 14.5-19.5
Rear roll support bracket bolt 43-55 4.3-5.5 31.1-39.7
Transaxle support bracket bolts 43-55 4.3-5.5 31.1-39.7
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 vehicle occupants.
LUBRICANTS
Items Recommnend lubricant Quantity
SAE 75W/85
API GL-4
TGO-7(MS517-14)
Transaxle gear oil 1.9L(2.0US qt, 1.67lmp qt)
ZIC G-F TOP 75W/85(SK)
HD GEAR OIL XLS
75W/85(H.K.SHELL)
Air breather MS721-38 As requried
Transaxle housing MS721-40 or MS721-38 As requried
Surface of release fork and bearing Grease (CASMOLY L9508) release bearing 0.5~1.0g
release bearing and fork 0.3~0.5g
release fork and fulcram 0.5~10.g
release fork and clutch felease cylinder 0.4~0.8g
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2010 > G 1.0 SOHC >

TOOL
Illustration Use
(Number and Name)
09431-21000 Installation of differential oil seal.
Oil seal installer
09200-38001 Removal and installation of the transaxle.

Engine support fixture
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2010 > G 1.0 SOHC >
TROUBLESHOOTING
Symptom Probable cause Remedy
Vibration, noise Loose or damaged transaxle and engine mounts Tighten or replace mounts
Inadequate shaft end play Correct end play
Worn or damaged gears Replace gears
Inadequate grade of oil Replace with specified oil
Low oil level Replenish
Inadequate engine idle speed Adjust idle speed
Oil leakage Broken or damaged, oil seal or O-ring Replace control cable oil seal or O-ring
Hard shift Faulty control cable Replace control cable
Poor contact or wear of synchronizer ring and gear
Correct or replace
cone
Weakened synchronizer spring Replace synchronizer spring
Inadequate grade of oil Replace with specified oil
Jumps out of gear Worn gear shift fork or broken poppet spring Replace shift fork or poppet spring
Synchronizer hub-to-sleeve spline clearance too
Replace synchronizer hub and sleeve
large
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2010 > G 1.0 SOHC >
SERVICE ADJUSTMENT PROCEDURE

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 contaminated, it is necessary to replace it with new oil.
1. Remove oil filler plug (A).
2. Check level with finger.

Oil level must be up to fill the hole, add oil until it runs over.
3. Install the filler plug with new washer.
TORQUE :
60-80 Nm (6.0-8.0 kgf.m, 43.4-57.8 lb-ft)
REPLACEMENT
1. With the vehicle parked on a level surface, remove the drain plug.
2. Drain the transaxle oil after loosening the drain plug (A).
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3. Install the drain plug with new washer.
TORQUE :
60-80 Nm (6.0-8.0 kgf.m, 43.4-57.8 lb-ft)
4. Add new oil through the fille plug hole and, fill it ot just below the plug opening.
Standard oil : SAE 75W/85, API GL-4

Oil capacity: 1.9 liter (2.0 US qt, 1.67 lmp qt)
BACKUP LAMP SWITCH

INSPECTION
1. Disconnect the backup lamp switch connector(A).
2. Check the continuity between no. 1 and 2 terminals of backup lamp switch.
When the shift lever is in reverse, there should be contunuity.
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3. If necessary, repair or replace the backup lamp switch.
TORQUE :
30-35 Nm (3.0-3.5 kgf.m, 21.7-25.3 lb-ft)
DRIVE SHAFT OIL SEAL

REPLACEMENT
1. Remove the drive shaft from the transaxle. (refer to Front Driveshaft in DS group)
2. Using a flat-tip screwdriver, remove the oil seal.
3. Using the special tool(09431-21000), tap the drive shaft oil seal into the transaxle.
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Manual Transaxle System - Manual Transaxle
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL

1. Remove the battery after removing the battery (A) terminal.
2. Remove the battery tray (A).
3. Remove the upper cover (B) of the air cleaner by loosening the clamp (A).
4. Remove the lower cover of the air cleaner assembly.
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5. Remove the clutch cable bracket (A).
6. Remove the wire harness bracket bolts.

7. Disconnect the back up lamp switch connector (A) and the vehicle speed sensor connector (B).
8. Remove the transaxle control cables.
Move the bending parts to the arrow direction in the illustration before removing the 'one-touch' clips (A) from
the bracket.
9. Remove the transaxle control cable bracket.
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10. Remove the ground cable.
11. Installing the engine supporter(09200-38001), hold the enigne and transaxle assembly safely.
12. Remove the transaxle upper mounting bolts (A) and the starter mounting bolts (B).
13. Remove the transaxle mounting support bracket bolts.
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14. Remove the front tires.
15. Remove the under cover.
16. Remove the drive shaft from transaxle. (Refer to Front Driveshaft in DS group)
17. Remove the rear roll stopper bracket (A).
18. Remove the transaxle mounting bolts (A) from the engine side and the other (B) from the transaxle side.
19. Remove the dust cover (A).
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20. Remove the transaxle assembly from the engine assembly.
When removing the transaxle assembly, be careful not to damage any surrounding parts or body components
INSTALLATION
1. Temporarily install the transaxle assembly to the engine assembly.
Be careful not to damage any surrounding parts or body components.
2. Install the dust cover (A).
TORQUE :
8~10Nm(0.8~1.0kgf.m, 5.8~7.2lb-ft)
3. Install the transaxle mounting bolts (A) from the engine side and the other (B) from the transaxle side.
TORQUE :
43~55Nm(4.3~5.5kgf.m, 31.1~39.7lb-ft)
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4. Install the rear roll stopper bracket (A).
TORQUE :
43~55Nm(4.3~5.5kgf.m, 31.1~39.7lb-ft)
5. Install the drive shaft to the transaxle assembly. (Refer to Front Driveshaft in DS group)
6. Install the under cover.
7. Install the front tires.
8. Install the transaxle mounting support bracket bolts.
TORQUE :
43~55Nm(4.3~5.5kgf.m, 31.1~39.7lb-ft)
9. Install the transaxle upper mounting bolts (A) and the starter mounting bolts (B).
TORQUE :
[A] : 43~55Nm(4.3~5.5kgf.m, 31.1~39.7lb-ft)
[B] : 27~34Nm(2.7~3.4kgf.m, 19.5~24.6lb-ft)
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10. Remove the engine supporter(09200-38001).
11. Install the transaxle control cable bracket.
TORQUE :
20~27Nm(2.0~2.7kgf.m, 14.5~19.5lb-ft)
12. Install the transaxle control cable by using new 'one-touch' clips (A).
13. Install the wire harness bracket bolts.

14. Connect the backup lamp switch connector (A) and the vehicle speed sensor connector (B).
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15. Install the clutch cable bracket (A).
16. Install the lower cover of the air cleaner assembly.
17. Install the upper cover (B) of the air cleaner assembly by tightening the clamp (A).
18. Install the battery tray (A).
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19. Install the battery and the battery (A) terminal.
Perform the following :

• Adjust the shift cable.
• Refill the transaxle with fluid.
• Clean the battery posts and cable terminals with sandpaper, assemble them, then apply grease to prevent
corrosion.
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Manual Transaxle Control System - Manual

Transaxle Shift Control
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2010 > G 1.0 SOHC >
COMPONENTS
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Automatic Transaxle System
General Information
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2010 > G 1.0 SOHC >
SPECIFICATIONS
Transaxle model A4CF0
Engine model Gasoline 1.1L/ 1.0L
T/con 3 elements 2 phases 1 stage
T/con size (!) 210
O/PUMP type Parachoid
T/M CASE type Separated
Clutch: 3EA
Friction elements Brake: 2EA
OWC : 1EA
Planetary gear 2EA
1st 2.919
2nd 1.551
Gear ratio 3rd 1.000
4th 0.713
Reverse 2.480
Final gear ratio 4.587(1.1L)/ 4.336(1.0L)
Fluid pressure balance piston 2EA
Stall speed 2,000~2,700 rpm
Accumulator 4EA
Solenoid valve 6EA (PWM:5EA, VFS:1EA)
Gear shift position 6 range (P,R,N,D,2,L)
Oil filter 1EA
• PWM : Pulse Width Modulation

• VFS : Variable Force Solenoid
Tightening torques
Item Nm kgf.m lb-ft
Transaxle lower mounting bolts 43~55 4.3~5.5 31.1~39.8
Rear roll stopper mounting bolts 50~65 5.0~6.5 36.2~47
Torque converter mounting bolts 46~53 4.6~5.3 33.3~38.3
Transaxle insulator mounting bracket 50~65 5.0~6.5 36.2~47
Transaxle upper mounting bolts 43~55 4.3~5.5 31.1~39.8
Starter motor mounting bolts 27~34 2.7~3.4 19.5~24.6
Control cable assembly 10~14 1.0~1.4 7.2~10.1
Retainer and bolts 10~14 1.0~1.4 7.2~10.1
Shift lever assembly 10~14 1.0~1.4 7.2~10.1
Lubricants
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Item Specified lubricant Quantity
Transaxle fluid liter (US qt, lmp.qt) GENUINE DIAMOND ATF SP-III or SK ATF SP -III 6.1(6.45, 5.37)
Sealant
Item Specified sealant
Rear cover
Torque converter housing LOCTITE FMD-546
Oil pan
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2010 > G 1.0 SOHC >
Special service tools

Tool
Illustration Use
(Number and name)
09200-38001 Removal and installation of the transaxle.
Engine support fixture
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2010 > G 1.0 SOHC >
Description
The new small sized automatic transaxle (A4CF0) is for Epsilon 1.1 gasoline engine.
The transaxle (A4CF0) is improved on the durability, fuel consumption and efficiency by the new main features as
followed.
The new main features

1. The hydraulic centrifugal oil pressure balance piston.
2. The full line pressure variable control system.
3. The long travel damper clutch.
4. The disc type return spring.
5. The ultra flat torque converter.
Functions
Item Contents
The full line pressure variable control operates in the valve body to improve the fuel consumption.
The long travel damper clutch is applied to the torque converter to improve the engine revolution
change reduction capability and the fuel consumption. (14~16°)
The oil pump of the trochocentric type is changed to parachoid type to improve the processing and
the capacity efficiency at the low RPM range.
Components The disc type return spring is applied to the low&reverse brake to improve the durability and reduce
the length.
The hydraulic centrifugal oil pressure balance piston is applied to the inside of clutch to improve the
durability and the shift control capability.
The low noise gear and the gear teeth face grinding are applied to the transfer driven gear to
improve the noise and the durability.
The oil pressure value set by TCM is coupled with the engine torque so that the stable shift feeling
can be improved.
The engine torque reduction control operates effectively to improve the shift feeling and the
durability.
It can be the skip shift of 1!3 and 2!4 when shifting.
The reverse clutch, not L/R brake is controlled when controlling the N"R shift so that the N"R
Electronic shift feeling can be improved.
control system The range of the damper clutch direct control expands to improve the fuel consumption.
The current control chip is installed into the TCM to regulate the solenoid control current and
control the oil pressure securely according to the change of the temperature and voltage.
The FPC(Flexible Printed Circuit) harness is composed of the thin and flat copper in the insulating
film like electric wire.
The tachometer is operated by the change of the frequency forwarded from the TCM to the
instrument cluster, not vehicle speed sensor.
Mechanical system
Function
Torque Converter
The torque converter, as the power plant which delivers the power of engine to the automatic transaxle, consists of 3
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elements, 2 phases and 1 stage type.
- The flowing section form of the torque converter changes the round type to the flat type to reduce the length of
the torque converter.
- The maximum operating degree of the damper clutch installed inside the transaxle increases from 11° to 15° to
improve the engine revolution change reduction capability and the fuel consumption.
Oil pump
The oil pump is made of the aluminum (the reaction shaft support) to loose the weight and selects the parachoid
type to improve the processing and the capacity efficiency at the low RPM range.
Brakes
The automatic transaxle (A4CF0) uses the low and reverse brake and the second brake. The low and reverse brake
fixes the low and reverse annulus gear and overdrive planetary carrier.
- The disc type return spring is applied to the low and reverse brake and it minimizes the slip of the friction material
from the uniform spring operation power to improve the durability and reduce the length.
The reverse sun gear is held on the transaxle case by the second brake.
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Clutch
The multiple clutches and the one way clutch are used as the transaxle device.
The retainer of each clutch is composed of the precision sheet metal parts to realize the productivity and the light
weight.
The hydraulic centrifugal oil pressure balance device places inside the clutch assembly.
Generally the oil remained in the piston oil pressure chamber pushes the piston by the centrifugal force. But to
prevent the piston from being pushed, the oil filled in between the piston and the return spring retainer occurs the
centrifugal force and both of the power is offset so that the piston don't move. In result, it improves the durability and
the shift control ability.
1. Underdrive Clutch
The driving force of input shaft is delivered to the underdrive sun gear.
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The operating oil pressure in the underdrive clutch components operates between the piston and the retainer and
pushes the piston to the clutch discs to deliver the driving force from the retainer to the hub.
2. Reverse clutch and overdrive clutch

The reverse clutch delivers the driving force of input shaft to the reverse sun gear.
The overdrive clutch delivers the driving force of input shaft to the overdrive planetary carrier and the low and reverse
annulus gear.
The operating oil pressure of the reverse clutch operates between the reverse clutch retainer and reverse clutch
piston and it has the whole overdrive clutch moved through hub splines.
Structure of the reverse and the overdrive clutch
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Parking system
The parking system for A4CF0 model is the cam type.
The roller type installed to the existing new generation AT needs the support to move the roller when operating the
parking system and is so complicated. But the cam type for A4CF0 model doesn't need the support and the structure
is simply. It only needs the guide to prevent from moving the cam idly.
OPERATION
Hydraulic control system
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MAIN FEATURES
The VFS (Variable Force Solenoid) installed in the valve body is applied to transaxle(A4CF0). VFS varies the line
pressure from 4.5bar to 10.5bar according to throttle open angle and shift range to improve the fuel consumption and
shift ability.
And the reducing valve which is installed in the valve body makes the solenoid control pressure using the reducing
pressure instead of the line pressure like the HIVEC transaxle.
The material of spool valve in the valve body is changed from the steel to aluminum to reduce the oil leakage by the
thermal expansion between the valve body and spool valve at the high temperature.
The switch valve, the solenoid valve and the fail safe valve are operated to drive the vehicle at the 3rd speed and
reverse even though the malfunction of the electronic control parts occur.
ELECTRONIC CONTROL SYSTEM
SENSOR AND ACTUATOR FUNCTION
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ITEM FUNCTION
Input speed sensor Detect the input shaft rpm(TURBINE RPM) at the OD/RVS retainer
Output speed sensor Detect the output shaft rpm(T/F DRIVEN GEAR RPM) at the T/F driven gear
Engine rpm signal Receive the engine rpm via CAN communication with ECM
Oil temperature sensor Detect the temperature of ATF through the thermistor
Inhibitor switch Detect the position of select lever through the contact switch
ON/OFF solenoid valve
Control the hydraulic passage for the shift control
(SCSV-A)
Change the line pressure from 4.5 bar to 10.5 bar according to throttle open angle and
VFS solenoid valve
shift ranges
PCSV-A(SCSV-B) Control the OD or L/R hydraulic pressure to the pressure control valve for shift control
Control the 2nd/B or REV hydraulic pressure to the pressure control valve for shift
PCSV-B(SCSV-C)
control
PCSV-C(SCSV-D) Control the UD hydraulic pressure to the pressure control valve for shift control
PCSV-D(TCC) Control the hydraulic pressure for the damper clutch control
Cluster Send the signal of the current position of shift lever and vehicle speed
CAN Communication
layout
ECM- TCM CAN Communication error management
No. Item Error management

1 Engine rpm 3,000 RPM
2 Engine torque 80%
3 Vehicle speed 0 km/h
4 A/C Switch OFF
5 Engine coolant temperature 70°C
6 TPS 50%
7 Shift range hold signal OFF
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2010 > G 1.0 SOHC >
TROUBLESHOOTING
DIAGNOSTIC TROUBLE CODES (INSPECTION PROCEDURE)
Check the Diagnostic Trouble Codes
1. Turn the ignition switch to OFF.
2. Connect the Hi-scan tool to the DLC connector for diagnosis.
3. Turn the ignition switch to ON.
4. Check the diagnostic trouble codes using the Hi-scan tool.
5. Read the output diagnostic trouble codes. Then follow the remedy procedures according to the "DIAGNOSTIC
TROUBLE CODE DESCRIPTION" on the following pages.
• A maximum of 5 diagnostic trouble codes (in the sequence of occurrence) can be stored in the Random
Access Memory (RAM) incorporated within the control module.
• The same diagnostic trouble code can be stored one time only.
• If the number of stored diagnostic trouble codes or diagnostic trouble patterns exceeds 5, 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 cancelled when
the battery is disconnected.
• All diagnostic trouble codes are deleted from memory the 200th time the ATF temperature reaches
50°C(122°F) after memorization of the most recent diagnostic code.
6. Delete the diagnostic trouble code.

7. Disconnect the Hi-scan tool.
DTC cleaning should only be done with the scan tool.
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2010 > G 1.0 SOHC >
BASIC INSPECTION ADJUSTMENT

TRANSAXLE FLUID LEVEL
INSPECTION
1. Drive the vehicle until the fluid reaches normal operating temperature [70~80°C(158~176°F)].
2. Place the vehicle on a level surface.
3. Move the gear selector lever through all gear positions. This will fill the torque converter with trans fluid. Set the
selector lever to the "N" (Neutral) position.
4. Before removing the oil level gauge, wipe all contaminants from around the oil level gauge. Then take out 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
bushes and friction materials, a transmission overhaul may be necessary.
5. Check that the fluid level is in the "HOT" mark on the oil level gauge. If fluid level is low, add automatic transaxle
fluid until the level reaches the "HOT" mark.
Automatic transaxle fluid :

DIAMOND ATF SP-III, SK ATF SP-III
Automatic transaxle fluid capacity:
6.1liter(6.45 US qt, 5.37lmp.qt)
Low fluid level can cause a variety of abnormal conditions because it allows the pump to take in air along with
fluid. Air trapped in the hydraulic system forms bubbles, which are compressible. Therefore, pressures will be
erratic, causing delayed shifting, slipping clutches and brakes, etc. Improper filling can also raise fluid level too
high. When the transaxle has too much fluid, gears churn up foam and cause the same conditions which occur
with low fluid level, resulting in accelerated deterioration of automatic transaxle fluid. In either case, air bubbles
can cause overheating, and fluid oxidation, which can interfere with normal valve, clutch, and brake operation.
Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak.
6. Insert the oil level gauge securely.
When new, automatic transmission fluid should be red, The red dye is added so the assembly plant can
identify it as transmission fluid and distinguish it from engine oil or antifreeze. The red dye, which is not an
indicator of fluid quality, is not permanent. As the vehicle is driven the transmission fluid will begin to look
darker. The color may eventually appear light brown.
REPLACEMENT
If you have a fluid changer, use this changer to replace the fluid. If you do not have a fluid 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
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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(A) from the bottom of the transmission case to drain the fluid.
4. Install the drain plug via the gasket, and tighten it the specified torque.
TORQUE:
40~50 Nm (4.0~5.0kgf.m, 28.9~36.2lb-ft)
5. Pour the new fluid in through the oil filler tube.
Stop pouring if the full volume of fluid cannot be poured in.
6. Repeat the procedure in step (2).
Check the old fluid for contamination. If it has been contaminated, repeat the steps (5) and (6).
7. Pour the new fluid in through the oil filler tube.

8. Reconnect the hose, which was disconnected in step (1) above, and firmly replace the oil level gauge.
(In case of this "replace", this means after wiping off any dirt around the oil level gauge, insert it into the filler tube.)
9. Start the engine and run it at idle for 1~2 minutes.
10. Move the select lever through all positions, and then move it to the "N" or "P" position.
11. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80°C(158~176°F)), and then
check the fluid level again. The fluid level must be at the HOT mark.
12. Firmly insert the oil level gauge into the oil filler tube.
TORQUE CONVERTER STALL TEST

This test measures the maximum engine speed when the select 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 (176~212°F)
C. Engine coolant temperature : 80~100°C (176~212°F)
2. Check both rear wheels (left and right).
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3. Pull the parking brake lever on, with the brake pedal fully depressed.
5. Move the select lever to the "D" position, fully depress the accelerator pedal and take a reading of the maximum
engine speed at this time.
• The throttle should not be left fully open for any more than 5 seconds.
• If carrying out the stall test two or more times, move the select lever to the "N" position and run the engine
at 1,000 r/min to let the automatic transaxle fluid cool down before carrying out subsequent tests.
• Move the select lever to the "R" position and carry out the same test again.
Stall rpm : 2,000~2,700 RPM
Range Condition Passable cause

REV in D range normal
R range slip Reverse
L/R in D range abnormal
L/R in reverse range abnormal
D1 range slip D range 1st/ Sports mode 1st
UD in reverse range normal
OD in 3rd gear slip
D3 range slip 3rd gear hold
(1st and 2nd gear normal)
Torque converter
Forwarding, reverse
D range, R range Oil pump, Manual valve in the valve
slip
Driving device abnormal
HYDRAULIC PRESSURE TEST

1. Warm up the engine until the automatic transaxle fluid temperature is 80~100°C(176~212°F).
2. Jack up the vehicle so that the wheels are free to turn.
3. Connect the special tools(09452-21500, 09452-21000) 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.
5. If a value is outside the standard range, correct the problem while referring to the hydraulic pressure test diagnosis
table.
A. Bottom side
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STANDARD HYDRAULIC PRESSURE TABLE
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Automatic Transaxle System - Automatic

Transaxle
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2010 > G 1.0 SOHC >
COMPONENTS (1)
COMPONENTS (2)
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2010 > G 1.0 SOHC >
REMOVAL

1. Remove the battery (A).
2. Remove the battery tray (A).
3. Remove the upper cover (B) of the air cleaner by loosening the clamp (A).
4. Remove the lower cover (A) of the air cleaner.
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5. Remove the inhibitor switch connector (A) and radiator hose clip (B) and connector.
6. Remove the connector clip and connector bracket (A).
7. Disconnect the solenoid valve connector (A) and the input speed sensor connector (B).
8. Disconnect the output speed sensor connector (A).
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9. Remove the control cable assembly (A).
10. Remove the oil level gauge (A).
11. Remove the oil cooler hoses (A) and the ground cable from transaxle (B).
12. Remove the wiring harness clip (A).
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13. Remove the transaxle upper mounting bolts (A-2ea) and the starter motor mounting bolts (B-2ea).
14. Install the special tools (09200-38001), the engine support fixture and the adapter on the engine assembly.
15. Remove the transaxle support mounting bracket bolts (A).
16. Remove the front wheels and tires.

17. Drain the transaxle fluid by removing the oil drain plug (A).
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18. Remove the under shield cover (A).
19. Disconnect the LH/RH drive shafts from the transaxle. (refer to Front Driveshaft in DS group)
20. Remove the torque converter mounting bolts cover (A).
21. Remove the torque converter mounting bolts (A-3ea).
Remove the bolts (A-3ea) rotating the crankshaft clockwise.
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22. Install the transaxle jack.
23. Remove the rear roll stopper mounting (A) bolts.
24. Remove the transaxle lower mounting bolts (A,B).
25. Lowering the jack slowly, remove the transaxle (A).
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When removing the transaxle assembly, be careful not to damage any surrounding parts or body
components.
INSTALLATION
1. Install the transaxle (A).
2. Install the transaxle lower mounting bolts (A,B)
TORQUE :
43~55Nm (4.3~5.5kgf.m, 31.1~39.8lb-ft)
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3. Install the rear roll stopper mounting (A) bolts.
TORQUE :
50~65Nm (5.0~6.5kgf.m, 36.2~47lb-ft)
4. Install the torque converter mounting bolts (A-3ea).
TORQUE :
46~53Nm (4.6~5.3kgf.m, 33.3~38.3lb-ft)
Install the bolts (A-3ea) rotating the crankshaft colckwise.
5. Install the torque converter mounting bolts cover (A).
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6. Connect the drive shafts to the transaxle. (refer to Front Driveshaft in DS group)
7. Install the under shield cover (A).
8. Install the front wheels and tires.

9. Install the transaxle support mounting bracket bolts (A).
TORQUE :
50~65Nm (5.0~6.5kgf.m, 36.2~47lb-ft)
10. Remove the special tool (09200-38001).
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11. Install the transaxle upper mounting bolts (A-2ea) and the starter motor mounting bolts (B-2ea).
TORQUE :
[A] 43~55Nm (4.3~5.5kgf.m, 31.1~39.8lb-ft)
[B] 27~34Nm (2.7~3.4kgf.m, 19.5~24.6lb-ft)
12. Install the wiring harness clip (A).
13. Install the oil cooler hoses (A) and the ground cable from transaxle (B).
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14. Install the oil level gauge (A).
15. Install the control cable assembly (A).
TORQUE :
10~14Nm (1.0~1.4kgf.m, 7.2~10.1lb-ft)
16. Install the output speed sensor connector (A).
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17. Connect the solenoid valve connector (A) and the input speed sensor connector (B).
18. Install the connector clip and connector bracket (A).
19. Install the inhibitor switch connector (A) and radiator hose clip (B) and connector.
20. Install the lower cover (A) of the air cleaner.
21. Install the upper cover (B) of the air cleaner assembly by connecting and tightening the clamp (A).
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22. Install the battery tray (A).
23. Install the battery (A).
24. After completing the installation perform the following procedure.

A. Adjust the shift cable.
B. Refill the transaxle fluid.
C. Clean the battery posts and cable terminals with sandpaper and grease them to prevent corrosion before
installing.
When replacing the automatic transaxle, reset the automatic transaxle's values by using the High- Scan Pro.
1. Connect the Hi-Scan Pro connector to the data link connector under the crash pad and power cable to the
cigar jack under the center facia.
2. Turn the ignition switch on and power on the Hi-Scan Pro.
3. Select the vehicle's name.
4. Select 'AUTOMATIC TRANSAXLE'.
5. Select 'RESETTING AUTO T/A VALUES' and perform the procedure
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6. Perform the procedure by pressing F1 (REST).
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Valve Body System - Solenoid Valve
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2010 > G 1.0 SOHC >
DESCRIPTION
TCM calculates the best condition using the information from all kinds of sensors. If the solenoid valve receives the
information on the oil pressure, the solenoid valve actuates according to the driving signal. All kinds of regulators in
the valve body are controlled to change the oil passage and also the line pressure is controlled by TCM.
! PWM (Pulse Width Modulation) SOLENOID VALVE

Structure and functions
PWM solenoid valve is composed of five solenoid valves and the oil capacity in the solenoid valve is changed by the
electric duty value of TCM. The oil pressure of the valve body and the torque converter engages or disengages the
damper clutch. The solenoid valves send the operating oil pressure to the clutches and brakes at the each range and
also control the strength and weakness of oil pressure to reduce the shock when shifting the range.
PWM (Pulse Width Modulation) solenoid valve control feature
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PWM solenoid valve is controlled linearly according to the duty ratio.
Oil pressure range:

0~4.3 kgf/cm! (0~422kPa, 0~61.2psi)
Type 3way & Normal High

Input voltage 12V
Coil resistance 3.2±0.2" (at 25°C, 77°F)
Cycle 50Hz
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2010 > G 1.0 SOHC >
Removal
1. Remove the battery terminal.
2. Lift the vehicle.
4. Loosen the drain plug and drain the transaxle oil.
5. Remove the oil pan. (Refer to Automatic transaxle's disassembly in 'A4CF0' overhaul manual)
6. Remove the oil filter.
7. Remove the valve body. (Refer to Valve body's disassembly in 'A4CF0' overhaul manual)
8. Disconnect the main harness(A) from valve body.
9. Remove the PWM solenoid valve assembly(A).
Installation
1. Install the solenoid valve.
Apply the ATF oil or White Vaseline to the O-ring not to be damaged.
2. Connect the solenoid valve connector to the valve body.
When connecting the solenoid valve connector, check the connector for rust, dirt, or oil, then reconnect it.
3. Install the valve body. (Refer to Valve body's reassembly in 'A4CF0' overhaul manual)
TORQUE :
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)
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4. Install the oil filter.
TORQUE :
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)
5. Continue to apply liquid gasket at application points at the oil pan with Ø2.5mm (0.098in) thickness.
Liquid gasket Part name : Threebond 1281B
6. Tighten the mounting bolt with the specified torque after installing the oil pan.
TORQUE :
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)
7. Install the drain plug.
TORQUE :
40~50Nm(4.0~5.0kgf.m, 28.9~36.2lb-ft)
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Valve Body System - VFS (Variable Force

Solenoid) Valve
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2010 > G 1.0 SOHC >
Description
VFS valve controls the regulator valve and varies the line pressure from 4.5bar to 10.5bar according to the throttle
open angle and the shift range. The holder is installed on the upper side of the case and the filter is installed to the
two places on the holder outside to prevent in the strange material from flowing in the VFS.
VFS (Variable Force Solenoid) valve control feature
VFS solenoid valve is controlled linearly according to the current value.

type 3way & Normal High
Input voltage 12V
Coil resistance 3.5±0.2!(at 25°C, 77°F)
Operating current 0 ~ 1100 mA
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2010 > G 1.0 SOHC >
Removal
8. Disconnect the VFS solenoid valve connector (A).
9. Remove the solenoid valve assembly (B).
Installation
1. Install the solenoid valve (B).
Apply the ATF oil or White Vaseline to the O-ring not to be damaged.
2. Connect the solenoid valve connector (A).
When connecting the solenoid valve connector, check the connector for rust, dirt, or oil, then reconnect it.
TORQUE :
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)
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TORQUE :
5~7Nm(0.5~0.7kgf.m, 4~5lb-ft)
5. Continue to apply liquid gasket at application points at the oil pan with Ø2.5mm (0.098in) thickness.
6. Tighten the mounting bolt with the specified torque after installing the oil pan.
TORQUE :
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)
TORQUE :
40~50Nm(4.0~5.0kgf.m, 28.9~36.2lb-ft)
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Automatic Transaxle Control System - Input

Speed Sensor
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2010 > G 1.0 SOHC >
Description
1. Type : HALL SENSOR
Sensor type 2. Operating voltage : DC 12V
3. Current consumption : 22mA (Max)
1. Input speed sensor: Detect the input shaft rotation at the OD & REV retainer side to control oil
pressure when shifting.
Function
2. Feedback control, clutch-clutch control, damper clutch control, shift range control, incorrect ratio
control and sensor trouble detection signal.
Connector
SPECIFICATION
Item Inspection item Standard value
Air gap Input speed sensor 0.05in(1.3mm)
Sensor resistance Input speed sensor Over 500V, 1M!
HIGH Over 4.8V
Output voltage
LOW Below 0.8V
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2010 > G 1.0 SOHC >
Removal
2. Remove the battery and battery tray.
3. Remove the air duct.
4. Remove the air cleaner assembly. (Refer to Automatic transaxle's Removal)
5. Remove the input speed sensor connector (A).
6. Remove the input speed sensor (A).
Installation
1. Install the new O-ring to the input speed sensor.
2. Install the input speed sensor (A).
TORQUE:
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)
While installing the input shaft speed sensor, do not allow dust or other foreign particles to enter the transaxle.
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3. Check the connector for dust, dirt, or oil, and then connect the input speed sensor connector (A) securely.
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Automatic Transaxle Control System -

Output Speed Sensor
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2010 > G 1.0 SOHC >
Description
1. Type : HALL SENSOR
Sensor type 2. Output voltage : DC 12V
3. Current consumption : 22mA (Max)
1. Output speed sensor : Detect the output shaft rpm(T/F DRIVEN GEAR RPM) at the T/F driven
gear
Function
2. Feedback control, clutch-clutch control, damper clutch control, shift range control, incorrect ratio
control and sensor trouble detection signal.
Connector
SPECIFICATION
Item Inspection item Standard value
Air gap Output speed sensor 0.033in(0.85mm)
Sensor resistance Output speed sensor Over 500V, 1M!
HIGH Over 4.8V
Output voltage
LOW Below 0.8V
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2010 > G 1.0 SOHC >
Removal
5. Remove the output speed sensor connector (A).
6. Remove the output speed sensor (A).
Installation
1. Install the new O-ring to the output speed sensor.
2. Remove the output speed sensor (A).
TORQUE:
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)
While installing the output speed sensor, do not allow dust or other foreign particles to enter the transaxle.
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3. Check the connector for dust, dirt, or oil, then connect the output speed sensor connector (A) securely.
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Transaxle Oil Temperature Sensor
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2010 > G 1.0 SOHC >
DESCRIPTION
1. Type : Thermister
Sensor type
2. Use available temperature :-40~160°C(-40~320°F)
1. Detect the temperature of ATF through the thermistor which is exposed outside.
Function and feature
2. When shifting the range, it is used as the oil pressure control information.
Connector
Temp.[°C(°F)] Resistance (k!) Temp.[°C(°F)] Resistance (k!)

-40(-40) 139.5 80(176) 1.08
-20(-4) 47.4 100(212) 0.63
0(32) 18.6 120(248) 0.38
20(68) 8.1 140(284) 0.25
40(104) 3.8 160(320) 0.16
60(140) 1.98
Installation location
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2010 > G 1.0 SOHC >
Removal
8. Disconnect the main harness connector (A) from the valve body.
Installation
1. Connect the main harness connector (A) to the valve body.
When connecting the oil temperature connector, check the connector for rust, dirt, or oil, then reconnect it.
TORQUE:
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)
TORQUE :
5~7Nm(0.5~0.7kgf.m, 4~5lb-ft)
4. Continue to apply liquid gasket at application points at the oil pan with Ø0.098in(2.5mm) thickness.
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5. Tighten the mounting bolt with the specified TORQUE after installing the oil pan.
TORQUE:
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)
TORQUE :
40~50Nm(4.0~5.0kgf.m, 28.9~36.2lb-ft)
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Inhibiter Switch
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2010 > G 1.0 SOHC >
Description
1. Type : ROTARY
Sensor tyep 2. Available temperature range : -40~150°C(-40~320°F)
3. TORQUE : 10~12Nm(1.0~1.2kgf.m, 7~8lb-ft )
Detect the position of select lever through the contact switch. It makes starting possible in "P" and
Function
"N".
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2010 > G 1.0 SOHC >
Removal
5. Disconnect the inhibitor switch connector (A).
6. Remove the control cable (A) from the manual control lever.
7. Remove the inhibitor switch and manual control lever.
Installation
1. Set the inhibitor switch to the "N" position.
2. Set the inhibitor switch control shaft to the "N" position.
3. Install the inhibitor switch and manual control lever.
TORQUE
Shaft nut: 17~21Nm(1.7~2.1kgf.m, 12~15lb-ft)
Bolt(2EA): 10~12Nm(1.0~1.2kgf.m, 7~8lb-ft )
4. Install the control cable (A) to the manual control lever.
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5. Connect the inhibitor switch connector (A).

7. Turn the ignition switch ON after installation.
Move the shift lever from "P" range to "L" range, and verify that the A/T gear position indicator follows the transaxle
range switch.
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Automatic Transaxle Control System - Shift

Lever
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL
1. Remove the center console. (refer to Console in BD group)
2. Remove the control cable assembly by removing the clamp (A) and the snap pin (B).
3. Remove the shift lever assembly (B) and the Disconnect the interlock switch connector (A).
4. Remove the retainer (A) and bolts (B).
5. Remove the control cable assembly from the transaxle assembly (refer to Automatic transaxle's removal).
6. Remove the control cable assembly.
INSTALLATION
1. Install the control cable assembly to transaxle assembly. (refer to Automatic transaxle's installation)
2. Install the retainer (A) and bolts (B).
TORQUE :
10~14Nm (1.0~1.4kgf.m, 7.2~10.1Ib-ft)
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3. Install the shift lever assembly (B) and the connect the interlock switch connector (A).
TORQUE :
10~14Nm (1.0~1.4kgf.m, 7.2~10.1Ib-ft)
4. Install the control cable assembly by installing the clamp (A) and the snap pin (B).
5. Install the center console. (refer to Console in BD group)
ADJUSTMENT
Adjusting method for the control cable
1. Set room side lever and T/M side lever (A) to "N" position.
2. Connect the room side lever and shift cable. (refer to Shift lever's 'Installation')
3. Connect the T/M side lever (A) to cable (B) in this following order;
(1) Push the cable (B) lightly to "F" direction shown to eliminate FREE PLAY of the cable (B).
(2) Tighten the adjusting nut(C).
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4. After adjusting the cable (B) according to procedure no. 2-3, check to be sure that this part operates surely at each
range of T/M side corresponding to each position of room lever.
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Restraint
General Information
Restraint
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2010 > G 1.0 SOHC >
PRECAUTIONS AND PROCEDURES

• Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative
cable from the battery, and wait at least three minutes before beginning work.
The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are
disconnected from the battery.
• Use the replacement parts which are manufactured to the same standards as the original parts and quality.
Do not install used SRS parts from another vehicle.
Use only new parts when making SRS repairs.
• Carefully inspect any SRS part before you install it.
Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or
deformation.
• Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS
connector.
AIRBAG HANDLING AND STORAGE

For temporary storage of the air bag during service, please observe the following precautions.
• Store the removed airbag with the pad surface up.
• Never twist the Curtain Airbag (CAB) module.
• Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly.
• Store the removed airbag on secure, flat surface away from any high heat source (exceeding 200°F/93°C).
• Never perform electrical inspections to the airbags, such as measuring resistance.
• Do not position yourself in front of the airbag assembly during removal, inspection, or replacement.
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• Refer to the scrapping procedures for disposal of the damaged airbag.
• Be careful not to bump or impact the SRS unit or the side impact sensors whenever the ignition switch is ON, or at
wait least for three minutes after the ignition switch is turned OFF before begin work.
• During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the
SRS unit and the side impact sensor. The airbags could accidentally deploy and cause damage or injury.
• After a collision in which the airbags were deployed, replace the front airbags and the SRS unit. After a collision in
which the side airbag was deployed, replace the side air bag and side impact sensor on the side where the side
airbag deployed and the SRS unit. After a collision in which the airbags or the side air bags did not deploy, inspect
for any damage or any deformation on the SRS unit and the side impact sensors. If there is any damage, replace
the SRS unit and/or the side impact sensors.
• Do not disassemble the SRS unit or the side impact sensors.
• Turn the ignition switch OFF, disconnect the battery negative cable and wait at least three minutes before
beginning installation or replacement of the SRS unit.
• Be sure the SRS unit and side impact sensors are installed securely with the mounting bolts.
• Do not spill water or oil on the SRS unit or the side impact sensors and keep them away from dust.
• Store the SRS unit and the side impact sensors in a cool (less than 104°F/40°C) and dry (less than 80% relative
humidity, no moisture) area.
WIRING PRECAUTIONS
SRS wiring can be identified by special yellow outer covering (except the SRS circuits under the front seats).
Observe the instructions described in this section.
• Never attempt to modify, splice, or repair SRS wiring.
If there is an open or damage in SRS wiring, replace the harness.
• Be sure to install the harness wires so that they are not pinched, or interfere with other parts.
• Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal
contact. Poor grounding can cause intermittent problems that are difficult to diagnose.
PRECAUTIONS FOR ELECTRICAL INSPECTIONS.
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• When using electrical test equipment, insert the probe of the tester into the wire side of the connector.
Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector.
• Use a u-shaped probe. Do not insert the probe forcibly.

• Use specificed service connectors for troubleshooting.
Using improper tools could cause an error in inspection due to poor metal contact.
SPRING-LOADED LOCK CONNECTOR

Some SRS system connectors have a spring-loaded lock.
AIRBAG CONNECTOR (I)
1. To reconnect, hold the pawl-side connector half, and press on the back of the sleeve-side connector half in the
direction shown. As the two connectpr halves are pressed together, the sleeve (A) is pushed back by the pawl (C).
Do not touch the sleeve.
2. When the connector halves are completely connected, the pawl is released, and the spring-loaded sleeve locks the
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connector.
AIRBAG CONNECTOR (II)
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2010 > G 1.0 SOHC >

Tool
Illustration Use
(Number and name)
0957A-34100A Airbag deployment tool
Deployment tool
0957A-38100 Use with deployment tool.

Deployment adapter
(SAB)
0957A-38500 Use with deployment tool.

Deployment adapter
(DAB, PAB, BPT)
0957A-38200 Simulator to check the resistance of each

Dummy wiring harness
0957A-38300 Use with dummy.

Dummy adapter
(SAB)
0957A-2G000 Use with dummy.

