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CONTENTS
GENERAL INFORMATION................... SECTION 1A
ENGINE MECHANICAL ...................... SECTION 1B
ENGINE COOLING ............................... SECTION 1D
ENGINE ELECTRICAL ..........................SECTION 1E
ENGINE CONTROLS ............................ SECTION 1F
ENGINE INTAKE & EXHAUST ............. SECTION 1G
SECTION
1A
GENERAL
INFORMATION
1A-1
SECTION
00 1A
GENERAL INFORMATION
Table of Contents
DESCRIPTION AND OPERATION .................................. 1A-2
Cleanliness and care ................................................. 1A-2
On-engine service ..................................................... 1A-2
COMPONENT LOCATOR ............................................... 1A-3
Front view .................................................................. 1A-3
Side view .................................................................... 1A-4
DIAGNOSTIC INFORMATION AND PROCEDURE ....... 1A-5
Oil leak diagnosis ....................................................... 1A-5
Compression pressure test ....................................... 1A-6
Cylinder pressure leakage test ................................. 1A-8
General diagnosis .................................................... 1A-10
SPECIFICATIONS ......................................................... 1A-15
Engine specifications ............................................... 1A-15
Performance curve .................................................. 1A-16
SPECIAL TOOLS AND EQUIPMENT ........................... 1A-17
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1A-2
ON-ENGINE SERVICE
Caution
Disconnect the negative battery cable before removing
or installing any electrical unit, or when a tool or
equipment could easily come in contact with exposed
electrical terminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle.
The ignition must also be in LOCK unless otherwise
noted.
Notice
Any time the air cleaner is removed, the intake opening
should be covered. This will protect against accidental
entrance of foreign material, which could follow the
intake passage into the cylinder and cause extensive
damage when the engine is started.
Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or
other electrical parts.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-3
COMPONENT LOCATOR
FRONT VIEW
1. HFM sensor
9. Valve tappet
10. Injector
17. Starter
3. Resonance flap
18. Crankcase
5. Exhaust camshaft
6. Intake camshaft
7. Cylinder head
15. Crankshaft
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1A-4
SIDE VIEW
25. Piston
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-5
Gaskets
The fluid level/pressure is too high.
The crankcase ventilation system is malfunctioning.
The fasteners are tightened improperly or the
threads are dirty or damaged.
Powder Method
1. Clean the suspected area.
2. Apply an aerosol-type powder (such as foot powder)
to the suspected area.
3. Operate the vehicle under normal operating
conditoins.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the
white powder surface to the source.
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
Seals
The fluid level/pressure is too high.
The crankcase ventilation system is malfunctioning.
The seal bore is damaged (scratched, burred or
nicked).
The seal is damaged or worn.
Improper installation is evident.
There are cracks in the components.
The shaft surface is scratched, nicked or damaged.
A loose or worn bearing is causing excess seal wear.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1A-6
3. Adaptor
2. Diagram sheet
4. Sealing cone
M162 Engine
Compression ratio
10 : 1
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
80C (176F)
Normal
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-7
Tools Required
A9912 0012B
(001 589 76 21 00)
Measuring Procedure
1. Warm the engine up to normal operating temperature.
2. Remove the spark plugs using the spark plug wrench.
3. Place the diagram sheet to compression pressure
tester A9912 0012B (001 589 76 21 00).
4. Connect the adaptor to compression pressure tester
A9912 0012B (001 589 76 21 00) and install it into
the spark plug hole.
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1A-8
2. Vibration damper
Max. 25 %
Max. 10 %
Max. 20 %
OT (TDC)
a (120)
b (240)
1, 6
2, 5
3, 4
Universal Tool
Cylinder pressure leakage tester
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-9
Leakage Test
1. Warm the engine up to normal operating temperature.
2. Disconnect the negative battery cable.
3. Remove the spark plugs.
4. Check the coolant level by opening the coolant
reservoir cap and replenish if insufficient.
5. Open the engine oil filler cap.
6. Connect the tester to air pressure line and adjust the
scale of tester.
7. Install the connecting hose to spark plug hole.
8. Position the piston of No.1 cylinder at TDC by rotating
the crankshaft.
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1A-10
GENERAL DIAGNOSIS
Condition
Hard starting
(With normal
cranking)
Malfunction of
ignition system
Others
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AFFECTED VIN
Correction
Faulty fuse.
Malfunction of fuel
system
Lack of engine
power
Probable Cause
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-11
Rough engine
idling
Others
Dragging brakes.
Malfunction of fuel
system
Others
Others
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
Correction
Malfunction of fuel
system
Engine hesitate
(Upon pressing
accelerating
pedal, the engine
makes delayed
response This
situation is
remarkable when
cruising or
starting.)
Probable Cause
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1A-12
Overheat
Malfunction of
fuel system
Overtheated
engine
Malfunction of
fuel system
Malfunction of
ignition system
Others
Lack of coolant.
Refill coolant.
Refill oil.
Leakage of oil
Repair.
Malfunction of
ignition system
Malfunction of
cooling system
Malfunction of
lubrication
system
Other
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Correction
Decline of
compression
pressure
Others
Excessive
detonation
(According to the
opening range of
Malfunction of
metallic is made
with abnormal
explosion)
Probable Cause
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-13
Excessive
consumption of
engine oil
Malfunction of
fuel system
Malfunction of
ignition system
Malfunction of
cooling system
Others
Refill oil.
Leakage of
engine oil
Malfunction of
lubrication
system
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
Correction
Decline of
compression
pressure
Oil mixing in
combustion
chamber
Low oil
pressure
Probable Cause
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1A-14
Valve noise
CHANGED BY
AFFECTED VIN
Correction
Connecting rod
noise
Adjust or replace.
Crankshaft noise
EFFECTIVE DATE
Probable Cause
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-15
SPECIFICATIONS
ENGINE SPECIFICATIONS
Application
M162 Engine
M162.990
Engine model
Displacement
(CC)
3199
(mm)
89.9 x 84.0
MSE 3.63D
10 : 1
Compression ratio
Number of cylinders
DOHC
Chain-Driven
(ps/rpm)
220 / 6000
Max. torque
(kgm/rpm)
31.6 / 3900
Firing order
1-5-3-6-2-4
Ignition type
Ignition timing
Valve timing
Intake
Open/Close
ATDC 11 / ABDC 34
Exhaust
Open/Close
BBDC 31 / BTDC 14
Automatic control
(rpm)
(kg/cm)
(liter)
700 50
3~4
9
Forced by gear pump
Full flow with paper filter
Unleaded gasoline
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1A-16
PERFORMANCE CURVE
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-17
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-2
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
ENGINE ASSEMBLY
1. Engine assembly
Tools Required
A9946 0012A (000 589 40 37 00)
Hose Clamp
Oil Extractor
CHANGED BY
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AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-3
28 ~ 47 Nm
(21 ~ 35 lb-ft)
9 ~ 11 Nm
(80 ~ 97 lb-in)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-4
9. Disconnect the each connector.
(Electric fans, AQS sensor, ambient temperature switch,
receiver drier)
11. Disconnect the hoses from the radiator and remove the
cooling fan shroud.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
25 ~ 35 Nm
(18 ~ 26 lb-ft)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-5
13. Remove the radiator assembly.
40 ~ 50 Nm
(30 ~ 37 lb-ft)
20 ~ 30 Nm
(15 ~ 22 lb-ft)
21 ~ 25 Nm
(15 ~ 18 lb-ft)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-6
17. Separate the vacuum hose for brake booster.
18. Separate the other vacuum hoses.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-7
23. Disconnect the terminals from the alternator.
42 Nm (31 lb-ft)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
30 Nm (22 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-8
28. Remove the transmission mounting bolts and separate
the transmission from the engine.
Installation Notice
Tightening torque
54 ~ 68 Nm
(40 ~ 50 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-9
1. Poly V-belt
40.5 ~ 49.5 Nm
(29.9 ~ 36.5 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-10
5. Generator pulley
6. Idler
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-11
3. Pointed rib.
4. Belt cord visible in the base of rib.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-12
7. Rib detached from the base of belt.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-13
TENSIONING DEVICE
Preceding Work: Removal of poly v-belt
1. Belt (L = 2245)
4. Nut
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-14
40.5 ~ 49.5 Nm
(29.9 ~ 36.5 lb-ft)
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
26 ~ 32 Nm (19 - 24 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-15
1. Crankcase
4. Filter
5. Gasket
6. A/C bracket
A. Fresh air
8. Oil pan
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-16
Operation at Full-Load
The throttle valve (19) is fully opened.