Dummy adapter
(DAB, PAB, BPT)
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09561-11002 Removal of steering wheel
Steering wheel puller
* DAB :Driver Airbag

* PAB : Prassenger Airbag
* SAB : Side Airbag
* BPT : Seat Belt Pretensioner
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2010 > G 1.0 SOHC >
WARNING LAMP ACTIVATION

! WARNING LAMP OPERATION DURING PROVE-OUT PHASE
The SRSCM shall perform a warning lamp bulb check. The lamp shall blink for 6 seconds (±10%), at 1Hz (± 10%),
50% duty cycle (± 10%), during the module power-on prove-out phase and be turned off afterwards.
The SRSCM shall perform a warning lamp check for 1 second after the initial 6 second prove-out period. If a recorded
crash or an active fault is present at power-up or at least 10 different fault qualifications have been recorded, the
airbag warning lamp output will be activated ON immediately after the 1 second lamp check.
When a current fault is detected at power-up, the lamp will not be affected until the end of prove-out. The lamp will
blink normally at the rate defined in Case #1 above.
! NORMAL WARNING LAMP OPERATION AFTER PROVE-OUT PHASE

1. A current fault condition is present after prove-out phase
2. Loss of internal operating voltage (Vdd)
3. During SRSCM reset
4. Hi-Scan (Pro) communication is active, the SRSCM resets at the end of communication.
The airbag warning lamp shall be deactivated (OFF), after a fault is dequalified.
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2010 > G 1.0 SOHC >
COMPOENTS LOCATION
DRIVER AIRBAG (DAB) / PASSENGER AIRBAG (PAB)
SIDE AIRBAG (SAB)
SEAT BELT PRETENSIONER (BPT) / SIDE IMPACT SNESOR (SIS)
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SRSCM
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2010 > G 1.0 SOHC >
SPECIFICATION
ITEM CONDITION SPECIFICATION
Driver Airbag (DAB) Resistance (!) 1.6 ~ 6.1 !
Passenger Airbag (PAB) Resistance (!) 1.6 ~ 6.1 !
Side Airbag (SAB) Resistance (!) 1.6 ~ 6.1 !
Seat Belt Pretensioner (BPT) Resistance (!) 1.6 ~ 6.1 !
TIGHTENING TORQUES
ITEM N!m lb!ft kgf!m
Driver Airbag Mounting Bolts 7.8 ~ 17.7 5.8 ~ 13.0 0.8 ~ 1.8
Passenger Airbag Mounting Nuts 5.9 ~ 9.8 4.3 ~ 7.2 0.6 ~ 1.0
Seat Belt Lower Anchor Bolt 39.2 ~ 53.9 28.9 ~ 39.8 4.0 ~ 5.5
SRSCM Mounting Bolt 7.8 ~ 9.8 5.8 ~ 7.2 0.8 ~ 1.0
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Restraint
Supplemental Restraint System Control

Module
Restraint
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2010 > G 1.0 SOHC >
CIRCUIT DIAGRAM
SRSCM CONNECTOR TERMINAL

SRSCM HARNESS CONNECTOR
Pin Function Pin Function

1~24 Shorting Bar 50 Battery Supply (Vbatt)
25 - 51 K-Line Diagnostic
26 - 52 -
27 - 53 -
28 - 54 -
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29 - 55 PAB Switch
30 - 56 -
31 - 57 -
32 Battery Ground 58 Crach Output (To ETACM)
33 Airbag warning Lamp 59 -
34 Seat Belt Pretensioner [Front-Passenger] Low 60 -
35 Seat Belt Pretensioner [Front-Passenger] High 61 -
36 Seat Belt Pretensioner [Front-Driver] High 62 Side Impact Sensor [Passenger] High
37 Seat Belt Pretensioner [Front-Driver] Low 63 Side Impact Sensor [Passenger] Low
38 (1st Stage) Passenger Airbag Low 64 Side Impact Sensor [Driver] High
39 (1st Stage) Passenger Airbag High 65 Side Impact Sensor [Driver] Low
40 (1st Stage) Driver Airbag High 66 -
41 (1st Stage) Driver Airbag Low 67 -
42 Side Airbag [Front-Passenger] Low 68 -
43 Side Airbag [Front-Passenger] High 69 -
44 Side Airbag [Front-Driver] High 70 -
45 Side Airbag [Front-Driver] Low 71 -
46 - 72 PAB cut off indicator
47 - 73 -
48 - 74 -
49 - 75 -
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Restraint
Supplemental Restraint System Control

Module - SRS Control Module
Restraint
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2010 > G 1.0 SOHC >
DESCRIPTION
The primary purpose of the SRSCM (Supplemental Restraints System Control Module) is to discriminate between an
event that warrants restraint system deployment and an event that does not. The SRSCM must decide if and when to
deploy the restraint system pretensioners and airbags. After determining that pretensioners and/or airbag deployment
is required, the SRSCM must supply sufficient power to the pretensioners and airbag igniters to initiate deployment.
The SRSCM determines that an impact may require deployment of the pretensioners and airbags from data obtained
from impact sensors and other components in conjunction with a safing function. The SRSCM will not be ready to
detect a crash or to activate the restraint system devices until the signals in the SRSCM circuitry stabilize. It is
possible that the SRSCM could activate the safety restraint devices in approximately 2 seconds but is guaranteed to
fully function after prove-out is completed. The SRSCM must perform a diagnostic routine and light a system
readiness indicator at key-on. The system must perform a continuous diagnostic routine and provide fault annunciation
through a warning lamp indicator in the event of fault detection. A serial diagnostic communication interface will be
used to facilitate servicing of the restraint control system.
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL
1. Disconnect the negative (-) cable from battery and wait for at least three minutes.
2. Remove ignition key from the vehicle.

3. Disconnect the DAB, PAB, SAB and BPT connectors.
4. Remove the center console (Refer to "BD" group in this Workshop Manual).
5. Disconnect the SRSCM harness connector (A) from the SRSCM (B).
6. Remove the SRSCM mounting bolts (A) from the SRSCM and pull out the SRSCM from the bracket.
Tightening Torque (SRSCM Mounting Bolt)

: 7.8 ~ 9.8 N·m (5.8 ~ 7.2 lb·ft)
INSTALLATION
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3. Install a SRSCM (B) on the bracket with the three mounting bolts (A).
Tightening Torque (SRSCM Mounting Bolt)

: 7.8 ~ 9.8 N·m (5.8 ~ 7.2 lb·ft)
4. Connect the SRSCM harness connector (A) with SRSCM (B).
5. Install the center console (Refer to " BD" group in this Workshop Manual).
6. Connect the DAB, PAB, SAB and BPT connectors.
7. After installing the SRSCM, confirm proper system operation:
A. Turn the ignition switch ON; the SRS indicator light should blink for about six seconds and then go off.
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Restraint
SRSCM - Side Impact Sensor (FIS)
Restraint
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2010 > G 1.0 SOHC >
DESCRIPTION
The Side Impact Sensor (SIS) system consist of two front SIS which are installed inside the B-Pillar (LH and RH) and
two rear SIS which are installed in the C-Pillar (LH and RH). They are remote sensor that detect acceleration due to
collision at their mounting locations. The primary purpose of the Side Impact Sensor (SIS) is to provide an indication of
a collision. The Side Impact Sensor (SIS) sends acceleration data to the SRSCM.
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2010 > G 1.0 SOHC >
COMPONENTS
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Restraint
Airbag Module
Restraint
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2010 > G 1.0 SOHC >
AIRBAG MODULE DISPOSAL PROCEDURES

Before 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.
When handling the deployed airbag be careful that not the dust enters your eyes and always wear gloves to
avoid direct contact with the dust.
AIRBAG REMOTE DEPLOYMENT DEVICES

Tool Name Use
1. Deployment tool To deploy a airbag module by compulsion.
2. Deployment tool adapter
DISPOSAL PLAN
Take the following disposal steps.
CASE DISPOSAL PLAN
Car scrapping DAB, PAB, BPT, SAB Deploy the airbag module with the SST
Crash (Deployed) Discard
UNDEPLOYED AIRBAG MODULE DISPOSAL
• If the vehicle is to be scrapped, junked, or otherwise disposed of, deploy the airbag inside the vehicle.
• 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.
• 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 :
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1. Open all windows and doors of the vehicle. Move the vehicle to an isolated spot.
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. Remove the Airbag SRSCM connector.
5. Connect the deployment tool to the connector of each module.
6. As far away from the vehicle as possible, press the push button on the depolyment tool to deploy the airbag.
• Before diploying the airbag in this manner, first check to be sure that there is no one in or near the vehicle.
Wear safety glasses.
• The inflator will be quite hot immediately following the deployment, so wait at least 30minutes to allow it to
cool before attempting to handle it. Although not poisonous, do not inhale gas from airbag deployment. See
the Deployed Airbag Module Disposal Procedures for post-deployment handling instructions.
• If the airbag fails to deploy when the procedures above are followed, do not go near the module. Clntact
your DPSM.
DEPLOYED AIRBAG MODULE DISPOSAL PROCEDURES

After deployment, the airbag module should be disposed of in the same manner as any other scrap part, except thath
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 hte 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 your eyes or on your skin, immediately rinse the affected area with a large amount of clean water, If any
irritation develops, seek medical attention.
4. Tightly seal the airbag module in a strong viny bag for disposal.
5. Be sure to always wash your hands after completing this operation.
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Restraint
Airbag Module - Driver Airbag (DAB) Module

and Clock Spring
Restraint
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2010 > G 1.0 SOHC >
DESCRIPTION
Driver Airbag (DAB) is installed in steering wheel and electrically connected to SRSCM via clockspring. It protects the
driver from danger with deploying a bag when frontal crash occurs. The SRSCM determines deployment of Driver
Airbag (DAB).
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.
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL
• Turn the front wheel to the straight-ahead position when removing/installing the Driver Airbag or Clockspring.
• Prior to installing the clockspring, set the clockspring on NEUTRAL position and after turning the front wheels
to the straight-ahead position, install the clockspring to the column switch. If the mating mark of the
clockspring is not properly aligned, the steering wheel may not completely rotate during a turn, or the flat
cable within the clockspring may be broken obstructing normal operation of the SRS and possibly leading to
serious injury to the vehicle's driver.
• Never attempt to disassemble or repair the airbag module or clockspring. If faulty, replace it.
• Do not drop the airbag module or clockspring or allow contact with water, grease or oil. Replace it if a dent,
crack, deformation or rust is detected.
• 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.
• Do not expose the air bag module to temperatures over 93°C(200°F).
• After deployment of an airbag, replace the clockspring with a new one.
• Wear gloves and safety glasses when handing an air bag that has been deployed.
• An undeployed airbag module should only be disposed of in accordance with the procedures mentioned in the
restraints section.
• When you disconnect the air bag module-clockspring connector, take care not to apply excessive force.
• The removed air bag module should be stored in a clean, dry place.

3. Unscrew the DAB mounting bolts (A) and disconnect the DAB connector.
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4. Remove the Driver Airbag (DAB) module from the steering wheel.
The removed airbag module should be stored in a clean, dry place with the pad cover face up.
5. Remove the steering-wheel lock nut (A).
6. After setting the steering shaft to the mark on wheel, remove the steering wheel (A) with the SST (09561-11002).
Don't strike the steering wheel with a hammer or other device. Damage to the steering wheel or components
could occur.
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7. Unscrew the three bolts (A) and remove the column shroud (B).
8. After disconnecting the clockspring connector, remove the clockspring.
INSTALLATION
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3. Install the clockspring and the steering wheel.
As described direction on the clock spring warning label, align the centerline with adjusting the setting
mark(▶◀) when installing the clock spring.
4. Connect the Driver Airbag (DAB) harness connectors, then install a Driver Airbag (DAB) module on the steering
wheel.
5. Secure the Driver Airbag (DAB) with the new mounting bolts (A).
Tightening Torque (DAB Mounting Bolt)

: 7.8 ~ 17.7 N·m (5.8 ~ 13.0 lb·ft)
6. Connect the battery negative cable.

7. After installing the airbag, confirm proper system operation:
A. Turn the ignition switch ON; the SRS indicator light should blink for about six seconds and thengo off.
B. Make sure both horn buttons work.
INSPECTION
personal injury.
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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 deformities, and harness for binds.
4. Check airbag inflator case for dents, cracks or deformities.
5. Install the airbag module to the steering wheel to check for fit or alignment with the wheel.
A. If, as a result of the following checks, even one abnormal point is discovered, replace the clock spring with a
new one.
B. Check connectors and protective tube for damage, and terminals for deformities.
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Restraint
Airbag Module - Passenger Airbag (PAB)

Module
Restraint
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2010 > G 1.0 SOHC >
DESCRIPTION
The passenger Airbag (PAB) is installed inside the dash and protects the front passenger in the event of a frontal
crash. The SRSCM determines if and when to deploy the PAB.
personal injury.
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL
• Never attempt to disassemble or repair the airbag module.

• Do not drop the airbag module or allow contact with water, grease or oil. Replace it if a dent, crack,
deformation or rust is detected.
• Do not expose the airbag module to temperature over 93°C(200°F).
• An undeployed airbag module should only be disposed in accordance with the procedures.
• 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.
• Whenever the PAB is deployed it should be replaced with a new one assembled with an extension wire. The
squib is melt down if the PAB is deployed making the extension wire useless.

3. Remove the Crashpad-main assembly.
A. Refer to "BD" group in this Workshop Manual.
4. Remove the PAB mounting bolts (2).
5. Remove the PAB module from the Crashpad-main asembly.
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INSTALLATION

3. Place a Passenger Airbag (PAB) on the instrument panel and tighten the Passenger Airbag (PAB) mounting nuts.
Tightening Torque (PAB Mounting Nut)

: 5.9 ~ 9.8 N·m (4.3 ~ 7.2 lb·ft)
4. Install the instrument panel (Refer to BD group in this Service Manual).

5. Connect the Passenger Airbag (PAB) harness connector to the SRS main harness connector.
Attach the Passenger Airbag (PAB) connector to the connector holder, then reinstall the glove box.
6. Reconnect the battery negative cable.
7. After installing the Passenger Airbag (PAB), confirm proper system operation:
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Restraint
Airbag Module - Side Airbag (SAB) Module
Restraint
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2010 > G 1.0 SOHC >
DESCRIPTION
The two Side Airbags (SAB) are installed inside the driver and passenger seat and protects the driver and front
passenger from danger when side crash occurs. The SRSCM determines deployment of side airbag by using Side
Impact Sensor (SIS) signal.
personal injury.
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL
• Never attempt to disassemble or repair the airbag module.

• Do not drop the airbag module or allow contact with water, grease or oil. Replace it if a dent, crack,
deformation or rust is detected.
• Do not expose the airbag module to temperature over 93°C(200°F).
• An undeployed airbag module should only be disposed in accordance with the procedures.
• 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.
• Whenever the SAB is deployed it should be replaced with a new one assembled with an extension wire. The
squib is melt down if the SAB is deployed making the extension wire useless.

3. Remove the driver or passenger seat (Refer to "BD" group in this Workshop Manual).
4. Remove the seat-back cover (Refer to "BD" group in this Workshop Manual).
5. Disconnect the SAB connector (A).
6. Unscrew the SAB mounting nuts (B) and remove the Side Airbag (SAB) module (A).
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INSTALLATION
Be sure to install the harness wires so that they are not pinched or interfering with other parts.
• Do not open the lid of the side airbag cover.

• Use a new mounting nuts when you replace a side airbag.
• Make sure that the seat-back cover is installed properly. Improper installation may prevent the proper
deployment.
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3. Place a Side Airbag (A) on the seat back-frame and tighten the side airbag mounting nuts (B).
4. Install the seat-back cover.
If the side airbag was deployed, replace the seat-back cover with a new one.
5. Install the seat assembly, then connect the Side Airbag (SAB) harness connector (A).
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6. Reconnect the battery negative cable.
7. After installing the Side Airbag (SAB), confirm proper system operation:
8. Recline and slide the front seat forward fully, make sure the harness wires are not pinched or interfering with other
parts.
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Restraint
Seat Belt Pretensioner - Seat Belt

Pretensioner (BPT)
Restraint
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2010 > G 1.0 SOHC >
DESCRIPTION
The Seat Belt Pretensioners (BPT) are installed inside B-Pillar (LH & RH). When a vehicle crashes with a certain
degree of frontal impact, the pretensioner seat belt helps to reduce the severity of injury to the front seat occupants by
retraction the seat belt webbing. This prevents the front occupants from thrusting forward and hitting the steering
wheel or the instrument panel when the vehicle crashes.
Never attempt to measure the circuit resistance of the Seat Belt Pretensioner (BPT) even if you are using the
specified tester. If the circuit resistance is measured with a tester, the pretensioner will be ignited accidentally.
This will result in serious personal injury.
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL
• Never attempt to disassemble or repair the Seat Belt Pretensioner (BPT).

• Do not drop the Seat Belt Pretensioner (BPT) or allow contact with water, grease, oil. Replace it if a dent,
crack, deformation or rust is detected.
• Do not place anything on the Seat Belt Pretensioner (BPT).
• Do not expose the Seat Belt Pretensioner (BPT) to temperature over 93°C(200°F).
• Seat Belt Pretensioner (BPT) functions one time only. Be sure to replace the Seat Belt Pretensioner (BPT)
after it is deployed.
• Be sure to wear gloves and safety goggles when handling the deployed Seat Belt Pretensioner (BPT).

3. Remove the seat belt lower anchor bolt.
Tightening Torque (Seat Belt Lower Anchor Bolt)

: 40 ~ 55 N·m (28.9 ~ 39.8 lb·ft)
4. Remove the center pillar lower trim.

A. After removing the fasteners (4), remove the front door scuff trim.
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B. After removing the screws (2) and the fastener, remove the rear door scurf trim.
C. Remove the center pillar lower trim.
5. Remove the center piller upper trim.

A. Remove the front seat belt upper anchor cover.
B. Remove the bolt and the upper anchor.
Tightening Torque : 40 ~ 55 N·m (28.9 ~ 39.8 lb·ft)
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C. Remove the center pillar upper trim.
6. Remove the seat belt prefensioner (BPT) connector stopper (A).
7. Remove the seat belt pretensioner (BPT) module.
INSTALLATION
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3. Place a Seat Belt Pretensioner (BPT) with bolt.
4. Install the upper anchor bolt.
Tightening Torque (Seat Belt Upper Anchor Bolt)

: 40 ~ 55 N·m (28.9 ~ 39.8 lb·ft)
5. Install the lower anchor bolt.
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Tightening Torque (Seat Belt Lower Anchor Bolt)
: 40 ~ 55 N·m (28.9 ~ 39.8 lb·ft)
6. Connect the BPT connector (A).
7. Install the center pillar trim.

8. Reconnect the negative battery cable.
9. After installing the Seat Belt Pretensioner (BPT), confirm proper system operation:
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Suspension System
General Information
Suspension System
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2010 > G 1.0 SOHC >
SPECIFICATION
FRONT SUSPENSION SYSTEM
Item Specification
Suspension type MacPherson Strut
Shock Type Oil

absorber Stroke [I.D. color] 159mm (6.26in.) [Red]
GSL M/T 337.8mm (13.30in.) [Green-Green]
General GSL A/T 341.6mm (13.45in.) [Blue-Blue]
Free Height DSL M/T 338.0mm (13.31in.) [Pink-Pink]

Coil spring
[I.D. color] GSL M/T 347.8mm (13.70in.) [Red-Red]
High
GSL A/T 351.6mm (13.84in.) [Brown-Brown]
Suspension
DSL M/T 348.0mm (13.70in.) [Violet-Violet]
REAR SUSPENSION SYSTEM

Item Specification
Suspension type Torsion Axle
Type Oil
Shock absorber GSL 182mm (7.17in.) [Red]
Stroke [I.D. color]
DSL 182mm (7.17in.) [Yellow]
GSL 263.5mm (10.37in.) [Yellow-Yellow]
General
Free Height DSL 241.3mm (9.50in.) [Pink-Pink]
Coil spring
[I.D. color] GSL 272.2mm (10.72in.) [Red-Red]
High
Suspension DSL 249.6mm (9.83in.) [Violet-Violet]
WHEEL AND TIRE

Item Specification
155/70 R13
165/60 R14
Tire
175/60 R14
175/50 R15
4.0B!13
Steel
5.0J!14
Wheel
5.0J!14
Aluminum
5.5J!15
Tire pressure 2.2kg/cm2 (32psi)
WHEEL ALIGNMENT
Specification
Item
Front Rear
Total 0°±0.2° 0.4°±0.2°
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Total 0°±0.2° 0.4°±0.2°
Toe-in
Individual 0°±0.1° 0.2°±0.1°
Camber 0°±0.5° -1°±0.5°
Caster 2.72°±0.5° -
King-pin 13°±0.5° -
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2010 > G 1.0 SOHC >

Tool (Number and Name) Use Illustration
09532-11600 Measurement of the lower arm ball joint &
Preload socket stabilizer link starting torque
09545-11000 Installation of the lower arm ball joint

Ball joint remover and
installer
09545-1C000 Lower arm ball joint snapring installation

Lower arm ball joint
snapring installer
09545-21100 Installation of the lower arm ball joint dust

Ball joint dust cover installer cover
09568-34000 Separation of the lower arm ball joint

Ball joint puller
0K2A1 341 AA1A Compression of the rear coil spring

Coil spring compresser
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2010 > G 1.0 SOHC >
TROUBLESHOOTING
SUSPENSION SYSTEM
Symptom Probable cause Remedy
Hard steering Improper front wheel alignment Correct
Excessive turning resistance of lower arm ball joint Replace
Flat tire Adjust
No power assist Repair or replace
Poor return of steering
Improper front wheel alignment Correct
wheel to center
Poor riding Improper front wheel alignment Correct
Damaged shock absorber Repair or replace
Broken or worn stabilizer Replace
Broken or worn coil spring Replace
Worn lower arm bushing Replace
Improper tire inflation pressure Correct
Abnormal tire wear Improper front wheel alignment Correct
Worn shock absorber Replace
Wandering Improper front wheel alignment Correct
Poor turning resistance of lower arm ball joint Repair
Loose or worn lower arm bushing Retighten or replace
Vehicle pulls to one side Improper front wheel alignment Correct
Bent lower arm Repair
Steering wheel shimmy Improper front wheel alignment Correct
Broken or worn stabilizer Replace
Worn lower arm bushing Replace
Worn shock absorber Replace
Bottoming Broken or worn coil spring Replace
Malfunctioning shock absorber Replace
Abnormal sound Loose parts Retighten
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
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Sagging or broken coil spring Replace
Vehicle body tilts to one Defective tire Replace
side
Worn bushing Replace
Deformation of torsional axle and arm assembly Replace
Worn bushings Replace
Sagging or broken coil spring Replace
WHEEL AND TIRE DIAGNOSIS

BOTH SIDES OF ONE SIDE OF TIRE
CENTER OF TREAD WORN CHUNKING OF TIRE
TREAD WORN WORN
• Over-Inflation • Center-tread down • Under-Inflation • When a patch of • Incorrect camber

to fabric due to • Bulge at the tread has angle
excessive over- shoulder loosened, torn off
Inflation • Rapid wear the tire by
centrifugal force at
high speed
TOTALLY UNSAFE
FLAT SPOT FEATHERING BAD PLUGGING UNEVEN TIRE WEAR
TIRE
• Caused by high- • Excessive toe-in • Using more than • Bad wheel • Tread worn below
speed braking toe-out one plug in a leak balance, fault in the limit
hard enough to distorts the tread, suspension,
lock up the wheel resulting in steering gear or
carcass failure bearing
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Suspension System
Front Suspension System
Suspension System
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2010 > G 1.0 SOHC >
COMPONENT
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Suspension System
Front Suspension System - Front Strut

Assembly
Suspension System
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2010 > G 1.0 SOHC >
COMPONENT
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2010 > G 1.0 SOHC >
REMOVAL
1. Remove the wheel and tire.
2. Remove the upper mounting nut cover.
3. Remove the upper mounting nut.
4. Remove the lower mounting bolts(2EA), the wheel speed sensor harness mounting bolt(A) and the stabilizer link
nut(B).
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5. Remove the front thrust assembly.
INSTALLATION
1. When installing the strut, clean the contact surface.
2. Install the lower mounting bolt, the wheel speed sensor and the stabilizer link mounting nut.
3. Install the upper mounting nut.
4. Install the upper mounting nut cover.
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DISASSEMBLY
1. Install the special service tool (0K2A1 341 AA1A) on the spring.
2. Fix the lower part of shock absorber on the vise.
3. Using the special tool, compress the spring and then remove the locking nut.
Do not loosen fully the nut.
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4. Installation is in the reverse order of removal.
INSPECTION
1. Check the strut insulator for wear and damage.
2. Check the rubber parts for damage or deformation.
3. Check the coil spring for sagging and deformation.
4. Check the shock absorber for abnormal resistance or noise.
DISPOSAL
1. Fully extend the piston rod.
2. Drill a hole on the "A" section to remove gas from the cylinder.
The discharged gas is harmless, but be careful not to hurt by broken pieces when drilling.
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Suspension System
Front Suspension System - Front Lower Arm
Suspension System
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2010 > G 1.0 SOHC >
COMPONENT
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2010 > G 1.0 SOHC >
REMOVAL
2. Using the special service tool (09568-34000), remove the tie rod end ball joint from the knuckle.
3. Remove the lower arm joint from the knuckle.
4. Remove the lower arm mounting bolt.
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5. Remove the lower arm assembly.
INSTALLATION
Installation is in the reverse order of removal.
Tighten the following parts to the specified torque.
Tightening torque : N·m (kgf·m, lb·ft)

Wheel nut : 88~108 (9~12, 65~80)
Lower arm ball joint nut : 59~71 (6~7.2, 43~52)
Lower arm bushing(A) : 127~147 (13~15, 94~109)
Lower arm bushing(B) : 93~118 (9.5~12, 69~87)
Stabilizer link nut : 34~44 (3.5~4.5, 25~33)

1. Using the flat-tipped (-) screwdriver, remove the lower arm ball joint.
2. Remove the snap ring.
3. Using the plastic hammer, separate the ball joint from the lower arm.
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4. Using the special service tool(09545-1100A/B), press-fit the lower arm assembly.
5. Using the special service tool (09545-1C00A/B), install the snap ring.
Be careful not to damage the snap ring.
6. Using the special service tool(09545-1C00A/B), install the snap ring.
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Apply the grease to the inner surface of dust and stud
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Suspension System
Rear Suspension System
Suspension System
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2010 > G 1.0 SOHC >
COMPONENT
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2010 > G 1.0 SOHC >
REMOVAL
2. Remove the rear hub unit bearing.
3. Remove the parking brake cable.
4. Remove the rear brake hose and brake tube.

5. After supporting the bottom of the rear torsion axle beam with a jack, remove the rear shock absorber lower
mounting bolt.
6. Remove the rear coil spring, lowering the jack slowly.

7. Remove the rear torsion axle beam bracket mounting bolts to the body.
INSTALLATION
2. Tighten the components below to the specified torque as follows.
Items Torque N!m (kgf!m, lb!ft)
80~90
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80~90
Rear hub unit bearing mounting bolt
(8~9, 59~67)
100~200
Rear shock absorber lower mounting
(10~12, 74~88)
100~200
Rear torsion axle beam mounting bolt
(10~12, 74~88)
100~120
Rear torsion axle beam bracket
(10~12, 74~88)
3. Install the parking brake cable.
4. Bleed the brake line system (Refer to the adjustment precedure in the Brake system).
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Suspension System
Rear Suspension System - Rear Shock

Absorber
Suspension System
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2010 > G 1.0 SOHC >
COMPONENT
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2010 > G 1.0 SOHC >
REMOVAL
2. Remove the luggage tray cover from the quarter trim and pry the service cover loose with a (-) screwdriver.
3. Remove the rear shock absorber upper mounting nut.
4. After supporting the rear torsion axle beam with a jack, remove the rear shock absorber lower mounting bolt.
5. Remove the rear shock absorber.
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INSTALLATION
1. Tighten the rear shock absorber upper mounting bolt to the specified torque as follows.
2. After placing a jack at the bottom of the rear torsion axle beam and jacking up the vehicle to the proper location,
tighten the rear shock absorber lower mounting bolt.
Specified torque :
100~120 N·m (10~12 kgf·m, 74~88 lb·ft)
Check that the rear coil spring is located in the proper position.
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Suspension System
Rear Suspension System - Rear Coil Spring
Suspension System
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2010 > G 1.0 SOHC >
COMPONENT
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2010 > G 1.0 SOHC >
REMOVAL
2. Remove the brake hose fixing bracket.
The brake hose should not expand when the rear torsion axle beam is hanged down from the body.
3. After placing a jack at the bottom of the rear torsion axle beam, remove the rear shock absorber lower mounting
bolt.
4. Remove the rear torsion axle beam and three body fixing bracket bolts.
5. Remove the rear coil spring.
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INSTALLATION
1. The end of the rear coil spring should be inserted into the groove of the coil spring upper pad.
2. Insert the lower pad into the coil spring.

3. Fix the rear torsion axle beam bracket on the body, after placing the coil spring at its previous location and lifting
the vehicle with a jack.
4. Fix the rear shock absorber.
INSPECTION
1. Check the coil spring for crack and deformation.
2. Check the coil spring pad for damage and deformation.
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Suspension System
Tires/Wheels - Tires
Suspension System
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2010 > G 1.0 SOHC >
TIRE ROTATION
Rotate the tires in the pattern illustrated.
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Suspension System
Tires/Wheels - Wheel
Suspension System
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2010 > G 1.0 SOHC >
WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT
When using a commercially-available computerized four wheel alignment equipment (caster, camber, toe) to inspect
the front wheel alignment, always position the car on a level surface with the front wheels facing straight ahead.
Prior to inspection, make sure that the front suspension and steering system are in normal operating condition and
that the wheels and tires face straight ahead and the tires are inflated to the specified pressure.
TOE-IN
Toe is a measurement of how much the front of the wheels are turned in or out from the straight-ahead position.
ITEM Description
A Negative (-) toe (toe out)
B Positive (+) toe (toe in)
When the wheels are turned in toward the front of the vehicle, toe is positive (+) (toe in). When the wheels are turned
out toward the front of the vehicle, toe is negative (-) (toe out). Toe is measured in degrees, from side to side, and
totaled.
Toe-in (B-A or angle a+b) 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-in change is adjusted by turning the tie rods for the right and left
wheels simultaneously at the same amount as follows.
Toe-in
Total : 0°±0.2°
Individual : 0°±0.1°
• Toe-in adjustment should be made by turning the right and left tie rods at the same amount.
• When adjusting toe-in, loosen the outer bellows clip to prevent twisting the bellows.
• After the adjustment, tighten the tie rod end lock nuts firmly and reinstall the bellows clip.
• Adjust each toe-in to be the range of ±0.1°.
Tie rod end lock nuts tightening torque :

50~60 N·m (5~6 kgf·m, 37~43 lbf·ft)
Toe-in
Total : 0°±0.2°
Individual : 0°±0.1°
CAMBER
Camber is the inward or outward tilting of the wheels at the top.
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ITEM Description
A Positive camber angle
B True vertical
C Pivot centerline
When the wheel tilts out at the top, then the camber is positive (+).
When the wheel tilts in at the top, then the camber is negative (-).
The steering knuckle which is installed with the strut assembly is pre-set to the specified camber at the factory and
doesn't need to be adjusted.
Camber : 0° ± 0.5°
CASTER
Caster is the tilting of the strut axis either forward or backward from vertical. A backward tilt is positive (+) and a
forward tilt is negative (-).
Caster is pre-set at the factory and doesn't need to be adjusted. If the caster is not within the standard value, replace
the bent or damaged parts.
Caster : 2.72° ± 0.5°
1. The worn loose or damaged parts of the front suspension assembly must be replaced prior to measuring front
wheel alignment.
2. Measure the wheel alignment by using special tool.
3. Camber and caster are pre-set to the specified value at the factory and don't need to be adjusted.
4. If the camber and caster are not within specifications, replace bent or damaged parts.
5. The difference of left and right wheels about the camber and the caster must be within the range of 0° ± 0.5°.
TIGHTENING WHEEL NUT

1. Tightening torque
Steel and aluminum alloy wheel.
Specified torque :
90~110 N·m (9~11 kgf·m, 65~80 lbf·ft)
When using an impact gun, final tightening torque should be checked using a torque wrench.
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2. Tightening order
Check the torque again after tightening the wheel nuts diagonally.
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Brake System
General Information
Brake System
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2010 > G 1.0 SOHC >

Tool(Number and Name) Illustration Use
09581-11000 Spreading the front disc brake piston
Piston expander
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2010 > G 1.0 SOHC >
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Symptom Suspect Area Reference
Lower pedal or 1. Brake system (Fluid leaks) repair
spongy pedal 2. Brake system (Air in) air·bleed
3. Piston seals (Worn or damaged) replace
adjust
4. Rear brake shoe clearance(Out of adjustment)
replace
5. Master cylinder (Inoperative)
Brake drag 1. Brake pedal freeplay (Minimum) adjust
2. Parking brake lever travel (Out of adjustment) adjust
3. Parking brake wire (Sticking) repair
adjust
replace
5. Pad or lining (Cracked or distorted)
replace
6. Piston (Stuck) replace
7. Piston (Frozen) replace
8. Anchor or Return spring (Inoperative) repair
9. Booster system (Vacuum leaks) replace
Brake pull 1. Piston (Sticking) replace
2. Pad or lining (Oily) replace
replace
4. Disc (Scored)
replace
Hard pedal but brake 1. Brake system (Fluid leaks) repair
inefficient 2. Brake system (Air in) air·bleed
3. Pad or lining (Worn) replace
replace
adjust
adjust
7. Pad or lining (Glazed) replace
8. Disc (Scored) repair
9. Booster system (Vacuum leaks)
Noise from brake 1. Pad or lining (Cracked or distorted) replace
2. Installation bolt (Loosen) adjust
3. Disc (Scored) replace
replace
4. Sliding pin (Worn)
clean
5. Pad or lining (Dirty)
replace
7. Anchor or Return spring (Faulty) replace
8. Brake pad shim (Damage) replace
9. Shoe hold-down spring (Damage)
Brake fades 1. master cylinder replace
1. brake booster replace

2. pedal free play adjust
Brake vibration, 3. master cylinder replace
pulsation replace
4. caliper
replace
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replace
5. master cylinder cap seal
replace
6. damaged brake lines
Brake chatter is usually caused by loose or worn components, or
glazed or burnt linings. Rotors with hard spots can also contribute to
Brake Chatter brake chatter. Additional causes of chatter are out-of-tolerance rotors,
brake lining not securely attached to the shoes, loose wheel bearings
and contaminated brake lining.
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2010 > G 1.0 SOHC >
SPECIFICATIONS
Item Specification
Type Tandem
Cylinder I.D. 20.64 mm (0.813 in)
Master cylinder
Piston stroke 30 mm (1.18 in)
Fluid level switch Provided
Size (TYPE) 8 in (Vacuum)
Brake booster
Boosting ratio 4.5: 1
Type Ventilated disc
Cylinder I.D 51.1 mm (2.01 in)
252 mm (9.92 in)
Disc O.D.
Front brake 241 mm (9.48 in)
Disc thickness 18 mm (0.71 in)
Pad thickness 10 mm (0.39 in)
Caliper piston Double
Type Solid disc
Cylinder I.D 34 mm (1.34 in)
Disc O.D. 234 mm (9.21 in)
Rear brake
Pad thickness 9mm (0.35 in)
Caliper piston Single
O.D. : Outer Diameter

I.D : Inner Diameter
SPECIFICATION (ABS)
Part Item Standard value Remark
4 Channel 4 Sensor (MGH-
System
40)
Type ABS + EBD
HECU Operating Voltage 10 ~ 16 V
-40 ~ 110 °C (-40 ~ 230 °F
Operating Temperature
)
Motor power 160 W
Min. Operating Voltage 12 V
Warning lamp
Max. Current consumption 80 mA
Supply voltage DC 4.5 ~ 20 V
Output current low 5.9 ~ 8.4 mA Typ. 7 mA
Active Wheel speed sensor Output current high 11.8 ~ 16.8 mA Typ. 14 mA
(ABS)
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(ABS) Output range 1 ~ 2500 Hz
Tone wheel 48 teeth
Air gap 0.4 ~ 1.5 mm
SPECIFICATION(ESP)
System
40)
Motor, valve relay
Type
intergrated type Total control
HECU
(ABS, EBD, ESP)
Operating Voltage 10 ~ 16 V
Operating Temperature -40 ~ 110 °C (-40 ~ 230 °F)
Motor power 210 W
Warning lamp
Output current high 11.8 ~ 16.8 mA Typ. 14 mA
Active Wheel speed sensor
Output range 1 ~ 2500 Hz
(ABS)
Tone wheel 48 teeth
Front 0.4 ~ 1.5 mm
Air gap
Rear 0.2 ~ 0.7 mm
Operating Angular velocity Max. 1500 °/sec
Operating temperature -30 ~ 75 °C (-22 ~ 167 °F)
Steering Wheel Angle
Sensor Max Consumption Current 100 mA
Max Output Current 10 mA
Max Output Absorption
50 mA
Current
Operating Voltage 10 V ~ 16 V
Current Consumption Max. 140 mA
Yaw rate & Operating Temperature -40 ~ 85 °C (-40 ~ 185 °F)
Lateral G sensor
Yaw rate sensor
(CAN TYPE) ± 75 °/sec
measurement range
Lateral G sensor
± 1.5 g
measurement range
SERVICE STANDARD
Items Standard vale
Brake pedal height 189.3 mm (7.45 in)
Brake pedal stroke 120 mm (4.72 in)
Stop lamp clearance 1.0 ~ 2.0 mm (0.04 ~ 0.08 in)
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Brake pedal free play 3 ~ 8 mm (0.12 ~ 0.31 in)
Front brake disc thickness 18 mm (0.708 in)
Front brake disc pad thickness 10 mm (0.39 in)
Rear brake disc thickness 10 mm (0.39 in)
Rear brake disc pad thickness 9 mm (0.35 in)
TIGHTENING TORQUES
Items Nm kgf.m lb-ft
Hub nut 88.3 ~ 107.9 9.0 ~ 11.0 65.1 ~ 79.6
Master cylinder to brake booster 7.9 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Brake booster mounting nuts 7.9 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Air bleeding screw 5.9 ~ 9.8 0.6 ~ 1.0 4.3 ~ 7.2
Brake tube flare nuts 12.7 ~ 16.7 1.3 ~ 1.7 9.4 ~ 12.3
Front caliper guide rod bolts 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
Rear caliper guide rod bolts 21.6 ~ 31.4 2.2 ~ 3.2 15.9 ~ 23.1
Front caliper assembly to knuckle 83.4 ~ 93.1 8.5 ~ 9.5 61.5 ~ 68.7
Rear caliper assembly to knuckle 83.4 ~ 93.1 8.5 ~ 9.5 61.5 ~ 68.7
Brake hose to caliper 16.7 ~ 19.6 1.7 ~ 2.0 12.3 ~ 14.5
Brake pedal mounting bracket bolts 12.7 ~ 21.6 1.3 ~ 2.2 9.4 ~ 15.9
Brake pedal shaft nut 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3
Stop lamp switch lock nut 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Wheel speed sensor mounting bolt 8.0 ~ 9.5 0.82 ~ 0.97 5.9 ~ 7.0
HECU bracket bolt & nuts 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
HECU bracket nut 11 ~ 14 1.1 ~ 1.4 8.1 ~ 10.3
Yaw rate & G sensor mounting bolts 7.8 ~ 10.8 0.8 ~ 1.1 5.8 ~ 8.0
LUBLICANTS
Items Recommended Quantity
Brake pedal bushing and bolt Chassis grease As required
Parking brake shoe and backing plate contacting surface Heat resistance grease As required
0.8 ~ 2.0 g (Front)
Caliper guide rod and boot AI-11P
0.7 ~ 1.5 g (Rear)
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Brake System
Brake System
Brake System
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2010 > G 1.0 SOHC >
Operation and Leakage Check

Check all of the following items:
Component Procedure
Brake Booster (A) Check brake operation by applying the brakes during a test drive. If the brakes do not
work properly, check the brake booster. Replace the brake booster as an assembly if it
does not work properly or if there are signs of leakage.
Piston cup and pressure cup • Check brake operation by applying the brakes. Look for damage or signs of fluid
inspection (B) leakage. Replace the master cylinder as an assembly if the pedal does not work
properly or if there is damage or signs of fluid leakage.
• Check for a difference in brake pedal stroke between quick and slow brake
applications. Replace the master cylinder if there is a difference in pedal stroke.
Brake hoses (C) Look for damage or signs of fluid leakage. Replace the brake hose with a new one if it
is damaged or leaking.
Caliper piston seal and Check brake operation by applying the brakes.
piston boots (D) Look for damage or signs of fluid leakage. If the pedal does not work properly, the
brakes drag, or there is damage or signs of fluid leakage, disassemble and inspect the
brake caliper. Replace the boots and seals with new ones whenever the brake caliper
is disassembled.
BRAKE SYSTEM BLEEDING
• Do not reuse the drained fluid.

• Always use genuine DOT3/DOT4 brake Fluid.
Using a non-genuine DOT3/DOT4 brake fluid can cause corrosion and decrease the life of the system.
• Make sure no dirt of other foreign matter is allowed to contaminate the brake fluid.
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• Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it
off immediately with water.
• The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding procedure
and checked after bleeding each brake caliper. Add fluid as required.
1. Make sure the brake fluid in the reservoir is at the MAX (upper) level line.
2. Have someone slowly pump the brake pedal several times, and then apply pressure.
3. Loosen the right-rear brake bleed screw (A) to allow air to escape from the system. Then tighten the bleed screw
securely.
4. Repeat the procedure for wheel in the sequence shown below unit air bubbles no longer appear in the fluid.
5. Refill the master cylinder reservoir to MAX (upper) level line.
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Brake System
Brake System - Brake Booster
Brake System
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COMPONENTS
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2010 > G 1.0 SOHC >
BRAKE BOOSTER OPERATING TEST

For simple checking of the brake booster operation, carry out the following tests
1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains
unchanged, thebooster is defective.
2. With the engine stopped, step on the brake pedal several times.
Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good
condition. If there is no change, the booster is defective
3. With the engine running, step on 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
the pedal rises, the booster is defective.
If the above three tests are okay, the booster performance can be determined as good.
Even if one of the above three tests is not okay, check the check valve, vacuum hose and booster for defect.
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VACUUM HOSE (CHECK VALVE)
INSPECTION
1. Disconnect the brake booster vacuum hose (check valve built in) (A) at the booster (B).
2. Start the engine and let it idle. There should be vacuum available. If no vacuum is available, the check valve is not
working properly. Replace the brake booster vacuum hose and check valve and retest.
Removal
1. Remove the master cylinder.
2. Disconnect the vacuum hose (A) from the brake booster (B).
3. Remove the snap pin (A), pin (B) and washer (C).
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4. Remove the four booster mounting nuts (D).
5. Remove the brake booster (A) from the engine compartment.
INSTALLATION
1. Adjust push rod length of the booster, and then install the seal on the booster assembly.
Standard length : 107.9 ± 0.5 mm(4.25 ± 0.02 in.)
2. Insert the booster and tighten the nut (D).
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3. Connect the booster push rod and brake pedal with a pin (B) and install a snap pin (A) to the pin (B).
When installing the snap pin, it must be used new one.
4. Adjust push rod length.

(1) Insert the gasket onto the master cylinder.
(2) Put the SST onto the gasket and tighten the adjusting bolt until the bolt touches the bottom of the push rod
hole.
(3) Apply 500 mmHg vacuums with a vacuum pump.

(4) Invert the tool used in step 2 and place it on the booster.
(5) Check whether the clearance between the edge of the adjusting bolt and the push rod of the booster is 0 - 0.1
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mm (0 - 0.004 in.).
If it is not standard clearance, loosen the lock nut of the push rod, and turn the push rod to make the
adjustment.
Standard clearance : 0.6 ~ 1.4 mm (0.023 ~ 0.055 in.)
5. Install the master cylinder.

6. Connect the vacuum hose to the brake booster.
7. After filling the brake reservoir with brake fluid, bleed the system.
8. Check for fluid leakage.
9. Check and adjust the brake pedal for proper operation.
10. After installing, apply grease to the contact parts of the joint pin and brake pedal.
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Brake System
Brake System - Master Cylinder
Brake System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REPLACEMENT
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off
immediately with water.
1. Remove the air cleaner cover, air filter, air cleaner mounting bolts and air cleaner body from the air cleaner
mounting bracket.
2. Disconnect the brake fluid level switch connectors (A), and remove the reservoir cap.
3. Remove the brake fluid from the master cylinder reservoir with a syringe.
4. Disconnect the brake lines from the master cylinder. To prevent spills, cover the hose joints with rags or shop
towels.
5. Remove the master cylinder mounting nuts and washers.

6. Remove the master cylinder from the brake booster. Be careful not to bend or damage the brake lines when
removing the master cylinder.
7. Install the master cylinder in the reverse order of removal, and note these items:
A. Replace all rubber parts with new ones whenever, removed.
DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a suitable container.
2. Remove the fluid level sensor.
3. Remove the proportioning valves (A) - Conventional brake system.
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4. Remove the retainer ring by using the snap ring pliers.
5. Remove the pin with the primary piston pushed completely using a screwdriver. Remove the primary piston
assembly.
6. Remove the pin with the secondary piston pushed completely using a screwdriver. Remove the secondary piston
assembly.
Do not disassemble the primary and secondary piston assembly.
INSPECTION
1. Check the master cylinder bore for rust or scratch.
2. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.
• If the cylinder bore is damaged, replace the master cylinder assembly.

• Wash the contaminated parts in alcohol.
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REASSEMBLY
1. Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.
2. Carefully insert the springs and pistons in the proper direction.
3. Press the piston with a screwdriver and install the cylinder pin.
4. Press the piston with a screwdriver and install the snap ring.
5. Install the proportioning valves.

6. Mount two grommets.
7. Install the reservoir on the cylinder.
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Brake System
Brake System - Proportioning Valve
Brake System
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2010 > G 1.0 SOHC >
DESCRIPTION
Do not disassemble the proportioning valve. The proportioning valve makes the ideal distribution of fluid pressure to
the front and rear brakes to prevent the brakes from skidding in the event of rear wheel lock up and to obtain a higher
brake efficiency within the range of service brake application.
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2010 > G 1.0 SOHC >
Proportioning valve function test

1. Remove the front brake tube (B) and rear brake tube (C) from the master cylinder (A).
2. Connect two pressure gauges (D); one to the output valve of the front (B) and rear (C) brake.
Be sure to bleed the system after connecting the pressure gauges.
3. With the brake applied, measure the front pressure and the rear pressure.
If the measured pressures are within the specified range as illustrated, the proportioning valve is good.
4. Reconnect the brake lines in their original positions and bleed the system.
This table shows characteristics of the proportioning valve as the pressure increases.
Front Rear
(Output of master cylinder) (Output of proportioning valve)
A : 26 kg/cm! A' : 26 kg/cm!
(2.55MPa, 370psi) (2.55MPa, 370psi)
B : 80 kg/cm! B' : 40.6 ± 3 kg/cm!
(7.84MPa, 1137psi) (3.98 ± 0.3MPa, 577 ± 42psi)
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Brake System
Brake System - Brake Line
Brake System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
INSPECTION
1. Inspect the brake hoses, for damage, deterioration, leaks, interference and twisting.
2. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines.
3. Check for leaks at hose and line joints or connections, and retighten if necessary.
4. Check the master cylinder for damage and leakage.
5. Replace the brake hose clip whenever the brake hose is serviced.
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Brake System
Brake System - Brake Pedal
Brake System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
SERVICE ADJUSTMENT
PROCEDURES
PEDAL HEIGHT
1. Measure the brake pedal height. If the brake pedal height is not within the standard value, adjust as follows.
Standard value : 189 mm (7.24 in.)
2. Disconnect the stop lamp switch connector, loosen the lock nut(A), and move the stop lamp switch to a position
where it does not contact the brake pedal arm.
3. Adjust the brake pedal height by turning the operating rod with pliers (with the operating rod lock nut loosened),
until the correct brake pedal height is obtained.
4. After turning the stop lamp switch(A) until it contacts the brake pedal stopper(B) (just before the brake pedal is
caused to move), return the stop lamp switch 1/2 to 1 turn and secure by tightening the lock nut.
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5. Connect the connector of the stop lamp switch.
6. Check that the stop lamp is not illuminated with the brake pedal unpressed.
PEDAL FREE PLAY

1. With the engine stopped, depress the brake pedal two or three times. After eliminating the vacuum in the power
brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met
(the free play) is within the standard value.
Standard value : 3 - 8 mm (0.118 - 0.315 in.)
2. If free play does not reach the standard value, check that clearance between the outer case of stop light switch and
brake pedal is within the standard value.
If free play exceeds the standard value, it is probably due to excessive clearance between the clevis pin and brake
pedal arm.
Check for excessive clearance and replace faulty parts as required.
REMOVAL
1. Remove the lower crash pad.
2. Remove the stop lamp switch connector.
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3. Remove the pin and snap pin.
4. Remove the brake pedal member assembly mounting nuts and then remove the brake pedal assembly.
SERVICE ADJUSTMENT
PROCEDURES
PEDAL HEIGHT
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PEDAL FREE PLAY

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pedal arm.
INSTALLATION
Coat the inner surface of the bushings with the specified grease.
2. Before inserting the pin, apply the specified grease to the joint pin.
3. Adjust the brake pedal height and free play.

4. Install the stop lamp switch.
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Brake System
Brake System - Front Disc Brake
Brake System
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2010 > G 1.0 SOHC >
General information
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies.
Remove, disassemble, inspect, reassemble, and install the caliper and note these items:
- Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off
- To prevent dripping, cover disconnected hose joints with rags or shop towels.
- Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
- Before reassembling, check that all parts are free of dirt and other foreign particles.
- Replace parts with new ones as specified in the illustration.
- Make sure no dirt or other foreign matter gets into the brake fluid.
- Make sure no grease or oil gets on the brake discs or pads.
- When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency.
- Do not reuse drained brake fluid.
- Always use Genuine DOT 3 or DOT 4 brake fluid. Non Genuine DOT 3 or DOT 4 brake fluid can cause corrosion
and shorten the life of the system.
- Coat the piston, piston seal groove, and caliper bore with clean brake fluid.
- Replace all rubber parts with new ones.
- After installing the caliper, check the brake hose and line for leaks, interference, and twisting.
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2010 > G 1.0 SOHC >
COMPONENTS(1)
COMPONENTS(2)
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2010 > G 1.0 SOHC >
INSPECTION OF FRONT DISC BRAKE PAD

1. Check the brake pad thickness through the caliper body inspection hole.
Pad thickness
Service limit : 2.0 mm (0.079 in.)
• If the pad lining thickness is out of specification, left and right pads must be replaced as a complete set.
• When the thickness difference between the left pad and right pad is large, check the sliding condition of
the piston and the guide rod.
REMOVAL
1. Remove guide rod (B) and the caliper (C) up out of the way. Check the hoses and pin boots for damage and
deterioration.
2. Remove the pad shims (A), pad retainers (B) and pads (C).
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INSTALLATION
1. Install the pad retainers (A).
2. Check the foreign material at the pad shims and the back of the pads.
Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
3. Install the brake pads and pad shims correctly. Install the pad with the wear indicator on the inside.
If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss
of braking efficiency.
4. Push in the piston (A) so that the caliper will fit over the pads. Make sure that the piston boot is in position to
prevent it damaging when pivoting the caliper down.
5. Pivot the caliper down into position. Being careful not to damage the pin boot, install the guide rod bolt (B) and
torque it to proper specification.
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Insert the piston in the cylinder using the special tool (09581-11000).
6. Depress the brake pedal several times to make sure the brakes work, then test-drive.
Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been
replaced as a set.Several applications of the brake will restore the normal pedal stroke.
7. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.

Pad thickness
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Brake System
Brake System - Rear Disc Brake
Brake System
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2010 > G 1.0 SOHC >
General information
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2010 > G 1.0 SOHC >
COMPONENTS(1)
COMPONENTS(2)
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2010 > G 1.0 SOHC >
INSPECTION OF REAR DISC BRAKE PAD

Pad thickness
Standard value : 9.0 mm (0.35 in.)
• If the pad thickness is out of specification, left and right pads must be replaced as a complete set.
REMOVAL
1. Raise the rear of the vehicle and make sure it is securely supported. Remove the rear wheel.
2. Release the parking brake.
3. Remove the brake hose (A) from the suspension arm by removing the brake hose clip (B).
4. Thoroughly clean the outside of the caliper to prevent dust and dirt from entering inside.
Support the caliper with a piece of wire so that it does not hang from the brake hose.
5. Remove the two guide rods (C) and caliper (D) from the bracket.
6. Remove the pad shim (A) and brake pads (B).
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INSTALLATION
1. Install the pad springs(A) to the carrier(B).
2. Check the foreign material at the pad shim (A) and the back of the pads (B).
3. Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
4. Install the brake pads (B) and pad shim (A) on the caliper bracket. Install the inner pad with its wear indicator (C)
facing down ward.
5. Rotate the caliper piston (A) clockwise into the cylinder, align the cutout (B) in the piston with the tab (C) on the
inner pad by turning the piston back. Lubricate the boot with rubber grease to avoid twisting the piston boot. If the
piston boot is twisted, back it out so it is positioned properly.
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6. Install the brake caliper (D).
7. Install and torque the guide rods (E) to proper specification.
8. Install the brake hose (F) onto the suspension arm with the brake hose clip (G).
9. After installation, check for leaks at hose and line joints and connections, and retighten if necessary.
replaced as a set.Several applications of the brake pedal will restore the normal pedal stroke.

Pad thickness
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Brake System
Brake System - Rear Drum Brake
Brake System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
INSPECTION
• Contaminated brake linings or drums reduce stopping ability.

• Block the front wheels before jacking up the rear of the vehicle.
1. Raise the rear of the vehicle, and make sure it is securely supported.
2. Release the parking brake, and remove the rear brake drum.
3. Check the wheel cylinder (A) for leakage.
4. Check the brake linings (B) for cracking, glazing, wear, and contamination.
5. Measure the brake lining thickness (C).
Measurement does not include brake shoe thickness.
Brake lining thickness

Standard : 4.5 mm (0.177 in.)
6. If the brake lining thickness is less than the service limit, replace the brake shoes as a set.
7. Check the bearings in the hub unit for smooth operation. If it requires servicing, replace it.
8. Measure the inside diameter of the brake drum with inside vernier calipers.
Drum inside diameter:

Standard : 180 mm (7.09 in.)
Service limit : 182 mm (7.165 in.)
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9. If the inside diameter of the brake drum is more than the service limit, replace the brake drum.
10. Check the brake drum for scoring, grooves, and cracks.
REMOVAL
1. Remove the shoe hole down pins (B) by pushing the shoe hold pin (C) and turning them.
2. Disengage the upper return spring (A).
3. Lower the brake shoe assembly (A), and remove the lower return spring (B). Make sure not to damage the dust
cover on the wheel cylinder.
4. Disconnect the parking brake cable from the parking brake lever.
5. Remove the brake shoe assembly.
6. Remove the upper return spring (C), self-adjuster lever (D) and self-adjuster spring (E), and separate the brake
shoes.
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7. Disconnect the brake line (A) from the wheel cylinder (B).
8. Remove the bolt (C) and the wheel cylinder from the backing plate.
INSTALLATION
• Do not spill brake fluid on the vehicle: it may damage the paint; if brake fluid does contact the paint. Wash it
• To prevent spills, cover the hose joints with rags or shop towels.
• Use only a genuine wheel cylinder special bolt.
1. Apply sealant (C) between the wheel cylinder (A) and backing plate (B), and install the wheel cylinder.
2. Connect the brake tubes (D) to the wheel cylinder.
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3. Connect the parking brake cable to the parking brake lever.
4. Clean the threaded portions of adjuster sleeve (A) and push rod female (B).
5. Hook the self-adjuster spring (D) to the strut assembly, then to the brake shoe.
6. Install the strut assembly and upper return spring (E), noting the installation direction. Be careful not to damage the
wheel cylinder dust covers.
7. Install the lower return spring (F).
8. Apply brake cylinder grease or equivalent rubber grease to the sliding surfaces shown. Wipe off any excess. Don't
get grease on the brake linings.
9. Apply brake cylinder grease or equivalent rubber grease to the brake shoe ends and opposite edges of the shoes
shown. Wipe off any excess. Don't get grease on the brake linings.
10. Install the brake shoes (A) onto the backing plate. Be careful not to damage the wheel cylinder dust covers.
11. Install the shoe hole down pins (B) and the shoe hold pin (C).
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12. Hook the upper return spring (D).
13. Install the brake drum.
14. If the wheel cylinder has been removed, bleed the brake system.
15. Depress the brake pedal several times to set the self-adjusting brake.
16. Adjust the parking brake.
INSPECTION

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Brake System
Parking Brake System - Parking Brake

Assembly
Brake System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
Parking brake check and adjustment

INSPECTION
1. Pull the parking brake lever (A) with 196 N (20 kg, 44lbf) force to fully apply the parking brake. The parking brake
lever should be locked within the specified number of clicks (B).
Lever locked clicks:

Vehicle with rear disc brakes: 8~9
Vehicle with rear drum brakes: 8
2. Adjust the parking brake if the lever clicks are out of specification.
ADJUSTMENT
After rear brake caliper servicing, loosen the parking brake adjusting nut, start the engine and depress the brake
pedal several times to set the self-adjusting brake before adjusting the parking brake.
1. Block the front wheels, then raise the rear of the vehicle and make sure it is securely supported.
2. Make sure the parking brake arm (A) on the rear brake caliper contacts the brake caliper pin (B).
3. Pull the parking brake lever up one click.
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4. Remove the console.
5. Tighten the adjusting nut (A) until the parking brakes drag slightly when the rear wheels are turned.
6. Release the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are turned.
Readjust if necessary.
7. Make sure that the parking brakes are fully applied when the parking brake lever is pulled up fully.
8. Reinstall the console.
REMOVAL
The parking brake cables must not be bent or distorted.

This will lead to stiff operation and premature failure.
Rear drum brake

2. Loosen the adjusting nut (A) and the parking brake cables.
3. Disconnect the connector(A) of parking brake switch.
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4. Remove the parking brake lever assembly(A).

6. Remove the brake drum and the brake shoe (Refer to the rear drum brake).
7. Remove the parking brake cable from the brake shoe.
8. Remove the parking brake cable retaining (B), from the parking brake cable (A).
9. Remove the parking brake cable (A) from the backing plate (B).
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10. Remove the clamps of parking brake cables and then remove the parking brake cables.
Rear disc brake

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5. Remove the parking cable clip (A) from the parking brake cable(B).
6. Disconnect the parking brake cable (B) from the lever (C).
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INSTALLATION
1. Check the parking brake cables for an identification mark paint and install as appropriate on the left and right sides.
Identification color
Left side : -
Right side : Red
2. Install the removed parts in the reverse order of removal.

3. Apply a coating of the specified grease to each sliding parts of the ratchet plate or the ratchet pawl.
Specified grease :
Multi purpose grease SAE J310, NLGI No.2
4. After installing the cable adjuster, adjust the parking brake lever stroke (Refer to the parking brake check and
adjustment).
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Brake System
ABS (Anti-Lock Brake System)
Brake System
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2010 > G 1.0 SOHC >
ABS CIRCUIT DIAGRAM
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ABS Connector Input/Output
Connector Terminal
Specification Remark
No Description
High level of wake up voltage : 4.5V < V < 16.0V
29 IGNITION1(+) Low level of wake up voltage : V < 2.4V
Max. current : I < 50mA
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Over voltage range : 17.0 ± 0.5V
Operating voltage range : 10.0 ± 0.5V < V < 16.0 ± 0.5V
25 POS. BATTERY 1.(SOLENOID) Low voltage range : 7.0 ± 0.5V < V < 9.5 ± 0.5V
Max. current : I < 25A
Max. leakage current : I < 0.25mA
Operating voltage range: 10.0 ± 0.5V < V < 16.0 ± 0.5V
Rush current : I < 110A
1 POS. BATTERY 2.(MOTOR)
Rated current : I <550mA
38 GROUND
Max. current: I < 25A
13 PUMP MOTOR GROUND
Input voltage (Low) : V < 2V
23 BRAKE LIGHT SWITCH Input voltage (High) : V > 6V
Max. Input current : I < 3mA
External pull up resistance :1 K! < R
28 SENSOR FRONT RIGHT OUTPUT
Output duty :50 ± 20%
14 CAN BUS LINE(LOW)
26 CAN BUS LINE(HIGH)
18 SENSOR FRONT LEFT POWER
34 SENSOR FRONT RIGHT POWER Output voltage : V_BAT1 -0.6V ~ V_BAT1 -1.1V
19 SENSOR REAR LEFT POWER Output current : Max. 30mA
33 SENSOR REAR RIGHT POWER

31 SENSOR FRONT LEFT SIGNAL
Input current Low : 5.9 ~ 8.4mA
21 SENSOR FRONT RIGHT SIGNAL Input current High :11.8 ~ 16.8mA Typ. 7mA
32 SENSOR REAR LEFT SIGNAL Frequency range :1 ~ 2500Hz Typ. 14mA
Input duty : 50 ± 10%
20 SENSOR REAR RIGHT SIGNAL
6 ABS/EBD LAMP
Max. output Low voltage : V< 0.7V
Input voltage Low : V< 0.3 IGN[V]
Input voltage High : V >0.7 IGN[V]
30 DIAGNOSIS INPUT/OUTPUT
Output voltage Low : V< 0.2 IGN[V]
Output voltage High : V >0.8 IGN[V]
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2010 > G 1.0 SOHC >
DESCRIPTION
This specification applies to HCU(Hydraulic Control Unit) and ECU(Electronic Control Unit) of the HECU.(Hydraulic and
Electronic Control Unit)
This specification is for the wiring design and installation of ABS/ESP ECU.
This unit has the functions as follows.
- Input of signal from Pressure sensor, Steering angle sensor, Yaw & Lateral G sensor,the wheel speed sensors
attached to each wheel.
- Control of braking force / traction force / yaw moment.
- Failsafe function.
- Self diagnosis function.
- Interface with the external diagnosis tester.
Installation position : engine compartment
- Brake tube length from Master cylinder port to HECU inlet port should be max. 1m
- The position should not be close to the engine block and not lower than the wheel.
OPERATION
The ECU shall be put into operation by switching on the operating voltage (IGN).
On completion of the initialization phase, the ECU shall be ready for operation.
In the operating condition, the ECU shall be ready, within the specified limits (voltage and temperature), to process the
signals offered by the various sensors and switches in accordance with the control algorithm defined by the software
and to control the hydraulic and electrical actuators.
Wheel Sensor signal processing

The ECU shall receive wheel speed signal from the four active wheel sensors.
The wheel signals are converted to voltage signal by the signal conditioning circuit after receiving current signal from
active wheel sensors and given as input to the MCU.
Solenoid Valve Control

When one side of the valve coil is connected to the positive voltage that is provided through the valve relay and the
other side is connected to the ground by the semiconductor circuit, the solenoid valve goes into operation.
The electrical function of the coils are always monitored by the valve test pulse under normal operation conditions.
Voltage limits
- Overvoltage
When overvoltage is detected(above 17 ± 0.5 V), the ECU switches off the valve relay and shuts down the
system.
When voltage is returned to operating range, the system goes back to the normal condition after the initialization
phase.
- Undervoltage
In the event of undervoltage(below 10V), ABS control shall be inhibited and the warning lamp shall be turned on.
When voltage is returned to operating range, the warning lamp is switched off and ECU returns to normal operating
mode.
Pump Motor Checking

The ECU performs a pump motor test at a speed of 30 km/h(18 MPH) once after IGN is switched on.
Diagnostic Interface
Failures detected by the ECU are encoded on the ECU, stored in a EEPROM and read out by diagnostic equipment
when the ignition switch is turned on.
The diagnosis interface can also be used for testing the ECU during production of the ECU and for actuating the HCU
in the test line of manufactories (Air-bleeding line or Roll and Brake Test line).
WARNING LAMP MODULE
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1. ABS Warning Lamp module
The active ABS warning lamp module indicates the self-test and failure status of the ABS.
The ABS warning lamp shall be on:
A. During the initialization phase after IGN ON. (continuously 3 seconds).
B. In the event of inhibition of ABS functions by failure.
C. During diagnostic mode.
D. When the ECU Connector is seperated from ECU.
2. PARKING/EBD warning lamp module
The active EBD warning lamp module indicates the self-test and failure status of the EBD.
However, in case the Parking Brake Switch is turned on, the EBD warning lamp is always turned on regardless of
EBD functions.
The EBD warning lamp shall be on:
B. When the Parking Brake Switch is ON or brake fluid level is low.
C. When the EBD function is out of order.
D. During diagnostic mode.
E. When the ECU Connector is seperated from ECU.
ABS CONTROL
1. NORMAL BRAKING without ABS
Under the normal braking, voltage is not supplied to solenoid valve, inlet valve is opened and outlet valve is
closed.When the brake is depressed, brake fluid is supplied to the wheel cylinder via solenoid valve to activate the
brake.When the brake is released, brake fluid is back to the master cylinder via inlet valve and check valve.
Pump
Solenoid valve State Valve Passage
motor
Inlet valve (NO) OFF Open Master cylinder Wheel cylinder
OFF
Outlet valve (NC) OFF Close Wheel cylinder Reservoir
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2. DUMP MODE
Under the emergency braking, if the wheels start to lock up, HECU sends a signal to the solenoid valve to decrease
the brake fluid, then voltage is supplied to each solenoid. At this time inlet valve is closed and brake fluid is blocked
from the master cylinder. Conversely outlet valve is opened and brake fluid passes through wheel cylinder to reservoir,
resulting in pressure decrease.
Pump
Solenoid State Valve Passage
motor
Inlet valve (NO) ON Close Master cylinder Wheel cylinder ON
Outlet valve (NC) ON Open Wheel cylinder Reservoir
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3. HOLD MODE
When the brake fluid pressure is maximally decreased in wheel cylinder, HECU sends a signal to solenoid valve to
keep the fluid pressure, voltage is supplied to inlet valve but it is not supplied to outlet valve. At this time inlet and
outlet valves are closed and brake fluid is kept in wheel cylinder.
Pump
motor
Inlet valve (NO) ON Close Master cylinder Wheel cylinder OFF
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4. INCREASE MODE
If HECU determines there's no lock-up in the wheel, HECU cuts voltage to solenoid valve. So voltage is not supplied to
each solenoid valve, brake fluid passes through the inlet valve to wheel cylinder, resulting in pressure increase.
Pump
motor
Inlet valve (NO) OFF Open Master cylinder Wheel cylinder ON
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ABS HECU EXTERNAL DIAGRAM
HYDRAULIC SYSTEM DIAGRAM
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2010 > G 1.0 SOHC >
COMPONENTS
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STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING

The phenomena listed in the following table are not abnormal.
Phenomenon Explanation
System check sound When starting the engine, a thudding sound can sometimes be heard coming
from inside the engine compartment. This is because the system operation check
is being performed.
ABS operation sound 1. Sound of the motor inside the ABS hydraulic unit operation (whine).
2. Sound is generated along with vibration of the brake pedal (scraping).
3. When ABS operates, sound is generated from the vehicle chassis due to
repeated brake application and release
(Thump : suspension; squeak: tires)
ABS operation (Long braking For road surfaces such as snow-covered and gravel roads, the braking distance
distance) for vehicles with ABS can sometimes be longer than that for other vehicles.
Accordingly, advise the customer to drive safely on such roads by lowering the
vehicle speed.
Diagnosis detection conditions can vary depending on the diagnosis code. When checking the trouble symptom after
the diagnosis code has been erased, ensure that the requirements listed in "Comment" are met.
ABS CHECK SHEET
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If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem
symptom in the order given in the table below and proceed to the relevant troubleshooting page.
Symptom Suspect Area

ABS does not operate. Only when 1~4. are all normal and the problem is still
occurring, replace the HECU.
1. Check the DTC reconfirming that the normal code is
output.
2. Power source circuit.
3. Speed sensor circuit.
4. Check the hydraulic circuit for leakage.
ABS does not operate intermittently. Only when 1~4. are all normal and the problem is still
occurring, replace the ABS actuator assembly.
output.
2. Wheel speed sensor circuit.
3. Stop lamp switch circuit.
Communication with GDS is not possible. 1. Power source circuit
(Communication with any system is not possible) 2. Diagnosis line
Communication with GDS is not possible. 1. Power source circuit
(Communication with ABS only is not possible) 2. Diagnosis line
3. HECU
When ignition key is turned ON (engine OFF), the ABS 1. ABS warning lamp circuit
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warning lamp does not light up. 2. HECU
Even after the engine is started, the ABS warning lamp 1. ABS warning lamp circuit
remains ON. 2. HECU
During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such phenomena are
due to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is
not an abnormality.
DETECTING CONDITION
Trouble Symptoms Possible Cause
Brake operation varies depending on driving conditions and road - Faulty power source circuit
surface conditions, so diagnosis can be difficult.However if a normal - Faulty wheel speed sensor circuit
DTC is displayed, check the following probable cause. When the - Faulty hydraulic circuit for leakage
problem is still occurring, replace the ABS control module.
- Faulty HECU
INSPECTION PROCEDURES
DTC INSPECTION
1. Connect the GDS with the data link connector and turn the ignition switch ON.
2. Verify that the DTC code is output.
Is the DTC code output?
▶ Check the power source circuit.
▶ Erase the DTC and recheck using GDS.
CHECK THE POWER SOURCE CIRCUIT

1. Disconnect the connector from the ABS (ESP) control module.
2. Turn the ignition switch ON, measure the voltage between terminal 29 of the ABS (ESP) control module harness
side connector and body ground.
Specification : approximately B+
Is the voltage within specification?
▶ Check the ground circuit.
▶ Check the harness or connector between the fuse (10A) in the engine compartment junction block and the ABS
(ESP) control module. Repair if necessary.
CHECK THE GROUND CIRCUIT

2. Check for continuity between terminals 13, 38 of the ABS (ESP) control module harness side connector and ground
point.
Is there continuity?
▶ Check the wheel speed sensor circuit.
▶ Repair an open in the wire and ground point.
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CHECK THE WHEEL SPEED SENSOR CIRCUIT
Refer to the DTC troubleshooting procedures.
Is it normal?
▶ Check the hydraulic circuit for leakage.
▶ Repair or replace the wheel speed sensor.
CHECK THE HYDRAULIC CIRCUIT FOR LEAKAGE

Refer to the hydraulic lines.
Inspect leakage of the hydraulic lines.
Is it normal?
▶ The problem is still occurring, replace the ABS (ESP) control module.
▶ Repair the hydraulic lines for leakage.
DETECTING CONDITION

surface conditions, so diagnosis can be difficult. However if a normal - Faulty wheel speed sensor circuit
- Faulty HECU
DTC INSPECTION
1. Connect the GDS with the data link connector and turn the ignition switch ON.
2. Verify that the DTC code is output.
Is the DTC code output?
▶ Erase the DTC and recheck using GDS.
CHECK THE WHEEL SPEED SENSOR CIRCUIT

Is it normal?
▶ Check the stop lamp switch circuit.
CHECK THE STOP LAMP SWITCH CIRCUIT

1. Check that stop lamp lights up when brake pedal is depressed and turns off when brake pedal is released.
2. Measure the voltage between terminal 23 of the ABS (ESP) control module harness side connector and body
ground when brake pedal is depressed.
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▶ Repair the stop lamp switch. Repair an open in the wire between the ABS (ESP) control module and the stop
lamp switch.
CHECK THE HYDRAULIC CIRCUIT FOR LEAKAGE

Is it normal?
▶ The problem is still occurring, replace the ABS control module.
DETECTING CONDITION

Possible defect in the power supply system (including ground) for the - An open in the wire
diagnosis line. - Poor ground
- Faulty power source circuit
CHECK THE POWER SUPPLY CIRCUIT FOR THE DIAGNOSIS
Measure the voltage between terminal 9 of the data link connector and body ground.
Is voltage within specification?
▶ Check the ground circuit for the diagnosis.
▶ Repair an open in the wire. Check and replace fuse (15A) from the engine compartment junction block.
CHECK THE GROUND CIRCUIT FOR THE DIAGNOSIS

Check for continuity between terminal 5 of the data link connector and body ground.
▶ Repair an open in the wire between terminal 5 of the data link connector and ground point.
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DETECTING CONDITION
When communication with scan tool is not possible, the cause may - An open in the wire
be probably an open in the HECU power circuit or an open in the - Faulty HECU
diagnosis output circuit. - Faulty power source circuit
CHECK FOR CONTINUITY IN THE CAN LINE
1. Disconnect the connector from the ABS control module.
2. Check for continuity between terminals 26, 14 of the ABS (ESP) control module connector and 3, 11 of the data
link connector.
▶ Check the power source of ABS (ESP) control module.
▶ Repair an open in the wire.
CHECK THE POWER SOURCE OF ABS (ESP) CONTROL MODULE

2. Turn the ignition switch ON, measure the voltage between terminal 29 of the ABS (ESP) control module harness
side connector and body ground.
▶ Check for poor ground.
(ESP) control module.Repair if necessary.
CHECK FOR POOR GROUND

Check for continuity between terminal 5 of the data link connector and ground point.
▶ Replace the ABS (ESP) control module and recheck.
▶ Repair an open in the wire or poor ground.
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DETECTING CONDITION
When current flows in the HECU the ABS warning lamp turns from - Faulty ABS warning lamp bulb
ON to OFF as the initial check. Therefore if the lamp does not light - Blown fuse is related to ABS in the
up, the cause may be an open in the lamp power supply circuit, a engine compartment junction block
blown bulb, an open in the both circuits between the ABS warning - Faulty ABS warning lamp module
lamp and the HECU, and the faulty HECU.
- Faulty HECU
PROBLEM VERIFICATION
Disconnect the connector the ABS (ESP) HECU and turn the ignition switch ON.
Does the ABS waring lamp light up?
▶ Check the power source for the ABS warning lamp.
▶ Inspect again after replacing the ABS (ESP) HECU.
CHECK THE POWER SOURCE FOR THE ABS WARNING LAMP

1. Disconnect the instrument cluster connector (M07-2) and turn the ignition switch ON.
2. Measure the voltage between terminal (M07-2) 11 of the cluster harness side connector and body ground.
▶ Check for blown fuse.
▶ Check the CAN circuit resistance for ABS warning lamp.
CHECK FOR BLOWN FUSE

Check continuity of fuse (10A) from the engine compartment junction block.
▶ Repair an open in the wire between CLUSTER fuse and 12 of cluster connector(M07-2)
▶ Replace the blown fuse.
DETECTING CONDITION
If the HECU detects trouble, it lights the ABS warning lamp while at - An open in the wire
the same time prohibiting ABS control. At this time, the HECU - Inoperative instrument cluster assembly
records a DTC in memory. Even though the normal code is output, - Inoperative ABS warning lamp module
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- Inoperative ABS warning lamp module
the ABS warning lamp remains ON, then the cause may be probably
- Inoperative HECU
an open or short in the ABS warning lamp circuit.
CHECK DTC OUTPUT.
1. Connect the GDS to the 16P data link connector located behind the driver's side kick panel.
2. Check the DTC output using Scan Tool.
Is DTC output?
▶ Repair circuit indicated by code output.
▶ Check instrument cluster.
CHECK INSTRUMENT CLUSTER

Disconnect the cluster connector and turn the ignition switch ON.
Does the ABS warning lamp remains ON?
▶ Replace the instrument cluster.
▶ Check for open the wire.
CHECK FOR OPEN IN THE WIRE

Check for continuity in the wire between cluster and ABS control module.
▶ Replace the ABS control module and recheck.
▶ Repair an open in the wire between cluster and ABS control module.
BLEEDING OF BRAKE SYSTEM

This procedure should be followed to ensure adequate bleeding of air and filling of the ABS unit, brake lines and
master cylinder with brake fluid.
1. Remove the reservoir cap and fill the brake reservoir with brake fluid.
If there is any brake fluid on any painted surface, wash it off immediately.
When pressure bleeding, do not depress the brake pedal.

Recommended fluid........ DOT3 or DOT4
2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half filled
clear plastic bottle.
3. Connect the GDS to the data link connector located underneath the dash panel.
4. Select and operate according to the instructions on the GDS screen.
You must obey the maximum operating time of the ABS motor with the GDS to prevent the motor pump from burning.
(1) Select vehicle name.

(2) Select Anti-Lock Brake system.
(3) Select HCU air bleeding mode.
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(4) Press "OK" to operate motor pump and solenoid valve.
(5) Wait 60 sec. before operating the air bleeding.

(If not, you may damage the motor.)
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(6) Perform the air bleeding.
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.
FRONT
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REAR
6. Repeat step 5 until there are no more bubbles in the fluid for each wheel.
7. Tighten the bleeder screw.
Bleed screw tightening torque:

5.9 ~ 9.8 Nm (0.6 ~ 1.0 kgf.m, 4.3 ~ 7.2 lb-ft)
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Brake System
ABS (Anti-Lock Brake System) - ABS

Control Module
Brake System
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2010 > G 1.0 SOHC >
Components
1. Front-left tube 6. MC1

2. Rear-right tube 7. ABS control module(HECU)
3. Rear-left tube 8. Bracket
4. Front-right tube 5. MC2 9. Damper screw
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2010 > G 1.0 SOHC >
Removal
1. Turn the ignition switch OFF.
2. Pull up the lock of the ABS control unit connector (A), then disconnect the connector.
3. Disconnect the brake tubes from the HECU by unlocking the nuts counterclockwise with a spanner.
4. Loosen the ABS HECU bracket bolts and nut then remove HECU and bracket.
1. Never attempt to disassemble the HECU.

2. The HECU must be transported and stored in.
3. Never shock to the HECU.
5. Remove the bolts, then remove the bracket from HECU.
INSTALLATION
2. Tighten the HECU mounting bolts and nuts to the specified torque.
Tightening torque
HECU bracket nuts :
11 ~ 14 Nm (1.1 ~ 1.4 kgf.m, 8.1 ~ 10.3 Ib-ft)
HECU bracket mounting bolt :
16.7 ~ 25.5 Nm (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 Ib-ft)
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Brake System
ABS (Anti-Lock Brake System) - Front Wheel

Speed Sensor
Brake System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL
1. Remove the front wheel speed sensor mounting bolt.
2. Remove the mounting bolt fixed on the strut.
3. Remove the mounting bolt fixed on the chassis.
4. Remove the mounting bolt fixed on the upper of chassis.
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5. Remove the front wheel speed sensor after disconnecting the wheel speed sensor connector.
INSPECTION
1. Measure the output voltage between the terminal of the wheel speed sensor and the body ground.
In order to protect the wheel speed sensor, when measuring output voltage, a 100 ! resister must be used as
shown.
2. Compare the change of the output voltage of the wheel speed sensor to the normal change of the output voltage
as shown below.
V_low : 0.59V ~ 0.84V

V_high : 1.18V ~ 1.68V
Frequency range : 1 ~ 2,500Hz
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Brake System
ABS - Rear Wheel Speed Sensor
Brake System
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COMPONENTS
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2010 > G 1.0 SOHC >
INSPECTION
shown.
as shown below.
V_low : 0.59V ~ 0.84V

V_high : 1.18V ~ 1.68V
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Brake System
ABS - EBD (Electronic Brake-force

Distribution)
Brake System
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2010 > G 1.0 SOHC >
EBD (ELECTRONIC BRAKE-FORCE DISTRIBUTION) OPERATION

The EBD system (Electronic Brake force Distribution) as a sub-system of the ABS system is to control the effective
adhesion utilization by the rear wheels.
It further utilizes the efficiency of highly developed ABS equipment by controlling the slip of the rear wheels in the
partial braking range.
The brake force is moved even closer to the optimum and controlled electronically, thus dispensing with the need for
the proportioning valve.
The proportioning valve, because of a mechanical device, has limitations to achieve an ideal brake force distribution
tothe rear wheels as well as to carry out the flexible brake force distribution proportioning to the vehicle load or weight
increasing. And in the event of malfunctioning, driver cannot notice whether it fails or not.
EBD controlled by the ABS Control Module, calculates the slip ratio of each wheel at all times and controls the brake
pressure of the rear wheels not to exceed that of the front wheels.
If the EBD fails, the EBD warning lamp (Parking brake lamp) lights up.
ADVANTAGES
- Function improvement of the base-brake system.
- Compensation for the different friction coefficients.
- Elimination of the proportioning valve.
- Failure recognition by the warning lamp.
Comparison between Proportioning valve and EBD
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Brake System
EPS (Electronic Stability Program) System
Brake System
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CIRCUIT DIAGRAM - ESP(1)
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ESP Connector Input/Output
Connector Terminal
No Description
High level of wake up voltage :4.5V < V < 16.0V
29 IGNITION1(+) Low level of wake up voltage : V < 2.4V
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Over voltage range : 17.0 ± 0.5V
Operating voltage range : 10.0 ± 0.5V < V < 16.0 ±
0.5V
25 POS. BATTERY 1.(SOLENOID)
Low voltage range : 7.0 ± 0.5V < V < 9.5 ± 0.5V
Operating voltage range: 10.0 ± 0.5V < V < 16.0 ±
0.5V
1 POS. BATTERY 2.(MOTOR) Rush current : I < 110A
38 GROUND
23 BRAKE LIGHT SWITCH Input voltage (Low) : V < 2V
Input voltage (High) : V > 6V
9 BRAKE SWITCH Max. Input current : I < 3mA
11 SENSOR GROUND Rated current : I <250mA
Max. current Capability : I < 250mA
4 SENSOR POWER
Max. voltage : V_BAT1 -0.8V
22 PARKING BRAKE SWITCH Input voltage (High) : V > 6V
Max input current : I < 5mA
External pull up resistance :1 K! < R
28 SENSOR FRONT RIGHT OUTPUT
34 SENSOR FRONT RIGHT POWER Output voltage : V_BAT1 -0.6v ~ V_BAT1 -1.1V
19 SENSOR REAR LEFT POWER Output current : Max. 30mA

Input current LOW : 5.9 ~ 8.4mA
21 SENSOR FRONT RIGHT SIGNAL Input current HIGH :11.8 ~ 16.8mA Typ. 7mA
10 ESP ON/OFF SWITCH Input voltage (High) : V > 6V
Max. input current:I <3mA
12 CAN SENSOR LINE (HIGH)
Max. input current : I < 10mA
24 CAN SENSOR LINE (LOW)
6 ABS/EBD LAMP
7 ESP OFF LAMP
Max. Output low voltage : V < 0.7V
8 ESP FUNCTION LAMP
15 STEERING ANGLE SENSOR PHASE A Input duty (STG A, STG B) : 50 ± 10%
phase Differenoe (STG A, STG B) 2 ± 0.6deg
16 STEERING ANGLE SENSOR PHASE B
High voltage : 3.0V < VH < 4.1V
27 STEERING ANGLE SENSOR PHASE Z
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27 STEERING ANGLE SENSOR PHASE Z Low voltage : 1.3V < VL < 2.0V
Input voltage (Low) : V < 0.3V IGN1 [V]
Input voltage (High) : V > 0.7V IGN1 [V]
30 K-LINE DIAGNOSTICS
Output voltage (Low) : V < 0.2V IGN1 [V]
Output voltage (High) : V > 0.8V IGN1 [V]
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2010 > G 1.0 SOHC >
description of ESP
Optimum driving safety now has a name : ESP, the Electronic Stability Control.
ESP is based on the MGH 60 ABS Hydraulic System. ESP recognizes critical driving conditions, such as panic
reactions in dangerous situations, and stabilizes the vehicle by wheel-individual braking and engine control intervention
with no need for actuating the brake or the gas pedal.
ESP adds a further function known as Active Yaw Control (AYC) to the ABS, TCS, EBD and EDC functions. Whereas
the ABS/TCS function controls wheel slip during braking and acceleration and, thus, mainly intervenes in the
longitudinal dynamics of the vehicle, active yaw control stabilizes the vehicle about its vertical axis.
This is achieved by wheel individual brake intervention and adaptation of the momentary engine torque with no need
for any action to be taken by the driver.
ESP essentially consists of three assemblies : the sensors, the electronic control unit and the actuators.
The electronic control unit incorporates the technological experience accumulated in connection with the MGH 60
system, but has been substantially expanded in terms of capacity and monitoring concept in order to permit the
additional sensor signals and arithmetic operations to be processed and converted into corresponding valve, pump and
engine control commands. Two 16-bit processors and one 8-bit processor, which monitor each other, cooperate to
handle these requirements.
Of course, the stability control feature works under all driving and operating conditions. Under certain driving
conditions, the ABS/TCS function can be activated simultaneously with the ESP function in response to a command
by the driver.
In the event of a failure of the stability control function, the basic safety function, ABS, is still maintained.
DESCRIPTION OF ESP CONTROL

ESP system includes ABS/EBD, TCS and AYC function.
ABS/EBD function : The ECU changes the active sensor signal (current shift) coming from the four wheel sensors to
the square wave.By using the input of above signals, the ECU calculates the vehicle speed and the acceleration &
deceleration of the four wheels.And, the ECU judges whether the ABS/EBD should be actuated or not.
TCS function prevents the wheel slip of drive direction by adding the brake pressure and engine torque reduction via
CAN communication.TCS function uses the wheel speed sensor signal to determine the wheel slip as far as ABS
function.
AYC function prevents unstable maneuver of the vehicle. To determine the vehicle maneuver, AYC function uses the
maneuver sensor signals(Yaw Rate Sensor, Lateral Acceleration Sensor, Steering Wheel Angle Sensor).If vehicle
maneuver is unstable (Over Steer or Under Steer), AYC function applies the brake pressure on certain wheel, and
send engine torque reduction signal by CAN.
After the key-on, the ECU continually diagnoses the system failure. (self-diagnosis)If the system failure is detected,
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the ECU informs driver of the system failure through the BRAKE/ABS/ESP warning lamp. (fail-safe warning)
INPUT AND OUTPUT DIAGRAM
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ESP OPERATION MODE
ESP HYDRAULIC SYSTEM DIAGRAM
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1. ESP Non-operation : Normal braking.
Solenoid valve Continuity Valve Motor pump TC Valve
IN (NO) OFF OPEN
OFF OFF
OUT (NC) OFF CLOSE
2. ESP operation
Understeering IN(NO) OFF OPEN
(Only inside of
rear wheel) OUT(NC) OFF CLOSE
ON ON
Oversteering IN(NO) OFF OPEN
(Only outside
of front wheel) OUT(NC) OFF CLOSE
ESP HECU EXTERNAL DIAGRAM
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ABS Warning Lamp module
The active ABS warning lamp module indicates the self-test and failure status of the ABS .The ABS warning lamp
shall be on:
- During the initialization phase after IGN ON. (continuously 3 seconds).
- In the event of inhibition of ABS functions by failure.
- During diagnostic mode.
- When the ECU Connector is seperated from ECU.
EBD/PARKING BRAKE WARNING LAMP MODULE

The active EBD warning lamp module indicates the self-test and failure status of the EBD. However, in case the
Parking Brake Switch is turned on, the EBD warning lamp is always turned on regardless of EBD functions. The EBD
warning lamp shallbe on:
- When the Parking Brake Switch is ON or brake fluid level is low.
- When the EBD function is out of order .
ESP/OFF Warning Lamp (ESP system)

The ESP warning lamp indicates the self-test and failure status of the ESP.
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The ESP warning lamp is turned on under the following conditions :
- In the event of inhibition of ESP functions by failure.
- When driver trun off the ESP function by on/off switch.
ESP Function Lamp (ESP system)

The ESP function lamp indicates the self-test and operating status of the ESP.
The ESP Function lamp operates under the following conditions :
- When the ESP control is operating. (Blinking - 2Hz)
ESP On/Off Switch (ESP system)

The ESP On/Off Switch shall be used to toggle the ESP function between On/Off states based upon driver input.
The On/Off switch shall be a normally open, momentary contact switch.Closed contacts switch the circuit to ignition.
Initial status of the ESP function is on and switch toggle the state.
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
FAILURE DIAGNOSIS
1. In principle, ESP and TCS controls are prohibited in case of ABS failure.
2. When ESP or TCS fails, only the failed system control is prohibited.
3. However, when the solenoid valve relay should be turned off in case of ESP failure, refer to the ABS fail-safe.
4. Information on ABS fail-safe is identical to the fail-safe in systems where ESP is not installed.
MEMORY OF FAIL CODE

1. It keeps the code as far as the backup lamp power is connected. (O)
2. It keeps the code as far as the HCU power is on. (X)
FAILURE CHECKUP
1. Initial checkup is performed immediately after the HECU power on.
2. Valve relay checkup is performed immediately after the IG2 ON.
3. It executes the checkup all the time while the IG2 power is on.
4. Initial checkup is made in the following cases.
(1) When the failure is not detected now
(2) When ABS and ESP are not in control.
(3) Initial checkup is not made after ECU power on.
(4) If the vehicle speed is over 5 mph(8 km/h) when the brake lamp switch is off.
(5) When the vehicle speed is over 24.8 mph(40 km/h).
5. Though, it keeps on checkup even if the brake lamp switch is on.