All the blowby gases flow into the intake air duct (13) after
passing through the oil separator (15, 16) of the cylinder
head cover (14) when fully loaded. This dilluted air will be
supplied to the combustion chamber through the intake
manifold (12).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-17
ALTERNATOR
25 Nm (18 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-18
1. Vent hose
2. Bolt (M8 x 91, 2 pieces)
............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)
3. Power steering pump
4. Bolt (M8 x 105, 4 pieces)
............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)
5. Washer
6. A/C compressor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-19
40.5 ~ 49.5 Nm
(29.9 ~ 36.5 lb-ft)
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-20
5. Disconnect the vent hose from the A/C bracket.
Installation Notice
20 ~ 30 Nm
Tightening torque
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(15 ~ 22 lb-ft)
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-21
ENGINE MOUNT
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-22
70 Nm (52 lb-ft)
38 Nm (28 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-23
4. Spacer sleeve
5. Thrust piece
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-24
9 ~ 11 Nm
(80 ~ 97 lb-in)
9 ~ 11 Nm
(80 ~ 97 lb-in)
Unscrew the seven (M6 x 60) bolts and remove the spark
plug cover.
4. Unscrew all the bolts (2, 3) and remove the head cover
and the gasket.
Installation Notice
Tightening torque
9 ~ 11 Nm
(80 ~ 97 lb-in)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-25
2. Camshaft actuator
3. Upper guide rail
6. Front cover
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
9 ~ 11 Nm
(80 ~ 97 lb-in)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-26
2. Remove the cylinder head front cover (6).
Installation Notice
Tightening torque
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-27
CYLINDER HEAD
Preceding Work: Removal of cylinder head cover
Removal of cylinder head front cover
Removal of upper intake manifold
2nd step: 90
3rd step: 90
7. Dowel sleeve
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-28
Tools Required
A9913 0061B (116 589 01 34 00)
Threaded Pin
Sliding Hammer
(13 ~ 16 lb-ft)
2nd step: 90 5
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-29
6. Remove the guide rail fixing pin from the cylinder head
using the threaded pin A9913 0061B (116 589 01 34 00)
(1) and sliding hammer A9913 0080B (116 589 20 33 00)
(2).
2nd step: 90
3rd step: 90
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-30
OIL PAN
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-31
M8 X 40, 4 pieces
M6 X 85, 3 pieces
M6 X 35, 3 pieces
Others
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
M6 X 22, 6 pieces
M6 X 20, 28 pieces
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-30
OIL PAN
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-31
M8 X 40, 4 pieces
M6 X 85, 3 pieces
M6 X 35, 3 pieces
Others
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
M6 X 22, 6 pieces
M6 X 20, 28 pieces
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-32
2. A/C bracket
6. Seal
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
8. Roll pin
9. Bolt (M6 x 22, 6 pieces)
...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-33
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
Tightening torque
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 Ib-ft)
9 ~ 11 Nm
(80 ~ 97 Ib-ft)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-34
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4. Sleeve
5. Bolt (M6 x 85, 2 pieces)
...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
6. Washer
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-35
Tools Required
W9911 0020B (601 589 03 43 00) Crankshaft Rear Seal Installer
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
9 ~ 11 Nm
(80 ~ 97 lb-in)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-36
CRANKSHAFT ASSEMBLY
BELT PULLEY AND VIBRATION DAMPER
Preceding Work: Removal of cooling fan and viscous clutch
Removal of fan shroud
Removal of drive belt
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-37
Components
9. Crankshaft
4. Woodruff key
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
Radial Runout
0.6 mm
Axial Runout
0.6 mm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-38
Tools Required
A9910 0150B (602 589 00 40 00)
Engine Lock
2. Remove the start motor and install the engine lock A9910
0150B (602 589 00 40 00) to the flywheel ring gear.
3. Remove the vibration damper center bolt.
Installation Notice
1st step: 180 ~ 220 Nm
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-39
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-40
Tools Required
A9911 0060B (601 589 03 14 00)
Crankshaft Front Seal Installer
Replacement Procedure
1. Remove the radial seal with a screw driver.
Notice
Use a clean cloth not to damage the radial seal
mounting hole and the crankshaft.
2. Coat the radial sealing lip with engine oil.
3. Using the crankshaft front seal installer A9911 0060B
(601 589 03 14 00), assemble the radial seal.
4. Align the sleeve groove and the woodruff key and tighten
the center bolt until the center bolt and the damper disk
stop in the movement.
Installation Notice
1st step: 180 ~ 220 Nm
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-41
1. Special tool
2. Special tool
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-42
Tools Required
W9911 0020B (601 589 03 43 00)
Crankshaft Rear Seal Installer
Replacement Proceudre
1. Remove the radial seal with a screw driver.
Notice
Use a clean cloth not to damage the radial seal
mounting hole and the crankshaft.
2. Install the crankshaft rear seal installer W9911 0020B
(601 589 03 43 00) (2) to the crankshaft.
3. Apply the engine oil on the crankshaft rear seal installer
W9911 0020B (601 589 03 43 00) (2).
Notice
Do not use the grease.
4. Install the radial seal on the inner parts assembler.
5. Press in the crankshaft rear seal installer W9911 0020B
(601 589 03 43 00) (1) until the radial seal is stopped.
6. Check for leaks while operating the engine.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-43
CRANKSHAFT
Preceding Work: Removal of engine assembly
Removal of timing gear case cover
Removal of cylinder head
Removal of crankshaft sealing rear cover
Removal of oil pan
Removal of oil pump
Removal of baffle plate
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-44
A. Crankcase side
3. Crankshaft
D. Radial bearing
1 - 12
j1 - j7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-45
Color Dot Marking Crankshaft Journal Diameter (mm)
Blue
57.960 ~ 57.965
Yellow
57.955 ~ 57.960
Red
57.950 ~ 57.955
White
57.945 ~ 57.950
Violet
57.940 ~ 57.945
Blue
Yellow
Red
White
Violet
Service Data
Unit: mm
Crankshaft
Crankshaft
Connecting Rod
Crankshaft Standard
Thrust Washer
Bearing Journal
Journal Width Bearing Journal
and Repair Size
Thickness
Diameter
at fit bearing
Diameter
Standard size
57.950 ~ 57.965
57.700 ~ 57.715
57.450 ~ 57.465
57.200 ~ 57.215
56.950 ~ 56.965
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
2.15 or 2.20
2.25 or
2.35 or
2.40
24.50 ~ 24.533
47.94 ~ 47.96
Connecting Rod
Bearing Jourmal
Width
27.958 ~ 28.042
47.75
-
47.50
47.25
47.00
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-46
(37 ~ 44 lb-ft)
2nd step: 90
Notice
Make sure the crankshaft bearing cap properly
seated in place in the crankcase side. When perfectly
installed, the projected part (arrow) locates in the
left side (intake manifold side).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-47
Inspection
1. If the length L of the crankshaft bearing cap bolt exceeds
63.8 mm, replace it.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-48
Measuring Position
Gap (mm)
Static condition: 0.015 ~ 0.039
Radial
(NO. 1, 5, 7)
Axial
0.010 ~ 0.254
Static condition: 0.011 ~ 0.039
Radial
(NO. 3, 4, 6)
Axial
0.010 ~ 0.254
Measuring Position
Gap (mm)
Radial
0.030 ~ 0.050
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-49
CONNECTING ROD
Preceding Work: Removal of piston
5. Fit sleeve
2. Oil gallery
3. Balance weight
2nd step 90 + 10
145 0.05 mm
21.940 ~ 22.000 mm
21.940 ~ 22.000 mm
51.600 ~ 51.614 mm
24.500 ~ 24.571 mm
22.007 ~ 22.013 mm
0.007 ~ 0.018 mm
0.005 mm
Permissible twist of connecting rod bearing bore to connecting rod bushing bore
0.15 mm
Permissible deviation of axial paralleism of connecting rod bearing bore to connecting rod
0.07 mm
bushing core
Permissible deviation of connecting rod bearing bore from concentricity
0.01 mm
0.4 g
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-50
Inspection
1. Measure the basic bore of the connecting rod bearing.
Notice
If the basic bore exceeds the value of 51.614 mm,
replace the bearing or check the connecting rod.