6. When performing ABS or ESP control before the initial checkup, stop the initial checkup and wait for the HECU
power input again.
7. Judge failure in the following cases.
(1) When the power is normal.
(2) From the point in which the vehicle speed reaches 4.9 mph(8 km/h) after HECU power on.
COUNTERMEASURES IN FAIL
1. Turn the system down and perform the following actions and wait for HECU power OFF.
2. Turn the valve relay off.
3. Stop the control during the operation and do not execute any until the normal condition recovers.
WARNING LAMP ON
1. ESP operation lamp turn on for 3sec after IGN On.
2. ESP operation lamp blinks when ESP Act.
3. ESP OFF warning lamp turn on in case of
A. ESC Switch OFF
B. ESC Failure Detect
C. 3sec after IGN On
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Brake System
EPS (Electronic Stability Program) System -

Yaw-rate And Lateral G Sensor
Brake System
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2010 > G 1.0 SOHC >
DESCRIPTION
When the vehicle is turning with respect to a vertical axis the yaw rate sensor detects the yaw rate electroniclly by the
vibration change of plate fork inside the yaw rate sensor.
If yaw velocity reaches the specific velocity after it detects the vehicle’ yawing, the VDC control is reactivated.
The later G sensor senses vehicle’s lateral G. A small element inside the sensor is attached to a deflectable leverarm
by later G.
Direction and magnitude of lateral G loaded to vehicle can be known with electrostatic capacity changing according to
lateral G.
It interchanges signals with HECU through extra CAN line which only used for communication between HECU and
sensor.
specifications
Description Specification Remarks
Operating voltage 10 ~ 16V
Current consumption Max. 140mA
Operating temperature -40 ~ 85°C
Measurement range -75 ~ 75°/sec
Yaw-rate sensor
Frequency response 18 ~ 22Hz
Measurement range -14.715 ~ +14.715m/s!
Lateral G sensor
Frequency response 50Hz ± 60%
External Diagram
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2010 > G 1.0 SOHC >
REPLACEMENT
1. Remove the front passenger seat. (refer to BD-"seat")
2. Disconnect the yaw rate & lateral G sensor connector.
3. Remove the mounting bolts(A).
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Brake System

ESP OFF Switch
Brake System
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2010 > G 1.0 SOHC >
DESCRIPTION
1. The ESP OFF switch is for the user to turn off the ESP system.
2. The ESP OFF lamp is on when ESP OFF switch is engaged.
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2010 > G 1.0 SOHC >
INSPECTION
1. Remove the ESP OFF switch from the switch panel.
2. Check the continuity between the switch terminals as the ESP OFF switch is engaged.
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Brake System

Steering Wheel Angle Sensor
Brake System
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2010 > G 1.0 SOHC >
DESCRIPTION
The steering angle speed sensor detects the angle of the steering wheel in order to which direction a user chooses.
The sensor is detached on the MPS(Mutil-Function Switch) under the steering wheel.
MEASUREING PRINCIPLE
The split of the steering angle sensor detects a steering angle of the steering wheel by a ON/OFF pulse caused by
whether or not the LED lights go through the hole of the split, rotating as the steering wheel revolves. There are three
LEDs, two(ST1, ST2) for detecting a steering direction, and the other for the neutral position. The HECU calculates
the steering angle by the pulse from the steering angle sensor.
SPECIFICATION
Description Specification
Current consumption Max.100mA
Steering angle velocity Max. ± 1500°/sec
Voltage(high) 3.0V ~ 4.1V
Voltage(low) 1.3V ~ 2.0V
Pulse duty 40 ~ 60%
CIRCUIT DIAGRAM( STEERING WHEEL SPEED ANGLE SENSOR)
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OUTPUT CHARACTERISTIC
No. INPUT OUTPUT Steering direction Remark

ST1 L L
Right
ST2 L H
1
ST1 L H
Left
ST2 L L
ST1 L L
Left
ST1 H L
2
ST1 L H
Right
ST2 H H
ST1 H H
Left
ST2 L H
3
ST1 H L
Right
ST2 L L
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ST1 H H
Right
ST2 H L
4
ST1 H L
Left
ST2 H H
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Brake System
General Information
Brake System
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2010 > G 1.0 SOHC >

Tool(Number and Name) Illustration Use
09581-11000 Spreading the front disc brake piston
Piston expander
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2010 > G 1.0 SOHC >
TROUBLESHOOTING
Symptom Suspect Area Reference
Lower pedal or 1. Brake system (Fluid leaks) repair
spongy pedal 2. Brake system (Air in) air·bleed
3. Piston seals (Worn or damaged) replace
adjust
replace
Brake drag 1. Brake pedal freeplay (Minimum) adjust
2. Parking brake lever travel (Out of adjustment) adjust
3. Parking brake wire (Sticking) repair
adjust
replace
replace
6. Piston (Stuck) replace
8. Anchor or Return spring (Inoperative) repair
9. Booster system (Vacuum leaks) replace
Brake pull 1. Piston (Sticking) replace
replace
4. Disc (Scored)
replace
Hard pedal but brake 1. Brake system (Fluid leaks) repair
inefficient 2. Brake system (Air in) air·bleed
3. Pad or lining (Worn) replace
replace
adjust
adjust
8. Disc (Scored) repair
9. Booster system (Vacuum leaks)
Noise from brake 1. Pad or lining (Cracked or distorted) replace
2. Installation bolt (Loosen) adjust
3. Disc (Scored) replace
replace
4. Sliding pin (Worn)
clean
5. Pad or lining (Dirty)
replace
7. Anchor or Return spring (Faulty) replace
8. Brake pad shim (Damage) replace
9. Shoe hold-down spring (Damage)
Brake fades 1. master cylinder replace
1. brake booster replace

2. pedal free play adjust
Brake vibration, 3. master cylinder replace
pulsation replace
4. caliper
replace
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replace
5. master cylinder cap seal
replace
6. damaged brake lines
Brake chatter is usually caused by loose or worn components, or
glazed or burnt linings. Rotors with hard spots can also contribute to
Brake Chatter brake chatter. Additional causes of chatter are out-of-tolerance rotors,
brake lining not securely attached to the shoes, loose wheel bearings
and contaminated brake lining.
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2010 > G 1.0 SOHC >
SPECIFICATIONS
Item Specification
Type Tandem
Cylinder I.D. 20.64 mm (0.813 in)
Master cylinder
Piston stroke 30 mm (1.18 in)
Fluid level switch Provided
Size (TYPE) 8 in (Vacuum)
Brake booster
Boosting ratio 4.5: 1
Type Ventilated disc
Cylinder I.D 51.1 mm (2.01 in)
252 mm (9.92 in)
Disc O.D.
Front brake 241 mm (9.48 in)
Pad thickness 10 mm (0.39 in)
Caliper piston Double
Type Solid disc
Cylinder I.D 34 mm (1.34 in)
Disc O.D. 234 mm (9.21 in)
Rear brake
Pad thickness 9mm (0.35 in)
Caliper piston Single
O.D. : Outer Diameter

I.D : Inner Diameter
SPECIFICATION (ABS)
System
40)
Type ABS + EBD
HECU Operating Voltage 10 ~ 16 V
-40 ~ 110 °C (-40 ~ 230 °F
Operating Temperature
)
Motor power 160 W
Warning lamp
Active Wheel speed sensor Output current high 11.8 ~ 16.8 mA Typ. 14 mA
(ABS)
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(ABS) Output range 1 ~ 2500 Hz
Tone wheel 48 teeth
Air gap 0.4 ~ 1.5 mm
SPECIFICATION(ESP)
System
40)
Motor, valve relay
Type
intergrated type Total control
HECU
(ABS, EBD, ESP)
Operating Temperature -40 ~ 110 °C (-40 ~ 230 °F)
Motor power 210 W
Warning lamp
Output current high 11.8 ~ 16.8 mA Typ. 14 mA
Active Wheel speed sensor
Output range 1 ~ 2500 Hz
(ABS)
Tone wheel 48 teeth
Front 0.4 ~ 1.5 mm
Air gap
Rear 0.2 ~ 0.7 mm
Operating Angular velocity Max. 1500 °/sec
Operating temperature -30 ~ 75 °C (-22 ~ 167 °F)
Steering Wheel Angle
Sensor Max Consumption Current 100 mA
Max Output Current 10 mA
Max Output Absorption
50 mA
Current
Operating Voltage 8 V ~ 17 V
Current Consumption Max. 140 mA
Yaw rate & Operating Temperature -40 ~ 85 °C (-40 ~ 185 °F)
Lateral G sensor
Yaw rate sensor
(CAN TYPE) ± 75 °/sec
measurement range
Lateral G sensor
± 1.5 g
measurement range
SERVICE STANDARD
Items Standard vale
Brake pedal height 189.3 mm (7.45 in)
Brake pedal stroke 120 mm (4.72 in)
Stop lamp clearance 1.0 ~ 2.0 mm (0.04 ~ 0.08 in)
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Brake pedal free play 3 ~ 8 mm (0.12 ~ 0.31 in)
Front brake disc thickness 18 mm (0.708 in)
Front brake disc pad thickness 10 mm (0.39 in)
Rear brake disc thickness 10 mm (0.39 in)
Rear brake disc pad thickness 9 mm (0.35 in)
TIGHTENING TORQUES
Items Nm kgf.m lb-ft
Hub nut 88.3 ~ 107.9 9.0 ~ 11.0 65.1 ~ 79.6
Master cylinder to brake booster 7.9 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Brake booster mounting nuts 7.9 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Air bleeding screw 5.9 ~ 9.8 0.6 ~ 1.0 4.3 ~ 7.2
Brake tube flare nuts 12.7 ~ 16.7 1.3 ~ 1.7 9.4 ~ 12.3
Front caliper guide rod bolts 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
Rear caliper guide rod bolts 21.6 ~ 31.4 2.2 ~ 3.2 15.9 ~ 23.1
Front caliper assembly to knuckle 83.4 ~ 93.1 8.5 ~ 9.5 61.5 ~ 68.7
Rear caliper assembly to knuckle 83.4 ~ 93.1 8.5 ~ 9.5 61.5 ~ 68.7
Brake hose to caliper 16.7 ~ 19.6 1.7 ~ 2.0 12.3 ~ 14.5
Brake pedal mounting bracket bolts 12.7 ~ 21.6 1.3 ~ 2.2 9.4 ~ 15.9
Brake pedal shaft nut 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3
Stop lamp switch lock nut 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Wheel speed sensor mounting bolt 8.0 ~ 9.5 0.82 ~ 0.97 5.9 ~ 7.0
HECU bracket bolt & nuts 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
HECU bracket nut 11 ~ 14 1.1 ~ 1.4 8.1 ~ 10.3
Yaw rate & G sensor mounting bolts 7.8 ~ 10.8 0.8 ~ 1.1 5.8 ~ 8.0
LUBLICANTS
Items Recommended Quantity
Brake pedal bushing and bolt Chassis grease As required
Parking brake shoe and backing plate contacting surface Heat resistance grease As required
0.8 ~ 2.0 g (Front)
Caliper guide rod and boot AI-11P
0.7 ~ 1.5 g (Rear)
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Brake System
Brake System
Brake System
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2010 > G 1.0 SOHC >
Operation and Leakage Check

Check all of the following items:
Component Procedure
Brake Booster (A) Check brake operation by applying the brakes during a test drive. If the brakes do not
work properly, check the brake booster. Replace the brake booster as an assembly if it
does not work properly or if there are signs of leakage.
Piston cup and pressure cup • Check brake operation by applying the brakes. Look for damage or signs of fluid
inspection (B) leakage. Replace the master cylinder as an assembly if the pedal does not work
properly or if there is damage or signs of fluid leakage.
• Check for a difference in brake pedal stroke between quick and slow brake
applications. Replace the master cylinder if there is a difference in pedal stroke.
Brake hoses (C) Look for damage or signs of fluid leakage. Replace the brake hose with a new one if it
is damaged or leaking.
Caliper piston seal and Check brake operation by applying the brakes.
piston boots (D) Look for damage or signs of fluid leakage. If the pedal does not work properly, the
brakes drag, or there is damage or signs of fluid leakage, disassemble and inspect the
brake caliper. Replace the boots and seals with new ones whenever the brake caliper
is disassembled.
BRAKE SYSTEM BLEEDING
• Do not reuse the drained fluid.

• Always use genuine DOT3/DOT4 brake Fluid.
Using a non-genuine DOT3/DOT4 brake fluid can cause corrosion and decrease the life of the system.
• Make sure no dirt of other foreign matter is allowed to contaminate the brake fluid.
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• Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it
• The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding procedure
and checked after bleeding each brake caliper. Add fluid as required.
1. Make sure the brake fluid in the reservoir is at the MAX (upper) level line.
2. Have someone slowly pump the brake pedal several times, and then apply pressure.
3. Loosen the right-rear brake bleed screw (A) to allow air to escape from the system. Then tighten the bleed screw
securely.
4. Repeat the procedure for wheel in the sequence shown below unit air bubbles no longer appear in the fluid.
5. Refill the master cylinder reservoir to MAX (upper) level line.
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Brake System
Brake System - Brake Booster
Brake System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
BRAKE BOOSTER OPERATING TEST

For simple checking of the brake booster operation, carry out the following tests
1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains
unchanged, thebooster is defective.
2. With the engine stopped, step on the brake pedal several times.
Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good
condition. If there is no change, the booster is defective
3. With the engine running, step on 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
the pedal rises, the booster is defective.
If the above three tests are okay, the booster performance can be determined as good.
Even if one of the above three tests is not okay, check the check valve, vacuum hose and booster for defect.
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VACUUM HOSE (CHECK VALVE)
INSPECTION
1. Disconnect the brake booster vacuum hose (check valve built in) (A) at the booster (B).
2. Start the engine and let it idle. There should be vacuum available. If no vacuum is available, the check valve is not
working properly. Replace the brake booster vacuum hose and check valve and retest.
Removal
1. Remove the master cylinder.
2. Disconnect the vacuum hose (A) from the brake booster (B).
3. Remove the snap pin (A), pin (B) and washer (C).
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4. Remove the four booster mounting nuts (D).
5. Remove the brake booster (A) from the engine compartment.
INSTALLATION
1. Adjust push rod length of the booster, and then install the seal on the booster assembly.
Standard length : 107.9 ± 0.5 mm(4.25 ± 0.02 in.)
2. Insert the booster and tighten the nut (D).
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3. Connect the booster push rod and brake pedal with a pin (B) and install a snap pin (A) to the pin (B).
When installing the snap pin, it must be used new one.
4. Adjust push rod length.

(1) Insert the gasket onto the master cylinder.
(2) Put the SST onto the gasket and tighten the adjusting bolt until the bolt touches the bottom of the push rod
hole.
(3) Apply 500 mmHg vacuums with a vacuum pump.

(4) Invert the tool used in step 2 and place it on the booster.
(5) Check whether the clearance between the edge of the adjusting bolt and the push rod of the booster is 0 - 0.1
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mm (0 - 0.004 in.).
If it is not standard clearance, loosen the lock nut of the push rod, and turn the push rod to make the
adjustment.
Standard clearance : 0.6 ~ 1.4 mm (0.023 ~ 0.055 in.)
5. Install the master cylinder.

6. Connect the vacuum hose to the brake booster.
7. After filling the brake reservoir with brake fluid, bleed the system.
8. Check for fluid leakage.
9. Check and adjust the brake pedal for proper operation.
10. After installing, apply grease to the contact parts of the joint pin and brake pedal.
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Brake System
Brake System - Master Cylinder
Brake System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REPLACEMENT
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off
1. Remove the air cleaner cover, air filter, air cleaner mounting bolts and air cleaner body from the air cleaner
mounting bracket.
2. Disconnect the brake fluid level switch connectors (A), and remove the reservoir cap.
3. Remove the brake fluid from the master cylinder reservoir with a syringe.
4. Disconnect the brake lines from the master cylinder. To prevent spills, cover the hose joints with rags or shop
towels.
5. Remove the master cylinder mounting nuts and washers.

6. Remove the master cylinder from the brake booster. Be careful not to bend or damage the brake lines when
removing the master cylinder.
7. Install the master cylinder in the reverse order of removal, and note these items:
A. Replace all rubber parts with new ones whenever, removed.
DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a suitable container.
2. Remove the fluid level sensor.
3. Remove the proportioning valves (A) - Conventional brake system.
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4. Remove the retainer ring by using the snap ring pliers.
5. Remove the pin with the primary piston pushed completely using a screwdriver. Remove the primary piston
assembly.
6. Remove the pin with the secondary piston pushed completely using a screwdriver. Remove the secondary piston
assembly.
Do not disassemble the primary and secondary piston assembly.
INSPECTION
1. Check the master cylinder bore for rust or scratch.
2. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.
• If the cylinder bore is damaged, replace the master cylinder assembly.

• Wash the contaminated parts in alcohol.
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REASSEMBLY
1. Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.
2. Carefully insert the springs and pistons in the proper direction.
3. Press the piston with a screwdriver and install the cylinder pin.
4. Press the piston with a screwdriver and install the snap ring.
5. Install the proportioning valves.

6. Mount two grommets.
7. Install the reservoir on the cylinder.
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Brake System
Brake System - Proportioning Valve
Brake System
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2010 > G 1.0 SOHC >
DESCRIPTION
Do not disassemble the proportioning valve. The proportioning valve makes the ideal distribution of fluid pressure to
the front and rear brakes to prevent the brakes from skidding in the event of rear wheel lock up and to obtain a higher
brake efficiency within the range of service brake application.
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2010 > G 1.0 SOHC >
Proportioning valve function test

1. Remove the front brake tube (B) and rear brake tube (C) from the master cylinder (A).
2. Connect two pressure gauges (D); one to the output valve of the front (B) and rear (C) brake.
Be sure to bleed the system after connecting the pressure gauges.
3. With the brake applied, measure the front pressure and the rear pressure.
If the measured pressures are within the specified range as illustrated, the proportioning valve is good.
4. Reconnect the brake lines in their original positions and bleed the system.
This table shows characteristics of the proportioning valve as the pressure increases.
Front Rear
(Output of master cylinder) (Output of proportioning valve)
A : 26 kg/cm! A' : 26 kg/cm!
(2.55MPa, 370psi) (2.55MPa, 370psi)
B : 80 kg/cm! B' : 40.6 ± 3 kg/cm!
(7.84MPa, 1137psi) (3.98 ± 0.3MPa, 577 ± 42psi)
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Brake System
Brake System - Brake Line
Brake System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
INSPECTION
1. Inspect the brake hoses, for damage, deterioration, leaks, interference and twisting.
2. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines.
3. Check for leaks at hose and line joints or connections, and retighten if necessary.
4. Check the master cylinder for damage and leakage.
5. Replace the brake hose clip whenever the brake hose is serviced.
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Brake System
Brake System - Brake Pedal
Brake System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
SERVICE ADJUSTMENT
PROCEDURES
PEDAL HEIGHT
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PEDAL FREE PLAY

pedal arm.
REMOVAL
1. Remove the lower crash pad.
2. Remove the stop lamp switch connector.
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3. Remove the pin and snap pin.
4. Remove the brake pedal member assembly mounting nuts and then remove the brake pedal assembly.
SERVICE ADJUSTMENT
PROCEDURES
PEDAL HEIGHT
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PEDAL FREE PLAY

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pedal arm.
INSTALLATION
Coat the inner surface of the bushings with the specified grease.
2. Before inserting the pin, apply the specified grease to the joint pin.
3. Adjust the brake pedal height and free play.

4. Install the stop lamp switch.
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Brake System
Brake System - Front Disc Brake
Brake System
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2010 > G 1.0 SOHC >
General information
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2010 > G 1.0 SOHC >
COMPONENTS(1)
COMPONENTS(2)
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2010 > G 1.0 SOHC >

Pad thickness
REMOVAL
1. Remove guide rod (B) and the caliper (C) up out of the way. Check the hoses and pin boots for damage and
deterioration.
2. Remove the pad shims (A), pad retainers (B) and pads (C).
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INSTALLATION
1. Install the pad retainers (A).
2. Check the foreign material at the pad shims and the back of the pads.
Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
3. Install the brake pads and pad shims correctly. Install the pad with the wear indicator on the inside.
4. Push in the piston (A) so that the caliper will fit over the pads. Make sure that the piston boot is in position to
prevent it damaging when pivoting the caliper down.
5. Pivot the caliper down into position. Being careful not to damage the pin boot, install the guide rod bolt (B) and
torque it to proper specification.
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Insert the piston in the cylinder using the special tool (09581-11000).
replaced as a set.Several applications of the brake will restore the normal pedal stroke.
7. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.

Pad thickness
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Brake System
Brake System - Rear Disc Brake
Brake System
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2010 > G 1.0 SOHC >
General information
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2010 > G 1.0 SOHC >
COMPONENTS(1)
COMPONENTS(2)
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2010 > G 1.0 SOHC >

Pad thickness
REMOVAL
1. Raise the rear of the vehicle and make sure it is securely supported. Remove the rear wheel.
3. Remove the brake hose (A) from the suspension arm by removing the brake hose clip (B).
4. Thoroughly clean the outside of the caliper to prevent dust and dirt from entering inside.
Support the caliper with a piece of wire so that it does not hang from the brake hose.
5. Remove the two guide rods (C) and caliper (D) from the bracket.
6. Remove the pad shim (A) and brake pads (B).
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INSTALLATION
1. Install the pad springs(A) to the carrier(B).
2. Check the foreign material at the pad shim (A) and the back of the pads (B).
3. Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
4. Install the brake pads (B) and pad shim (A) on the caliper bracket. Install the inner pad with its wear indicator (C)
facing down ward.
5. Rotate the caliper piston (A) clockwise into the cylinder, align the cutout (B) in the piston with the tab (C) on the
inner pad by turning the piston back. Lubricate the boot with rubber grease to avoid twisting the piston boot. If the
piston boot is twisted, back it out so it is positioned properly.
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6. Install the brake caliper (D).
7. Install and torque the guide rods (E) to proper specification.
8. Install the brake hose (F) onto the suspension arm with the brake hose clip (G).
9. After installation, check for leaks at hose and line joints and connections, and retighten if necessary.
replaced as a set.Several applications of the brake pedal will restore the normal pedal stroke.

Pad thickness
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Brake System
Brake System - Rear Drum Brake
Brake System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
INSPECTION



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REMOVAL
1. Remove the shoe hole down pins (B) by pushing the shoe hold pin (C) and turning them.
2. Disengage the upper return spring (A).
3. Lower the brake shoe assembly (A), and remove the lower return spring (B). Make sure not to damage the dust
cover on the wheel cylinder.
4. Disconnect the parking brake cable from the parking brake lever.
5. Remove the brake shoe assembly.
6. Remove the upper return spring (C), self-adjuster lever (D) and self-adjuster spring (E), and separate the brake
shoes.
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7. Disconnect the brake line (A) from the wheel cylinder (B).
8. Remove the bolt (C) and the wheel cylinder from the backing plate.
INSTALLATION
• Do not spill brake fluid on the vehicle: it may damage the paint; if brake fluid does contact the paint. Wash it
• To prevent spills, cover the hose joints with rags or shop towels.
• Use only a genuine wheel cylinder special bolt.
1. Apply sealant (C) between the wheel cylinder (A) and backing plate (B), and install the wheel cylinder.
2. Connect the brake tubes (D) to the wheel cylinder.
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3. Connect the parking brake cable to the parking brake lever.
4. Clean the threaded portions of adjuster sleeve (A) and push rod female (B).
5. Hook the self-adjuster spring (D) to the strut assembly, then to the brake shoe.
6. Install the strut assembly and upper return spring (E), noting the installation direction. Be careful not to damage the
wheel cylinder dust covers.
7. Install the lower return spring (F).
8. Apply brake cylinder grease or equivalent rubber grease to the sliding surfaces shown. Wipe off any excess. Don't
get grease on the brake linings.
9. Apply brake cylinder grease or equivalent rubber grease to the brake shoe ends and opposite edges of the shoes
shown. Wipe off any excess. Don't get grease on the brake linings.
10. Install the brake shoes (A) onto the backing plate. Be careful not to damage the wheel cylinder dust covers.
11. Install the shoe hole down pins (B) and the shoe hold pin (C).
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12. Hook the upper return spring (D).
13. Install the brake drum.
14. If the wheel cylinder has been removed, bleed the brake system.
15. Depress the brake pedal several times to set the self-adjusting brake.
16. Adjust the parking brake.
INSPECTION

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Brake System
Parking Brake System - Parking Brake

Assembly
Brake System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
Parking brake check and adjustment

INSPECTION
1. Pull the parking brake lever (A) with 196 N (20 kg, 44lbf) force to fully apply the parking brake. The parking brake
lever should be locked within the specified number of clicks (B).
Lever locked clicks:

Vehicle with rear disc brakes: 8~9
Vehicle with rear drum brakes: 8
2. Adjust the parking brake if the lever clicks are out of specification.
ADJUSTMENT
After rear brake caliper servicing, loosen the parking brake adjusting nut, start the engine and depress the brake
pedal several times to set the self-adjusting brake before adjusting the parking brake.
1. Block the front wheels, then raise the rear of the vehicle and make sure it is securely supported.
2. Make sure the parking brake arm (A) on the rear brake caliper contacts the brake caliper pin (B).
3. Pull the parking brake lever up one click.
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5. Tighten the adjusting nut (A) until the parking brakes drag slightly when the rear wheels are turned.
6. Release the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are turned.
Readjust if necessary.
7. Make sure that the parking brakes are fully applied when the parking brake lever is pulled up fully.
8. Reinstall the console.
REMOVAL
The parking brake cables must not be bent or distorted.

This will lead to stiff operation and premature failure.
Rear drum brake

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6. Remove the brake drum and the brake shoe (Refer to the rear drum brake).
7. Remove the parking brake cable from the brake shoe.
8. Remove the parking brake cable retaining (B), from the parking brake cable (A).
9. Remove the parking brake cable (A) from the backing plate (B).
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Rear disc brake

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5. Remove the parking cable clip (A) from the parking brake cable(B).
6. Disconnect the parking brake cable (B) from the lever (C).
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INSTALLATION
1. Check the parking brake cables for an identification mark paint and install as appropriate on the left and right sides.
Identification color
Left side : -
Right side : Red
2. Install the removed parts in the reverse order of removal.

3. Apply a coating of the specified grease to each sliding parts of the ratchet plate or the ratchet pawl.
Specified grease :
Multi purpose grease SAE J310, NLGI No.2
4. After installing the cable adjuster, adjust the parking brake lever stroke (Refer to the parking brake check and
adjustment).
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Brake System
ABS (Anti-Lock Brake System)
Brake System
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2010 > G 1.0 SOHC >
ABS CIRCUIT DIAGRAM
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ABS CONNECTOR INPUT/OUTPUT
Connector Terminal
No Description
Over voltage range: 17 ± 0.5V
Operating voltage range:
9.5 ± 0.5V < V < 17 ± 0.5V
3 IGNITION1(＋)
Low voltage range:
7.0 ± 0.5V < V < 9.5 ± 0.5V
Max. current: I < 300mA
Max leakage current : I < 0.8mA
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2 POS. BATTERY.(SOLENOID)
9.5 ± 0.5V < V < 17 ± 0.5V
Max current : I < 40A
9.5 ± 0.5V < V < 16.5 ± 0.5V
1 POS, BATTERY.(MOTOR) Rush current : I < 100A
Rated current : I < 300mA
26 GROUND
G SENSOR GROUND (4WD
10 - Rated current : I < 10mA
Only)
- Max Output current : I < 10mA
18 G SENSOR POWER (4WD Only)
- Max Output voltage : 4.75V ! V ! 5.25V
- Input voltage : 0V ! V ! 5.0V

7 G SENSOR SIGNAL (4WD Only)
- Zero offset voltage : 2.5 ± 0.1V
Input voltage low: 0V ! V ! 3.0V
14 BRAKE LIGHT SWITCH
Input voltage High: 7.0V ! V ! 16.0V
17 SENSOR FRONT RIGHT POWER - Output voltage : IGN[V] ± 1V
9 SENSOR REAR LEFT POWER - Output current : Max 30mA

- Input current LOW : 5.9 ~ 8.4mA
24 SENSOR FRONT RIGHT SIGNAL - Input current HIGH : 11.8 ~ 16.8mA
8 SENSOR REAR LEFT SIGNAL - Frequency range : 1 ~ 2500Hz
- Input duty : 50 ± 20%
Input voltage :
VIL < 0.3 IGN[V]
VIH > 0.7 IGN[V]
Output voltage :
VOL < 0.2 IGN[V]
VOH > 0.8 IGN[V]
13 CAN BUS LINE (LOW)
6 CAN BUS LINE (HIGH)
SENSOR FRONT RIGHT
4 External pull up resister : 1k" < R
OUTPUT
Output duty : 50 ± 20%
Current : I < 300mA (12V)
5 ABS/EBD W/LAMP DRIVE Voltage range : 0 ~ 18V
Min. shunt resistance : 500k"
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2010 > G 1.0 SOHC >
DESCRIPTION
This specification applies to HCU(Hydraulic Control Unit) and ECU(Electronic Control Unit) of the HECU.(Hydraulic and
Electronic Control Unit)
This specification is for the wiring design and installation of ABS/ESP ECU.
This unit has the functions as follows.
- Input of signal from Pressure sensor, Steering angle sensor, Yaw & Lateral G sensor,the wheel speed sensors
attached to each wheel.
- Control of braking force / traction force / yaw moment.
- Failsafe function.
- Self diagnosis function.
- Interface with the external diagnosis tester.
Installation position : engine compartment
- Brake tube length from Master cylinder port to HECU inlet port should be max. 1m
- The position should not be close to the engine block and not lower than the wheel.
OPERATION
The ECU shall be put into operation by switching on the operating voltage (IGN).
On completion of the initialization phase, the ECU shall be ready for operation.
In the operating condition, the ECU shall be ready, within the specified limits (voltage and temperature), to process the
signals offered by the various sensors and switches in accordance with the control algorithm defined by the software
and to control the hydraulic and electrical actuators.
Wheel Sensor signal processing

The ECU shall receive wheel speed signal from the four active wheel sensors.
The wheel signals are converted to voltage signal by the signal conditioning circuit after receiving current signal from
active wheel sensors and given as input to the MCU.
Solenoid Valve Control

When one side of the valve coil is connected to the positive voltage that is provided through the valve relay and the
other side is connected to the ground by the semiconductor circuit, the solenoid valve goes into operation.
The electrical function of the coils are always monitored by the valve test pulse under normal operation conditions.
Voltage limits
- Overvoltage
When overvoltage is detected(above 17 ± 0.5 V), the ECU switches off the valve relay and shuts down the
system.
When voltage is returned to operating range, the system goes back to the normal condition after the initialization
phase.
- Undervoltage
In the event of undervoltage(below 10V), ABS control shall be inhibited and the warning lamp shall be turned on.
When voltage is returned to operating range, the warning lamp is switched off and ECU returns to normal operating
mode.
Pump Motor Checking

The ECU performs a pump motor test at a speed of 12 km/h(7 MPH) once after IGN is switched on.
Diagnostic Interface
Failures detected by the ECU are encoded on the ECU, stored in a EEPROM and read out by diagnostic equipment
when the ignition switch is turned on.
The diagnosis interface can also be used for testing the ECU during production of the ECU and for actuating the HCU
in the test line of manufactories (Air-bleeding line or Roll and Brake Test line).
WARNING LAMP MODULE
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1. ABS Warning Lamp module
The active ABS warning lamp module indicates the self-test and failure status of the ABS.
The ABS warning lamp shall be on:
B. In the event of inhibition of ABS functions by failure.
C. During diagnostic mode.
D. When the ECU Connector is seperated from ECU.
2. PARKING/EBD warning lamp module
The active EBD warning lamp module indicates the self-test and failure status of the EBD.
However, in case the Parking Brake Switch is turned on, the EBD warning lamp is always turned on regardless of
EBD functions.
The EBD warning lamp shall be on:
B. When the Parking Brake Switch is ON or brake fluid level is low.
C. When the EBD function is out of order.
D. During diagnostic mode.
E. When the ECU Connector is seperated from ECU.
ABS CONTROL
1. NORMAL BRAKING without ABS
Under the normal braking, voltage is not supplied to solenoid valve, inlet valve is opened and outlet valve is
closed.When the brake is depressed, brake fluid is supplied to the wheel cylinder via solenoid valve to activate the
brake.When the brake is released, brake fluid is back to the master cylinder via inlet valve and check valve.
Pump
Solenoid valve State Valve Passage
motor
Inlet valve (NO) OFF Open Master cylinder Wheel cylinder
OFF
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2. DUMP MODE
Under the emergency braking, if the wheels start to lock up, HECU sends a signal to the solenoid valve to decrease
the brake fluid, then voltage is supplied to each solenoid. At this time inlet valve is closed and brake fluid is blocked
from the master cylinder. Conversely outlet valve is opened and brake fluid passes through wheel cylinder to reservoir,
resulting in pressure decrease.
Pump
motor
Inlet valve (NO) ON Close Master cylinder Wheel cylinder ON
Outlet valve (NC) ON Open Wheel cylinder Reservoir
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3. HOLD MODE
When the brake fluid pressure is maximally decreased in wheel cylinder, HECU sends a signal to solenoid valve to
keep the fluid pressure, voltage is supplied to inlet valve but it is not supplied to outlet valve. At this time inlet and
outlet valves are closed and brake fluid is kept in wheel cylinder.
Pump
motor
Inlet valve (NO) ON Close Master cylinder Wheel cylinder OFF
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4. INCREASE MODE
If HECU determines there's no lock-up in the wheel, HECU cuts voltage to solenoid valve. So voltage is not supplied to
each solenoid valve, brake fluid passes through the inlet valve to wheel cylinder, resulting in pressure increase.
Pump
motor
Inlet valve (NO) OFF Open Master cylinder Wheel cylinder ON
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ABS HECU EXTERNAL DIAGRAM
HYDRAULIC SYSTEM DIAGRAM
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2010 > G 1.0 SOHC >
COMPONENTS
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STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING

The phenomena listed in the following table are not abnormal.
Phenomenon Explanation
System check sound When starting the engine, a thudding sound can sometimes be heard coming
from inside the engine compartment. This is because the system operation check
is being performed.
ABS operation sound 1. Sound of the motor inside the ABS hydraulic unit operation (whine).
2. Sound is generated along with vibration of the brake pedal (scraping).
3. When ABS operates, sound is generated from the vehicle chassis due to
repeated brake application and release
(Thump : suspension; squeak: tires)
ABS operation (Long braking For road surfaces such as snow-covered and gravel roads, the braking distance
distance) for vehicles with ABS can sometimes be longer than that for other vehicles.
Accordingly, advise the customer to drive safely on such roads by lowering the
vehicle speed.
Diagnosis detection conditions can vary depending on the diagnosis code. When checking the trouble symptom after
the diagnosis code has been erased, ensure that the requirements listed in "Comment" are met.
ABS CHECK SHEET
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If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem
symptom in the order given in the table below and proceed to the relevant troubleshooting page.

ABS does not operate. Only when 1. -4. are all normal and the problem is still
occurring, replace the HECU.
output.
2. Power source circuit.
3. Speed sensor circuit.
ABS does not operate intermittently. Only when 1. -4. are all normal and the problem is still
occurring, replace the ABS actuator assembly.
output.
2. Wheel speed sensor circuit.
3. Stop lamp switch circuit.
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Communication with Scan tool is not possible. 1. Power source circuit
(Communication with any system is not possible) 2. Diagnosis line
Communication with Scan tool is not possible. 1. Power source circuit
(Communication with ABS only is not possible) 2. Diagnosis line
3. HECU
When ignition key is turned ON (engine OFF), the ABS 1. ABS warning lamp circuit
warning lamp does not light up. 2. HECU
Even after the engine is started, the ABS warning lamp 1. ABS warning lamp circuit
remains ON. 2. HECU
During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such phenomena are
due to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is
not an abnormality.
DETECTING CONDITION

surface conditions, so diagnosis can be difficult.However if a normal - Faulty wheel speed sensor circuit
- Faulty HECU
DTC INSPECTION
1. Connect the scan tool with the data link connector and turn the ignition switch ON.
2. Verify that the normal code is output.
Is the normal code output?
▶ Check the power source circuit.
▶ Erase the DTC and recheck using scan tool.
CHECK THE POWER SOURCE CIRCUIT.

2. Turn the ignition switch ON, measure the voltage between terminal 3 (31) of the ABS (ESP) control module
harness side connector and body ground.
▶ Check the ground circuit.
(ESP) control module. Repair if necessary.
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CHECK THE GROUND CIRCUIT.
2. Check for continuity between terminals 25 (45), 26 (46) of the ABS (ESP) control module harness side connector
and ground point.
▶ Repair an open in the wire and ground point.
CHECK THE WHEEL SPEED SENSOR CIRCUIT.

Is it normal?
CHECK THE HYDRAULIC CIRCUIT FOR LEAKAGE.

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Is it normal?
▶ The problem is still occurring, replace the ABS (ESP) control module.
DETECTING CONDITION

surface conditions, so diagnosis can be difficult. However if a normal - Faulty wheel speed sensor circuit
- Faulty HECU
DTC INSPECTION
1. Connect the scan tool with the data link connector and turn the ignition switch ON.
2. Verify that the normal code is output.
Is the normal code output?
▶ Erase the DTC and recheck using scan tool.
CHECK THE WHEEL SPEED SENSOR CIRCUIT.

Is it normal?
▶ Check the stop lamp switch circuit.
CHECK THE STOP LAMP SWITCH CIRCUIT.

1. Check that stop lamp lights up when brake pedal is depressed and turns off when brake pedal is released.
2. Measure the voltage between terminal 14 (34) of the ABS (ESP) control module harness side connector and body
ground when brake pedal is depressed.
▶ Repair the stop lamp switch. Repair an open in the wire between the ABS (ESP) control module and the stop
lamp switch.
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CHECK THE HYDRAULIC CIRCUIT FOR LEAKAGE.
Is it normal?
▶ The problem is still occurring, replace the ABS control module.
DETECTING CONDITION

Possible defect in the power supply system (including ground) for the - An open in the wire
diagnosis line. - Poor ground
- Faulty power source circuit
CHECK THE POWER SUPPLY CIRCUIT FOR THE DIAGNOSIS
Measure the voltage between terminal 9 of the data link connector and body ground.
▶ Check the ground circuit for the diagnosis.
▶ Repair an open in the wire. Check and replace fuse (15A) from the engine compartment junction block.
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CHECK THE GROUND CIRCUIT FOR THE DIAGNOSIS
Check for continuity between terminal 5 of the data link connector and body ground.
▶ Repair an open in the wire between terminal 5 of the data link connector and ground point.
DETECTING CONDITION

When communication with scan tool is not possible, the cause may - An open in the wire
be probably an open in the HECU power circuit or an open in the - Faulty HECU
diagnosis output circuit. - Faulty power source circuit
CHECK FOR CONTINUITY IN THE DIAGNOSIS LINE
1. Disconnect the connector from the ABS control module.
2. Check for continuity between terminals 11 (13) of the ABS (ESP) control module connector and 1 of the data link
connector.
▶ Check the power source of ABS (ESP) control module.
▶ Repair an open in the wire.
CHECK THE POWER SOURCE OF ABS (ESP) CONTROL MODULE

2. Turn the ignition switch ON, measure the voltage between terminal 3 (31) of the ABS (ESP) control module
harness side connector and body ground.
▶ Check for poor ground.
(ESP) control module.Repair if necessary.
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CHECK FOR POOR GROUND
Check for continuity between terminal 5 of the data link connector and ground point.
▶ Replace the ABS (ESP) control module and recheck.
▶ Repair an open in the wire or poor ground.
DETECTING CONDITION

When current flows in the HECU the ABS warning lamp turns from - Faulty ABS warning lamp bulb
ON to OFF as the initial check.Therefore if the lamp does not light up, - Blown fuse is related to ABS in the
the cause may be an open in the lamp power supply circuit, a blown engine compartment junction block
bulb, an open in the both circuits between the ABS warning lamp and - Faulty ABS warning lamp module
the HECU, and the faulty HECU.
- Faulty HECU
PROBLEM VERIFICATION
Disconnect the connector the ABS (ESP) HECU and turn the ignition switch ON.
Does the ABS waring lamp light up?
▶ Check the power source for the ABS warning lamp.
▶ Inspect again after replacing the ABS (ESP) HECU.
CHECK THE POWER SOURCE FOR THE ABS WARNING LAMP

1. Disconnect the instrument cluster connector (M07-2) and turn the ignition switch ON.
2. Measure the voltage between terminal (M07-2) 11 of the cluster harness side connector and body ground.
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▶ Check for blown fuse.
▶ Check the CAN circuit resistance for ABS warning lamp.
CHECK FOR BLOWN FUSE

Check continuity of fuse (10A) from the engine compartment junction block.
▶ Repair an open in the wire between CLUSTER fuse and 12 of cluster connector(M07-2)
▶ Replace the blown fuse.
DETECTING CONDITION

If the HECU detects trouble, it lights the ABS warning lamp while at - An open in the wire
the same time prohibiting ABS control. At this time, the HECU - Inoperative instrument cluster assembly
records a DTC in memory. Even though the normal code is output, - Inoperative ABS warning lamp module
the ABS warning lamp remains ON, then the cause may be probably
- Inoperative HECU
an open or short in the ABS warning lamp circuit.
CHECK DTC OUTPUT.
1. Connect the Scan Tool to the 16P data link connector located behind the driver's side kick panel.
2. Check the DTC output using Scan Tool.
Is DTC output?
▶ Repair circuit indicated by code output.
▶ Check instrument cluster.
CHECK INSTRUMENT CLUSTER

Disconnect the cluster connector and turn the ignition switch ON.
Does the ABS warning lamp remains ON?
▶ Replace the instrument cluster.
▶ Check for open the wire.
CHECK FOR OPEN IN THE WIRE

Check for continuity in the wire between cluster and ABS control module.
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▶ Replace the ABS control module and recheck.
▶ Repair an open in the wire between cluster and ABS control module.
BLEEDING OF BRAKE SYSTEM

This procedure should be followed to ensure adequate bleeding of air and filling of the ABS unit, brake lines and
master cylinder with brake fluid.
1. Remove the reservoir cap and fill the brake reservoir with brake fluid.
If there is any brake fluid on any painted surface, wash it off immediately.
When pressure bleeding, do not depress the brake pedal.

Recommended fluid........ DOT3 or DOT4
2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half filled
clear plastic bottle.
3. Connect the scan tool to the data link connector located underneath the dash panel.
4. Select and operate according to the instructions on the scan tool screen.
You must obey the maximum operating time of the ABS motor with the scan tool to prevent the motor pump
from burning.
(1) Select vehicle name.

(2) Select Anti-Lock Brake system.
(3) Select air bleeding mode.
(4) Press "YES" to operate motor pump and solenoid valve.
(5) Wait 120 sec. before operating the air bleeding.

(If not, you may damage the motor.)
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(6) Perform the air bleeding.
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.
FRONT
REAR
6. Repeat step 5 until there are no more bubbles in the fluid for each wheel.
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7. Tighten the bleeder screw.
Bleed screw tightening torque:

5.9 ~ 9.8 Nm (0.6 ~ 1.0 kgf.m, 4.3 ~ 7.2 lb-ft)
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Brake System
ABS (Anti-Lock Brake System) - ABS

Control Module
Brake System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL
1. Turn the ignition switch OFF.
2. Pull up the lock (A) of the ABS control unit 26P connector , then disconnect the connector.
3. Disconnect the brake tubes from the HECU by unlocking the nuts counterclockwise with a spanner.
4. Loosen the 3 ABS HECU bracket bolts, then remove HECU and bracket.
1. Never attempt to disassemble the HECU.

2. The HECU must be transported and stored in.
3. Never shock to the HECU.
5. Remove the 3 bolts, then remove the bracket from HECU.
INSTALLATION
2. Tighten the HECU mounting bolts and nuts to the specified torque.
Tightening torque
HECU bracket nuts :
11 ~ 14 Nm (1.1 ~ 1.4 kgf.m, 8.1 ~ 10.3 Ib-ft)
HECU bracket mounting bolt :
16.7 ~ 25.5 Nm (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 Ib-ft)
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Brake System
ABS (Anti-Lock Brake System) - Front Wheel

Speed Sensor
Brake System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL
1. Remove the front wheel speed sensor mounting bolt.
2. Remove the mounting bolt fixed on the strut.
3. Remove the mounting bolt fixed on the chassis.
4. Remove the mounting bolt fixed on the upper of chassis.
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5. Remove the front wheel speed sensor after disconnecting the wheel speed sensor connector.
INSPECTION
shown.
as shown below.
V_low : 0.59V ~ 0.84V

V_high : 1.18V ~ 1.68V
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Brake System
ABS - Rear Wheel Speed Sensor
Brake System
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
INSPECTION
shown.
as shown below.
V_low : 0.59V ~ 0.84V

V_high : 1.18V ~ 1.68V
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Brake System
ABS - EBD (Electronic Brake-force

Distribution)
Brake System
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2010 > G 1.0 SOHC >
EBD (ELECTRONIC BRAKE-FORCE DISTRIBUTION) OPERATION

The EBD system (Electronic Brake force Distribution) as a sub-system of the ABS system is to control the effective
adhesion utilization by the rear wheels.
It further utilizes the efficiency of highly developed ABS equipment by controlling the slip of the rear wheels in the
partial braking range.
The brake force is moved even closer to the optimum and controlled electronically, thus dispensing with the need for
the proportioning valve.
The proportioning valve, because of a mechanical device, has limitations to achieve an ideal brake force distribution
tothe rear wheels as well as to carry out the flexible brake force distribution proportioning to the vehicle load or weight
increasing. And in the event of malfunctioning, driver cannot notice whether it fails or not.
EBD controlled by the ABS Control Module, calculates the slip ratio of each wheel at all times and controls the brake
pressure of the rear wheels not to exceed that of the front wheels.
If the EBD fails, the EBD warning lamp (Parking brake lamp) lights up.
ADVANTAGES
- Function improvement of the base-brake system.
- Compensation for the different friction coefficients.
- Elimination of the proportioning valve.
- Failure recognition by the warning lamp.
Comparison between Proportioning valve and EBD
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Brake System
EPS (Electronic Stability Program) System
Brake System
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2010 > G 1.0 SOHC >
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ESP connector input/output
Connector Terminal
No Description
Over voltage range : 17 ± 0.5V
Operating voltage range :
9.5 ± 0.5V < V < 17 ± 0.5V
31 IGNITION1(+)
Low voltage range :
7.0 ± 0.5V < V < 9.5 ± 0.5V
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Operating voltage range :
1 POS.BATTERY.(SOLENOID)
9.5 ± 0.5V < V < 17 ± 0.5V
9.5 ± 0.5V < V < 16.5 ± 0.5V
2 POS.BATTERY.(MOTOR) Rush current : I < 100A
46 GROUND
YAW & LATERAL G SENSOR
16 Rated current : I <150mA
GROUND
STEERING ANGLE SENSOR
30 Rated current : I <100mA
GROUND
Max Output current : I < 150mA
17 YAW SENSOR POWER
Max Output voltage : V(IGN) ± 1V
STEERING ANGLE SENSOR Max Output current : I < 100mA
3
POWER Max Output voltage : V(IGN) ± 1V
34 BRAKE LIGHT SWITCH Input voltage (Low) : 0V ! V ! 3.0V
32 BRAKE SWITCH Input voltage (High) : 7.0V ! V ! 16.0V
Input voltage (Low) : 0V ! V_Low ! 3.0V

8 PARKING BRAKE SWITCH Input voltage (High) : 7.0V ! V_High ! 16.0V
Max input current : I < 10mA
Max current : I < 16mA
SENSOR FRONT RIGHT
27 External pull up resistance :1 K" < R
OUTPUT
Input voltage (Low) :0V ! V ! 3.0V
18 ESP ON/OFF SWITCH Input voltage (High) : 7.0V ! V ! 16.0V
Max input current:I <10mA
5 SENSOR FRONT RIGHT POWER Output voltage : IGN (V) ± 1V
7 SENSOR REAR LEFT POWER Output current : Max 30mA

Input current LOW : 5.9 ~ 8.4mA
10 SENSOR FRONT RIGHT SIGNAL Input current HIGH :11.8 ~ 16.8mA Typ. 7mA
24
PHASE 1
Input duty (ST1, ST2): 50 ± 10%
Typ. 20deg
STEERING ANGLE SENSOR Phase difference (ST1, ST2): 2 ± 0.6deg
25 Typ. 3.5V
PHASE 2 High voltage: 3.0 V < V < 4.1V
Typ. 1.5V
Low voltage: 1.3 V < V < 2.0V
26
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26
PHASE N
Input voltage
IL(V) < 0.3 IGN (V)
IH(V) > 0.7 IGN (V)
Output voltage
OL(V) < 0.2 IGN (V)
OH(V) > 0.8 IGN (V)
37 ESP W/LAMP DRIVE
Current : I < 300mA (12V)
38 ABS/EBD W/LAMP DRIVE Voltage range : 0 ~ 18V
Min. shunt resistance : 500K"
40 ESP F/LAMP DRIVE
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2010 > G 1.0 SOHC >
description of ESP
Optimum driving safety now has a name : ESP, the Electronic Stability Control.
ESP is based on the MGH 40 ABS Hydraulic System. ESP recognizes critical driving conditions, such as panic
reactions in dangerous situations, and stabilizes the vehicle by wheel-individual braking and engine control intervention
with no need for actuating the brake or the gas pedal.
ESP adds a further function known as Active Yaw Control (AYC) to the ABS, TCS, EBD and EDC functions. Whereas
the ABS/TCS function controls wheel slip during braking and acceleration and, thus, mainly intervenes in the
longitudinal dynamics of the vehicle, active yaw control stabilizes the vehicle about its vertical axis.
This is achieved by wheel individual brake intervention and adaptation of the momentary engine torque with no need
for any action to be taken by the driver.
ESP essentially consists of three assemblies : the sensors, the electronic control unit and the actuators.
The electronic control unit incorporates the technological experience accumulated in connection with the MGH 40
system, but has been substantially expanded in terms of capacity and monitoring concept in order to permit the
additional sensor signals and arithmetic operations to be processed and converted into corresponding valve, pump and
engine control commands. Two 16-bit processors and one 8-bit processor, which monitor each other, cooperate to
handle these requirements.
Of course, the stability control feature works under all driving and operating conditions. Under certain driving
conditions, the ABS/TCS function can be activated simultaneously with the ESP function in response to a command
by the driver.
In the event of a failure of the stability control function, the basic safety function, ABS, is still maintained.
DESCRIPTION OF ESP CONTROL

ESP system includes ABS/EBD, TCS and AYC function.
ABS/EBD function : The ECU changes the active sensor signal (current shift) coming from the four wheel sensors to
the square wave.By using the input of above signals, the ECU calculates the vehicle speed and the acceleration &
deceleration of the four wheels.And, the ECU judges whether the ABS/EBD should be actuated or not.
TCS function prevents the wheel slip of drive direction by adding the brake pressure and engine torque reduction via
CAN communication.TCS function uses the wheel speed sensor signal to determine the wheel slip as far as ABS
function.
AYC function prevents unstable maneuver of the vehicle. To determine the vehicle maneuver, AYC function uses the
maneuver sensor signals(Yaw Rate Sensor, Lateral Acceleration Sensor, Steering Wheel Angle Sensor).If vehicle
maneuver is unstable (Over Steer or Under Steer), AYC function applies the brake pressure on certain wheel, and
send engine torque reduction signal by CAN.
After the key-on, the ECU continually diagnoses the system failure. (self-diagnosis)If the system failure is detected,
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the ECU informs driver of the system failure through the BRAKE/ABS/ESP warning lamp. (fail-safe warning)
INPUT AND OUTPUT DIAGRAM
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ESP OPERATION MODE
ESP HYDRAULIC SYSTEM DIAGRAM
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1. ESP Non-operation : Normal braking.
IN (NO) OFF OPEN
OFF OFF
OUT (NC) OFF CLOSE
2. ESP operation
Understeering IN(NO) OFF OPEN
(Only inside of
rear wheel) OUT(NC) OFF CLOSE
ON ON
Oversteering IN(NO) OFF OPEN
(Only outside
of front wheel) OUT(NC) OFF CLOSE
ESP HECU EXTERNAL DIAGRAM
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ABS Warning Lamp module
The active ABS warning lamp module indicates the self-test and failure status of the ABS .The ABS warning lamp
shall be on:
- In the event of inhibition of ABS functions by failure.
EBD/PARKING BRAKE WARNING LAMP MODULE

The active EBD warning lamp module indicates the self-test and failure status of the EBD. However, in case the
Parking Brake Switch is turned on, the EBD warning lamp is always turned on regardless of EBD functions. The EBD
warning lamp shallbe on:
- When the Parking Brake Switch is ON or brake fluid level is low.
- When the EBD function is out of order .
ESP Warning Lamp (ESP system)

The ESP warning lamp indicates the self-test and failure status of the ESP.
The ESP warning lamp is turned on under the following conditions :
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- In the event of inhibition of ESP functions by failure.
- When driver trun off the ESP function by on/off switch.
ESP Function Lamp (ESP system)

The ESP function lamp indicates the self-test and operating status of the ESP.
The ESP Function lamp operates under the following conditions :
- When the ESP control is operating. (Blinking - 2Hz)
ESP On/Off Switch (ESP system)

The ESP On/Off Switch shall be used to toggle the ESP function between On/Off states based upon driver input.
The On/Off switch shall be a normally open, momentary contact switch.Closed contacts switch the circuit to ignition.
Initial status of the ESP function is on and switch toggle the state.
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2010 > G 1.0 SOHC >
COMPONENTS
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FAILURE DIAGNOSIS
1. In principle, ESP and TCS controls are prohibited in case of ABS failure.
2. When ESP or TCS fails, only the failed system control is prohibited.
3. However, when the solenoid valve relay should be turned off in case of ESP failure, refer to the ABS fail-safe.
4. Information on ABS fail-safe is identical to the fail-safe in systems where ESP is not installed.
MEMORY OF FAIL CODE

1. It keeps the code as far as the backup lamp power is connected. (O)
2. It keeps the code as far as the HCU power is on. (X)
FAILURE CHECKUP
1. Initial checkup is performed immediately after the HECU power on.
2. Valve relay checkup is performed immediately after the IG2 ON.
3. It executes the checkup all the time while the IG2 power is on.
4. Initial checkup is made in the following cases.
(1) When the failure is not detected now
(2) When ABS and ESP are not in control.
(3) Initial checkup is not made after ECU power on.
(4) If the vehicle speed is over 5 mph(8 km/h) when the brake lamp switch is off.
(5) When the vehicle speed is over 24.8 mph(40 km/h).
5. Though, it keeps on checkup even if the brake lamp switch is on.

6. When performing ABS or ESP control before the initial checkup, stop the initial checkup and wait for the HECU
power input again.
7. Judge failure in the following cases.
(1) When the power is normal.
(2) From the point in which the vehicle speed reaches 4.9 mph(8 km/h) after HECU power on.
COUNTERMEASURES IN FAIL
1. Turn the system down and perform the following actions and wait for HECU power OFF.
2. Turn the valve relay off.
3. Stop the control during the operation and do not execute any until the normal condition recovers.
WARNING LAMP ON
1. ESP operation lamp turn on for 3sec after IGN On.
2. ESP operation lamp blinks when ESP Act.
3. ESP OFF warning lamp turn on in case of
A. ESC Switch OFF
B. ESC Failure Detect
C. 3sec after IGN On
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Brake System

Yaw-rate And Lateral G Sensor
Brake System
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2010 > G 1.0 SOHC >
DESCRIPTION
When the vehicle is turning with respect to a vertical axis the yaw rate sensor detects the yaw rate electroniclly by the
vibration change of plate fork inside the yaw rate sensor.
If yaw velocity reaches the specific velocity after it detects the vehicle’ yawing, the VDC control is reactivated.
The later G sensor senses vehicle’s lateral G. A small element inside the sensor is attached to a deflectable leverarm
by later G.
Direction and magnitude of lateral G loaded to vehicle can be known with electrostatic capacity changing according to
lateral G.
It interchanges signals with HECU through extra CAN line which only used for communication between HECU and
sensor.
The sensor is located in the front passenger seat lower floor on vehicle.
specifications
Description Specification Remarks
Current consumption Max. 140mA
Measurement range -75 ~ 75°/sec
Yaw-rate sensor
Frequency response 18 ~ 22Hz
Measurement range -14.715 ~ +14.715m/s!
Lateral G sensor
Frequency response 50Hz ± 60%
output characteristic
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external diagram
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2010 > G 1.0 SOHC >
REPLACEMENT
1. Remove the floor console. (refer to BD- "console")
2. Disconnect the yaw rate & lateral G sensor connector.
3. Remove the mounting bolts(A).
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Brake System

ESP OFF Switch
Brake System
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2010 > G 1.0 SOHC >
DESCRIPTION
1. The ESP OFF switch is for the user to turn off the ESP system.
2. The ESP OFF lamp is on when ESP OFF switch is engaged.
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2010 > G 1.0 SOHC >
INSPECTION
1. Remove the ESP OFF switch from the switch panel.
2. Check the continuity between the switch terminals as the ESP OFF switch is engaged.
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Brake System

Steering Wheel Angle Sensor
Brake System
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2010 > G 1.0 SOHC >
DESCRIPTION
The steering angle speed sensor detects the angle of the steering wheel in order to which direction a user
chooses.The sensor is detached on the MPS(Mutil-Function Switch) under the steering wheel.
MEASUREING PRINCIPLE
The split of the steering angle sensor detects a steering angle of the steering wheel by a ON/OFF pulse caused by
whether or not the LED lights go through the hole of the split, rotating as the steering wheel revolves. There are three
LEDs, two(ST1, ST2) for detecting a steering direction, and the other for the neutral position.The HECU calculates the
steering angle by the pulse from the steering angle sensor.
SPECIFICATION
Description Specification
Current consumption Max.100mA
Steering angle velocity Max. ± 1500°/sec
Voltage(high) 3.0V ~ 4.1V
Voltage(low) 1.3V ~ 2.0V
Pulse duty 40 ~ 60%
CIRCUIT DIAGRAM( STEERING WHEEL SPEED ANGLE SENSOR)
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OUTPUT CHARACTERISTIC
No. INPUT OUTPUT Steering direction Remark

ST1 L L
Right
ST2 L H
1
ST1 L H
Left
ST2 L L
ST1 L L
Left
ST1 H L
2
ST1 L H
Right
ST2 H H
ST1 H H
Left
ST2 L H
3
ST1 H L
Right
ST2 L L
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ST1 H H
Right
ST2 H L
4
ST1 H L
Left
ST2 H H
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Body (Interior and Exterior)
General Information
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2010 > G 1.0 SOHC >
SPECIFICATIONS
Hood
• Type Rear hinged, front opening type (open stay rod type)
Front door
• Construction Front hinged, full door construction
• Regulator system Wire drum type
Rear door
• Construction Front hinged, full door construction
• Regulator system Single arm type
Tail gate
• Type Inner hinged, gas lifter type
Glass thickness
• Windshield glass 5.0mm
• Front door glass 3.2mm
• Rear door glass 3.2mm
3.5mm
• Tail gate glass
Seat belts
• Driver's seat 3 point type
• Front passenger seat & Rear seats (LH/RH) 3 point type
• Rear seat (center) Fixed 2 point type
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2010 > G 1.0 SOHC >
TIGHTENING TORQUE
Item Description N!m kg!m lb!ft
Front fender Mounting bolts 7~9 0.7 ~ 0.9 5~7
Hood Hinge bolt (body side) 22 ~ 27 2.2 ~ 2.7 16 ~ 20
Hinge nut (body side) 22 ~ 27 2.2 ~ 2.7 16 ~ 20
Hinge bolt (Hood side) 22 ~ 27 2.2 ~ 2.7 16 ~ 20
Striker bolt 7 ~ 11 0.7 ~ 1.1 5~8
Latch bolt 7 ~ 11 0.7 ~ 1.1 5~8
Tail gate Hinge nut (body side) 21 ~ 30 2.1 ~ 3.1 15 ~ 22
Hinge bolt (tail gate side) 7 ~ 11 0.7 ~ 1.1 5~8
Latch bolt 7 ~ 11 0.7 ~ 1.1 5~8
Striker bolt 9 ~ 14 0.9 ~ 1.4 7 ~ 10
Actuator nut 7 ~ 11 0.7 ~ 1.1 5~8
Lifter stud ball (body side) 22 ~ 27 2.2 ~ 2.7 16 ~ 20
Lifter bracket bolt (tail gate side) 7 ~ 11 0.7 ~ 1.1 5~8
Outside handle 7 ~ 11 0.7 ~ 1.1 5~8
Side guide bumper (body side) 7~9 0.7 ~ 0.9 5~7
Side guide bumper (tail gate side) 7~9 0.7 ~ 0.9 5~7
Front/Rear door Hinge (body side) 33 ~ 41 3.4 ~ 4.2 25 ~ 30
Hinge (door side) 10 ~ 20 1.0 ~ 2.0 7 ~ 14
Checker bolt (body side) 22 ~ 32 2.2 ~ 3.3 16 ~ 24
Checker bolt (door side) 7 ~ 11 0.7 ~ 1.1 5~8
Latch screw 8 ~ 11 0.8 ~ 1.1 6~8
Striker screw 17 ~ 22 1.7 ~ 2.2 12 ~ 16
Outside handle bolt 8 ~ 12 0.8 ~ 1.2 6~9
Front seat Mounting bolt 34 ~ 54 3.5 ~ 5.5 25 ~ 40
Rear seat seat cushion nut 34 ~ 54 3.5 ~ 5.5 25 ~ 40
Seatback bolt 34 ~ 54 3.5 ~ 5.5 25 ~ 40
Seatback nut 17 ~ 25 1.7 ~ 2.6 12 ~ 19
Seatback striker nut 17 ~ 25 1.7 ~ 2.6 12 ~ 19
Seat belt Anchor bolt 39 ~ 54 4.0 ~ 5.5 29 ~ 40
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2010 > G 1.0 SOHC >

09793-21000 Adjustment, removal, and installation of the
Door hinge adjusting wrench door hinge
09800-21000 Trim removal

Ornament remover
09853-31000 Removal of the headliner clip

Headliner clip remover
09861-31100 Cutting the sealant of the windshield

Sealant cut-out tool (Use with 09861-31200)
09861-31200 Cutting the sealant of the windshield

Sealant cutting blade (Use with 09861-31100)
09861-31300 Application of the sealant to the windshield

Sealant gun
09861-31400 Removal and installation of the windshield
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09861-31400 Removal and installation of the windshield
Glass holder
09861-31000 Removal of the windshield moulding

Windshield moulding
remover
09861-22000 Removal and installation of the torsion bar in

Torsion bar wrench the luggage compartment
09840-1E100 Center fascia removal

Center fascia remover
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2010 > G 1.0 SOHC >
TROUBLESHOOTING
Symptom Suspect Area Remedy
Door glass fails to operate up and Incorrect window glass installation Adjust position
down
Damaged or faulty regulator arm or regulator Correct or replace
Door does not open or close Incorrect door installation Adjust position
completely
Defective door check assembly Correct or replace
Door hinge requires grease Apply grease
Hood does not open or close Striker and latch not properly aligned Adjust
completely
Incorrectly installed hood Adjust
Incorrect hood bumper height Adjust
Water leaks through windshield Defective seal Fill with sealant
and rear window
Defective flange Correct
Wind noise around door Weatherstrip not holding firmly Adjust fit or door
Improperly installed weatherstrip Repair or replace
Improperly closed door Adjust
Improperly fit door Adjust
Improperly clearance between door glass and Adjust
division channel
Deformed door Repair or replace
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Exterior - Fender
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2010 > G 1.0 SOHC >
REPLACEMENT
1. After loosening the mounting nuts, then remove the wiper arm (A).
2. After loosening the mounting screws, then remove the cowl top cover (B).
3. Remove the side seal molding cover (C).
4. Remove the side seal molding (D).
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5. Remove the wheel guide (E).
6. Remove the side bumper cover bracket (F).
7. After loosening the mounting bolts, then remove the fender (G).
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Exterior - Hood
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
ADJUSTMENT
HOOD HINGE
1. Check that the hood can be closed easily and properly. If there is a problem, open the hood and tighten the hood
hinge mounting bolts.
Tightening torque :
22~27 N.m (2.2~2.7 kg!m, 15.9~19.5 lb!ft)
2. To adjust the hood-to-body offset, loosen the hood hinge mounting bolts and make the adjustment.
HOOD LATCH
1. Check that the hood can be closed easily and properly. If there is a problem, loosen the latch mounting bolts and
adjust the hood by moving the latch vertically or horizontally.
Tightening torque :
7~11 N.m (0.7~1.1 kg!m, 5.1~8.0 lb!ft)
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2. Adjust the front offset of the hood to the body by moving the hood over slam bumper vertically.
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Exterior - Taligate
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL AND INSTALLATION

1. Remove luggage side trim.
(1) Remove the fasteners(2) and rear transverse trim.
(2) Raise the rear seat cushion.

(3) Remove the screws(2), fastener and the rear door scuff trim.
(4) Remove the screws(2) and luggage side trim.
(5) Disconnect the lamp connector from the back side of the luggage side trim(LH).
2. Remove rear pillar trim.
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3. Remove tail gate wire harness.
(1) Disconnect the tail gate main wire harness connector and remove the ground bolt.
(2) Remove the tail gate main wire harness from the body frame.
4. Remove rear wiper/washer hose.
5. Remove tail gate lifter.
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6. Remove tail gate hinge.
(1) Remove the tail gate mounting bolts(4)(LH/RH).
Tightening torque :
7~11 N!m (0.7~1.1 kg!m, 5.1~8.0 lb!ft)
7. Remove tail gate panel.

1. Remove tail gate trim.
(1) Remove the screws(4).

(2) Remove the tail gate trim.
2. Remove rear wiper arm/blade.
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(1) Remove the head cap.
(2) Remove the one nut.
3. Remove rear wiper motor.
(1) Remove the bolts(2).

(2) Disconnect the rear wiper motor connector.
4. Remove tail gate latch.
(1) Remove the actuator rod, outside handle rod, and lock rod.
(3) Disconnect the connector and tail gate latch.
5. Remove tail gate actuator.
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(1) Remove the nuts(2).
(2) Disconnect the connector.
6. Remove tail gate outside handle.
(1) Remove the nuts(2).
7. Remove tail gate lock.
(1) Remove the one bolt.
8. Remove tail gate garnish.
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9. Install in reverse order of removal.
ADJUSTMENT
TAIL GATE HINGE
1. Check that the tail gate can be closed easily and properly. If there is a problem, open the tail gate and tighten the
tail gate hinge mounting bolts.
2. To adjust the tail gate-to-body offset, loosen the tail gate hinge mounting bolts and make the adjustment.
TAIL GATE STRIKER

1. Check that the tail gate can be closed easily and properly. If there is a problem, loosen the striker mounting bolts
and adjust the tail gate by moving the striker vertically or horizontally.
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2. Adjust the rear offset of the tail gate to the body by moving the tail gate over slam bumper vertically.
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Exterior - Front Door
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >

1. Remove door quadrant inner cover.
2. Remove door inside handle.
(1) Remove the one screw.

(2) Remove the door inside handle rod.
(3) Remove the door inside handle from the door trim.
3. Remove door trim.
(1) Remove the door trim screws(5).

(2) Disconnect the power window switch connector from the back side of the door trim.
(3) Remove the door trim from the door frame.
4. Remove door speaker.
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(2) Disconnect the door speaker connector.
5. Remove door screen.
Peel door screen off carefully so that it can be reused.
6. Remove door glass.

(1) Connect the power window switch connector.
(2) Connect the negative battery terminal.
(3) Turn the ignition switch "ON" and set the window glass on access hole.
(4) Turn the ignition switch "OFF".
(5) Remove the window glass mounting screws(2).
(6) Remove the door glass from the door frame.
Remove the glass carefully to avoid brakeage.
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(7) Disconnect the negative battery terminal.
(8) Disconnect the power window switch connector.
7. Remove power window regulator.

(1) Remove the power window regulator mounting nuts(7).
(2) Disconnect the power window regulator connector.
8. Remove door safety lock rod cover.
9. Remove door latch.

(1) Remove the door outside handle rod.
(2) Remove the door lock rod.
(3) Disconnect the actuator connector.
(4) Remove the door latch screws(3).
Tightening torque :
8~11 N!m (0.8~1.1kg!m, 6~8 lb!ft)
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10. Remove door outside handle.
Tightening torque :
8~12 N!m (0.8~1.2kg!m, 6~9 lb!ft)
(2) Remove the door lock connector.

(3) Remove the handle from the door frame.
11. Remove outside rearview mirror.

(1) Remove the actuator connector.
Tightening torque :
4~6 N!m (0.4~0.6kg!m, 3~4 lb!ft)
(3) Remove the outside rearview mirror from the door frame.
12. Remove the door checker bolts from the body frame.
Tightening torque :
Body side : 22~32 N!m (2.2~3.3 kg!m, 16~24 lb!ft)
Door side : 7~11 N!m (0.7~1.1 kg!m, 5~8 lb!ft)
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13. Remove door main connector.
14. Remove the door upper hinge bolts(2) and lower hinge bolts(2).
Tightening torque :
15. Remove door frame.
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ADJUSTMENT
DOOR HINGE
1. Check that the door can be closed easily and properly. If there is a problem, open the door and tighten the door
hinge mounting bolts.
Tightening torque
Body side : 33~41 N.m (3.4~4.2 kg.m, 25~30 lb.ft)
Door side : 10~20 N.m (1.0~2.0 kg.m, 7~14 lb.ft)
2. To adjust the door-to-body offset, loosen the door hinge mounting bolts and make the adjustment.
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DOOR STRIKER
1. Check that the door can be closed easily and properly. If there is a problem, loosen the striker mounting bolts and
adjust the door by moving the striker vertically or horizontally.
Tightening torque :
17 ~22 N!m (1.7~2.2 kg!m, 12~16 lb!ft)
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2. Adjust the rear offset of the door to the body by loosening the striker screws and moving the striker horizontally.
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Exterior - Rear Door
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >

1. Remove door inside handle.

(2) Remove the door inside handle rod.
(3) Remove the door inside handle from the door trim.
2. Remove door trim.
(1) Remove the door trim screws(5).

(2) Remove the power window switch connector from the back side of the door trim.
(3) Remove the door trim from the door frame.
3. Remove door speaker.

(2) Disconnect the door speaker connector.
4. Remove door screen.
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Peel door screen off carefully so that it can be reused.
5. Remove door glass.

(1) Connect the negative battery terminal.
(2) Turn the ignition switch "ON" and set the window glass on access hole.
(4) Remove the one screw and bolt securing the division channel to the door frame.
(5) Remove the fixed glass and door glass run from the door frame.
(6) Remove the division channel from the door frame.

(7) Remove the window glass from the door window regulator.
Remove the glass carefully to avoid brakeage.
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(8) Disconnect the negative battery terminal.
(9) Disconnect the power window switch connector.
6. Remove door safety lock rod cover.
7. Remove door window regulator.

(1) Remove the door window regulator mounting nuts(4).
(2) Disconnect the door window regulator connector.
8. Remove door latch.

(1) Remove the door outside handle rod.
(2) Remove the door safety lock rod.
(4) Remove the door latch screws(3).
Tightening torque :
8~11 N!m (0.8~1.1 kg!m, 6~8 lb!ft)
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9. Remove door outside handle.
Tightening torque :
8~12 N!m (0.8~1.2 kg!m, 6~9 lb!ft)
(2) Remove the handle from the door frame.
10. Remove the one door checker bolt from the body frame.
Tightening torque
Bolts(body side) : 22~32 N!m (2.2~3.3 kg!m, 16~24 lb!ft)
Bolts(door side) : 7~11 N!m (0.7~1.1 kg!m, 5~8 lb!ff)
11. Disconnect door main connector.
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12. Remove the door upper hinge bolts(2) and lower hinge bolts(2).
Tightening torque
13. Remove door frame.
ADJUSTMENT
DOOR HINGE
1. Check that the door can be closed easily and properly. If there is a problem, open the door and tighten the door
hinge bolts.
Tightening torque
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2. Check the offset of the door to the body. If there is a problem, loosen the door hinge bolts and adjust the door.
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DOOR STRIKER
1. Check that the door can be closed easily and properly. If there is a problem, loosen the striker screws and adjust
the door by moving the striker vertically or horizontally.
Tightening torque :
17~22 N!m (1.7~2.2 kg!m, 12~16 lb!ft)
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2. Adjust the rear offset of the door to the body by loosening the striker screws and moving the striker horizontally.
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Exterior - Body Side Moldings
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2010 > G 1.0 SOHC >
REPLACEMENT
BUMPER GIRILL REPLACEMENT
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the
related parts, to prevent damage.
• Put on gloves to protect your hands.
• Take care not to scratch the body surface.
1. Remove the bumper cover.

2. After loosening the mounting screws, then remove the bumper girill (A).
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Exterior - Mirror
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >

1. Remove door quadrant inner cover.
2. Remove outside rearview mirror.

Tightening torque :
4~6 N!m (0.4~0.6 kg!m, 3~4 lb!ft)
(3) Remove the outside rearview mirror from the door frame.
Wear gloves to remove and install mirror holder.
1. Insert a flat bladed screwdriver between the outside rearview mirror holder and mirror actuator. Remove the mirror.
When prying with a flat bladed screwdriver, wrap it with a shop towel to prevent damage.
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2. Remove the outside rearview mirror actuator from the outside rearview mirror housing.
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Interior - Console
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2010 > G 1.0 SOHC >
REPLACEMENT
FLOOR CONSOLE REPLACEMENT
• When prying with a flat-up screwdriver, wrap it with protective tape, and apply protective tape around the
1. Gently detach the hook, remove the parking brake cover (A).
2. Remove the console mat (B).
3. Disconnect the connector (C).
4. After loosening the console mounting screws, remove the floor console assembly (D).
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• Make sure the connector is plugged in properly.

• Replace any damage clips.
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Interior - Crash Pad
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2010 > G 1.0 SOHC >
REPLACEMENT
CLUSTER FASCIA REPLACEMENT
1. Tilt the steering column down.

2. After loosening the mounting screws, remove the cluster fascia panel (A).
3. After loosening the mounting screws, then remove the cluster fascia (B).
4. Installation is the reverse the removal.
CENTER FASCIA PANEL REPLACEMENT
1. Put the SST (09840-1E100) (A) into the space between the center fascia and crash pad.
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• Be care not to damage the center fascia and crash pad.
2. Separate the center fascia panel (B) from the crash pad pulling the SST (09840-1E100) as shown on the photo.
• Pull the SST slowly not to damage the center fascia panel.
3. Pull the other side of center fascia panel with the SST in the way of "step 2)".
4. Disconnect the connector (C).
LOWER PANEL REPLACEMENT

1. Remove the crash pad side cover.
2. After loosening the crash pad lower panel mounting screws, then remove the lower panel (A).
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3. Disconnecting the connector (B).
4. Disconnecting the connector (C).
HEATER CONTROL UNIT REPLACEMENT

1. Remove the center fascia panel.
2. Remove the lower fascia panel (A).
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3. Disconnect the heater control unit connector (B).
4. After loosening the heater control mounting screws,remove the heater control unit (C).
AUDIO ASSEMBLY REPLACEMENT

2. Loosen the audio (A) mounting screws.
3. Disconnect the connector (B).
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GLOVE BOX REPLACEMENT

2. Remove the front door scuff trim.
3. Disconnect the damper (B) from the glove box (A).
4. Disconnect the pine (C), then remove the glove box (C).
5. After loosening the mounting screws, then remove the glove box housing (D).
SHROUD REPLACEMENT
1. Loosen the screws.
2. Remove the shroud assembly (A).
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CRASH PAD REPLACEMENT
1. Remove the following items.

A. Front seat.
B. Cluster fascia panel, cluster.
C. Audio assembly.
D. Glove box.
E. Crash pad side cover.
F. Front pillar trim.
2. Remove the cover (A).
3. Remove the photo sensor (B).
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4. Disconnect the passenger`s air bag connector.
Loosen the bolts and nuts, then remove the crash pad (C).
• Make sure the crash pad fits onto the guide pins correctly.
• Before tightening the bolts, make sure the crash pad wire harnesses are not pinched.
• Make sure the connectors are plugged in properly, and the antenna lead is connected properly.
• Enter the anti-theft code for the radio, then enter the customer`s radio station presets.
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Interior - Roof Trim
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >

1. Remove front pillar trim.
(1) Remove the body side weather strip.

(2) Remove the trim from the front pillar.
2. Remove center pillar lower trim.

(1) Remove the fasteners(4) and front door scuff trim.
(3) Remove the center pillar lower trim.
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3. Remove center pillar upper trim.
(1) Unsnap the front seat belt upper anchor cover.
(2) Remove the one bolt and the upper anchor.
Tightening torque :
40~55 N!m (4.0~5.5 kg!m, 28.9~39.8 lb!ft)
(3) Remove the center pillar upper trim.

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(3) Disconnect the lamp connector from the back side of the rear pillar trim.
(4) Remove the trim from the rear pillar.
5. Remove sunvisor.
(1) Remove the mounting screws(4)(LH/RH).

(2) Remove the sunvisor from the headlining.
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(3) Remove the sunvisor retainer screws(2)(LH/RH).
6. Remove assist handle.
(1) Remove the front assist handle mounting bolts(2).

(2) Remove the front assist handle from the headlining.
(3) Remove the rear assist handles(2).
7. Remove roof side tray.
(1) Remove the mounting bolts(2).

(2) Remove the roof side tray from the headlining.
8. Remove room lamp.
(1) Remove the room lamp cover and screws(2).

(2) Remove the lamp from the headlining and disconnect the connector.
9. Remove headlining assembly.
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(1) Remove the fasteners(3).
(2) Remove the headlining from the vehicle.
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Interior - Trunk Lid Trim
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >

1. Remove rear transverse trim.

(2) Remove the rear transverse trim.
2. Remove rear door scuff trim.
(1) Raise the rear seat cushion before removing the trim.
(2) Remove the screws(2) and fastner.
(3) Remove the rear door scuff trim.
3. Remove luggage side trm.

(2) Remove the luggage side trim.
(3) Disconnect the lamp connector from the back side of the trim.
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Interior - Interior Trim
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >

FRONT PILLAR TRIM
1. Remove body side weather strip.
CENTER PILLAR LOWER TRIM

2. Remove front door scuff trim.

(2) Remove the trim.
3. Remove rear door scuff trim.
(1) Raise the rear seat cushion before removing the trim.
(2) Remove the screws(2) and fastener.
(3) Remove the trim.
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CENTER PILLAR UPPER TRIM

(2) Raise the rear seat cushion before removing the rear door scuff trim.
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3. Remove front seat belt upper anchor.
(2) Remove the bolt and front seat belt upper anchor.
Tightening torque :
40~55 N!m (4.0~5.5 kg!m, 28.9~39.8 lb!ft)
REAR PILLAR TRIM

1. Remove luggage side trim.
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(2) Raise the rear seat cushion before removing the rear door scuff trim.
(5) Disconnect the lamp connector from the back side of the luggage side trim(LH).
3. Remove rear seat belt lower anchor.
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(1) Remove the bolt and lower anchor.
(2) Remove the lower anchor and seat belt trim guide from the rear pillar trim.
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Interior - Windshield Glass
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2010 > G 1.0 SOHC >
REMOVAL
(1) Remove the body side weather strip.