51.7 ~ 52 mm
52.9 mm
Tightening torque
1st step: 40 + 5 Nm
(30 + 3.7 lb-ft)
2nd step: 90 + 10
Notice
If the length exceeds max. length, replace it.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-51
PISTON
Preceding Work: Removal of engine
Removal of cylinder head
Removal of oil pan
Removal of oil pump
Removal of baffle plate
4. Piston
2. Connecting rod
5. Snap ring
6. Piston pin
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-54
PISTON RING
Preceding Work: Removal of piston
5. Hook spring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-55
Replacement Procedure
1. Measure the piston rings gap.
Groove 1 0.20 ~ 0.40 mm
End Gap of the
Piston Ring
Gap between the
Piston and the
Piston Ring
Notice
If out of specification, replace the piston ring.
2. Remove the piston ring with a pliers.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-56
FLYWHEEL/DRIVEN PLATE
Preceding Work: Removal of manual or automatic transmission
4. Dowel pin
M x 1.5
When new
8.5 ~ 0.2 mm
Min. diameter
8.0 mm
When new
21.8 ~ 22.2 mm
Bolt length
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-57
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-58
Sectional View
1. Oil pan
8. Washer
2. Cover
9. Bolt
5. Crankshaft
12. Rivet
6. Dowel pin
13. Segment
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-64
(13 ~ 16 lb-ft)
2nd step: 90 5
(13 ~ 16 lb-ft)
2nd step: 90 5
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-65
CAMSHAFT
Preceding Work: Removal of cylinder head cover
Removal of cylinder head front cover
Removal of coolant connection fitting
6. Chain
7. Wrench
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-66
Tools Required
A9917 0012B (DW 110-120)
Holding Pin
Removal Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston
at BTDC 30.
2. Remove the Alternator.
3. Remove the chain tensioner. Refer to Chain Tensioner
in this section.
4. Remove the cylinder head front cover and the upper guide
rail.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-67
8. Unscrew the intake side bolts (8, 11, 13, 14) and the
exhaust side bolts (1, 4, 6, 7).
9. Loosen the remaining bolts and unscrew the intake and
exhaust side camshaft bearing cap bolts.
Notice
Number the camshaft bearing cap bolts when
removing them, so that they dont get mixed up.
10. Remove the intake and exhaust camshafts.
Installation Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston
at BTDC 30.
Notice
Turn the crankshaft in the direction of engine rotation.
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-68
4. Align the holes on intake and exhaust camshaft to the
hole on cylinder head. Insert the holding pin A9917 0012B
(DW 110-120) into the holes.
(13 ~ 16 lb-ft)
2nd step: 90 5
(2) : 72 ~ 88 Nm
(53 ~ 65 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-69
8. Rotate the crankshaft 2 revolutions and check followings:
- TDC of no. 1 cylinder: OT
- Alignment between camshaft adjustment hole and
cylinder head surface.
- Alignments between timing chain and sprocket
marks.
Notice
Turn the crankshaft in the direction of engine
rotation.
Read just if not aligned.
9. Install the upper guide rail and cylinder head front cover.
10. Install the Alternator.
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-70
5. Wrench
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-71
Tools Required
A9917 0012B (DW 110-120)
Holding Pin
Inspection
1. Position the No.1 cylinder piston to TDC (OT) by turning
the crankshaft.
Notice
When the OT mark on vibration damper is aligned
with timing gear case cover, the intake and exhaust
cam of cylinder will make the slope to the center and
will face up. In this way, the adjustment hole of the
intake and exhaust camshaft will match in line with
the cylinder head upper end, at 3 oclock, and 9
oclock direction each other.
2. Check the timing as below procedure;
- Check if the camshaft adjustment hole is positioned
to 3 oclock direction at the intake side and to 9
oclock direction at the exhaust side, respectively
and align with the cylinder head mating surface.
- At this condition, check if the OT mark on vibration
damper aligns with the marker on the timing gear
case.
Adjustment Procedure
1. Position the No.1 cylinder to BTDC 30.
2. Remove the chain tensioner.
3. Remove the exhaust camshaft sprocket.
4. Align the intake and exhaust camshaft flange hole with
the cylinder head upper surface.
Intake Side: 3 oclock direction
Exhaust Side: 9 oclock direction
5. Align the holes on intake and exhaust camshaft to the
hole on cylinder head. Insert the holding pin A9917 0012B
(DW 110-120) into the hole.
6. Secure the intake and exhaust camshaft.
7. Position the piston of No.1 cylinder at TDC (OT) by
turning the crankshaft.
8. Turn the camshaft adjuster of the intake camshaft to the
left as much as possible (cam adjuster retarded
position).
9. Install the chain to the intake camshaft sprocket.
Notice
Timing chain must be placed on the guide rail in
gear case cover.
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-72
10. Install the chain to the exhaust camshaft sprocket and
install it to the camshaft.
Installation Notice
1st step: 18 ~ 22 Nm
Tightening torque
(13 ~ 16 lb-ft)
2nd step: 90 5
Tightening torque
Screw plug
40 Nm (30 lb-ft)
Tensioner
assembly
72 ~ 88 Nm
(53 ~ 65 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-73
VALVE SPRING
Preceding Work: Removal of camshaft
Removal of spark plug
1. Valve cotter
2. Upper retainer
5. Lower retainer
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-74
Tools Required
A9917 0101B (111 589 01 59 00)
Supporting Bar
Lever Pusher
Thrust Piece
Engine Lock
Connecting Hose
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
Cylinder
OT
1, 6
120
2, 5
240
3, 4
Notice
Remove the valve spring only at TDC.
Always rotate the crankshaft by holding the chain
to prevent from timing chain damage and tangling,
and for smooth rotation.
3. Remove the valve tappet (1) using the valve tappet remover.
4. Install the connecting hose A9911 0012B (DW 110-090)
to the spark plug hole.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-75
5. Install the engine lock to the ring gear to prevent the
crankshaft from rotating.
6. Blow up with compressed air.
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-76
(d)
8.5
(D)
12.3
(a)
0.8 ~ 1.0
(B)
9.0
(H)
9.2 ~ 9.8
Valve Cotter
Size (mm)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-77
3. Protective sleeve
Tools Required
A9917 0171B (119 589 00 43 00)
Drift
Replacement Procedure
1. Remove the valve stem seal (2) using the pliers.
Notice
Check the valve stem seal for damage and replace if
necessary.
2. Coat the valve stem seal with oil and assemble it with
the protective sleeve.
3. Insert the valve stem seal by pressing it with the drift
A9917 0171B (119 589 00 43 00).
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-78
CHAIN TENSIONER
6. Thrust pin
2. Seal
3. Filler pin
4. Compression spring
5. Snap ring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-79
Removal Procedure
1. Position the No.1 cylinder to TDC (OT).
Notice
Remove the oil filler cap at adjustment position, and
check whether the intake camshaft cams lobe (arrow)
stays in the upper side.
2. Cover the generator with a clean cloth.
3. Release the tension by unscrewing the screw plug once.
Notice
In case that the tension is reduced by unscrewing the
screw plug, reinstall after completely removing the
chain tensioner. If the chain tensioner is tightened
again without completely reducing its tension, then
the detent spring doesnt return to the original
position and the tension gets exceeded.
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-80
Installation Procedure
1. Connect the thrust pin (6) and the snap ring (5) to the
chain tensioner housing (7).
Notice
When connecting the thrust pin, push in the thrust
pin far enough so that it doesnt protrude at the chain
tensioner housing.
2. Install the chain tensioner housing (7), thrust pin (6), snap
ring (5), and the seal (8).
Installation Notice
Tightening torque
72 ~ 88 Nm
(53 ~ 65 lb-ft)
3. Insert the compression spring (4) with the filler pin (3)
into chain tensioner housing.
4. Lightly apply the grease to the seal (2) and install the
screw plug (1).
Installation Notice
Specified value
40 Nm (30 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-81
Sectional View
1. Screw plug
14. Seal
3. Compression spring
4. Ball guide
5. Seal (aluminum)
17. Bolt/Washer
6. Filler pin
7. Compression spring
8. Snap ring
9. Thrust pin
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-82
TIMING CHAIN
Preceding Work: Removal of cylinder head cover
Removal of spark plug
1. Pin
5. Link
6. Center plate
7. Outer plate
4. Wedge
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-83
Tools Required
A9913 0010B (000 589 58 43 00)
Chain Assembly
Holding Pin
Replacement Procedure
1. Position the No.1 cylinder to TDC (OT).
5. Cover the chain housing with a clean cloth, and grind off
the timing chain pin from the intake camshaft sprocket
with the grinder.
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-84
6. Remove the outer plate (7) with the screw driver and
remove the link.