(2) Remove the front pillar trim.
2. Remove inside rearview mirror.

(1) Remove the inside rearview mirror from the mirror base.
3. Remove wiper arms.

(1) Remove the wiper arm caps(2).
(2) Remove the wiper arm nuts(2).
Tightening torque :
28~33 kg!m (2.8~3.3 kg!m, 20~24 lb!ft)
(3) Remove the wiper arms(LH/RH).
4. Remove cowl top cover.

5. Remove windshield glass side molding.
6. Pierce the sealant with a knife.
7. Remove the windshield glass using the glass holders.
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INSTALLATION
1. Remove the excess sealant from the glass with a window scraper.
2. Remove the excess sealant and foam dam from the body with a knife.
When removing the sealant, pay attention not to scrape the paint on the body off.
3. Clean the inside of the glass with a commercial glass cleaner and a lint-free cloth.
4. Prime an area approximately 20 mm(3/4 inch) wide around the complete perimeter of the glass.
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5. Prime the contact area on the body.
6. Reprime the same area on the inside surface of the glass.
Do not permit any primed surface to become contaminated with dirt, water, oil, etc. Do not touch primed
surfaces with your hands. Contamination will affect adhesion.
7. Install the self-adhesive foam dam to the body where the original dam had been.
8. Apply the sealant bead to the body just outside the dam. The bead should be slightly higher than the dam.
The following cure times may be critical. Attempting to replace a windshield in ambient temperature over
35°C(95°F) should be avoided before completing the application.
Time required until vehicle can be returned

Temperature Surface hardening time
to service
5°C(41°F) approx 1.5 hrs 12 hrs
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20°C(68°F) approx 1 hrs 4 hrs
9. Install molding on the glass.
10. Install the glass into the body making sure the glass rests upon the two spacers at the bottom of the windshield.
11. Press glass firmly into place.
Lower both front door windows and leave them in that condition until the vehicle can be put back into service.
If the vehicle were completely closed, quickly closing a door could break the seal.
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12. Remove excess sealant, if any.
13. Install windshield glass side molding.
14. Perform water leak test immediately.
15. Install cowl top cover.
16. Install wiper arm(LH/RH).
Tightening torque :
28~33 kg!m (2.8~3.3 kg!m, 20~24 lb!ft)
17. Install inside rearview mirror.

18. Install front pillar trim(LH/RH).
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Interior - Tailgate Glass
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2010 > G 1.0 SOHC >
REMOVAL
1. Remove tail gate trim.

(2) Remove the tail gate trim.
2. Remove rear wiper blade and wiper arm.
(1) Remove the head cap.

(2) Remove the one nut.
3. Remove rear wiper motor.

(2) Disconnect the connector.
4. Disconnect rear window defogger connector.

5. Remove the sealant with a knife.
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6. Remove the rear window glass using the glass holders.
INSTALLATION
1. Remove the excess sealant from the glass with a window scraper.
2. Remove the excess sealant and foam dam from the body with a knife.
When removing the sealant, pay attention not to scrape the paint on the body off.
3. Clean the inside of the glass with commercial glass cleaner and a lint-free cloth.
4. Prime an area approximately 20 mm(3/4 inch) wide around the complete perimeter of the glass.
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5. Prime the contact area on the body.
6. Reprime the same area on the inside surface of the glass.
Do not permit any primed surface to become contaminated with dirt, water, oil, etc. Do not touch primed
surfaces with your hands. Contamination will affect adhesion.
7. Install the self-adhesive foam dam to the body where the original dam had been.
8. Apply the sealant bead to the body just outside the dam. The bead should be slightly higher than the dam.
The following cure times may be critical. Attempting to replace a tail gate glass in ambient temperature over
35°C(95°F) should be avoided before completing the application.
Time required until vehicle can be returned

Temperature Surface hardening time
to service
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9. Install molding on the glass.
10. Install the glass into the body making sure the glass rests upon the two spacers at the bottom of the tail gate
glass.
11. Press glass firmly into place.
Lower both front door windows and leave them in that condition until the vehicle can be put back into service.
If the vehicle were completely closed, quickly closing a door could break the seal.
12. Remove excess sealant, if any.

13. Install tail gate glass side molding.
14. Install rear wiper motor.
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15. Install rear wiper blade and wiper arm.
16. Install tail gate trim.
17. Perform water leak test immediately.

18. Connect rear window defogger connector.
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Bumper - Front Bumper
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2010 > G 1.0 SOHC >
REPLACEMENT

• When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
• Take care not bend or scratch the cover and other parts.
1. Remove the front bumper cover (A).
2. Disconnect the fog lamp connector (B).
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Bumper - Rear Bumper
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2010 > G 1.0 SOHC >
REPLACEMENT
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the
related parts your hands.
• Take care not bend or scratch the cover and other parts.
1. Remove the rear combination lamp (A).
2. Disconnect the connector (B).
3. Remove the wheel guide (C).
4. Remove the rear bumper (D).
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5. Disconnect the connector (E).
• Replace any damage clips.
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Seat & Power Seat - Front Seat
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REPLACEMENT
SEAT ASSEMBLY REPLACEMENT
1. After loosening the seat assembly mounting bolts, then remove the seat assembly (A).
2. Disconnect the airbag connector (A), seat heater connector (B), seat buckle connector (C) and then remove the
seat assembly.
SEAT MOUNTING BOLT INSTALLATION PROCE-DURE (manual seat only)

- Set the into the most rearward position.
Check then each slide is locked, and then
Tighten the front mounting bolt temporarily.
- Set the seat into most forward position.
- Check that each slide is locked, and then
Tighten the rear mounting bolt completely.
- Set the seat into the most rearward position.
Check the front mounting bolt completely.
- Check that the seat operates to and fro smoothy and the locking portion locks properly.
RECLINER COVER REPLACEMENT

1. Remove the recliner lever (A).
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1. After loosening the mounting screws, then remove the height (B).
2. After loosening the mounting screws, remove the recliner cover (C).
SEAT CUSHION COVER REPLACEMENT

1. Remove front seat assembly.
2. Remove the recliner cover.
3. Disconnect the airbag connecter (A) and heater connector (B).
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4. Disconnect the seat back (A) and seat cushion (B).
5. After loosening the mounting nuts, then remove the seat cushion (C).
6. Disconnect the scuff band (D).
7. After removing the hogring clip on the front of seat cushion and remove the seat cushion cover (E).
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SEAT BACK COVER REPLACEMENT

1. Remove front seat assembly.
2. Remove the recliner cover.
3. Disconnect the scuff band (A).
4. Remove theseat back panel (B).
5. Disconnect the protector (C) from the back frame.
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6. Remove the hogring clip (D).
7. Disconnect the airbag connect (A) and heater connect (B).
8. Disconnect the seat back (A) and seat cushion (B).
9. Pull out the headrest guides while pinching the end of the guides, and remove them.
10. After removing the tape on the front of seat back remove the seat back cover (E).
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SEAT FRAME REPLACEMENT

1. After loosening the mounting bolts, then disconnect the seat back frame (A) and seat cushion frame (B).
• Remove the side air bag for replacing side air bag installation seat.
• Be fore service, be fully aware of precautions and service procedure relevant to air bag (Refer to page RT-
Airbag)
2. Remove the following items.

A. Recliner cover.
B. Seat back panel.
C. Headrest guide.
D. Seat back cover.
SEAT CUSHION HEATER REPLACEMENT

1. Remove the seat cushion cover.
2. Cut the heater (A) attached to the sponge, as shown in the picture.
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• Take care not to damage the slave sponge.
3. Install the seat cushion cover.

A. Detach the paper from the cushion of the heater assembly.
B. Attach the heater to the main part of the sponge.
• Be sure to match the heater with main appearance.
SEAT BACK HEATER REPLACEMENT

1. Remove the seat back cover.
2. Cut the heater (A) attached to the sponge, as shown in the picture.
• Take care not to damage the slave sponge.
3. Install the seat back cover.

A. Detach the paper from the back of the heater assembly.
B. Attach the heater to the main part of the sponge.
• Be sure to match the heater with main appearance.
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Seat & Power Seat - Rear Seat
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >

1. Remove rear seat cushion.
(1) Remove the seat cushion mounting nuts(2)(LH).
Tightening torque :
35~55 N!m (3.5~5.5 kg!m, 25~40 lb!ft)
(2) Remove the seat cushion.

(3) Remove the seat cushion mounting nuts(2)(RH).
Tightening torque :
35~55 N!m (3.5~5.5 kg!m, 25~40 lb!ft)
(4) Remove the seat cushion.
2. Remove rear seatback.

(1) Remove the seatback mounting bolt and nuts(2)(LH).
Tightening torque (bolt) :

35~55 N!m (3.5~5.5 kg!m, 25~40 lb!ft)
Tightening torque (nut) :
17~26 N!m (1.7~2.6 kg!m, 12~19 lb!ft)
(2) Remove the seatback.
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Seat Belt - Front Seat Belt
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
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 center pillar lower trim.
6. Extend seat 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.
(1) Turn ignition key to “ON” position.
(2) 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.)
(3) Turn ignition key to “LOCK” position.
(4) Safety belt icon and chime will extinguish.
(5) Turn key to “ON” position. Just as before, safety belt icon will light up and chime will be heard.
(6) Buckle driver’s safety belt. Safety belt icon and chime will extinguish.
(7) Turn key to “LOCK” position and remove key.
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.

1. Remove seat belt lower anchor bolt.
Tightening torque :
40~55 N!m (4.0~5.5 kg!m, 28.9~39.8 lb!ft)

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(2) Remove the bolt and upper anchor.
Tightening torque :
40~55 N!m (4.0~5.5 kg!m, 28.9~39.8 lb!ft)
(3) Remove the center pillar upper trim.
4. Removal of pretensioner retractor.

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(2) Disconnect the negative battery cable.
(3) Wait for about 1 minute.
(4) Release the gas generator connector stopper.
(5) Disconnect the gas generator connector.
(6) Remove the pretensioner retractor.
1) A pretensioner functions one time only. Be sure to replace the pretensioner seat belt after it is deployed.
2) Do not attempt to disassemble or repair the seat belt pretensioner.
If it malfunctions, replace it with a new pretensioner seat belt.
3) Connect the battery only after the installation of the pretensioner seat belt has been correctly completed.
4) Removal of pretensioner retractor.
• Turn ignition switch "OFF".
• Disconnect negative battery cable.
• Wait for about 1 minute.
• Disconnect gas generator connector.
• Remove pretensioner retractor bolt.
5. Remove seat belt height adjustor.

Tightening torque :
40~55 N!m (4.0~5.5 kg!m, 28.9~39.8 lb!ft)
(2) Remove the height adjustor from the center pillar.
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Seat Belt - Rear Seat Belt
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2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
INSPECTION
1. Remove seat cushion.
2. Inspect buckle assembly mounting to ensure that it is secure.
3. Inspect anchor assembly mounting to ensure that it is secure.
5. Inspect retractor assembly mounting to ensure that it is secure.
6. Install rear pillar trim.
7. Extend seat belt fully to ensure its motion is smooth and easy.
8. Retract safety belt fully to ensure its motion is smooth and easy.
9. Buckle safety belt. Pull firmly on each side of buckle to ensure that it is secure.
10. 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.
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.

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(4) Disconnect the lamp connector from the back side of the trim(LH).
(5) Remove the trim from the rear pillar.
2. Remove the seat belt lower anchor.

(1) Remove the bolt and lower anchor.
Tightening torque :
40~55 N!m (4.0~5.5 kg!m, 28.9~39.8 lb!ft)
(2) Remove the lower anchor and seat belt trim guide from the rear pillar trim.
3. Remove rear seat belt retractor.

(1) Remove the one bolt.
Tightening torque :
40~55 N!m (4.0~5.5 kg!m, 28.9~39.8 lb!ft)
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(2) Remove the seat belt retractor.
4. Remove seat belt upper anchor.

(1) Remove mounting bolt
Tightening torque :
40~55 N!m (4.0~5.5 kg!m, 28.9~39.8 lb!ft)
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Body Electrical System
General Information
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2010 > G 1.0 SOHC >
General Troubleshooting Information

Before Troubleshooting
1. Check applicable fuses in the appropriate fuse/relay box.
2. Using the battery checker (MCR-570 KIT), check the battery for damage, state of charge, and clean and tight
connections.
(Refer to the Engine Electrical System - Battery)
• Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will
damage the alternator diodes.
• Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely
damage the wiring.
3. Check the alternator belt tension.
Handling Connectors
1. Make sure the connectors are clean and have no loose wire terminals.
2. Make sure multiple cavity connectors are packed with grease (except watertight connectors).
3. All connectors have push-down release type locks (A).
4. Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another
component. This clip has a pull type lock.
5. Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from
its mount bracket (A).
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6. Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead.
7. Always reinstall plastic covers.
8. Before connecting connectors, make sure the terminals (A) are in place and not bent.
9. Check for loose retainer (A) and rubber seals (B).
10. The backs of some connectors are packed with grease. Add grease if necessary. If the grease (A) is
contaminated, replace it.
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11. Insert the connector all the way and make sure it is securely locked.
12. Position wires so that the open end of the cover faces down.
Handling Wires And Harnesses

1. Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations.
2. Remove clips carefully; don't damage their locks (A).
3. Slip pliers (A) under the clip base and through the hole at an angle, and then squeeze the expansion tabs to
release the clip.
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4. After installing harness clips, make sure the harness doesn't interfere with any moving parts.
5. Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and
from exposed screws and bolts.
6. Seat grommets in their grooves properly (A). Do not leave grommets distorted (B).
Testing And Repairs

1. Do not use wires or harnesses with broken insulation.
Replace them or repair them by wrapping the break with electrical tape.
2. After installing parts, make sure that no wires are pinched under them.
3. When using electrical test equipment, follow the manufacturer's instructions and those described in this manual.
4. If possible, insert the remover tool from the wire side (except waterproof connector).
5. Use a probe with a tapered tip.
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Refer to the user's guide in the wiring repair kit (Pub No. : TRK 015.)
Five-step Troubleshooting
1. Verify the complaint
Turn on all the components in the problem circuit to verify the customer complaint. Note the symptoms. Do not
begin disassembly or testing until you have narrowed down the problem area.
2. Analyze the schematic
Look up the schematic for the problem circuit.
Determine how the circuit is supposed to work by tracing the current paths from the power feed through the circuit
components to ground. If several circuits fail at the same time, the fuse or ground is a likely cause.
Based on the symptoms and your understanding of the circuit operation, identify one or more possible causes of
the problem.
3. Isolate the problem by testing the circuit.
Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the
key to efficient troubleshooting.
Test for the most likely cause of failure first. Try to make tests at points that are easily accessible.
4. Fix the problem
Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures.
5. Make sure the circuit works
Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the
problem was a blown fuse, be sure to test all of the circuits on the fuse. Make sure no new problems turn up and
the original problem does not recur.
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Audio
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2010 > G 1.0 SOHC >
Component Location
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2010 > G 1.0 SOHC >
Troubleshooting
Customer Complaint Analysis Check Sheet
There are six areas where a problem can occur: wiring harness, the radio, the CD player, and speaker.
Troubleshooting enables you to confine the problem to a particular area.
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Chart 1
Chart 2
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Chart 3
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Chart 4
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Chart 5
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Chart 6
Chart 7
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2010 > G 1.0 SOHC >
Specification
Audio
Item Specification
Model RADIO/CD/(SA710) RADIO/CD/MP3 (PA710)
Power supply DC 14.4V
Rated output Max 43W x 4
Antenna 80PF 75!
Tuning type PLL synthesized type
FM 87.5 ~ 108.0 MHz/100 KHz (General), 50KHz(Europe)
Frequency range / Channel AM 531 ~ 1602 KHz/9 KHz (General)

space MW 522 ~ 1620 KHz/9 KHz (Europe)
LW 153 ~ 279 KHz/1 KHz (Europe)
Speaker
Item Specification
Front Max. 40
Input Power(W)
Rear Max. 40
Front 4.0 ± 0.6
Speaker Impedance(!)
Rear 4.0 ± 0.6
Speaker Number 4
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Audio - Audio Unit
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2010 > G 1.0 SOHC >
Components
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2010 > G 1.0 SOHC >
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the center facia panel(A).
(Refer to the Body group - Crash pad).
3. Remove the connectors (A) (Hazard lamp connector, seat heater switch).
4. Remove the mounting screws(4EA) then remove the audio unit (A).
Installation
1. Connect the audio connectors and cable to the audio unit.
2. Reassemble the audio unit.
3. Connector the connectors and reassemble the center facia pannel.
4. Connect the negative (-) battery terminal and then check the audio working.
Disassembly
1. Disassemble the top cover (A) after loosening 4 screws.
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2. Disassemble the front cover (A) then disconnect the connector (B) between the unit and front cover if necessary.
3. Disconnect the connector (B) between the unit and the deck after loosening 4screws.
4. Disassemble the deck (A) from the unit.
Reassenbly
1. Assemble the deck to the unit.
2. Assemble the front cover.
3. Assemble the top cover.
• Make sure the connectors are plugged in properly.
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Audio - Speakers
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2010 > G 1.0 SOHC >
Inspection
1. Troubleshooting for Speaker
(1) Basic inspection of speaker
Inspect the sound from speaker after verifying that the speaker mounting screws is removed and the wiring
connector is connected precisely to remove vibration transmitted from body trims and surrounding parts.
(2) Case Troubleshooting

No. Case Inspection/Remedy
1. Before replacing the speaker, inspect that the mounting screw is installed normally.
Trembling
1 2. After re-installing the speaker, verify that no trembling sound is heard.
sound
3. When hearing a trembling sound again, replace the speaker with new one.
1. Check if the wiring connector is connected normally. If not, reconnect the wiring
connector.
2. In case of radio static, check if there is a noise from cassette.
3. When a noise is heard on turning radio, cassette and CD on, replace the speaker
with new one.
2 Noise
In case there is only radio static, this causes from poor radio reception. Thus the
speaker needs no repair and replacement.
Inspection of the wiring connection between the battery and the speaker
1. Before replacing the speaker, inspect the wiring connection between the battery and
the speaker is normal.
2. Check the supplying power to the speaker and the resistance, then inspect the
sound quality.
! Specified impedance : 2 ~ 4"
3 Poor working
3. If the speaker works poorly, replace it with new one.
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- During dealing of speaker
- Do not damage the speaker with impact as like a drop and a throw.
- Be careful not to cover water and oil over the speaker.
- Caution during dealing of speaker because the material of diaphragm is paper which is easy to be torn
by impact and external force.
- When modifying audio system as customer pleases, this does electric damage to speaker.
- And, in this case the speakers are not covered by the manufacturer's warranty.
Removal
Front Speaker
1. Remove the front door trim.
(Refer to the Body group - Front door).
2. Remove the front speaker (A) after removing 4 screws.
Rear Speaker
1. Remove the rear door trim.
(Refer to the Body group - Rear door).
2. Remove the rear speaker (A) after removing 4 screws.
Tweeter Speaker
1. Remove the front door delta cover.
(Refer to the Body group - Front door).
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2. Remove the tweeter speaker after disconnecting the connector.
Installation
Tweeter Speaker
1. Reassemble the tweeter speaker after connecting the connector.
2. Reassemble the front door delta cover.
Front Speaker
1. Reassemble the front speaker in the front door trim.
2. Reassemble the front door trim.
Rear Speaker
1. Reassemble the rear speaker in the rear door trim.
2. Reassemble the rear door trim.
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Audio - Antenna
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2010 > G 1.0 SOHC >
Removal
Roof Antenna
1. Remove the rear roof trim.
(Refer to the Body group - Roof trim).
2. Disconnect the 1P power connector (A) and antenna jack (B) from the roof antenna.
Installation
Roof Antenna
1. Reassemble the roof antenna and connect the connectors and antenna jack.
2. Reassemble the rear roof trim.
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Audio - AUX (Auxiliary) Jack
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2010 > G 1.0 SOHC >
Description
The AUX JACK on the center console is for customers who like to listen to external portable music players like the
MP3, iPOD, earphone, CD player and etc., through the vehicle's sound system when it is linked to this jack. The
customer has this added option.
In case of distortions from media connected to the AUX source, the audio unit may not be defect but the output level
of the used media does not match the specification of the AUX input.
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2010 > G 1.0 SOHC >
Removal
Aux Jack
1. Disconnect the power outlet connector(A) and multi media jack connector (A) from under cover.
2. Remove the AUX jack(A).
Installation
Aux Jack
1. Install the AUX jack.
2. Connect the AUX jack connector.
3. Install the under cover to the floor console.
Inspection
1. Disconnect the negative(-) battery terminal.
2. Disconnect the AUX jack connector after removing the connector.
3. Using an ohmmeter, check for continuity between the terminals of AUX jack connector.
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NO. HEAD UNIT NO. AUX JACK
7 AUX1 R IN 6 AUX1 REF
9 AUX1 GND 7 AUX1 L IN
10 AUX1 L IN 14 AUX DET
12 AUX DETECT 15 GND
- - 16 AUX1 R IN
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Multifunction Switch
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2010 > G 1.0 SOHC >
Components
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2010 > G 1.0 SOHC >
Replacement
Prior to removing of the multifunction switch assembly in vehicles equipped with air bags, be careful to keep the
following items.
- 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 93°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 excessive 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.
Prior to doing any further work after disconnection of the battery cable, wait at least 30 seconds.
2. Remove the bolts (A) holding the air bag module.

3. Disconnect the horn connector and the air bag module connector, and remove the air bag module (B).
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4. Remove the steering wheel after removing a nut (A).
5. Align the steering shaft with wheel then remove the steering wheel (A) using special tool. (Refer to the RT group -
"Air Bag Module (Driver side)")
Do not hammer on the steering wheel to remove it; dong so may damage the collapsible mechanism.
6. Remove the steering column upper and lower shrouds after removing 3 screws (A).
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7. Remove the clock spring (A), then disconnect the connector (B) of multi-function switch.
8. Push down on the lock pin (A), and then remove the multi-function switch assembly.
Inspection
Lighting Switch Inspection
With the multi function switch in each position, make sure that continuity exists between the terminals below. If
continuity is not as specified, replace the multi-function switch.
[LHD]
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[RHD]
Lighting Switch
Dimmer And Passing Switch
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Turn Signal Switch
Wiper And Washer Switch Inspection

[LHD]
[RHD]
Wiper Switch
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Washer Switch
Rear Wiper & Washer Switch
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2010 > G 1.0 SOHC >
Specifications
Item Specifications
Rated voltage DC 12V
Operating temperature range -30°C ~ +80°C (-22 ~ +176°F)
High : 120W (Lamp load)
Dimmer & passing switch Low : 110W (Lamp load)
Passing : 120W (Lamp load)
Tail switch Tail : 66W (Lamp load)
Turn signal & lane change switch 69W (Lamp load)
Low, High: 5.0A (Motor load)
Rated load Intermittent : 7mA (Intermittent circuit
Wiper & mist switch load)
Lock : Max. 25A (Motor load)
Mist : 5.0A (Motor load)
Washer switch 5A (Motor load)
Rear wiper : 3.5A (Motor load)
Rear wiper & washer switch
Rear washer : 5.0A (Motor load)
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Horn
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2010 > G 1.0 SOHC >
Removal
1. Remove the upper tray after opening the hood.
2. Remove the bolt and disconnect the horn connector, then remove the horn.
Installation
1. Connect the horn connector, then reassemble the horn.
2. Reassemble the front bumper.
Inspection
Test the horn by connecting battery voltage to the 1 terminal and ground the 2 terminal.
The horn should make a sound. If the horn fails to make a sound, replace it.
Horn Relay Inspection

1. Remove the horn relay from the relay box at the engine room compartment.
2. Check for continuity between the terminals.
3. There should be continuity between the No.87 and No.30 terminals when power and ground are connected to the
No.86 and No.85 terminals.
4. There should be no continuity between the No.87 and No.30 terminals when power is disconnected.
A : Horn relay
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Adjustment
Operate the horn, and adjust the tone to a suitable level by turning the adjusting renz.
After adjustment, apply a small amount of paint around the screw head to keep it from loosening.
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Keyless Entry & Burglar Alarm
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2010 > G 1.0 SOHC >
Component Location
1. Hood switch 6. Front door lock actuator & switch

2. Burglar horn 7. Rear door lock actuator & switch
3. Body control module 8. Rear door switch
4. Key warning switch 9. Tailgate actuator & switch
5. Front door switch
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2010 > G 1.0 SOHC >
Specifications
ITEM SPECIFICATION
Keyless entry transmitter Lithium 3V battery (1EA)
Transmissible distance 10m or more
Modulation method FM (Frequency Modulation)
FREQUENCY 433.92MHz
Button 2 Button (Door lock / Unlock)
Lifetime of battery 2years or more (20 times / day)
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2010 > G 1.0 SOHC >
Description
Burglar Alarm System
The burglar alarm system is armed automatically after the doors, hood, and tailgate are closed and locked.
The system is set off when any of these things occur :
- A door is forced open.
- A door is unlocked without using the transmitter.
- The tailgate is opened without using the key.
- The hood is opened.
When the system is set off, the alarm horn sounds and the hazard lamp flashes for about two minutes or until the
system is disarmed by unlocking the transmitter.
For the system to arm, the ignition switch must be off and the key removed.
Then, the ETACS module must receive signals that the doors, hood, and tailgate are closed and locked. When
everything is closed and locked, none of the control unit inputs are grounded.
The door switches, hood switch and tailgate switch are all closed then immediately after locking the doors with the
remote transmitter the system arms.
If anything is opened or improperly unlocked after the system is armed, the ETACS module gets a ground signal from
that switch, and the system is set off.
If the tailgate is opened using the key after the system is armed, the doors and hood are continues arm state and the
system will be not set off. Then after the tailgate is closed, the tailgate hold arm state.
If one of the switches is misadjusted or there is a short in the system, the system will not arm. As long as the ETACS
module continues to get a ground signal, it thinks the vehicle is not closed and locked and will not arm.
Conversely, a switch that is slightly misadjusted can cause the alarm to sound for no apparent reason. In this case, it
may only take a significant change in outside temperature, the vibration of a passing truck, or someone bumping into
the vehicle to make the alarm sound.
KEYLESS ENTRY SYSTEM

The burglar alarm system is integrated with the keyless entry system. The keyless entry system allows you to lock and
unlock the vehicle with the remote transmitter. When you push the LOCK/ UNLOCK button, all doors lock. When you
push the LOCK/ UNLOCK button again all doors unlock.
You cannot lock or unlock the doors with the remote transmitter if the key is in the ignition switch.
The tailgate will be opened using the key.
The system will signal you when the doors lock and unlock by flashing the hazard lamp once when they lock, and
twice when they unlock.
The receiver is integrated in the ETACS module.
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Keyless Entry And Burglar Alarm -

Transmitter
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2010 > G 1.0 SOHC >
Inspection
1. Check that the red light flickers when the door lock/unlock button is pressed on the transmitter.
2. Remove the battery (A) and check voltage if the red light doesn't flicker.
Standard voltage : 3V
3. Replace the transmitter battery with a new one, if voltage is below 3V then try to lock and unlock the doors with the
transmitter by pressing the lock/unlock button five or six times.
4. If the doors lock and unlock, the transmitter is O.K, but if the doors don't lock and unlock, register the transmitter
code, then try to lock and unlock the doors.
5. If the doors lock and unlock, the transmitter is O.K, but if the doors don't lock and unlock, replace the transmitter.
An inappropriately disposed battery can be harmful to the environment and human health.
Dispose the battery according to your local law(s) or regulation.
Transmitter Code Registration

1. Connect the DLC cable of scan tool to the data link connector (16 pins) in driver side crash pad lower panel, turn
the power on scan tool.
2. Select the vehicle model and then do "CODE SAVING".
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3. After selecting "CODE SAVING" menu, push "ENTER" key, then the screen will be shown as below.
4. After removing the ignition key from key cylinder, push "ENTER" key to proceed to the next mode for code saving.
Follow steps 1 to 4 and then code saving is completed.
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Keyless Entry & Burglar Alarm - Receiver
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2010 > G 1.0 SOHC >
Functions
Anti-theft Function
1. ARM Function
(1) When using lock on the transmitter the doors will lock, the hazard lamp will blink once within 1 second and the
anti-theft system will arm, if the following conditions have been met.
A. The ignition key is removed from the ignition switch.
B. All entry points are closed (doors, tailgate, hood)
(2) If the door, tailgate or hood are open when activating lock using the transmitter, the doors will lock, however
the hazard lamp will not flash and the anti-theft system will not arm.
(3) In step 2) if the opened entry points are subsequently closed the door will lock, the hazard lamp will blink once
and the anti-theft system will arm.
(4) If lock is activated on the transmitter while the anti-theft system is already in the arm mode, the hazard lamp
will blink once. (If any of the vehicle entry points is unlocked the anti-theft system will lock the door, the hazard
lamp will blink once, and the system will re-arm itself).
(5) The arm mode of the anti-theft system can only be set using the lock feature of the transmitter. The door key
will not arm the anti-theft system.
T1 : 0.5 ± 0.1 sec,

T2 : within 2.0 sec,
T3 : 1.0 ± 0.2 sec
2. DISARM Function
(1) When unlock is pressed on the transmitter the anti-theft system will disarm, the hazard lamps blink 2 times and
the doors unlock.
(whether entry points are open or closed is irrelevant)
(2) If unlock is activated on the transmitter while the anti-theft system is already in the disarm mode, the hazard
lamp will blink twice.
(3) Once the ignition key is in (inserted into the ignition switch) and the ignition is turned to the on position the anti-
theft system will immediately disarm.
(4) If the unlock signal is sent by the transmitter, and either the ignition key is not inserted or entry (door, tailgate,
hood) to the vehicle is not made within 30 seconds, the lock mode will be automatically reset, the hazard lamps
will blink, and the anti-theft system will rearm. (Provided that there is no automatic lock function at a period of
30 seconds, when the unlock is done by the transmitter with an entry being open).
(5) In steps 4), when unlock is activated within the initial 30 seconds, another period of 30 seconds occurs.
(6) The disarm mode of the anti-theft system can only be set using the unlock feature of the transmitter. The door
key will not disarm the anti-theft system.
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T1, T2 : 0.5 ±0.1 sec
3. ALARM Function
(1) General
A. When a point of entry is opened while the anti-theft system is in the arm mode, the hazard lamp and horn
alarm will activate (on/off 3 times each) for a period of 27 seconds.
B. Output intervals for the horn alarm and hazard lamps are identical.
C. The alarm sequence, when activated will continue for the duration of the alarm period even when the entry
point is closed. (The alarm will reactivate three times if entry port is reopened after the initial alarm
sequence completes.)
T1 : 27 ± 2 sec,
T2, T4 : 0.4 ~ 0.5 sec,
T3 : 10 ± 1 sec
(2) Europe
A. When a point of entry is opened while the anti-theft system is in the arm mode, the hazard lamp and horn
alarm will activate (on/off 1 time each) for a period of 27 seconds.
B. Output intervals for the horn alarm and hazard lamps are identical.
C. The alarm sequence, when activated will continue for the duration of the alarm period even when the entry
point is closed. (The alarm will reactivate one time if entry port is reopened after the initial alarm sequence
completes.)
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T1 : 27 ± 2 sec,
T2, T3 : 0.4 ~ 0.5 sec
4. New alarm condition during active alarm activation.

(1) If a new alarm condition occurs during the initial alarm sequence, the start inhibitor will remain on and only the
horn alarm will continue. (The alarm will continue even if the point of entry is closed.)
5. Transmitter controlled unlock during the alarm sequence

(1) If a remote unlock occurs during an alarm sequence, unlock will activate, the hazard lamp will blink 2 times,
and then anti-theft system will disarm.
The horn, hazard lamp, and start inhibitor will be off.
T1, T2, T3 : 0.5 sec
6. Transmitter controlled lock during the alarm sequence

(1) When a transmitter controlled lock occurs during the alarm sequence, but after the door, that had been broken-
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in, has been closed the following occurs :
A. All entry points are checked and then lock occurs
B. Horn alarm and start inhibitor are set to off
C. Hazard lamp blinks once
D. Anti-theft system is set to arm
T1 : 0.5 sec,
T2 : 1.0 ± 0.2 sec
(2) When a transmitter controlled lock occurs during the alarm sequence, but the broken-in door remains opened
the following occurs :
A. All entry points are checked and then lock occurs
B. Horn alarm and start inhibitor are set to off
(If the door is then closed the hazard lamp will blink once and the anti-theft system will arm)
T1 : 0.5 sec,
T2 : 1.0 ± 0.1 sec
7. Alarm clearance
(1) If the ignition key is turned to ON for 30 seconds during alarm activation the alarm will be cleared and the start
inhibitor reset.
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8. Battery Separation
(1) When the battery is reconnected after having been disconnected/removed while in arm mode. Arm mode
continues.
(2) When the battery is reconnected after having been disconnected/removed, and after the alarm completes, the
alarm will restart.
(3) When battery is reconnected after having been disconnected/removed during an active alarm, the alarm
sequence will restart from the beginning.
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2010 > G 1.0 SOHC >
Inspection
Front Door Lock Actuator Inspection
1. Remove the front door trim panel. (Refer to the BD group - front door)
2. Disconnect the 6P connector from the actuator.
3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
Rear Door Lock Actuator Inspection

1. Remove the rear door trim panel. (Refer to the BD group - rear door)
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Front Door Lock Switch Inspection
3. Check for continuity between the terminals in each switch position according to the table.
Rear Door Lock Switch Inspection

1. Remove the rear door trim panel (Refer to the BD group - rear door).
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Tailgate Lock Actuator Inspection

1. Remove the tailgate trim panel (Refer to the BD group - Tailgate).
Tailgate Lock Switch Inspection

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Door Switch Inspection

Remove the door switch and check for continuity between the terminals.
[Front/Rear Door Switch]
[Tailgate Switch]
Hood Switch Inspection

1. Disconnect 1P connector from the hood switch.
2. Check for continuity between the terminals and ground according to the table.
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Key Warning Switch Inspection
1. Remove the driver's crash pad lower panel. (Refer to the BD group - crash pad)
2. Disconnect the 4P connector from the door warning switch.

3. Check for continuity between the terminals in each position according to the table.
Burglar Horn Inspection

1. Remove the burglar horn after removing 2 bolts and disconnect the 2P connector from the burglar horn.
2. Test the burglar horn by connecting battery power to the terminal 1 and ground the terminal 2.
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3. The burglar horn should make a sound. If the burglar horn fails to make a sound replace it.
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BCM (Body Control Module)- Body Control

Module
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2010 > G 1.0 SOHC >
System Block Diagram
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2010 > G 1.0 SOHC >
Description
BODY CONTROL MODULE (BCM) (A) receives various
input switch signals controlling time and alarm functions
for the seat belts warning, central door lock, ignition key
reminder, tail lamp auto cut, crash door unlock and
keyless entry & burglar alarm.
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2010 > G 1.0 SOHC >
Removal
2. Remove the crash pad lower panel (A). Avoid damaging retaining clip. (Refer to the Body group - Crash pad)
3. Remove the body control module (A) and after loosening 2 nuts and disconnecting connector.
Installation
1. Connect the connector and reassemble the body control module.
2. Reassemble the crash pad lower panel.
Inspection
Verify each components operation using related timing charts.
1. TAIL LAMP AUTO CUT
(1) With the tail lamp switched ON, if the ignition
Is switched OFF and the driver's door opened, the tail lamp should be automatically turned OFF.
(2) With the ignition switch ON, if the driver's door is opened and the ignition is switched to OFF, the tail lamp
should be automatically turned OFF.
(3) When the tail lamp is cut automatically and the tail lamp switch is turned OFF and ON, the tail lamp illuminates
and auto cut function is cancelled.
2. CRASH DOOR UNLOCK

(1) With ignition turned ON, if the air bag deploys, a crash signal is received and simultaneously sends an unlock
output to all doors.
(2) After unlock signal, if lock is set, unlock pulse is output again for 5 seconds period.
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T1 : 200 msec,
T2 : 40 msec,
T3 : 5 ± 0.5sec
3. IGNITION KEY REMINDER

(1) If the key is in the ignition, with either the driver's door or assist door open, and then the vehicle is locked
using the driver's knob or assist knob, the central locking system will issue an unlock pulse (1 sec. duration) to
all doors preventing locking of the vehicle. (When a knob remains locked, if the switch in the actuator is not
changed, the central locking will issue 1 pulse (1 sec. duration) and then 3 pulses (0.5 sec.) to unlock the
vehicle.)
T1 : 0.5 sec,
T2 : 1.0 sec,
T3 : 0 sec.<T3<0.5 sec.
4. SEAT BELT WARNING TIMER (Middle East, General, Australia only)

(1) Since the ignition is switched ON, the seat belt warning indicator is illuminated (with period : 0.6 sec., duty rate
: 50%) and the chime bell is sounded (with period : 0.9 sec., duty rate : 50%) for total time 6 seconds.
(2) If the ignition is swithced off during the indicator and the chime bell output, the indicator and the chime bell are
switched OFF.
If the seat belt is sensed as fastened during the indicator and the chime bell output, the chime bell is switched
OFF immediately and the seat belt warning indicator is illuminated for the remained seconds.
(3) When the ignition is already switched ON, if the seat belt is removed, the warning indicator and the chime bell
are output for total time 6 seconds.
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T1 : 6±1 sec.,
T2 : 0.45 ± 0.1 sec.,
T3 : 0.3 ± 0.1 sec.
5. SEAT BELT REMINDER (EC only)

(1) Warning lamp is turned ON when IGN is ON first time in the state that Seat belt is fastened or not.
(2) In the above (1), the warning lamp is turned OFF after fastening Seat belt.(Warning lamp continues to light for
6sec if seat belt is fastened within 6sec.)
(3) In the warning lamp and buzzer ON to OFF immediately when IGN OFF or Seat belt is fastened.
(4) Warning lamp is turned ON when IGN is ON and the warning lamp is turned OFF after the vehicle speed
becomes 9KPH or more.
(5) In the above (4), the indicator blinking is off after 55sec, the indicator blinking and buzzer is ON for 100sec.
(6) In the above (5), after the indicator blinking and buzzer is ON for 100sec, the indicator blinking continue.
(7) IGN ON and then seat belt is unfastened, speed is 9KPH or less and T1 is 9sec or less, the warning lamp
continues to flash. And if the speed is 9KPH or more, buzzer and warning lamp continue to flash.
6. KEY OPERATED WARNING

(1) If the key is in the ignition and the driver's door is opened, the buzzer is sounded (period: 1.0 sec., duty rate:
50%).
(2) If the ignition key is removed, or the door is closed, the buzzer is switched OFF immediately.
T1, T2 : 0.5 ± 0.1sec.
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2010 > G 1.0 SOHC >
Specifications
Items Specifications
Rated voltage DC 12V
Operating voltage DC 9 ~ 16V
Operating temperature -22°F ~ 176°F (-30°C ~ 80°C)
Insulation resistance 100M! or more
Below 4mA (With keyless entry)
Dark current
Below 3mA (Without keyless entry)
Burglar horn DC 12V, 3.5A (Inductance load)
Burglar horn relay DC 12V, 200mA (Inductance load)
Burglar relay DC 12V, 200mA (Inductance load)
Tail lamp relay DC 12V, 200mA (Inductance load)
Hazard lamp relay DC 12V, 200mA (Inductance load)
Rated load Door lock relay DC 12V, 200mA (Inductance load)

Door unlock relay DC 12V, 200mA (Inductance load)
General : DC 12V,
(27W+27W+5W+1.4W)*2 (Lamp load)
Hazard lamp
Europe : DC 12V,
(21W+21W+5W+1.4W)*2 (Lamp load)
Seat belt warning indicator DC 12V, 200mA (Inductance load)
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Seat Electrical
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2010 > G 1.0 SOHC >
Component Location
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2010 > G 1.0 SOHC >
Inspection
1. Check for continuity and measure the resistance between the terminals.
Standard value : 2.6! ± 10%
A : Back warmer
B : Seat warmer
C : Switch
D : Thermistor
E : Illumination
2. Operate the seat warmer after connecting the 2P connector, and then check for the thermostat by measuring the
temperature of seat surface.
3. Check for continuity between the terminals after disconnecting the 2P connector.
Standard value :
28 ± 3.5°C (82.4±6.3°F) (Continuity),
37 ± 3.0°C (98.6±5.4°F)(Short)
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Seat Electrical - Seat Heater
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2010 > G 1.0 SOHC >
Inspection
2. Carefully push out the seat warmer switch from behind the floor console upper cover, and then disconnect the
connector from the switch.
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Fuses And Relays
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2010 > G 1.0 SOHC >
Component Location
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Fuses and Relays - Relay Box (Engine

Compartment)
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2010 > G 1.0 SOHC >
Component Location
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2010 > G 1.0 SOHC >
Inspection
Power Relay Test (TYPE B)
Check for continuity between the terminals.
1. Radiator fan 1
2. Radiator fan 2
3. Air conditioner
4. Start
5. Tail lamp
6. Front fog
7. Horn
8. Rear fog
FUSE INSPECTION
1. Be sure there is no play in the fuse holders, and that the fuses are held securely.
2. Are the fuse capacities for each circuit correct?
3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why the fuse blew
first and completely eliminate the problem before installing a new fuse.
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Fuses And Relays - Relay Box (Passenger

Compartment)
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2010 > G 1.0 SOHC >
Component Location
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2010 > G 1.0 SOHC >
Inspection
Power Relay Test (TYPE A)
1. Power window relay
2. Blower relay
Power Relay Test (TYPE B)

1. Fuel pump relay
2. Rear window defogger relay
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Fuse Inspection
1. Be sure there is no play in the fuse holders, and that the fuses are held securely.
2. Are the fuse capacities for each circuit correct?
3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why the fuse blew
first and completely eliminate the problem before installing a new fuse.
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Fuses & Relay - ICM ( Integrated Circuit

Module) Relay Box
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2010 > G 1.0 SOHC >
Component Location
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2010 > G 1.0 SOHC >
ICM (Integrated Circuit Module) Relay Test

ICM is united with the door lock relay, door unlock relay and burglar alarm relay and installed at the T bar above the
BCM.
Door Lock
2. There should be continuity between the No.8 and No.3 terminals when power is disconnected.
Door Unlock
Burglar Alarm Relay

Main Relay Test

1. Remove the glove box housing (Refer to the BD group - crash pad)
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2. There should be continuity between the No.30, No.87 and No.87A terminals of main relay (A) when power and
ground are connected to the No.85 and No.86 terminals.
3. There should be no continuity between the No.30, No.87 and No.87A terminals when power is disconnected.
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Indicators And Gauges
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2010 > G 1.0 SOHC >
Component Location
1. Instrument Cluster assembly 7. Parking brake switch

2. Seat belt switch 8. Door switch
3. Vehicle speed sensor 9. Fuel gauge sender
4. Engine coolant temperature sender 10. Trunk lid switch
5. Oil pressure switch 11. Wheel speed sensor
6. Brake fluid level warning switch 12. ABS ECU
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2010 > G 1.0 SOHC >
Troubleshooting
Speedometer does not operate Instrument Cluster fuse (10A) blown Check for short and replace fuse
Speedometer faulty Check speedometer
Vehicle speed sensor faulty Check vehicle speed sensor
Wiring or ground faulty Repair if necessary
Tachometer does not operate Instrument Cluster fuse (10A) blown Check for short and replace fuse
Tachometer faulty Check tachometer
Fuel gauge does not operate Instrument Cluster fuse (10A) blown Check for short and replace fuse
Fuel gauge faulty Check gauge
Fuel sender faulty Check fuel sender
Low fuel warning lamp does not light Instrument Cluster fuse (10A) blown Check for short and replace fuse
up
Fuel sender faulty Check fuel sender
Water temperature (high) lamp does Instrument Cluster fuse (10A) blown Check for short and replace fuse
not light up
Water temperature sender faulty Check sender
Oil pressure warning lamp does not Instrument Cluster fuse (10A) blown Check for short and replace fuse
light up
Bulb burned out Replace bulb
Oil pressure switch faulty Check switch
Parking brake warning lamp does not Instrument Cluster fuse (10A) blown Check for short and replace fuse
light up
Brake fluid level warning switch faulty Check switch
Parking brake switch faulty Check switch
Open door warning lamp and tailgate Room lamp fuse (15A) blown Check for short and replace fuse
warning lamp do not light up
Door switch faulty Check switch
Seat belt warning lamp does not light Instrument Cluster fuse (10A) blown Check for short and replace fuse
up
Seat belt switch faulty Check switch
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Indicators And Gauges - Instrumental Cluster
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2010 > G 1.0 SOHC >
Components
[NON CAN Type]

No Connector A Connector B
1 Air Bag (-) High Beam
2 EPS Turn Left Signal
3 Brake Head Lamp Power
4 Oil Pressure A/Bag unit for PAB
5 Tacho/M Input -
6 S/M Signal ESP Off / Glow(DSL)
7 - Trunk Lid Opener
8 Immobilizer ESP / Water Seperator (DSL)
9 Air Bag (+) Check Engine
10 ABS/EBD Door SW
11 Charge Turn Right Signal
12 Seat Belt IGN +
13 GND (Fuel Gauge) Battery +
14 Fuel Sender GND (Micom Only)
15 Temp Sender -
16 - Ground
17 - ILL +
18 - ILL -
19 - -
[CAN Type]
No Connector A Connector B
1 Air Bag (-) High Beam
2 EPS Turn Left Signal
3 Brake Head Lamp Power
4 Oil Pressure A/Bag unit for PAB
5 - GND
6 S/M Signal ESP Off / Glow(DSL)
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7 - Trunk Lid Opener
8 Immobilizer ESP / Water Seperator (DSL)
9 Air Bag (+) "R" Input
10 ABS/EBD Door SW
11 Charge Turn Right Signal
12 Seat Belt IGN +
13 GND (Fuel Gauge) Battery +
14 Fuel Sender GND
15 - CAN High
16 - CAN Low
17 - ILL +
18 - ILL -
19 Check Engine -
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2010 > G 1.0 SOHC >
Inspection
Speedometer
1. Adjust the pressure of the tires to the specified level.
2. Drive the vehicle onto a speedometer tester. Use wheel chocks as appropriate.
3. Check if the speedometer indicator range is within the standard values.
Do not operate the clutch suddenly or increase/ decrease speed rapidly while testing.
Tire wear and tire over or under inflation will increase or decrease the indication error.
[A/T]
Velocity (km/h) 20 40 60 80 100
+3.5 +4.5 +6.0 +7.0 +8.5
Tolerance (km/h)
+1.0 +1.5 +2.0 +3.0 +5.0
Velocity (km/h) 120 140 160 180 200
+8.5 +10.5 +12.0 +13.5 +14.5
Tolerance (km/h)
+5.0 +7.0 +8.0 +9.0 +9.0
[M/T]
Velocity (km/h) 20 40 60 80 100
+3.0 +4.5 +4.5 +4.7 +4.7
Velocity (km/h)
+0.5 +1.0 +1.0 +1.2 +1.2
Velocity (km/h) 120 140 160 180 200
+5.0 +5.0 +5.5 +6.5 +7.0
Velocity (km/h)
+1.5 +1.5 +1.5 +2.0 +2.0
[MPH]
Tolerance (MPH)
Velocity (MPH)
A/T M/T
+3.0 +3.0
10
+0.5 +0.5
+3.0 +2.5
20
+1.0 +0.5
+4.0 +3.6
40
+1.5 +0.7
+5.0 +4.4
60
+2.0 +1.0
+6.0 +5.1
80
+2.5 +1.5
+7.0 +5.7
100
+3.5 +1.5
+8.0 +6.0
120
+4.0 +2.0
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TACHOMETER
1. Connect the scan tool to the diagnostic link connector or install a tachometer.
2. With the engine started, compare the readings of the tester with that of the tachometer. Replace the tachometer if
the tolerance is exceeded.
1) Reversing the connections of the tachometer will damage the transistor and diodes inside.
2) 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
(RPM)
Tolerance
±100 ±125 ±150 ±150
(RPM)
Revolution
5,000 6,000 7,000 -
(RPM)
Tolerance
±150 ±180 ±210 -
(RPM)
Fuel Gauge
1. Disconnect the fuel sender connector from the fuel sender.
2. Connect a 3.4 wattages, 12V test bulb to terminals 1 and 3 on the wire harness side connector.
3. Turn the ignition switch to the ON, and then check that the bulb lights up and the fuel gauge needle moves to full.
Fuel Gauge Sender

1. Using an ohmmeter, measure the resistance between terminals 1 and 3 of sender connector (A) at each float level.
2. Also check that the resistance changes smoothly when the float is moved from "E" to "F".
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Position Resistance(!)
E 200!
Warning lamp 175!
1/2 99!
Sender (F) 8!
3. If the height resistance is unsatisfied, replace the fuel sender as an assembly.
After completing this test, wipe the sender dry and reinstall it in the fuel tank.
Oil Pressure Switch

1. Check that there is continuity between the oil press switch terminal and ground with the engine off.
2. Check that there is no continuity between the terminal (A) and ground with the engine running.
3. If operation is not as specified, replace the switch.
Brake Fluid Level Warning Switch

1. Remove the connector (A) from the switch located at the brake fluid reservoir.
2. Verify that continuity exists between switch terminals 1 and 2 while pressing the switch (float) down with a rod.
Brake Fluid Level Warning Lamp

1. Ignition "ON".
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3. Remove the connector from the brake fluid level warning switch.
4. Ground the connector at the harness side.
5. Verify that the warning lamp lights.
Parking Brake Switch

The parking brake switch is a push type. It is located at the side of the parking brake pedal.
1. Check that there is continuity between the terminal and switch body with the switch (A) ON.
2. Check that there is no continuity between the terminal and switch body with the switch OFF.
If continuity is not as specified, replace the switch or inspect its ground connection.
Door Switch
Remove the door switch and check for continuity between the terminals.
Seat Belt Switch

1. Remove the connector from the switch.
2. Check for continuity between terminals.
Seat belt condition Continuity
Fastened Non-conductive ("!)
Not fastened Conductive (!)
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Seat Belt Warning Lamp
With the ignition switch turned ON, verify that the lamp glows.
Seat belt condition Warning lamp
Fastened OFF
Not fastened ON
Removal
2. Remove the instrument instrument cluster facia panel(A).
3. Pull out the instrument cluster (A) from the housing after removing 4 screws.
4. Disconnect the instrument cluster connecters and then remove the instrument cluster.
Installation
1. Connect the instrument cluster connectors and reassemble the instrument cluster.
2. Reassemble the instrument cluster facia panel.
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Power Door Locks
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2010 > G 1.0 SOHC >
Component Location
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Power Door Locks - Power Door Lock

Actuators
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2010 > G 1.0 SOHC >
Inspection
Front Door Lock Actuator Inspection
Rear Door Lock Actuator Inspection

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Front Door Lock Switch Inspection

Rear Door Lock Switch Inspection

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Tailgate Lock Actuator Inspection

Tailgate Lock Switch Inspection

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Power Door Mirrors - Power Door Mirrors

Switch
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2010 > G 1.0 SOHC >
Circuit Diagram
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2010 > G 1.0 SOHC >
Removal
1. Remove the front door trim panel. (Refer to the BD group-front door)
2. Remove the power window main switch by loosening the mounting screw of the power window main switch.
Installation
1. Reassemble the power window main switch module.
2. Reassemble the front door trim panel after connecting the connector.
Inspection
1. Remove the power door mirror switch from the door trim panel.
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Power Door Mirrors - Power Door Mirror

Actuator
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2010 > G 1.0 SOHC >
Inspection
1. Disconnect the power door mirror connector from the harness.
2. Apply battery voltage to each terminal as shown in the table and verify that the mirror operates properly.
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Power Windows - Power Window Motor
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2010 > G 1.0 SOHC >
Inspection
Front Power Window Motor Inspection
2. Disconnect the 2P connector from the motor.
3. Connect the motor terminals directly to battery voltage (12V) and check that the motor operates smoothly. Next,
reverse the polarity and check that the motor operates smoothly in the reverse direction. If the operation is
abnormal, replace the motor.
Rear Power Window Motor Inspection

1. Remove the rear door trim panel. (Refer to the BD group-rear door)
2. Disconnect the 2P connector from the motor.
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3. Connect the motor terminals directly to battery voltage (12V) and check that the motor operates smoothly. Next,
reverse the polarity and check that the motor operates smoothly in the reverse direction. If the operation is
abnormal, replace the motor.
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Power Windows - Power Window Switch
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2010 > G 1.0 SOHC >
Circuit Diagram
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2010 > G 1.0 SOHC >
Inspection
Power Window Main Switch
2. Remove the power window main switch (A) by loosening the mounting screw of the power window main switch.
3. Check for continuity between the terminals. When the continuity does not agree, it exchanges the switch.
Power Window Sub Switch

1. Remove the rear door trim panel. (Refer to the BD group-front door)
2. Remove the power window sub switch (A) by loosening the mounting screw of the power window sub switch.
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3. Check for continuity between the terminals. When the continuity does not agree, it exchanges the switch.
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Power Windows - Power Window Relay
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2010 > G 1.0 SOHC >
Inspection
1. Remove the power window relay from the junction box.
A. Power window relay
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Rear Glass Defogger
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2010 > G 1.0 SOHC >
Component Location
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Rear Glass Defogger - Rear Glass Defogger

Printed Heater
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2010 > G 1.0 SOHC >
Inspection
Wrap tin foil around the end of the voltmeter test lead to prevent damaging the heater line. Apply finger pressure
on the tin foil, moving the tin foil along the grid line to check for open circuits.
1. Turn on the defogger switch and use a voltmeter to measure the voltage of each heater line at the glass center
point. If a voltage of approximately 6V is indicated by the voltmeter, the heater line of the rear window is
considered satisfactory.
2. If a heater line is burned out between the center point and (+) terminal, the voltmeter will indicate 12V.
3. If a heater line is burned out between the center point and (-) terminal, the voltmeter will indicate 0V.
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4. To check for open circuits, slowly move the test lead in the direction that the open circuit seems to exist. Try to find
a point where a voltage is generated or changes to 0V. The point where the voltage has changed is the open-
circuit point.
5. Use an ohmmeter to measure the resistance of each heater line between a terminal and the center of a grid line,
and between the same terminal and the center of one adjacent heater line. The section with a broken heater line
will have a resistance twice as that in other sections. In the affected section, move the test lead to a position where
the resistance sharply changes.
Repair Of Broken Heater Line

Prepare the following items :
1. Conductive paint.
2. Paint thinner.
3. Masking tape.
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4. Silicone remover.
5. Using a thin brush :
Wipe the glass adjacent to the broken heater line, clean with silicone remover and attach the masking tape as
shown. Shake the conductive paint container well, and apply three coats with a brush at intervals of about 15
minutes apart. Remove the tape and allow sufficient time for drying before applying power. For a better finish,
scrape away excess deposits with a knife after the paint has completely dried. (Allow 24 hours).
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Switch
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2010 > G 1.0 SOHC >
Inspection
1. Disconnect the negative (-) vattery terminal.
2. Remove the rear window defogger switch after removing the center fascia panel(A). (Refer to the Body group -
Crash pad)
3. Using an ohmmeter, inspection the continuity betweenthe terminals after removing to the switchconnector
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Relay
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2010 > G 1.0 SOHC >
Inspection
1. Remove the negative (-) battery terminal.
2. Remove the rear window defogger relay from the junction box.
A. Power window relay
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Windshield Wiper/Washer
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2010 > G 1.0 SOHC >
Component Location
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Windshield Wiper/Washer - Windshield

Wiper/Washer Switch
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2010 > G 1.0 SOHC >
Removal
2. Remove the steering column upper and lower shrouds (A) after removing 3 screws and connector.
3. Remove the clock spring (A), then disconnect the connector (B) of multi-function switch.
4. Push down on the lock pin (A), and then remove the multi-function switch assembly.
Installation
1. Connect the connectors and reassemble the wiper switch assembly.
2. Reassemble the steering column upper and lower shrouds.
Inspection
Wiper And Washer Switch Inspection
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[LHD]
[RHD]
Wiper Switch
Washer Switch
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Rear Wiper & Washer Switch
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Windshield Wiper/Washer - Front Wiper

Motor
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2010 > G 1.0 SOHC >
Removal
1. Remove the windshield wiper arm (A) and blade after removing a nut.
2. Remove the weather strip and the cowl top cover (A) after removing screws.
3. Remove the windshield wiper motor and linkage assembly after removing 3 bolts. Disconnect the wiper motor
connector and windshield deicer connector from the wiper motor & linkage assembly.
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Installation
1. Reassemble the wiper motor & linkage assembly and connect the connector.
TORQUE: 7-11Nm (0.7-1.1, kgf.m, 5.0-7.9 lbf.ft)
2. Reassemble the cowl top cover.

3. Reassemble the windshield wiper arm and blade.
TORQUE: 28~32 Nm (2.8~3.2 kgf.m, 20~23.1 lbf.ft)
4. Install the wiper arm and blade to the specified position.

Specified position A B
0.98 ~ 1.37 0.98 ~ 1.37
Distance [in(mm)]
(25 ~ 35) (25 ~ 35)
5. Set the washer nozzle on the specified spray position.
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Windshield Wiper/Washer - Front Washer

Motor
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2010 > G 1.0 SOHC >
Inspection
1. With the washer motor connected to the reservoir tank, fill the reservoir tank with water.
Before filling the reservoir tank with water, check the filter for foreign material or contamination. if necessary,
clean the filter.
2. Connect positive (+) and negative (-) battery cables to terminals 2 and 1 respectively to see that the washer motor
runs and water sprays from the front nozzles.
3. Check that the motor operates normally.
Removal
- When servicing the washer pump, be careful not to damage the washer pump seal.
- Do not operate the washer pump before filling the washer reservoir.
Failure to do so could result in premature pump failure.
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2. Remove the headlamp unit.
3. Remove the washer hose (A) and the washer motor connector (B).
4. Remove the washer reservoir by pulling it.
Installation
1. Install the washer reservoir.
Before installing the pump motor, check the filter for foreign material or contamination. if necessary, clean the
filter into the pump motor.
2. Install the washer hose and the washer motor connector.

3. Install the headlamp unit.
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Rear Wiper/Washer
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2010 > G 1.0 SOHC >
Component Location
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Rear Wiper/Washer - Rear Wiper Motor
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2010 > G 1.0 SOHC >
Inspection
Rear Wiper And Nozzel
1. Install the rear wiper arm and blade to the specified position.
Specified position A
2.36 ~ 2.75 in
Distance
(60 ~ 70 mm)
※ Specified position : The first deicer line from bottom of the rear window.
2. Set the rear washer nozzle on the specified spray position.
Rear Wiper Motor

1. Remove the 4P connector from the rear wiper motor.
2. Connect battery positive (+) and negative (-) cables to terminals 2 and 4 respectively.
3. Check that the motor operates normally. Replace the motor if it operates abnormally.
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Automatic Stop Operation Check
1. Operate the motor at low speed using the stalk control.
2. Stop the motor operation anywhere except at the off position by disconnecting terminal 3.
3. Connect terminals 2 and 3.
4. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 4.
5. Check that the motor stops running at the off position.
Removal
1. Detach the wiper cap, then remove the rear wiper arm (A) after removing a nut (B).
2. Remove the rear wiper cap & pad (B) after removing a HEX nut (A).
3. Open the tailgate glass then remove the tailgate trim.

4. Disconnect the rear wiper motor connector then remove the rear wiper motor (A) after removing 2 bolts (B).
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Installation
1. Reassemble the rear wiper motor assembly.
Tightening torque Nut :

6.8 ~ 10.7 Nm (0.7 ~ 1.1 kgf.m, 5.1 ~ 7.9 lbf.ft)
2. Reassemble the tailgate trim.

3. Reassemble the HEX nut and the rear wiper cap & pad.
Tightening torque Nut (A) :

10 ~ 13.7 Nm (1.0 ~ 1.4 kgf.m, 7.2 ~ 10.1 lbf.ft)
4. Reassemble the rear wiper arm and rear wiper cap.
Tightening torque Nut(B) :

10 ~ 12.7 Nm (1.0 ~ 1.3 kgf.m, 7.2 ~ 9.4 lbf.ft)
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2010 > G 1.0 SOHC >
Inspection
1. With the washer motor connected to the reservoir tank, fill the reservoir tank with water.
Before filling the reservoir tank with water, check the filter for foreign material or contamination. if necessary,
clean the filter.
2. Connect positive (+) and negative (-) battery cables to terminals 3 and 2 respectively to see that the washer motor
runs and water is pumped.
3. Check that the motor operates normally.
Replace the motor if it operates abnormally.
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Lighting System
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2010 > G 1.0 SOHC >
Component Location
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2010 > G 1.0 SOHC >
Troubleshooting
One lamp does not light Bulb burned out Replace bulb
(all exterior)
Socket, wiring or ground faulty Repair if necessary
Head lamps do not light Bulb burned out Replace bulb
Ignition fuse (30A) blown Check for short and replace fuse
Head lamp fuse (10A) blown Check for short and replace fuse
Lighting switch faulty Check switch
Tail lamps and license plate lamps do Bulb burned out Replace bulb
not light
Tail lamp fuse (10A) blown Check for short and replace fuse
Battery fuse (30A) blown Replace the fuse
Tail lamp relay faulty Check relay
Lighting switch faulty Check switch
Stop lamps do not light Bulb burned out Replace bulb
Stop lamp fuse (10A) blown Check for short and replace fuse
Stop lamp switch faulty Adjust or replace switch
Stop lamps do not turn off Stop lamp switch faulty Repair or replace switch
Instrument lamps do not light Rheostat faulty Check rheostat
(Tail lamps light)
Turn signal lamp does not flash on Bulb burned out Replace bulb
one side
Turn signal switch faulty Check switch
Turn signal lamps do not light Bulb burned out Replace bulb
Turn signal lamp fuse (10A) blown Check for short and replace fuse
Flasher unit faulty Check flasher unit
Turn signal switch faulty Check switch
Hazard warning lamps do not light Bulb burned out Replace bulb
Hazard warning lamp fuse (15A)
Check for short and replace fuse
blown
Hazard switch faulty Check switch
Flasher rate too slow or too fast Lamp's wattages are smaller or larger
Replace lamps
than specified
Back up lamps do not light Bulb burned out Replace bulb
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Turn signal lamp fuse (10A) blown Check for short and replace fuse
Back up lamp switch (M/T) faulty Check switch
Transaxle range switch (A/T) faulty Check switch
Room lamp does not light Bulb burned out Replace bulb
Room lamp fuse (15A) blown Check for short and replace fuse
Room lamp switch faulty Check switch
Front fog lamps do not light Bulb burned out Replace bulb
Front fog lamp fuse (10A) blown Check for short and replace fuse
Front fog lamp relay faulty Check relay
Front fog lamp switch faulty Check switch
Rear fog lamps do not light Bulb burned out Replace bulb
Rear fog lamp fuse (10A) blown Check for short and replace fuse
Rear fog lamp switch faulty Check switch
Rear fog lamp relay faulty Check relay
Trunk room lamp does not light Bulb burned out Replace bulb
Room lamp fuse (15A) blown Check for short and replace fuse
Tailgate switch faulty Check switch
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2010 > G 1.0 SOHC >
SPECIFICATION
Items Bulb Wattage (W)
Head lamp (High) 60
Head lamp (Low) 55
FRONT Front turn signal lamp 28 (Europe : 21)
Front fog lamp 27
Side turn signal lamp 5
Rear stop/tail lamp
27/8 (Europe : 21/5)
(Outside)
Back up lamp 27 (Europe : 21)
REAR Rear turn signal lamp 27 (Europe : 21)

License plate lamp 5
High mounted stop lamp 16
Rear fog lamp 21
Room lamp (Front) 10
ROOM Trunk room lamp (Cargo
5
lamp)
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Lighting System - Head Lamps
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2010 > G 1.0 SOHC >
Removal
2. Loosen the mounting bolts(2EA) of head lamp. Remove the head lamp assembly(A) after disconnecting the lamp
connectors.
3. Remove the head lamp bulb after removing the bulb caps(A).
INSTALLATION
1. Install the head lamp bulbs.
2. Reassemble the head lamp bulb caps.
3. Reassemble the head assembly after connecting the lamp connector.
ADJUSTMENT
HEAD LAMP AIMING INSTRUCTIONS
The head lamps should be aimed with the proper beam-setting equipment, and in accordance with the equipment
manufacturer's instructions.
If there are any regulations pertinent to the aiming of head lamps in the area where the vehicle is to be used,
adjust so as to meet those requirements.
Alternately turn the adjusting gear to adjust the head lamp aiming. If beam-setting equipment is not available, proceed
as follows :
1. Inflate the tires to the specified pressure and remove any loads from the vehicle except the driver, spare tire, and
tools.
2. The vehicle should be placed on a flat floor.
3. Draw vertical lines (Vertical lines passing through respective head lamp centers) and a horizontal line (Horizontal
line passing through center of head lamps) on the screen.
4. With the head lamp and battery in normal condition, aim the head lamps so the brightest portion falls on the
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horizontal and vertical lines.
Make vertical and horizontal adjustments to the lower beam using the adjusting wheel.
FRONT FOG LAMP AIMING

The front fog lamps should be aimed as the same manner of the head lamps aiming.
With the front fog lamps and battery normal condition, aim the front fog lamps by turning the adjusting gear (A).
Head Lamp And Fog Lamp Aiming Point
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1. Turn the low beam on with driver.
The cut-off line should be projected in the allowable range (shaded region).
In case of equipping with the manual leveling device, set the leveling device switch on the "O" position.
2. Turn the high beam on with driver.

The hot point line should be projected in the allowable range shown in the poctire.
3. Turn the front fog lamp on with driver.

The cut-off line should be projected in the allowable range (shaded region)
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Lighting System - Turn Signal Lamp
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2010 > G 1.0 SOHC >
Removal
2. Loose the screws (2EA) holding the rear combination lamp then disconnect the connector.
3. Remove the rear combination lamp assembly (B) and the replace the bulbs(A).
Installation
1. Install the rear combination lamp assembly after assembling the bulbs after connecting the lamp connector.
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Lighting System - Room Lamp
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2010 > G 1.0 SOHC >
Inspection
1. Remove the room lamp assembly (A) then check for continuity between terminals.
Removal
2. Detach the lamp lens from the room lamp with a flat-tip screwdriver then replace the bulb (B).
3. Loosen the fixing screw (2EA) and disconnect the connector. And then remove the room lamp assembly (A).
Installation
1. Install the room lamp assembly after connecting the lamp connector.
2. Install the lamp lens after assembling the bulb.
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Lighting System - Hazard Lamp Switch
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2010 > G 1.0 SOHC >
Inspection
Hazard Lamp Switch
2. Remove the center fascia pannel (A).
(Refer to the Body group - Crash pad)
3. Disconnect the conectors.
4. Operate the switch and check for continuity between terminals with an ohmmeter.
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Lighting System - Flasher Unit
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2010 > G 1.0 SOHC >
Inspection
2. Remove the flasher unit from the passenger compartment relay box.
3. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 3.
4. Connect the two turn signal lamps in parallel to terminals 1 and 3. Check that the bulbs turn on and off.
A. Flasher unit
The turn signal lamps should flash 60 to 120 times per minute. If one of the front or rear turn signal lamps has
an open circuit, the number of flashes will be more than 120 per minute. If operation is not as specified,
replace the flasher unit.
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Lighting System - Front Fog Lamps
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2010 > G 1.0 SOHC >
Inspection
Front Fog Lamp Relay
1. Pull out the front fog lamp (A) relay from the engine compartment relay box.
2. Check for continuity between terminals. There should be continuity between the No.87 and No.30 terminals when
power and ground are connected to the No.85 and No.86 terminals.
A. Front fog lamp relay
Front Fog Lamp Switch

2. Remove the center fascia panel & switch. (Refer to the Body group - Crash pad)
3. Remove the front fog lamp switch from lower crash pad switch.
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Removal
2. Remove the front side cover screw.
3. Remove the front fog lamp assembly after loosening screws (4EA).
Installation
1. Install the front fog lamp bulb.
2. Connect the front fog lamp connector.
3. Install the front side cover.
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Lighting System - Rear Fog Lamps
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2010 > G 1.0 SOHC >
Inspection
Rear Fog Lamp Switch
2. Remove the center fascia panel & switch. (Refer to the Body group - Crash pad)
3. Remove the rear fog lamp switch from lower crash pad switch.
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Lighting System - License Lamps
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2010 > G 1.0 SOHC >
Removal
2. Remove the license lamp lens (A) by using the remover tool.
3. Disconnect the 2P connector and then replace the bulb (A).
Installation
1. Install the bulb.
2. Install the license lamp lens.
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Lighting System - High Mounted Stop Lamp
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2010 > G 1.0 SOHC >
Removal
High Mounted Stop Lamp
2. Remove the high mounted stop lamp cover (A).
3. Remove the connector (A) and, then loosening the bolts (B).
Installation
1. Install the high mounted stop lamp cover.
2. Install the high mounted stop lamp connector and cover.
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Daytime Running Lights - DRL Control

Module
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2010 > G 1.0 SOHC >
Inspection
1. Daytime running unit is installed at the below of battery.
2. Check that the light operate according to the following timing chart.
3. Remove the left headlamp and then disconnect the connector from the daytime running lights control unit.
4. Inspect the connector and terminals to be sure they are all making good contact.
If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system.
If the terminals look OK, go to step 5.
5. Make these input tests at the connector
If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, the control unit must be faulty; replace it.
Terminal Test condition Test : Desired result

Check for voltage to ground :
1 Headlamp ON
There should be battery voltage.
2 Blank -
3 Engine running
4 Blank -
5 Blank -
6 Under all conditions
There should be continuity.
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8 Blank -
9 Tail lamp ON
10 Tail lamp ON
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Head Lamp Leveling Device
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2010 > G 1.0 SOHC >
Circuit Diagram
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2010 > G 1.0 SOHC >
Component Location
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Head Lamp Leveling Device - Head Lamp

Leveling Switch
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2010 > G 1.0 SOHC >
Inspection
2. After loosening the crash pad lower panel mounting screws, then remove the lower panel (A).
3. Remove the head lamp leveling switch (A) from the lower crash pad switch.
4. Connect the battery voltage between terminals 3 and 2.

5. Measure the voltage between terminals 2 and 4 (V) at each position.
Position No. US (±5％) Rotation Voltage (V)
0 85 0° 11.05 ± 0.5V
1 73 30° 9.49 ± 0.5V
2 68 60° 8.84 ± 0.5V
3 63 90° 8.19 ± 0.5V
6. If the voltage is not as specified, replace the head lamp leveling switch.
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Immobilizer System
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2010 > G 1.0 SOHC >
Description
The immobilizer system will disable the vehicle unless the proper ignition key is used, in addition to the currently
available anti-theft systems such as car alarms, the immobilizer system aims to drastically reduce the rate of auto
theft.
1. Encrypted SMARTRA type immobilizer
A. The SMARTRA system consists of a passivie challenge - response (mutual authentication)transponder located
in the ignition key, an antenna coil, a encoded SMARTRA unit, an indicator light and the PCM(ECM).
B. The SMARTRA communicates to the PCM(ECM) (Engine Control Module) via a dedicated communications line.
Since the vehicle engine management system is able to control engine mobilization, it is the most suitable unit
to control the SMARTRA.
C. When the key is inserted in the ignition and turned to the ON position, the antenna coil sends power to the
transponder in the ignition key. The transponder then sends a coded signal back through the SMARTRA unit to
the PCM(ECM).
D. If the proper key has been used, the PCM(ECM) will energize the fuel supply system. The immobilizer indicator
light in the cluster will simultaneously come on for more than five seconds, indicating that the SMARTRA unit
has recognized the code sent by the transponder.
E. If the wrong key has been used and the code was not received or recognized by the PCM(ECM) the indicator
light will continue blinking for about five seconds until the ignition switch is turned OFF.
F. If it is necessary to rewrite the PCM(ECM) to learn a new key, the dealer needs the customer's vehicle, all its
keys and the Hi-scan (pro) equipped with an immobilizer program card. Any key that is not learned during
rewriting will no longer start the engine.
G. The immobilizer system can store up to eight key codes.
H. If the customer has lost his key, and cannot start the engine, contact Hyundai motor service station.
Components Operations
PCM (Power Train Control Module) (A)
1. The PCM(ECM) carries out a check of the ignition key using a special encryption algorithm, which is programmed
into the transponder as well as the PCM(ECM) simultaneously. Only if the results are equal, the engine can be
started. The data of all transponders, which are valid for the vehicle, are stored in the PCM(ECM).
[Gasoline]
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[Diesel]
Smartra Unit (A)

The SMARTRA carries out communication with the built-in transponder in the ignition key. This wireless
communication runs on RF (Radio frequency of 125 kHz). The SMARTRA is mounted behind of the crash pad close to
center cross bar.The RF signal from the transponder, received by the antenna coil, is converted into messages for
serial communication by the SMARTRA device. And, the received messages from the PCM(ECM) are converted into
an RF signal, which is transmitted to the transponder by the antenna.The SMARTRA does not carry out the validity
check of the transponder or the calculation of encryption algorithm. This device is only an advanced interface, which
converts the RF data flow of the transponder into serial communication to the PCM(ECM) and vice versa.
Transponder (Built-in Keys)

The transponder has an advanced encryption algorithm. During the key teaching procedure, the transponder will be
programmed with vehicle specific data. The vehicle specific data are written into the transponder memory. The write
procedure is once only; therefore, the contents of the transponder can never be modified or changed.
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Antenna Coil
The antenna coil has the following functions.
- The antenna coil supplies energy to the transponder.
- The antenna coil receives signal from the transponder.
- The antenna coil sends transponder signal to the SMARTRA.
It is located directly in front of the steering handle lock.
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2010 > G 1.0 SOHC >
Diagnosis Of Immobilizer Faults

- Communication between the ECM and the SMARTRA.
- Function of the SMARTRA and the transponder.
- Data (stored in the ECM related to the immobilizer function.
The following table shows the assignment of immobilizer related faults to each type:
Immobilizer Related Faults Fault types Diagnostic codes
PCM(ECM) fault 1. Non-Immobilizer-EMS connected to an Immobilizer P1610
1. Transponder not in password mode P1674
Transponder key fault
2. Transponder transport data has been changed. (Transponder status error)
P1675
Transponder key fault 1. Transponder programming error (Transponder programming
error)
P1676
SMARTRA fault 1. Invalid message from SMARTRA to PCM(ECM)
(SMARTRA message error)
1. Virgin SMARTRA at learnt EMS
2. Neutral SMARTRA at learnt EMS P169A(SMARTRA
SMARTRA fault
3. Incorect the Authentication of EMS and SMARTRA Authentication fail)
4. Locking of SMARTRA
1. No response from SMARTRA

2. Antenna coil error P1690
SMARTRA fault
3. Communication line error (Open/Short etc.) (SMARTRA no response)
4. Invalid message from SMARTRA to PCM(ECM)
P1691
Antenna coil fault 1. Antenna coil open/short circuit
(Antenna coil error)
Immobilizer indicator lamp P1692
1. Immobilizer indicator lamp error (Cluster)
fault (Immobilizer lamp error)
1. Corrupted data from transponder
2. More than one transponder in the magnetic field P1693
Transponder key fault (Antenna coil) (Transponder no response
3. No transponder (Key without transponder) in the error/invalid response)
magnetic field (Antenna coil)
1. Request from PCM(ECM) is invalid
P1694
PCM(ECM) fault (Protocol layer violation- Invalid request, check sum
(PCM(ECM) message error)
error etc.)
1. PCM(ECM) internal permanent memory (EEPROM)

PCM(ECM) internal
fault P1695
permanent memory
2. Invalid write operation to permanent memory (PCM(ECM) memory error)
(EEPROM) fault
(EEPROM)
1. Virgin transponder at PCM(ECM) status "Learnt"Learnt
P1696
Invalid key fault (Invalid) Transponder at PCM(ECM) status
(Authentication fail)
"Learnt"(Authentication fail)
Hi-Scan fault 1. Hi-Scan message error P1697
1. Exceeding the maximum limit of Twice IGN ON (⊇ 32 P1699
Locked by timer
times) (Twice IG ON over trial)
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2010 > G 1.0 SOHC >
Replacement
Problems And Replacement Parts:
Problem Part set Scan tool required?
All keys have been lost Blank key (4) YES
Antenna coil unit does not work Antenna coil unit NO
ECM does not work PCM(ECM) YES
Ignition switch does not work Ignition switch with Antenna coil unit YES
Unidentified vehicle specific data occurs Key, PCM(ECM) YES
SMARTRA unit does not work SMARTRA unit NO
Replacement Of Ecm And Smartra

In case of a defective ECM, the unit has to be replaced with a "virgin" or "neutral" ECM. All keys have to be taught to
the new ECM. Keys, which are not taught to the ECM, are invalid for the new ECM (Refer to key teaching procedure).
The vehicle specific data have to be left unchanged due to the unique programming of transponder.
In case of a defective SMARTRA, there is no special procedure required. A new SMARTRA device simply replaces
the old one. There are no transponder-related data stored in this device.
1. Things to remember before a replacement (PCM(ECM))
2. Things to remember before a replacement (Keys & Additional registration)
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1. When there is only one key registered and you wish to register another key, you need to re-register the key
which was already registered.
2. When the key #1 is registered and master key #2 is not registered, Put the key #1 in the IG/ON or the
start position and remove it. The engine can be started with the unregistered key #2.
(Note that key #2 must be used within 10 seconds of removing key #1)
3. When the key #1 is registered and key #2 is not registered, put the unregistered master key #2 in the
IG/ON or the start position.
The engine cannot be started even with the registered key #1.
4. When you inspect the immobilizer system, refer to the above paragraphs 1, 2 and 3.
Always remember the 10 seconds zone.
5. If the pin code & password are entered incorrectly on three consecutive inputs, the system will be locked
for one hour.
6. Be cautious not to overlap the transponder areas.
7. Problems can occur at key registration or vehicle starting if the transponders should overlap.
Neutralising Of ECM
The PCM(ECM) can be set to the "neutral" status by a tester.
A valid ignition key is inserted and after ignition on is recorded, the PCM(ECM) requests the vehicle specific data from
the tester. The communication messages are described at "Neutral Mode" After successfully receiving the data, the
PCM(ECM) is neutralized.
The ECM remains locked. Neither the limp home mode nor the "twice ignition on" function, is accepted by the
PCM(ECM).
The teaching of keys follows the procedure described for the virgin PCM(ECM). The vehicle specific data have to be
unchanged due to the unique programming of the transponder. If data should be changed, new keys with a virgin
transponder are requested.
This function is for neutralizing the PCM(ECM) and Key. Ex) when lost key, Neutralize the PCM(ECM) then teach
keys.(Refer to the Things to do when Key & PIN Code the PCM(ECM) can be set to the "neutral" status by a
scanner.If wrong vehicle specific data have been sent to SMATRA three times continuously or intermittently, the
SMATRA will reject the request to enter neutral mode for one hour. Disconnecting the battery or other manipulation
cannot reduce this time. After connecting the battery the timer starts again for one hour.
• Neutralizing setting condition

- In case of PCM(ECM) status "Learnt" regardless of user password "Virgin or Learnt"
- Input correct PIN code by scanner.
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- Neutralizing meaning .
: PIN code (6) & user password (4) deletion.
: Locking of ECM (except key teaching permission)
• Neutralizing meaning:
- PIN Code(6) & User P/Word(4) deletion
- Locking of EMS(except Key Learning permission)
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Neutralising Of Smartra
The EMS can be set to the status "neutral" by tester
Ignition key (regardlss of key status) is inserted and after IGN ON.If receiving the correct vehicle password from GST,
SMARTRA can be neutralized.The neutralization of SMARTRA is possible if DPN is same as the value inputted by
GST.
In case that the SMARTRA status is neutral, the EMS keeps the lock state. And the start is not possible by "twice
ignition".
In case of chaging the vehicle password, new virgin transponder must be only used. And in case of virgin key, after
Learning the key of vehicle password, it can be used.
If wrong vehicle specific data have been sent to SMATRA three times continuously or intermittently, the SMATRA will
reject the request to enter neutral mode for one hour. Disconnecting the battery or other manipulation cannot reduce
this time. After connecting the battery the timer starts again for one hour.
• Neutralizing Setting condition :