7. Connect the new timing chain (2) to the used timing chain
(3) with the link (5), center plate (6, thickness 1.6 mm),
and the outer plate (7).
8. Rotate the crankshaft in the direction if engine revolution
by pressing the new timing chain against the exhaust
camshaft sprocket to prevent it to be tangled.
Notice
Be sure to remove the wedge before cranking the
engine.
9. Take out the used timing chain out from the chain housing.
10. Connect both separators of the new timing chain with
the link (5) and the center plate (6).
11. Install the jaw (a) and the thrust piece (b) to the assembly
tool as shown in the figures.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-85
12. Place the outer plate (7, thickness 1.2 mm) inside the
thrust piece (b).
FUEL SYSTEM
M162 GSLENG SM - 2005.7
30 Nm (22 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-86
17. Rivet the link pin.
Check the condition and it again if necessary.
18. Install the chain tensioner.
Installation Notice
Tightening torque
Screw plug
40 Nm (30 lb-ft)
Tensioner
assembly
72 ~ 88 Nm
(53 ~ 65 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-87
TENSIONING RAIL
Preceding Work: Removal of timing gear case cover
1. Tensioning rail
2. Plastic guide
4. Guide rail
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-88
1. Chain tensioner
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Screw Plug
40 Nm (30 lb-ft)
Tensioner
72 ~ 88 Nm
Assembly
(53 ~ 65 lb-ft)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-89
1. Guide rail
2. Plastic guide
4. Tensioning rail
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-90
CRANKSHAFT SPROCKET
Preceding Work: Removal of oil pan
Removal of tensioning rail
Removal of crankcase guide rail
4. Crankshaft sprocket
8. Oil pump
5. Key
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-91
Tools Required
W9911 0050B (615 589 01 33 00) Crankshaft Sprocker Puller
29 ~ 35 Nm
(21 ~ 26 lb-ft)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-92
LUBRICATION SYSTEM
ENGINE OIL SPECIFICATION
2. Oil filter
4. Dipstick gauge
Specifications
Application
Capacity
Quality
Descrition
Min: 7.0L, Max: 9.0L
API SH or above grade
ACEA: A2 or A3
Approved oil by MB Sheet 229.1
Viscosity
Replacemant
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-93
REPLACEMENT
1. Install the socket wrench A9910 0050A (103 589 02 09
00) on the oil filter cover (2).
Notice
Tighten the bolts on the socket wrench to remove
the screw cover.
2. Set a wrench on the bolt on the top of socket wrench
and turn it to remove the oil filter cover.
3. Remove the oil filter element.
Notice
Wrap the used filter element with a shop cloth so
that the oil cannot drop on the floor.
4. Remove the drain plug (1) and drain the engine oil
completely.
Notice
To drain the oil easily, remove the oil filler cap (3).
5. Clean the drain plug and reinstall it.
Installation
Tightening torque
25 Nm
Notice
Replace the seal washer with new one.
6. Replace the O-ring (5) on the oil filter cover with new
one.
Notice
When replacing, apply the engine oil on the O-ring.
7. Insert new oil filter element into the oil filter housing.
8. Temporarily tighten the oil filter cover (2) by hands and
then tighten it with the socket wrench A9910 0050A
(103 589 02 09 00).
Installation
Tightening torque
25 Nm
9. Pour the engine oil through the engine oil filler hole.
10. Run the engine and check for oil leakage at normal
operating temperature.
11. Stop the engine and wait for 5 minutes. Check the oil
level and add if necessary.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-94
OIL CIRCULATION
1. Oil pump
3. Oil filter
9. Chain tensioner
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-95
Replacement Procedure
1. Install the oil filter remover A9910 0050A (103 589 02 09
00) on the oil filter cover.
Notice
Make the screw cover removable by tightening the
bolt at the side of the oil filter remover A9910 0050A
(103 589 02 09 00).
2. Install the wrench to the upper bolt in the oil filter remover
A9910 0050A (103 589 02 09 00) and remove the oil cover
by turning it.
3. Remove the oil filter element.
Notice
Work with a cloth under the vehicle when removing
the oil filter element to not drain the oil.
4. Remove the drain plug (1) and drain the engine oil.
Notice
Leave the oil filler cap open to ease the engine oil
discharge.
5. Tighten the engine oil drain plug after cleaning it.
Installation Notice
Tightening torque
25 Nm (18 lb-ft)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
25 Nm (18 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-96
9. Fill up engine oil through the engine oil filler opening (3).
10. Check for oil leaks at normal engine temperature after
starting the engine.
11. Stop the engine and wait 5 minutes.
Check the oil level and fill up as specified if necessary.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-97
OIL FILTER
Preceding Work: Removal of starter motor
Removal of upper intake manifold
1. Coolant line
6. Oil filter
3. Clip
4. Hose
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-98
3. Remove the oil filter bolt and then remove the oil filter.
Installation Notice
Tightening torque
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-99
OIL PUMP
Preceding Work: Removal of oil pan
29 ~ 35 Nm
(21 ~ 26 lb-ft)
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
Tighten the baffle plate and the oil pump with the two
bolts in right side first, and then tighten the other bolt.
3. Remove the oil pump and oil strainer assembly.
4. Replace the strainer in oil pump if necessary.
5. Installation should follow the removal procedure in the
reverse order.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-100
3. Guide pin
2. Compression spring
4. Piston
50 Nm (37 lb-ft)
2. Remove the spring (2), guide pin (3) and the piston (4).
3. Installation should follow the removal procedure in the
reverse order.
Notice
Dont use the seal for the screw plug.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-101
Functions
The non-return valve prevents the oil in the chain
tensioner from drying up. In other words, it stops
oil-returning in order to prevent the oil in the chain
tensioner from getting dry. As a result, the chain
tensioner can be activated with oil in itself.
Replacement Procedure
1. Remove the non-return valve using a pliers.
2. Insert new non-return valve with hand.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-102
3. O-ring
9 ~ 11 Nm
(80 ~ 97 lb-in)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-103
UNIT REPAIR
OIL GALLERY IN CRANKCASE
Preceding Work: Removal of crankshaft
Removal of oil spray nozzle
1. Plug
2. Steel ball
Cleaning Procedure
1. Remove the plug (1) with a screwdriver.
2. Using a round bar (3) and hammer, remove the steel ball
(2).
3. Using the compressed air, blow into the oil galleries and
clean it off.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-104
2. -
5. Screw plug
3. -
Tools Required
A9911 0050B (102 589 12 15 00)
Drift
Sealing Procedure
1. Enlarge the end of main oil gallery (4) to be diameter of
16 mm, depth of 15 mm.
2. Using an M16 x 1.5 thread (tap), make the thread at the
end of main oil gallery (4).
3. Throughly clean the oil gallery with compressed air and
tighten the screw plug (M16 x 1.5) after applying sealing
bond on it.
4. Apply Loctite 270 on new plug and tighten to the hole
until the drift A9911 0050B (102 589 12 15 00) is stopped
after inserting new plug into the drift.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-105
2. Seal
Cleaning Procedure
1. Remove the screw plug (1) and the seal (2).
Installation
Tightening torque
15 Nm (11 lb-ft)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-106
Sealing Procedure
1. Remove the screw plug (1) and the seal.
Installation
Tightening torque
15 Nm (11 lb-ft)
2. Remove the steel ball from the oil gallery (4), (5), (6) and
(7) using the round bar (12, 6 x 700 mm).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-107
8. Make a screw hole at the oil gallery using M10 x 1 thread.
9. All the oil gallery should be cleaned with the compressed air.
10. Apply the Loctite 270 to new plug and press in using a suitable
drift (arrow).