- In case of "SMARTRA status", "Learnt"
- Input correct Pin code by tester
• Neutralizing meaning :
- Vehicle password(DPN Code) & SEK Code deletion.
- Permission of New DPN Learning.
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Teaching Procedures
1. Key Teaching Procedure
Key teaching must be done after replacing a defective PCM(ECM) or when providing additional keys to the vehicle
owner.
The procedure starts with an PCM(ECM) request for vehicle specific data (PIN code: 6digits) from the tester. The
"virgin" PCM(ECM) stores the vehicle specific data and the key teaching can be started. The "learnt" PCM(ECM)
compares the vehicle specific data from the tester with the stored data. If the data are correct, the teaching can
proceed.
If incorrect vehicle specific data have been sent to the PCM(ECM) three times, the PCM(ECM) will reject the
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request of key teaching for one hour. This time cannot be reduced by disconnecting the battery or any other
manipulation. After reconnecting the battery, the timer starts again for one hour.
The key teaching is done by ignition on with the key and additional tester commands. The PCM(ECM) stores the
relevant data in the EEPROM and in the transponder. Then the PCM(ECM) runs the authentication required for
confirmation of the teaching process. The successful programming is then confirmed by a message to the tester.
If the key is already known to the PCM(ECM) from a previous teaching, the authentication will be accepted and the
EEPROM data are updated. There is no changed transponder content (this is impossible for a learnt transponder).
The attempt to repeatedly teach a key, which has been taught already during the same teaching cycle, is
recognized by the PCM(ECM). This rejects the key and a message is sent to the tester.
The PCM(ECM) rejects invalid keys, which are presented for teaching. A message is sent to the tester. The key
can be invalid due to faults in the transponder or other reasons, which result from unsuccessful programming of
data. If the PCM(ECM) detects different authenticators of a transponder and an PCM(ECM), the key is considered
to be invalid.
The maximum number of taught keys is 8
If an error occurs during the Immobilizer Service Menu, the PCM(ECM) status remains unchanged and a specific
fault code is stored.
If the PCM(ECM) status and the key status do not match for teaching of keys, the tester procedure will be stopped
and a specific fault code will be stored at PCM(ECM).
When teaching the 1st key, smartra regists at the same time.
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(1) PCM(ECM) learnt status.
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(2) PCM(ECM) virgin status.
After replacing new "PCM(ECM)" scantool displays that PCM(ECM) is virgin status in Key Teaching mode.
"VIRGIN" status means that PCM(ECM) has not matched any PIN code before.
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2. User Password Teaching Procedure
The user password for limp home is taught at the service station. The owner of the vehicle can select a number
with four digits.
User password teaching is only accepted by a "learnt" PCM(ECM). Before first teaching of user password to an
PCM(ECM), the status of the password is "virgin" No limp home function is possible.
The teaching is started by ignition on, with a valid key (learnt key) and sending the user password by tester. After
successful teaching, the status of the user password changes from "virgin" to "learnt"
The learnt user password can also be changed. This can be done if the user password status is "learnt" and the
tester sends authorization of access, either the old user password or the vehicle specific data. After correct
authorization, the PCM(ECM) requests the new user password. The status remains "learnt" and the new user
password will be valid for the next limp home mode.
If incorrect user passwords or wrong vehicle specific data have been sent to the PCM(ECM) three times, the
PCM(ECM) will reject the request to change the password for one hour. This time cannot be reduced by
disconnecting the battery or any other actions. After reconnecting the battery, the timer starts again for one hour.
(1) User password teaching
※ In case of putting wrong password, retry from first step after 10 seconds.
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※ In case of putting wrong password, retry from first step after 10 seconds.
(2) User password changing
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LIMP HOME FUNCTION
1. LIMP HOME BY TESTER
If the PCM(ECM) detects the fault of the SMARTRA or transponder, the PCM(ECM) will allow limp home function of
the immobilizer. Limp home is only possible if the user password (4 digits) has been given to the PCM(ECM)
before. This password can be selected by the vehicle owner and is programmed at the service station.
The user password can be sent to the PCM(ECM) via the special tester menu.
Only if the PCM(ECM) is in status "learnt" and the user password status is "learnt" and the user password is
correct, the PCM(ECM) will be unlocked for a period of time (30 sec.). The engine can only be started during this
time. After the time has elapsed, engine start is not possible.
If the wrong user password is sent, the PCM(ECM) will reject the request of limp home for one hour. Disconnecting
the battery or any other action cannot reduce this time. After connecting the battery to the PCM(ECM), the timer
starts again for one hour.
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2. LIMP HOME BY IGNITION KEY
The limp home can be activated also by the ignition key. The user password can be input to the PCM(ECM) by a
special sequence of ignition on/off.
Only if the PCM(ECM) is in status "learnt" and the user password status is "learnt" and the user password is
correct, the PCM(ECM) will be unlocked for a period of time (30 sec.). The engine can be started during this time.
After the time has elapsed, engine start is not possible. After a new password has been input, the timer (30 sec.)
will start again.
After ignition off, the PCM(ECM) is locked if the timer has elapsed 8 seconds. For the next start, the input of the
user password is requested again.
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Immobilizer System - Immobilizer Control Unit
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2010 > G 1.0 SOHC >
Removal
2. Remove the crash pad lower panel(A) after removing side cover. (Refer to the Body group - "Crash pad").
3. Disconnect the 5P connector of the SMARTRA unit and then remove the SMARTRA unit (A) mounted on the left
side cowl cross bar. after loosening a nut (B).
Installation
1. Reassemble the SMARTRA unit after connecting the connector.
2. Reassemble the driver crash pad lower panel.
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Immobilizer System - Antenna Coil
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2010 > G 1.0 SOHC >
Removal
2. Remove the crash pad lower panel (A). (Refer to the Body group - "Crash pad").
3. Disconnect the 6P connector of the coil antenna and then remove the coil antenna (A) after loosening the screw.
Installation
1. Reassemble the coil antenna after connecting the connector.
2. Reassemble the crash pad lower panel.
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Rear Parking Assist System - Control Unit
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2010 > G 1.0 SOHC >
Circuit Diagram
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2010 > G 1.0 SOHC >
Description
When reversing, the driver is not easy to find objects in the blind spots and to determine the distance from the object.
In order to provide the driver safety and convenience, back warning system will operate upon shifting to "R" Ultrasonic
sensor will emit ultrasonic wave rearward and detect the reflected wave. Control unit will calculate distance to the
object using the sensor signal input and output buzzer alarm in three steps (first, second and third alarm).
Alarm Range
Upon detecting an object at each range out of 3 ranges as stated below within the operation range, it will generate
alarm.
First alarm : Object comes near to the sensor located at the rear of vehicle, within 81-120cm ± 15cm
Second alarm : Object comes near to the sensor located at the rear of vehicle, within 41-80cm ± 10cm
Third alarm : Object comes near to the sensor located at the rear of vehicle, within 40cm ± 10cm
1. Time tolerance of the above waveform : Time ± 10%

2. At nearer distance than 40cm, detection may not occur.
3. Alarm will be generated with vehicle reversing speed 10km/h or less.
For moving target, maximum operation speed shall be target approach speed of 10km/h.
4. When the vehicle or the target is moving, sequential alarm generation or effective alarm may be failed.
5. False alarm, or failure of the alarm to trigger may occur in the following conditions.
- Irregular road surface, gravel road, reversing toward grass.
- Horn, motor cycle engine noise, large vehicle air brake, or other object generating ultrasonic wave is near.
- When a wireless transmitter is used near to the sensor.
- Dirt on the sensor.
- Sequential alarm may not occur due to the reversing speed or the target shape.
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2010 > G 1.0 SOHC >
Component Location
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2010 > G 1.0 SOHC >
Diagnosis
1. DIAGNOSIS
Turn the ignition switch ON, then shift the transaxle lever to 'R'. The Back Warning System is then checked.
If no trouble, it generates buzzer alarm sound for 0.3 seconds after 0.5 seconds from power approval.
2. DIAGNOSIS MODE
Switch on diagnosis mode upon system failure.
In case of system failure, then it indicates the failed point as follows.
Sensor Connection Checking

Transmit ultrasonic wave to the sensors, boost input signal, and detect wave.
Waveform will be found, oscillating for a certain period of time.
1. Waveform for a normal sensor connection
2. Waveform for a failed sensor connection
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Sensor connection will be checked for oscillating period of input signal 3V. If oscillating period is more than
0.8ms, it is normal.
A. Left sensor failure : beep-beep-beep

B. Right sensor failure : beep beep-beep beep-beep beep
C. Rear-right sensor failure : beep beep beep-beep beep beep-beep beep beep
D. Right side sensor failure : beep beep beep beep-beep beep beep beep-beep beep beep beep
Warning
1. Range detected by back sensors is limited.
Watch back before reversing
2. There is a blind spot below the bumper. Low objects (for example boundary barrier) may be detected from minimum
1.5m away unable to detect at nearer.
3. Besides there are some materials unable to be detected even in detection range as follows.
(1) Needles, ropes, rods, or other thin objects.
(2) Cotton, snow and other material absorbing ultrasonic wave
(for example, fire extinguisher device covered with snow)
4. Reversing toward the sloped walls.
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5. Reversing toward the sloped terrain.
6. False alarm may operate in the following condition: irregular road surface, gravel road, sloped road and grass.
Upon alarm generation by grass the alarm may be generated by rock behind grass. Always visually check the area
behind the vehicle before backing up.
The sensors cannot discriminate between materials.
7. Sensors may not operate correctly in the below conditions.
Ensure sensors are clean from mud or dirt
(1) When spraying the bumper, the sensor opening is covered with something in order not to be contaminated. If
sensor opening is contaminated with mud, snow, or dirt, detection range will be reduced and alarm may not be
generated under the crash condition. Dirt accumulated on the sensor opening shall be removed with water.
Do not wipe or scrape sensor with a rod or a hard object.
(2) If the sensor is frozen, alarm may not operate until sensor thaws.
(3) If a vehicle stays under extremely hot or cold environment, the detection range may be reduced. It will be
restored at the normal temperature.
(4) When heavy cargo is loaded in rear cargo area, it changes the vehicle balance, which reduces the detection
range.
(5) When other vehicle's horn, motor cycle engine noise, or other ultra-sonic wave sources are near.
(6) Under heavy rain.
(7) When reversing towards a vertical wall and the gap between the vehicle and the wall is 15cm. (Alarm may
sound despite the absence of a barrier)
(8) If radio antenna is installed at the rear.
(9) If the vehicle rear wiring is re-routed or electrical component is added at the rear part.
(10) Vehicle balance is changed due to the replacement of the rear spring.
(11) The unit will operate normally when the vehicle speed is 5km/h or less.
Above this speed, the unit may not operate normally
8. Check the rear bumper for installation condition and deformation. If installed improperly or the sensor orientation is
deviated, it may cause malfunction.
9. Be careful not to apply shock during sensor installation on the transmission or reception unit.
10. When adding electrical devices or modifying harness at the rear body of the vehicle, ensure not to change the
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transmission and reception unit wiring.
Tagging the transmission side and reception side, it may cause malfunction.
11. High power radio transmitter (above 10W) may cause malfunction. Do not install it on the vehicle.
12. Be careful that excessive heat or sharp objects shall not touch ultrasonic sensor surface.
Do not cover the sensor opening or press the sensor.
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2010 > G 1.0 SOHC >
Removal
1. Remove the rear right quarter trim of the trunk (Refer to the Body group - "Interior trim")
2. Loosen the mounting bolts and remove the rear parking assist system control module unit (A) from the quarter
panel.
Installation
1. Reassemble the rear parking assist system control module.
2. Reassemble the rear left quarter trim.
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Rear Parking Assist System - Sensor
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2010 > G 1.0 SOHC >
Operation
The sensor emits ultrasonic wave to the objects, and it measures the time until reflected wave returns, and calculates
the distance to the object.
Distance Detection Type

Direct detection type and indirect detection type are used together for improving effectiveness of the detection.
1. Direct detection type: One sensor transmits and receives signals to measure the distance.
2. Indirect detection type: One sensor transmits signals and the other sensor receives the signals to measure the
distance.
Measurement Principle
Back warning system (BWS) is a complementary device for reversing. BWS detects objects behind vehicle and
provides the driver with buzzer alarm finding objects in a certain area, using ultrasonic wave propagation speed and
time.
The propagation speed formula of ultrasonic wave in air is following :
v=331.5 + 0.6t (m/s)
v=ultrasonic wave propagation speed
t=ambient temperature
The basic principle of distance measurement using ultrasonic wave is :
Sensor Detection Range
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1. 14cm (Diameter) plastic rod is used for the test target.
2. The test result may differ by a different target object.
3. Detection range may be reduced by dirt accumulated on sensor, and extremely hot or cold weather.
4. The following object may not be detected.
- Sharp object or thin object like rope.
- Cotton, sponge, snow or other materials absorbing sonic wave.
- Smaller objects than 14cm (Diameter), 1m length.
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2010 > G 1.0 SOHC >
Removal
1. Remove the rear bumper ( Refer to the Body group - "Rear bumper")
2. Disconnect the sensor connector at the inside of the rear bumper, and then remove the sensor from the housing
(A).
Installation
1. Connect the connector, and then reassemble the sensor.
2. Reassemble the rear bumper.
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Ignition Switch Assembly
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2010 > G 1.0 SOHC >
Removeal
1. Remove the steering column shaft (Refer to the ST group).
2. If it is necessary to remove the key lock assembly (A), use a punch to make a groove on the head of the shear bolt
(B), and then use a screwdriver to remove the key lock assembly mounting bracket (C).
Punch the shear bolt using a centering punch.

And drill its head off with a drill bit.
Becarefull not to damage the key lock assembly.
3. Disassemble the key lock assembly (A) from the steering column and shaft assembly (B).
Installation
1. Install the key lock assembly and mounting bracket.
Tighten the shear bolt until the bolt head break off.
Inspection
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1. Disconnect the ignition switch connector (A) and door warning switch connector (B) from under the steering
column.
2. Check for continuity between the terminals.
3. If continuity is not specified, replace the switch.
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Heating, Ventilation, Air Condi-
tioning
General Information
Heating, Ventilation, Air Conditioning
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2010 > G 1.0 SOHC >
Air conditioner
Specification
Item !1.1 Engine U1.1 Engine
(Gasoline) (Diesel)
Type HS-II (Swashplate)
Oil type & Capacity FD46XG (PAG), 120 ± 10cc
Compressor
Pully type 4PK type
Displacement 110cc/rev
Condenser Heat rejection 9200 kcal/hr
APT(A/C pressure The method to measure the
Voltage = 0.00878835 * Pressure + 0.37081095 [PSIA]
transducer) pressure
Expansion valve Type Block
Type R-134a
Refrigerant
Capacity [oz.(g)] 15.8 ± 0.88 (450 ± 25)
Blower unit
Item Specification
Fresh and recirculation Operating method Actuator
Type Sirocco
Blower Speed step Auto + 8 speed (Automatic), 1-4 speed (Manual)
Speed control Power mosfet
Air filter Type Mesh filter
Heater and evaporator unit

Item Specification
Type Pin & Tube type
Heating capacity 4100 - 5% kcal/hr
Heater Mode operating method Actuator
Temperature operating
Actuator
method
Temperature control type Evaporator temperature sensor
Evaporator ON : 3.0 ± 0.3 (37.4 ± 32.5),
A/C ON/OFF [°C(°F)]
OFF: 2.0 ± 0.3 (35.6 ± 32.5)
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2010 > G 1.0 SOHC >

Tool
Illustration Use
(Number and name)
09977-29000 Removal and installation of the disc &
Disc & hub assembly bolt remover hub assembly bolt
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2010 > G 1.0 SOHC >
TROUBLESHOOTING
Before replacing or repairing air conditioning components, first determine if the malfunction is due to the refrigerant
charge, air flow or compressor.
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of
the problem. Check each part in order. If necessary, replace these parts.
After correcting the malfunction, check the complete system to ensure that performance is satisfactory.
STANDARD:
1. Blower fuse
2. Blower relay
3. Blower motor
No blower operation
4. Power mosfet
5. Blower speed control switch
6. Wire harness
1. Engine coolant capacity
No air temperature control
2. Heater control assembly
1. Refrigerant capacity
2. A/C Fuse
3. Magnetic clutch
4. Compressor
No compressor operation
5. A/C pressure transducer
6. A/C switch
7. Evaporator temperature sensor
8. Wire harness
2. Refrigerant pressure
3. Drive belt
4. Magnetic clutch
5. Compressor
No cool comes out
7. Evaporator temperature sensor
8. A/C switch
10. Wire harness
2. Drive belt
3. Magnetic clutch
4. Compressor
5. Condenser
Insufficient cooling
6. Expansion valve
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7. Evaporator
8. Refrigerant lines
No engine idle-up when A/C 1. Engine ECM

switch ON 2. Wire harness
No air inlet control 1. Heater control assembly
No mode control
2. Mode actuator
1. Cooling fan fuse
2. Fan motor
No cooling fan operation
3. Engine ECM
4. Wire harness
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Air Conditioning System
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2010 > G 1.0 SOHC >
INSTRUCTIONS
WHEN HANDLING REFRIGERANT
1. R-134a liquid refrigerant is highly volatile. A drop on the skin of your hand could result in localized frostbite. When
handling the refrigerant, be sure to wear gloves.
2. It is standard practice to wear goggles or glasses to protect your eyes, and gloves to protect your hands. If the
refrigerant splashes into your eyes, wash them with clean water immediately.
3. The R-134a container is highly pressurized. Never leave it in a hot place, and check that the storage temperature
is below 52°C (126°F)
4. An electronic leak detector should be used to check the system for refrigerant leakage. Bear in mind that the R-
134a, upon coming into contact with flame, produces phosgene, a highly toxic gas.
5. Use only recommended the lubricant for R-134a systems. If lubricants other than the recommended one used,
system failure may occur.
6. PAG lubricant absorbs moisture from the atmosphere at a rapid rate, therefore the following precautions must be
observed:
A. When removing refrigerant components from a vehicle, cap immediately the components to prevent from the
entry of moisture.
B. When installing refrigerant components to a vehicle, do not remove the cap until just before connecting the
components.
C. Complete the connection of all refrigerant tubes and hoses without delay to prevent the A/C system from taking
on moisture.
D. Use the recommended lubricant from a sealed container only.
7. If an accidental discharge in the system occurs, ventilate the work area before resuming service.
WHEN REPLACING PARTS ON A/C SYSTEM

1. Never open or loosen a connection before discharging the system.
2. Seal the open fittings of components with a cap or plug immediately to prevent intrusion of moisture or dust.
3. Do not remove the sealing caps from a replacement component until it is ready to be installed.
4. Before connecting an open fitting, always install a new sealing ring. Coat the fitting and seal with refrigerant oil
before making the connection.
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WHEN INSTALLING CONNECTING PARTS
FLANGE WITH GUIDE PIN
Check the new O-ring for damage (use only the specified) and lubricate it using compressor oil. Tighten the nut to
specified torque.
Tightening torque [ N.m (kg.m, lbf.ft) ]

Size General bolt, nut
4T 7T
5-6 9 - 11
M6
(0.5 - 0.6, 3.6 - 4.3) (0.9 - 1.1, 6.5 - 7.9)
12 - 14 20 - 26
M8
(1.2 - 1.4, 8.7 - 10) (2.0 - 2.6, 14 - 18)
25 - 28 45 - 55
M10
(2.5 - 2.8, 18 - 20) (4.5 - 5.5, 32 - 39)
Flange bolt, nut
Size
4T 7T
5-7 8 - 12
M6
(0.5 - 0.7, 3.6 - 5.0) (0.8 - 1.2, 5.8 - 8.6)
10 - 15 19 - 28
M8
(1.0 - 1.5, 7 - 10) (1.9 - 2.8, 14 - 20)
21 - 31 39 - 60
M10
(2.1 - 3.1, 15 - 22) (3.9 - 6.0, 28 - 43)
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T means tensile intensity, which is stamped on the head of bolt only numeral
HANDLING TUBING AND FITTINGS

The internal parts of the refrigeration system will remain in a state of chemical stability as long as pure moisture-free
refrigerant and refrigerant oil are used. Abnormal amounts of dirt, moisture or air can upset the chemical stability and
cause problems or serious damage.
THE FOLLOWING PRECAUTIONS MUST BE OBSERVED

1. When it is necessary to open the refrigeration system, have everything you will need to service the system ready so
the system will not be left open any longer than necessary.
2. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture.
3. All lines and components in parts stock should be capped or sealed until they are ready to be used.
4. Never attempt to rebind formed lines to fit. Use the correct line for the installation you are servicing.
5. All tools, including the refrigerant dispensing manifold, the gauge set manifold and test hoses, should be kept clean
and dry.
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2010 > G 1.0 SOHC >
REFRIGERATION CYCLE
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2010 > G 1.0 SOHC >
REFRIGERANT SYSTEM SERVICE BASICS

REFRIGERANT RECOVERY
Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove HFC-
134a(R-134a) from the air conditioning system.
- Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
- Be careful when connecting service equipment.
- Do not breathe refrigerant or vapor.
If accidental system discharge occurs, ventilate work area before resuming service.
Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
1. Connect an R-134a refrigerant
Recovery/Recycling/Charging System (A) to the high-pressure service port (B) and the low-pressure service port
(C) as shown, following the equipment manufacturer's instructions.
2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be
sure to install the same amount of new refrigerant oil back into the A/C system before charging.
SYSTEM EVACUATION
1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be
evacuated using an R-134a refrigerant Recovery/Recycling/Charging System. (If the system has been open for
several days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.)
2. Connect an R-134a refrigerant Recovery/Recycling/Charging System (A) to the high-pressure service port (B) and
the low-pressure service port (C) as shown, following the equipment manufacturer's instructions.
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3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 10 minutes, there is probably a
leak in the system. Partially charge the system, and check for leaks (see Leak Test.).
4. Remove the low pressure valve from the low-pressure service port.
SYSTEM CHARGING
1. Connect an R-134a refrigerant Recovery/Recycling/Charging System (A) to the high-pressure service port (B) as
shown, following the equipment manufacturer's instructions.
2. Add the same amount of new refrigerant oil to system that was removed during recovery. Use only specified
refrigerant oil. Charge the system with 15.8 ± 0.88 (450 ± 25) of R-134a refrigerant. Do not overcharge the system
the compressor will be damaged.
REFRIGERANT LEAK TEST

Always conduct a leak test with an electronic leak detector whenever leakage or refrigerant is suspected and when
conducting service operations which are accompanied by disassembly or loosening or connection fittings.
In order to use the leak detector properly, read the manual supplied by the manufacturer.
If a gas leak is detected, proceed as follows:

1. Check the torque on the connection fittings and, if too loose, tighten to the proper torque. Check for gas leakage
with a leak detector (A).
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2. If leakage continues even after the fitting has been tightened, discharge the refrigerant from the system, disconnect
the fittings, and check their seating faces for damage. Always replace, even if the damage is slight.
3. Check the compressor oil and add oil if required.
4. Charge the system and recheck for gas leaks. If no leaks are found, evacuate and charge the system again.
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Air Conditioning System - A/C Pressure

Transducer
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2010 > G 1.0 SOHC >
DESCRIPTION
A/C pressure transducer convert the pressure value of high pressure line into voltage value after measure it. By
converted voltage value, engine ECU controls cooling fan by operating it high speed or low speed. Engine ECU stop
the operation of compressor when the temperature of refrigerant line is so high or so low irregularly to optimize air
conditioning system.
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2010 > G 1.0 SOHC >
INSPECTION
1. Measure the pressure of high pressure line by measuring voltage output between NO.1 and NO.2 terminals.
2. Inspect the voltage value whether it is sufficient to be regular value or not.
Voltage = 0.00878835 * Pressure + 0.37081095 [PSIA]
3. If the measured voltage value is not specification, replace the A/C pressure transducer.
REPLACEMENT
2. Recover the refrigerant with a recovery/charging station.
3. Disconnect A/C pressure transducer connector (3P) (A).
4. Remove the A/C pressure transducer(B).
Take care that liquid & suction pipe are not bent.
TORQUE: 10~12N.m (1.0~1.2kgf.m, 7.4~8.8lbf.ft)
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Air Conditioning System - Evaporator

Temperature Sensor
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DESCRIPTION
The evaporator temperature sensor will detect the evaporator core temperature and interrupt compressor relay power
in order to prevent evaporator freezing by excessive cooling.
It is a negative type thermistor whose resistance is inversely proportional to temperature.
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2010 > G 1.0 SOHC >
INSPECTION
1. Ignition "OFF"
2. Disconnect evaporator temperature sensor.
3. Using the multi-tester, Measure resistance between terminal "1" and "2" of evaporator temperature sensor.
[Specification]
Evaporator core temperature [°C(°F)] Resistance [k!]
-10(14) 43.35
0(32) 27.62
10(50) 18.07
20 (68) 12.11
30(86) 8.30
40(104) 5.81
50(122) 4.15
4. If the measured resistance is not specification, substitute with a known-good evaporator temperature sensor and
check for proper operation.
5. If the problem is corrected, replace the evaporator temperature sensor.
REPLACEMENT
1. Removre the crash pad (Refer to BD group - Crash pad)
2. Remove the heater unit. (Refer to HA group - Heate unit)
3. Remove the lower heater case (A).
4. Remove the evaporator temperature sensor (A) from the evaporator core
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5. Installation is the reverse order of removal
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Air Conditioning System - In-Car Sensor
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2010 > G 1.0 SOHC >
DESCRIPTION
1. In-car air temperature sensor is located at the crash pad.
2. The sensor contains a thermistor which measures the temperature of the inside. The signal decided by the
resistance value which changes in accordance with perceived inside temperature, is delivered to heater control unit
and according to this signal the control unit regulates incar temperature to intended value.
3. It perceives the inside temperature, changes the resistance value, and enters the corresponding voltage into the
automatic temperature control module.
4. It will used for discharge temperature control, sensor failsafe, temperature door control, blower motor level control,
and A/C auto control.
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2010 > G 1.0 SOHC >
INSPECTION
1. Ignition "ON"
2. Blow air with changing temperature to the in car sensor air inlet. Measure sensor resistance between 2 and 4
terminals.
[Specification]
Temperature [°C(°F)] Resistance between terminals 2and 4 (k!)
-30 (-22) 509.577
-15 (5) 216.07
0 (32) 97.71
15 (59) 47.13
25 (77) 30.00
35 (95) 19.59
50 (122) 10.81
In car sensor is negative type thermistor that resistance will rise with lower temperature, and reduce with
higher tempera
REPLACEMENT
2. Remove the crash pad lower panel(A).
3. Disconnect the connector of in-car sensor (A).
4. Remove the in-car sensor(B) from crash pad lower panel.
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Air Conditioning System - Photo Sensor
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2010 > G 1.0 SOHC >
DESCRIPTION
1. The photo sensor (A) is located at the center of defrost nozzle.
2. The photo sensor contains a photovoltaic (sensitive to sunlight) diode. The solar radiation received by its light
receiving portion, generates 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.
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2010 > G 1.0 SOHC >
INSPECTION
1. Ignition "ON"
2. Using the scan tool.
3. Emit intensive light toward photo sensor using a lamp, and check the output voltage change.
4. The voltage will rise with higher intensive light and reduce with lower intensive light.
REPLACEMENT
2. With the (-) driver, remove the photo sensor (B) from the left of defrost nozzle (A).
3. Install in the reverse order of removal.
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Air Conditioning System - Water

Temperature Sensor
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2010 > G 1.0 SOHC >
DESCRIPTION
1. Water temperature sensor is located at the heater unit.
2. It detects coolant temperature. Its signal is used for cold engine lockout control. When the driver operates the
heater before the engine is warmed up, the signal from sensor causes the heater control unit to reduce blower
motor speed until coolant temperature reaches the threshold value.
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2010 > G 1.0 SOHC >
INSPECTION
1. Ignition "ON"
2. Using the multi-tester, Measure resistance between terminal "1" and "2" of water temperature sensor.
[Specification]
Coolant temperature [°C(°F)] Resistance (k!) Voltage (V)
-10(14) 55.85 4.24
0(32) 32.91 3.83
10(50) 19.99 3.33
20(68) 12.51 2.78
30(86) 8.047 2.23
40(104) 5.311 1.73
50(122) 3.588 1.32
60(140) 2.476 0.99
70(158) 1.742 0.74
80(176) 1.246 0.55
3. If the measured resistance is not specification, substitute with a known-good water temperature sensor and check
for proper operation.
4. If the problem is corrected, replace the water temperature sensor.
Negative type thermistor that resistance will rise with lower temperature, and reduce with higher temperature.
REPLACEMENT
2. Disconnect the connector (A) of water temperature sensor and then remove the water temperature sensor(B) by
pulling out.
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Take care that wire of water temperature sensor is not to be damaged
3. Install in the reverse order of removal.
- Apply caulk to the water temperature sensor.

- Make sure that there is no air leakage
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Air Conditioning System - Ambient Sensor
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2010 > G 1.0 SOHC >
DESCRIPTION
1. The ambient temperature sensor is located at the front of the condenser and detects ambient air temperature. It is
a negative type thermistor; resistance will increase with lower temperature, and decrease with higher temperatures.
2. The sensor output will be used for discharge temperature control, temperature regulation door control, blower
motor level control, mix mode control and in-car humidity control.
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2010 > G 1.0 SOHC >
INSPECTION
1. Ignition "OFF"
2. Disconnect ambient temperature sensor.
3. Check the resistance of ambient temperature sensor between terminals 1 and 2 whether it is changed by changing
of the ambient temperature.
Ambient Temperature
Resistance between terminals 1 and 2 (k! )
[°C (°F)]
-20 (-4) 271.21
-10 (14) 158.18
0 (32) 95.10
10 (50) 58.80
20 (68) 37.32
30 (86) 24.26
40 (104) 16.13
50 (122) 10.95
4. If the measured resistance is not specification, substitute with a known-good ambient temperature sensor and
check for proper operation.
5. If the problem is corrected, replace the ambient temperature sensor.
REPLACEMENT
2. Remove the front bumper. (Refer to BD group - Front bumper)
3. Remove the ambient temperature sensor (A).
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Heater - Heater Unit
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2010 > G 1.0 SOHC >
COMPONENTS LOCATION
COMPONENTS
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2010 > G 1.0 SOHC >
REPLACEMENT
2. Recover the refrigerant with a recovery/ recycling/ charging station.
3. When the engine is cool, drain the engine coolant from the radiator.
4. Remove the bolts (A) and the expansion valve (B) from the evaporator core.
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
5. Disconnect the inlet (A) and outlet (B) heater hoses from the heater unit.
Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let
coolant spill on electrical parts or painted surfaces. If any coolant spills, rinse it off immediately.
6. Remove the cowl top cover(Refer the BD group-hood)

7. Loosen the heater unit mounting bolt (A).
8. Remove the crash pad (Refer to BD group-crash pad).
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9. Remove the cowl cross bar assembly. (Refer to BD group-crash pad)
10. Disconnect the connectors from the temperature control actuator, the mode control actuator and the evaporator
temperature sensor.
11. Remove the heater & blower unit after loosening mounting bolts.
12. Remove the blower unit (B) from heater unit after loosening 3 screws.
13. Remove the heater core cover (A).
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14. Be careful that the inlet and outlet pipe are not bent during heater core removal, and pull out the heater core (A).
15. Remove the heater unit lower case(A).
16. Remove the evaporator core(A).
17. Install the heater core in the reverse order of removal.

18. Installation is the reverse order of removal, and note these items :
A. If you're installing a new evaporator, add refrigerant oil (ND-OIL8).
B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing
them. Be sure to use the right O-rings for R-134a to avoid leakage.
C. Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.
D. Do not spill the refrigerant oil on the vehicle ; it may damage the paint ; if the refrigerant oil contacts the paint,
wash it off immediately
E. Apply sealant to the grommets.
F. Make sure that there is no air leakage.
G. Charge the system and test its performance.
H. Do not interchange the inlet and outlet heater hoses and install the hose clamps securely.
I. Refill the cooling system with engine coolant
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Heater - Temperature Control Actuator
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2010 > G 1.0 SOHC >
DESCRIPTION
1. Heater unit includes mode control actuator and temperature control actuator.
2. Temperature control actuator is located at the heater unit. It regulates the temperature by the procedure as follows.
Signal from control unit adjusts position of temperature door by operating temperature switch and then temperature
will be regulated by the hot/cold air ratio decided by position of temperature door
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2010 > G 1.0 SOHC >
COMPONENT LOCATION
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2010 > G 1.0 SOHC >
INSPECTION
1. Ignition "OFF"
2. Disconnect the connector of temperature control actuator.
3. Verify that the temperature control actuator operates to the hot position when connecting 12V to the terminal 3 and
grounding terminal 4.
Verify that the temperature control actuator operates to the cool position when connecting in the reverse.
4. Check the voltage between terminals 5 and 6.

[Specification]
Door position Voltage (5-6) Error detecting

Max. cooling 0.3 ± 0.15V Low voltage : 0.1V or less
Max. heating 4.7 ± 0.15V High voltage : 4.9V or more
It will feedback current position of actuator to controls.

5. If the measured voltage is not specification, substitute with a known-good temperature control actuator and check
for proper operation.
6. If the problem is corrected, replace the temperature control actuator.
REPLACEMENT
3. Remove the BCM(A).
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4. Loosen the mounting screw and then remove the temperature control actuator (B).
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Heater - Mode Control Actuator
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2010 > G 1.0 SOHC >
DESCRIPTION
The mode control actuator is located at the heater unit.
It adjusts position of mode door by operating mode control actuator based on signal of A/C control unit. Pressing mode
select switch makes the mode control actuator shift in order of vent! B/L ! floor ! mix.
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2010 > G 1.0 SOHC >
COMPONENT LOCATION
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2010 > G 1.0 SOHC >
INSPECTION
1. Ignition "OFF"
2. Disconnect the connector of mode control actuator.
3. Verify that the mode control actuator operates to the defrost mode when connecting 12V to the terminal 3 and
grounding terminal 4.
4. Verify that the mode control actuator operates to the vent mode when connecting in the reverse.

Vent 0.3 ± 0.15V Low voltage : 0.1V or less
Defrost 4.7 ± 0.15V High voltage : 4.9V or more

6. If the measured voltage is not specification, substitute with a known-good mode control actuator and check for
proper operation.
7. If the problem is corrected, replace the mode control actuator.
REPLACEMENT
3. Remove the BCM(A).
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4. Loosen the mounting screws and then remove the mode control actuator (B).
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Blower - Blower Unit
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2010 > G 1.0 SOHC >
COMPONENT LOCATION
COMPONENTS
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2010 > G 1.0 SOHC >
REPLACEMENT
2. Remove the crash pad.(Refer to BD group - Crash pad)
3. Disconnect the connectors from the intake actuator, the blower motor and power mosfet.
4. Remove the cowl cross bar assembly.(Refer to BD group - Crash pad)
5. Remove the blower unit (A) from the heater unit after loosening a mounting bolt and 3 screws.
- Make sure that there is no air leaking out of the blower and duct joints.
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Blower - Power Mosfet
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2010 > G 1.0 SOHC >
INSPECTION
1. Ignition "ON"
2. Manually operate the control switch and measure the voltage of blower motor between pin 1 and 2.
3. Select the control switch to raise voltage until high speed.
[Specification]
Motor Voltage
Fan
Auto
First speed 3.8±0.5
Second speed 4.9±0.5
Third speed 6.1±0.5
Forth speed 7.2±0.5
Fifth speed 8.3±0.5
Sixth speed 9.5±0.5
Seventh speed 10.6±0.5
Eighth speed Battery (+)
AUTO COOLING: Auto speed (4.5V~B+)

AUTO HEATING: Auto speed (4.6V~10.6V)
4. If the measured voltage is not specification, substitute with a known-good power mosfet and check for proper
operation.
5. If the problem is corrected, replace the power mosfet.
REPLACEMENT
2. Disconnect the power mosfet connector (A) at the connecting part between heater and blower unit.
3. Remove the power mosfet (B) after loosening the mounting screws.
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tioning
Blower - Climate Control Air Filtar
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2010 > G 1.0 SOHC >
DESCRIPTION
The mesh filter filtrates such as leaves, large foreign materials at the above of the blower unit
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2010 > G 1.0 SOHC >
REPLACEMENT
1. Open the glove box (B). Lower the glove box down completely by removing the glove box stopper (A) to the glove
box.
2. Remove the filter cover (A) with pushing the knob.
3. Clan the mesh filter (B), install it after making sure of the direction of mesh filter.
In case of driving in maple streets or on dusty rough roads for a long period, check and clean the mesh filter
using air spray gun or vacuum cleaner as frequently as possible.
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tioning
Blower - Intake Actuator
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2010 > G 1.0 SOHC >
DESCRIPTION
1. The intake actuator is located at the blower unit.
2. It regulates the intake door by signal from control unit.
3. Pressing the intake selection switch will shift between recirculation and fresh air modes.
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2010 > G 1.0 SOHC >
COMPONENT LOCATION
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2010 > G 1.0 SOHC >
INSPECTION
1. Ignition "OFF"
2. Disconnect the intake actuator connector.
3. Verify that the actuator operates to the recirculation position when connecting 12V to the terminal 3 and grounding
terminal 4.
4. Verify that the intake actuator operates to the fresh position when connecting in the reverse.

Low voltage :
Fresh 0.3 ± 0.15V
0.1V or less
High voltage :
Recirculation 4.7 ± 0.15V
4.9V or more

6. If the intake actuator is not operated well, substitute with a known-good intake actuator and check for proper
operation.
7. If the problem is corrected, replace the intake actuator.
REPLACEMENT
2. Remove the crash pad. (Refer to BD group - Crash pad).
3. Disconnect the intake actuator connector.
4. Loosen the mounting screw and then remove the intake actuator (A) from the blower unit.
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tioning
Controller - Heater & A/C Control Unit

(Manual)
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2010 > G 1.0 SOHC >
COMPONENTS
CONNECTOR PIN FUNCTION

CONNECTOR PIN FUNCTION CONNECTOR PIN FUNCTION
CONNECTOR 1 Tail lamp (+) CONNECTOR 1 Sensor REF (+5V)
(A) (B)
2 Battery (+) 2 -
3 A/C Output 3 Ambient sensor (+)
4 A/C Select Signal 4 -
5 - 5 Incar sensor (+)
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Evaporator temperature
6 K-line 6
sensor (+)
Water temperature sensor
7 - 7
(+)
8 - 8 Vehicle Speed Signal
9 - 9 FET (G)
10 - 10 FET (D)
11 - 11 Blower motor (+)
12 - 12 Sensor GND
13 Rheostat 13 -
14 ING2 14 -
15 ING2 15 Photo sensor (-)
16 Temp actuator (cool) 16 -
17 Temp actuator (warm) 17 Incar motor (-)
18 Temp actuator (F/B) 18 -
19 Mode actuator (vent) 19 Blower on signal
20 Mode actuator (def) 20 PTC on signal
21 Mode actuator (F/B) 21 PTC RLY 2 (diesel only)
22 Intake actuator (fre) 22 PTC RLY 3 (diesel only)
23 Intake actuator (rec)
24 Intake actuator (F/B)
25 GND
26 GND
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2010 > G 1.0 SOHC >
SELF-DIAGNOSIS
1. Self-diagnosis process
The F.A.T.C. module self test feature will detect electrical malfunction and provide error codes for system components
with suspected failures.
DTC data can be retrieved from the control panel directly.
2. How to read self-diagnostic code

After the display panel flickers three times every 0.5 second, the corresponding fault code flickers on the setup
temperature display panel every 0.5 second and will show two figures. Codes are displayed in numerical format.
Fault code
Fault code
Fail description
Control unit
00 Normal
11 In-car temperature sensor open (High)
12 In-car temperature sensor short (Low)
13 Ambient temperature sensor open (High)
14 Ambient temperature sensor short (Low)
15 Water temperature sensor open (High)
16 Water temperature sensor short (Low)
17 Evaporator temperature sensor open (High)
18 Evaporator temperature sensor short (Low)
19 Temp door potentiometer open/short
20 Temp door motor
21 Mode door potentiometer open/short
22 Mode door control motor
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25 Intake door potentiometer open/short
26 Intake door potentiometer motor
3. Fault code display

(1) Continuance operation : DTC code is one
(2) Continuance operation : DTC code is more two
(3) Step operation

A. Nomal or one fault code is same a continuance operation.
B. DTC code is more two.
4. If fault codes are displayed during the check, Inspect malfunction causes by referring to fault codes.
5. Fail safe
(1) In-car temperature sensor: Control with the value of 25°C (77°F)
(2) Ambient temperature sensor: Control with the value of 20°C (67°F)
(3) Evaporator temperature sensor: Control with the value of -2°C (28.4°F)
(4) Water temperature sensor : Control with the value of -2°C (28.4°F)
(5) Photo sensor: Control with the value of ow/m!
(6) Temperature control actuator (Air mix potentiometer):
A. If temperature set 17°C-24.5°C, fix at maximum cooling position.
B. If temperature set 25°C-32°C, fix at maximum heating position.
(7) Mode control actuator (Direction potentiometer):
A. Fix fresh position, while selecting fresh mode.
B. Fix recirculation position, while selecting recirculation mode.
(8) Intake control actuator
A. Fix fresh position, while selecting fresh mode
B. Fix recirculation position, while selecting recirculating mode.
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REPLACEMENT
2. Remove the lower cover(A).
3. Remove the center facia (A) by pulling it using a screw driver (-). Avoid damaging retaining clips.
4. Disconnect the connectors (A) from the center facia.
5. Remove the A/C controller(A), from center facia.
6. Disconnect the connectors(A).
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7. Remove the heater & A/C controller (A) after loosening 4 screws.
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General Information

Identification Number Locations

Identification Number Description

Warning / Caution Label Locations

Battery Caution Label Describtion

Handling And Storage The Battery

Lift And Support Points

Tightening Torque Table Of Standartd Parts

M5 0.8 3 ~ 4 (30 ~ 40, 2.2 ~ 2.9) 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

General Service Information

Preparation Of Tools And Mesuring Equipment

3. Cleaning parts for reuse

Depending on their location.

Measuring Body Dimensiongs

Precautions For Catalytic Converter

1. Use only unleaded gasoline.

Engine Mechanical System

Flatness of manifold Intake Less than 0.15mm (0.0059in) 0.30mm (0.0118in)

Valve guide hole 0.05 OS 10.050 ~ 10.068mm (0.3957 ~ 0.3964in)

Thickness of Intake 0.8mm (0.0315in) 0.50mm (0.019in)

Valve stem to Intake 0.020 ~ 0.047mm (0.0008 ~ 0.0019in)

Cold (20°C) [68°F] Intake 0.15 ~ 0.21mm (0.0059 ~ 0.0083in)

Hot (80 ~ 95°C) Intake 0.22 ~ 0.28mm (0.0087 ~ 0.0110in)

COMPRESSION PRESSURE INSPECTION

(2) Fully open throttle.

(4) Repeat step (1) through (3) for each cylinder.

This measurement must be done in as short a time as possible.

5. Reinstall the spark plugs.

TIMING BELT TESION ADJUSTMENT

3. Temporarily loosen the water pump pulley (A) bolts.

9. Remove the drive belt pulley (B) and washer (A).

13. Adjust the timing belt tension.

A. Measuring belt length L : 24.9288 cm

Target value of timing belt tension (In cool condition) :

24. Install the RH under cover (A).

25. Install the RH front wheel.

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

Pulling or bending the cables may damage the conductor inside.

4. Inspection the valve clearance.

(4) If the adjustment is completed, tighten the lock nut.

SPECIAL SERVICE TOOLS

Crankshaft front oil seal Installation of the front oil seal

Camshaft oil seal installer Installation of the camshaft oil seal

Camshaft oil seal guide Installation of the camshaft oil seal

Valve spring lifer arm Removal and installation of the intake or

Valve spring lifter pivot Removal and installation of the intake or

Engine Mechanical System

3. Remove the RH front wheel.

5. Remove the engine mounting bracket.

6. Temporarily loosen the water pump pulley (A) bolts.

15. Remove the crankshaft position sensor target wheel (A).

16. Temporarily loosen the tensioner bolt (A).

18. Remove the crankshaft sprocket (A).

Do not bend, twist or turn the timing belt inside out.

6. Adjust the timing belt tension.

7. Use a SONIC TENSION GAUGE, measure the timing belt tension.

A. Measuring belt length L : 24.9288 cm

Target value of timing belt tension (In cool condition) :

14. Install the water pump pulley.

18. Install the engine mounting bracket.

19. Install the RH under cover (A).

20. Install the RH front wheel.

21. Install the cowl panel (A).

Cylinder Head Assembly