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-108
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-109
Tools Required
W9911 0010B (102 589 00 15 00)
Drift
Replacement Procedure
1. Remove the intake and exhaust manifolds.
2. Pull back the core plug until the end of one side comes
out using the screw driver.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-110
CYLINDER BORE
A or X
A, X or B
89.906 ~ 89.912
X or B
89.912 ~ 89.918
X+5
X+5
89.950 ~ 89.968
X + 10
X + 10
90.000 ~ 90.018
Type
89.906 ~ 89.912
89.912 ~ 89.918
90.150 ~ 90.156
89.156 ~ 90.162
90.162 ~ 90.168
90.400 ~ 90.406
90.406 ~ 90.412
90.412 ~ 90.418
Repair Size
1)
The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-111
0.1 mm
When new
0.007 mm
Wear limit
0.05 mm
0.05 mm
0.003 ~ 0.006 mm
Chamfer angle
60
Honing angle
50 10
Chamfer Angle
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-112
281.95 mm
0.03 mm
0.04 mm
Axial direction
0.1 mm
Transverse direction
0.05 mm
Peak-to-valley height
0.005 ~ 0.020 mm
0.025 mm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-113
Chamfering Procedure
1. Chamfer angle : 60
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-114
135.5 mm
Axial direction
0.08 mm
Transverse direction
0.0 mm
Standard size
Repair size
Intake
24.21 ~ 24.75 mm
Exhaust
22.21 ~ 22.75 mm
Intake
23.96 ~ 24.51 mm
Exhaust
21.96 ~ 22.51 mm
Notice
Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-115
Universal Tool
Sceledum, Type RTY
Surface Grinding Machine
Roaro
Schio/Italy
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-116
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Nm
Lb-Ft
Lb-In
22.5 ~ 27.5
16.6 ~ 20.3
35
26
40.5 ~ 49.5
29.9 ~ 36.5
9 ~ 11
80 ~ 97
60 ~ 70
44 ~ 52
22.5 ~ 27.5
16.6 ~ 20.3
72 ~ 88
53 ~ 65
40
30
40 + 5
30 + 3.7
90 + 10
90 + 10
22.5 ~ 27.5
16.6 ~ 20.3
50 ~ 60
37 ~ 44
90 + 5
90 + 5
9 - 11
80 ~ 97
30
22
55
41
+90
+90
+90
+90
9 ~ 11
80 ~ 97
22.5 ~ 27.5
16.6 ~ 20.3
70
52
18 ~ 22
13 ~ 16
90 5
90 5
30
22
45 + 5
33 + 3.7
90 + 10
90 + 10
21 ~ 25
15 ~ 18
25
18
9 ~ 11
80 ~ 97
18 ~ 22
13 ~ 16
90 5
90 5
38
28
9 ~ 11
80 ~ 97
22.5 ~ 27.5
16.6 ~ 20.3
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-117
Nm
Lb-Ft
Lb-In
22.5 ~ 27.5
16.6 ~ 20.3
25
18
15
11
M10
40
30
M8
22.5 ~ 27.5
16.6 ~ 20.3
M6
9 ~ 11
80 ~ 97
50
37
29 ~ 35
21 ~ 26
22.5 ~ 27.5
16.6 ~ 20.3
29 ~ 35
21 ~ 26
9 ~ 11
80 ~ 97
22.5 ~ 27.5
16.6 ~ 20.3
26 ~ 32
19 ~ 24
M8
22.5 ~ 27.5
16.6 ~ 20.3
M6
9 ~ 11
80 ~ 97
42
31
54 ~ 68
40 ~ 50
Under cover
28 ~ 47
21 ~ 35
70
52
180 ~ 220
133 ~ 162
90 + 10
90 + 10
22.5 ~ 27.5
16.6 ~ 20.3
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-118
000 589 58 43 00
Chain Assembly
Supporting Bar
Drift
Lever Pusher
Drift
Thrust Piece
Threaded Pin
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-119
Drift
Engine Lock
Connecting Hose
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-120
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-1
SECTION
00 1D
ENGINE COOLING
Table of Contents
DESCRIPTION AND OPERATION ......... 1D-2
General description ..........................
Radiator ............................................
Coolant reservoir ..............................
Thermostat ........................................
Water pump .......................................
Electric cooling fan ...........................
A/C Off or Non-AC model .................
A/C On ..............................................
Engine coolant temperature sensor .
Coolant temperature gauge .............
1D-2
1D-2
1D-2
1D-2
1D-3
1D-3
1D-3
1D-3
1D-3
1D-3
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-2
RADIATOR
This vehicle has a lightweight tube-and-fin aluminum
radiator. Plastic tanks are mounted on the upper and the
lower sides of the radiator core.
THERMOSTAT
A wax pellet-type thermostat controls the flow of the engine coolant through the engine cooling system. The thermostat is mounted in the thermostat housing to the front
of the cylinder head.
The thermostat stops the flow of the engine coolant from
the engine to the radiator to provide faster warm-up, and
to regulate the coolant temperature. The thermostat remains closed while the engine coolant is cold, preventing
circulation of the engine coolant through the radiator. At
this point, the engine coolant is allowed to circulate only
throughout the heater core to warm it quickly and evenly.
As the engine warms, the thermostat opens. This allows
the engine coolant to flow through the radiator where the
heat is dissipated. This opening and closing of the thermostat permits enough engine coolant to enter the radiator to keep the engine within proper engine temperature
operating limits.
The wax pellet in the thermostat is hermetically sealed in
a metal case. The wax element of the thermostat expands when it is heated and contracts when it is cooled.
COOLANT RESERVOIR
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-3
WATER PUMP
The belt-driven centrifugal water pump consists of an
impeller, a drive shaft, and a belt pulley.
The impeller is supported by a completely sealed bearing.
The water pump is serviced as an assembly and, therefore, cannot be disassembled.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
A/C ON
The ECM will turn the cooling fans on at low speed
when the A/C system is on. The ECM will change to
high speed when the high side A/C pressure reaches
1860 kPa (269.8 psi).
The cooling fans will return to low speed when the
high side A/C pressure reaches 1378 kPa (199.8 psi).
COOLANT TEMPERATURE
GAUGE
The coolant temperature gauge controls the instrument
panel temperature indicator. The coolant temperature
gauge is located with ECT sensor.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-4
COMPONENT LOCATOR
GASOLINE ENGINE
1. Radiator
19. Clamp
2. Electric fan
20. Clamp
3. Shroud
4. Deaeration tube
13. Plate
5. Clamp
14. Clip
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-5
Action
Check the front of the radiator for any dirt, any leaves,
or any insects.
Check for leakage from the hoses, the water pump, the
heater, the thermostat housing, the radiator, the core
plugs, or the head gasket.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-6
Loss of Coolant
Checks
Action
Coolant reservoir.
Coolant reservoir.
Hose.
Hose.
Intake manifold.
Action
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-7
Test Procedure
1. Loosen the cap a little and release pressure and remove
the cap.
Notice
For the risk of scalding, cap must not be opened unless
the coolant temperature is below 90 C (194 F).
2. Fill coolant up to upper edge (arrow) of reservoir.
3. Connect the leakage tester A9921 0012A (124 589 15 21
00) to the reservoir filler cap and apply 1.4 bar of pressure.
4. If the pressure on the tester drops, check leakage at the
all coolant hoses and pipes and each connections.
Replace or retighten if necessary.
THERMOSTAT TEST
Test Procedure
1. Remove the thermostat from the vehicle. Refer to
Thermostat in this section.
2. Make sure the valve spring is tight when the thermostat
is closed. If the spring is not tight, replace the thermostat.
3. Suspend the thermostat and a thermometer in a pan of
50/50 mixture of ethylene glycol and water. Do not let
the thermostat or the thermometer rest on the bottom of
the pan. The uneven concentration of heat on the bottom
could result in inaccurate temperature measurements.
4. Heat the pan on a burner.
5. Use the thermometer to measure the temperature of the
heated solution.
6. The thermostat should begin to open at 82C (180F)
and it should be fully be fully open at 95C (203F).
If it does not open at these temperatures, replace the
thermostat.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-8
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
COOLANT DRAIN AND FILL UP
Draining & Filling up Procedure
1. Loosen the cap a little and release pressure and remove
the cap.
Notice
For the risk of scalding, the cap must not be opened
unless the coolant temperature is below 90C (194F).
2. Loosen the radiator hose and drain the coolant.
Notice
Collect coolant by using a proper container.
30 Nm (22 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-9
6. Remove the de-aeration hose clamp in the coolant pump
and remove the de-aeration hose.
7. Fill up the coolant through the coolant reservoir tank.
Notice
Match the anti-freeze and the water ratio to
50 : 50.
Supplement the coolant until the coolant overflows
to the de-aeration hose.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-10
4. O-ring
5. Hose mounting clamp
6. Hose
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-11
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-12
WATER PUMP
Preceding Work: Removal of V-belt
Removal of air admission housing
8. Coolant hose
5. Coolant hose
6. Coolant hose
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-13
9 ~ 11 Nm
(80 ~ 97 lb-in)
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-14
9 ~ 11 Nm
(80 ~ 97 lb-in)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-15
THERMOSTAT
1. Thermostat cover
2. Thermostat
3. O-ring
7. Heater hose
9 ~ 11 Nm
(80 ~ 97 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-16
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-17
Tools Required
A9910 0150A (603 589 00 40 00)
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
9 ~ 11 Nm
(80 ~ 97 lb-in)
4. Hold the cooling fan pulley using the fan clutch holder
A9910 0150A (603 589 00 40 00).
40.5 ~ 49.5 Nm
(29.8 ~ 36.5 lb-ft)
Important
There are two chambers in the viscous clutch. Be
sure to make the viscous clutch stand on the ground
not to flow silicone oil into another chamber in the
viscous clutch. Do not lay down the clutch.
6. Installation should follow the removal procedure in the
reverse order.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-18
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-19
3 ~ 7 Nm
(27 ~ 62 lb-in)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-20
RADIATOR
Preceding Work: Removal of cooling fan shroud
1. Deaeration hose
2. Radiator
6. Plate
3. Inlet hose
7. Clip
4. Bolt
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-21
25 ~ 35 Nm
(18 ~ 26 lb-ft)
3 ~ 7 Nm
(27 ~ 62 lb-in)
3 ~ 7 Nm
(27 ~ 62 lb-in)
30 ~ 40 Nm
(22 ~ 30 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-22
SPECIFICATION
GENERAL SPECIFICATIONS
Application
Unit
Gasoline Engine
Cooling system
Type
Coolant
Capacity
11.3
Thermostat
Type
C (F)
82 (180)
C (F)
95 (203)
C (F)
80 (176)
mm
Type
Electric cooling
Blades
mm
320
C (F)
95 (203)
C (F)
90 (194)
C (F)
105 (221)
C (F)
100 (212)
kPa (psi)
269.8 (1860)
kPa (psi)
kPa (psi)
9.8 (1.4)
Turbo centrifugal
mm
65
Impeller blades
Type
Cross-flow
Core width
mm
701
Core height
mm
372
Core thickness
mm
18
Kcal/h
45,000
185.2
47.4
Stroke
Cooling fan
Diameter
Coolant reservoir
Water pump
Type
Impeller diameter
Radiator
Coolant temperature
gauge
28.2
Engine coolant
temperature sensor
3.33 ~ 37.8
0.32 ~ 0.35
Anti-freeze agent
Type
ALUTEC-P78
50 : 50
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-23
Nm
Lb-Ft
Lb-In
20
15
3~7
27 ~ 62
30
22
9 ~ 11
80 ~ 97
3~7
27 ~ 62
22.5 ~ 27.5
16.6 ~ 20.3
3~7
27 ~ 62
9 ~ 11
80 ~ 97
40.5 ~ 49.5
29.8 ~ 36.5
22.5 ~ 27.5
16.6 ~ 20.3
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-24
Holder
Leakage Tester
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1F-1
SECTION
00 1F
ENGINE CONTROLS
Table of Contents
ENGINE AND ECM PROBLEM CHECK
REPORT ................................................. 1F-3
Vehicle and customer information ..... 1F-3
Mil information .................................... 1F-3
Problem description ........................... 1F-3
Condition when problem occurs ........ 1F-3
DIAGNOSTIC INFORMATION AND
PROCEDURE ......................................... 1F-4
Failure code diagnosis ...................... 1F-4
IGNITION SYSTEM ................................ 1F-8
Ignition coil ......................................... 1F-9
Crankshaft position (CKP) sensor ... 1F-11
Camshaft position (CMP) sensor..... 1F-14
Camshaft actuator ........................... 1F-18
Knock Sensor (KS) .......................... 1F-20
Spark plug ........................................ 1F-22
System voltage ................................ 1F-24
Ignition switch ................................... 1F-25
FUEL SYSTEM ..................................... 1F-26
Fuel pump ........................................ 1F-27
Fuel injector ..................................... 1F-30
Purge control valve .......................... 1F-34
Fuel rail ............................................ 1F-36
Fuel pressure regulator ................... 1F-38
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-2
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-3
Vehicle Model
Driver Name
VIN
Purchase date
Engine Model
License No.
Mileage
Km
miles
MIL INFORMATION
Condition of MIL
Remains on
Sometimes illuminates
DTC inspection
Normal
(if available)
PROBLEM DESCRIPTION
Engine Does Not Start
No cranking
Hard to Start
Slow cranking
No initial combustion
No complete combustion
Others
Poor Idling
High (rpm)
Low (rpm)
Hesitation
Back fire
Surging
Knocking
Poor performance
Other
Shifting from N to D or D to N
At full steering Others
Others
Fine
Weather
Hot
Warm
Ambient Temperature
Highway
Suburbs
Place
Rough Road
Others
Cold
Warming Up
Any temp.
Others
Starting
Engine Temperature
Engine Operation
Constant speed
Acceleration
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
Cool
Cold (approx.____F/____C)
Inner City
Uphill Downhill
Before warming up
Idling
After warm-up
Racing
Deceleration
Other
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Driving
1F-4
Description
00
1F-56
01
1F-56
02
1F-56
03
1F-52
04
1F-52
05
1F-52
06
1F-56
08
1F-28
09
1F-52
10
1F-52
11
1F-52
17
1F-13
18
1F-13
19
1F-17
20
1F-13
21
1F-79
23
1F-77
24
1F-77
25
1F-82
26
1F-77
27
1F-78
29
1F-78
30
1F-78
31
1F-78
32
1F-68
33
1F-68
34
1F-33
35
1F-33
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-5
Description
40
1F-41
41
1F-41
44
1F-62
45
1F-62
54
1F-41
56
1F-23
57
1F-23
58
1F-17
59
1F-78
60
1F-78
62
1F-61
64
1F-11
65
1F-11
66
1F-11
67
1F-13
68
1F-25
Random/Multiple Misfire
71
1F-29
72
1F-37
73
1F-37
74
1F-37
75
1F-37
76
1F1-37
77
1F-38
78
1F-38
79
1F-38
80
1F-72
81
1F-73
Bank 1 system short term fuel trim adaptation below lean threshold
82
1F-72
83
1F-72
84
1F-72
85
1F-72
86
1F-72
87
1F-72
89
1F-72
93
1F-73
Bank 1 system short term fuel trim adaptation above rich threshold
96
1F-73
97
1F-73
98
1F-73
99
1F-73
100
1F-73
101
1F-73
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-6
Description
102
1F-73
103
1F-73
104
1F-47
105
1F-47
108
1F-47
109
1F-47
110
1F-80
116
1F-47
117
1F-80
119
1F-47
120
1F-80
121
1F-47
122
1F-59
123
1F-47
Different Mass air flow sensor signal with throttle position sensor
125
1F-47
126
1F-48
127
1F-48
129
1F-64
130
1F-64
131
1F-64
132
1F-64
133
1F-64
134
1F-64
135
1F-67
136
1F-79
137
1F-79
138
1F-80
Call monitoring
139
1F-80
140
1F-80
141
1F-82
142
1F-79
Uncoded/unprogramed ECU
143
1F-79
144
1F-79
145
1F-79
146
1F-79
150
1F-65
151
1F-65
160
1F-59
161
1F-59
162
1F-59
163
1F-59
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-7
Description
164
1F-59
Accelerator pedal position sensor 1 not plausible with pedal position sensor 2
167
1F-59
185
1F-48
186
1F-80
187
1F-80
188
1F-80
189
1F-80
190
1F-80
192
1F-38
193
1F-38
194
1F-38
195
1F-38
198
1F-66
199
1F-66
226
1F-21
227
1F-21
228
1F-63
229
1F-63
231
1F-80
232
1F-80
233
1F-80
234
1F-80
235
1F-80
236
1F-80
237
1F-80
238
1F-80
239
1F-81
240
1F1-81
241
1F-81
242
1F-81
243
1F-81
244
1F-81
Accelerator pedal position sensor setpoint fault between CPU 1 and CPU 2
245
1F-81
246
1F-81
247
1F-81
248
1F-81
249
1F-81
250
1F-81
251
1F-85
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-8
IGNITION SYSTEM
This ignition system does not use a conventional distributor and coil. It uses a crankshaft position sensor input to the Engine Control Module (ECM). The ECM then
determines Electronic Spark Timing (EST) and triggers
the electronic ignition system ignition coil.
This type of distributorless ignition system uses a waste
spark method of spark distribution. Each cylinder is paired
with the cylinder that is opposite it (1-6 or 2-5 or 3-4). The
spark occurs simultaneously in the cylinder coming upon
the compression stroke and in the cylinder coming up on
the exhaust stroke. The cylinder on the exhaust stroke
requires very little of the available energy tofire the spark
plug. The remaining energy is available to the spark plug
in the cylinder on the compression stroke.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
These systems use the EST signal from the ECM to control the EST. The ECM uses the following information:
Engine load (mass air flow sensor).
Engine temperature.
Intake air temperature.
Crankshaft position.
Engine speed (rpm).
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-9
IGNITION COIL
4. Coupling plug
The Electronic Ignition (EI) system ignition coil is located on the cylinder head cover. The double ended coils receive the
signal for the Engine Control Module (ECM) which controls the spark advance.
Each EI system ignition coil provides the high voltage to two spark plugs simultaneously;
T1/1: cylinder 2 and 5
T1/2: cylinder 3 and 4
T1/3: cylinder 1 and 6
The EI system ignition coil is not serviceable and must be replaced as an assembly.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-10
Failure Code
Description
64
No ignition voltage
output
(No. 1 ignition coil)
Trouble Area
Maintenance Hint
Inspection the ECM pin 70 (71 and 72)
about short circuit or open with bad
contact
Inspection the power source to ignition
65
No ignition voltage
output
(No. 2 ignition coil)
66
No ignition voltage
output
(No. 3 ignition coil)
Malfunction of ignition
circuit Primary current
values or secondary
short circuit
Circuit Description
The Electronic Ignition (EI) system uses a waste spark method of spark distribution. The Crankshaft Position (CKP)
sensor sends reference pulses to the ECM. The ECM then triggers the EI system ignition coils. Once the ECM triggers
the EI system ignition coils both of the connected spark plugs fire at the same time. One cylinder is on its compression
stroke at the same time that the other is on the exhaust stroke, resulting in lower energy needed to fire the spark plugin
the cylinder on its exhaust stroke.
This leaves there remainder of the high voltage to be used to fire the spark plug in the cylinder on its compression stroke.
Since the CKP sensor is in a fixed position, timing adjustments are not possible or needed.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-11
3. Segment
2. Bolt
4. Flywheel
This Electronic Ignition (EI) system uses inductive or pick up type magnetic Crankshaft Position (CKP) sensor. The
CKP sensor is located in the opposite side of the crankshaft pulley and triggers the pick-up wheel teeth which is
equipped 60 - 2 teeth with a gap of 2 teeth at 360 degree spacing. This sensor protrudes throughits mount to within 1.1
0.14 mm.
The output of the sensor is a sinusoidal signal. Each tooth of the pick-up 60 - 2 wheel generates a positive half wave.
The Engine Control Module (ECM) uses this sensor signal to generate timed ignition and injection pulses that it sends
to the ignition coils and to the fuel injectors.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-12
Failur Code
Description
Trouble Area
Maintenance Hint
17
Crankshaft position
sensor signal failure (no
engine revolution signal)
18
Crankshaft position
sensor signal failure
(rpm > max. value)
Crankshaft position
sensor signal failure
(gap recognition failure)
Crankshaft position
sensor adaptation failure
20
67
Circuit Description
The 58X reference signal is produced by the CKP sensor. During one crankshaft revolution, 58 crankshaft pulses will be
produced. The ECM uses the 58X reference signal to calculate engine rpm and CKP. The ECM constantly monitors the
number of pulses on the 58X reference circuit and compares them to the number of Camshaft Position (CMP) signal pulses
being received. If the ECM receives and incorrect number of pulses on the 58X reference circuit, this failure code will set.
1,050 ~ 1,400
Notice
Measure the insulator resistance of the CKP sensor if out of the specified value.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-13
>20 k
Notice
Measure the check and ground terminal of the CKP
sensor if out of the specified value.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-14
2. Bolt
4. O-ring
The Camshaft Position (CMP) sensor sends a CMP signal to the Engine Control Module (ECM). The ECM uses this
signal as a synchronized pulse to trigger the injectors in the proper sequence. The ECM uses the CMP signal to
indicate the position of the #1 piston during its power stroke. This allows the ECM to calculate true sequential fuel
injection mode of operation.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-15
Failur Code
Description
Trouble Area
19
Camshaft position
sensor signal : No. 1
cylinder recognition
failure
58
Camshaft position
sensor signal : No. 1
cylinder synchronization failure
Maintenance Hint
Inspection the source voltage of
CMP sensor
Inspection the ECM pin 106, 104
about short circuit or open with
bad contact
Inspection the CMP sensor
Inspection the damage of sensor
or sprocket
Inspection the ECM
Circuit Description
The CMP sensor sends a cam position signal to the ECM. If the cam position signal is lost while the engine is running,
the fuel injection system shifts to a calculated sequential fuel injection mode based on the last fuel injection pulse, and
the engine continuous to run.
1.2 ~ 1.7V
Notice
The signal voltage will be changed in the range of 1.2 ~ 1.7V.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-16
11 ~ 14V
Notice
If the measured value is not within the specified value,
check the cable.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-18
CAMSHAFT ACTUATOR
1. Bolt
4. Armature
2. Camshaft actuator
5. Roll pin
3. Bolt
6. Nut
When the engine is running, the camshaft actuator rotates the intake camshaft hydraulically and mechanically relative
to the camshaft sprocket by 32 crank angle to the advanced position and back to the retard position.
The camshaft actuator is actuated electro-mechanically by the Engine Control Module (ECM).
The positioning time of apporx. 1 second is dependent on the engine oil pressure at the camshaft actuator and on the oil
viscosity and oil temperature, respectively.
The camshaft indicator on the camshaft sprocket provides the camshaft rotational speed to the position sensor as an
input parameter for the engine ignition control unit.
Camshaft Position
Effect
Engine stop
Retard
0 ~ 1,500 rpm
Retard
Advanced
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Retard
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-19
Failur Code
Description
Trouble Area
226
Camshaft actuator
short circuit to ground
or open
227
Maintenance Hint
1 ~ 1.5 A
Notice
If the measured value is not within the specified value, check the cable.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-20
The Knock Sensor (KS) detects abnormal knocking in the engine. The two KS are mounted in the engine block near the
cylinders. The sensors produce an output voltage which increases with the severity of the knock. This signal is sent to
the Engine Control Module (ECM) via a shielded cable. The ECM then adjusts the ignition timing to reduce the spark
knock.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-21
Failur Code
56
Description
Trouble Area
Maintenance Hint
57
Circuit Description
The KS system is used to detect engine detonation, allowing the ECM to retard the ignition control spark timing based
on the KS signal being received. The KS signals amplitude and frequency depend upon the amount of knock being
experienced. The ECM monitors the KS signal and can diagnose the KS sensor and circuitry.
>10 M
Notice
Replace the KS if the measured values is out of the specified values. Check the connector and wire connection
between ECM and the KS if the measured values are normal.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-22
SPARK PLUG
2. Bolt
3. Spark plug
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-23
Failur Code
Description
Random / Multiple
Misfire
68
Trouble Area
Maintenance Hint
Circuit Description
The ECM monitors the crankshaft and camshaft positions to detect if the engine is misfiring. The ECM looks for a quick
drop in crankshaft speed. Misfire multiple cylinder is monitored by engine roughness measuring. The actual roughness
value is compared with the actual (emission and catalyst damage) threshold.
1.8 ~ 2.2 k
Notice: Replace the spark plug cable if the measured values is out of the specified values.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-24
SYSTEM VOLTAGE
Failur Code
Description
Trouble Area
Maintenance Hint
Monitoring the actual battery
voltages through the scan tool
08
Malfunction in recognition of
system source voltage. Less
than minimum 8 volts in
2,000 rpm below, or less than 10
volts in 2,000 rpm above.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-25
IGNITION SWITCH
Failur Code
Description
Trouble Area
71
Starter signal
recognition failure
Maintenance Hint
Inspection the Engine Control
Module (ECM) pin 2 circuit short
or open with bad contact
Inspection ECM
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-26
FUEL SYSTEM
The function of the fuel metering system is to deliver the correct
amount of fuel to the engine under all operating conditions.
The fuel is delivered to the engine by the individual fuel injectors mounted into the intake manifold near each cylinder.
The main fuel control sensors are the Mass Air Flow (MAF)
sensor and the oxygen (O2) sensors.
The MAF sensor monitors the mass flow of the air being
drawn into the engine. An electrically heated element is
mounted in the intake air stream, where it is cooled by the
flow of incoming air. Engine Control Module (ECM) modulates the flow of heating current to maintain the temperature
differential between the heated film and the intake air at a
constant level. The amount of heating current required to
maintain the temperature thus provides an index for the mass
air flow. This concept automatically compensates for variations in air density, as this is one of the factors that determines the amount of warmth that the surrounding air absorbs from the heated element. MAF sensor is located between the air filter and the throttle valve.
Under high fuel demands, the MAF sensor reads a high
mass flow condition, such as wide open throttle. The ECM
uses this information to enrich the mixture, thus increasing the fuel injector ontime, to provide the correct amount
of fuel. When decelerating, the mass flow decreases. This
mass flow change is sensed by the MAF sensor and
read by the ECM, which then decreases the fuel injector
ontime due to the low fuel demand conditions.
The O2 sensors are located in the exhaust pipe before
catalytic converter. The O2 sensors indicate to the ECM
the amount of oxygen in the exhaust gas, and the ECM
changes the air/fuel ratio to the engine by controlling the
fuel injectors. The best air/fuel ratio to minimize exhaust
emissions is 14.7 to 1, which allows the catalytic converter to operate most efficiently. Because of the constant measuring and adjusting of the air/fuel ratio, the
fuel injection system is called a closed loop system.
The ECM uses voltage inputs from several sensors to determine how much fuel to provide to the engine. The fuel is
delivered under one of several conditions, called modes.
Starting Mode
When the ignition is turned ON, the ECM turns the fuel
pump relay on for 1 second. The fuel pump then builds
fuel pressure. The ECM also checks the Engine Coolant
Temperature (ECT) sensor and the Throttle Position (TP)
sensor and determines the proper air/fuel ratio for starting the engine. This ranges from1.5 to 1 at
-36C (-33F) coolant temperature to 14.7 to 1 at
94C (201F) coolant temperature. The ECM controls the
amount of fuel delivered in the starting mode by changing
how long the fuel injector is turned on and off. This is
done by pulsing the fuel injectors for very short times.
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AFFECTED VIN
Run Mode
The run mode has two conditions called open loop and
closed loop.
Open Loop
When the engine is first started and it is above 690 rpm,
the system goes into open loop operation. In open loop,
the ECM ignores the signal from the O2S and calculates
the air/fuel ratio based on inputs from the ECT sensor
and the MAF sensor. The ECM stays in open loop until
the following conditions are met:
The O2 has a varying voltage output, showing that it
is hot enough to operate properly.
The ECT sensor is above a specified temperature (22.
5C).
A specific amount of time has elapsed after starting
the engine.
Closed Loop
The specific values for the above conditions vary with different engines and are stored in the Electronically Erasable programmable Read-Only Memory (EEPROM).
When these conditions are met, the system goes into
closed loop operation. In closed loop, the ECM calculates the air/fuel ratio (fuel injector on-time) based on the
signals from the O2 sensors. This allows the air/fuel ratio
to stay very close to 14.7 to 1.
Acceleration Mode
The ECM responds to rapid changes in throttle position
and airflow and provides extra fuel.
Deceleration Mode
The ECM responds to changes in throttle position and
airflow and reduces the amount of fuel. When deceleration is very fast, the ECM can cut off fuel completely for
short periods of time.
Battery Voltage Correction Mode
When battery voltage is low, the ECM can compensate
for a weak spark delivered by the ignition module by using the following methods:
Increasing the fuel injector pulse width.
Increasing the idle speed rpm.
Increasing the ignition dwell time.
Fuel Cut-Off Mode
No fuel is delivered by the fuel injectors when the ignition
is off. This prevents dieseling or engine run-on. Also, the
fuel is not delivered if there are no reference pulses received from the CKP sensor. This prevents flooding.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-27
FUEL PUMP
5. Thermistor
2. Spring
6. Float arm
3. Fuel pump
7. Thermistor housing
4. Float
Specified Value
3.8 bar
Item
Minimum delivery at 8v
Maximum pressure
Operating voltage
Minimum pressure
Nominal voltage
Minimum amount of fuel
supply
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
12 V
114 Liter/Hr (12 V, 3.8 bar,
-30 ~ +70 C)
Ambient temperature
Maximum amount of fuel
supply
Specified Value
30 Litre/Hr
8V
7.5 A
-30 ~ +70 C
165 Liter/Hr (12V, 3.8 bar,
-30 ~ +70 C)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-28
Failur Code
Description
Trouble Area
34
35
Maintenance Hint
Inspection the Engine Control
Module (ECM) pin 33 about short
circuit or open with bad contact
Inspection the fuel pump relay
Inspection the ECM
Circuit Description
When the ignition switch is turned ON, the ECM will activate the pump relay and run the in-tank fuel pump. The fuel
pump will operate as long as the engine is cranking or running and the ECMis receiving ignition reference pulses.
If there are no reference pulses, the ECM will shut off the fuel pump within 2 seconds after the ignition switch is turned
ON, engine stopped or engine stalled.
0 V (for1 ~ 2 sec.)
Cranking
0V
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AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-29
1 Liter/max. 35 sec.
Notice
Check the fuel filter and fuel line when the fuel delivery is not within specified value.
5~9A
Notice
Replace the fuel pump relay if the measured value is over 9 A.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-30
FUEL INJECTOR
1. Fuel rail
4. Injector
2. O-ring
5. O-ring
3. Injector bracket
The Multipoint Fuel Injection (MFI) assembly is a solenoid-operated device controlled by the Engine Control Module
(ECM) that meters pressurized fuel to an each individual cylinder. The injector sprays the fuel, in precise quantities at
a point in time determined by the ECM, directly to ward the cylinder intake valve. ECM energizes the fuel injector
solenoid to lift the needle valve and to flow the fuel through the orifice. This injectors discharge orifice is calibrated to
meet the effective fuel atomization necessary for both ensuring the maximum homogeneity in the air-fuel mixture and
holding the condensation along the walls of the intake tract to a minimum.
Fuel enters the top feed injector from above and flows through its vertical axis. The lower end extends into the intake
valve. Fuel from the tip is directed at the intake valve, causing it to become further atomized and vaporized before
entering the combustion chamber.
A fuel injector which is stuck partially open would cause a loss of fuel pressure after the engineis shut down. Also, an
extended crank time would be noticed on some engines. Dieseling could also occur because some fuel could be
delivered to the engine after the ignition is turned off.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-31
Failur Code
Description
72
Trouble Area
When malfunction of injector
circuit
Injector #1 short circuit to power
73
74
75
76
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
Maintenance Hint
Inspection the power to injector #1
or bad contact
Inspection the injector
Inspection the ECM
Inspection the ECM pin 63 about
short circuit or open with bad contact
Inspection the injector
Inspection the ECM
Inspection the power to injector #2
or bad contact
Inspection the injector
Inspection the ECM
Inspection the ECM pin 61 about
short circuit or open with bad contact
Inspection the injector
Inspection the ECM
Inspection the power to injector #3
or bad contact
Inspection the injector
Inspection the ECM
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-32
Failur Code
Description
77
78
79
192
193
194
195
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Trouble Area
Maintenance Hint
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-33
14 ~ 17
Notice
Replace the fuel injector if the measured value is out
of the specified values. Check the connector and wire
connection between the ECM and the injector if the
measured values are normal.
8.0 ms
Engine Idle
3 ~ 5 ms
14 ms
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-34
3. Line to conister
2. Line to engine
The fuel vaporization control system is in stalled to inhibit the fuel vaporized gas from discharging into the atmosphere.
The fuel vaporized gas that is accumulated in the canister abstracts through the purge control valve purification during
the engine combustion (except the decreasing mode) and coolant temperature of over 80C. For this reason, the Engine
Control Module (ECM) transacts the engine speed, air inflow quantity, coolant temperature, and intake temperature.
The purge control valve is activated by the ECM frequency according with the engine rotating speed to adjust the
purification rate. The purification rate is determined by the continuous valve opening interval.
The purge control valve is activated by the ECM for the following conditions:
Coolant temperature of over 80C
Engine speed of over 1,000 rpm
2 minutes after starting
When the fuel cut-off mode is not activated
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-35
Failur Code
Description
Trouble Area
40
41
54
Maintenance Hint
Inspection the ECM pin 34 about
short circuit or open with bad
contact.
Inspection the source power of
valve
Inspection the purge control
solenoid vale
Inspection the ECM
Test
1. Maintain the normal temperature and idling state by
operating the engine.
2. Connect the ECM terminal No. 11 and No. 34 and check
for normal operation through the output waves using
oscilloscope.
Notice
Test during purge control valve operation after the
minimum of 1 minute after the engine turned on.
3. Connect the ECM terminal No. 34 and No.10 and check
for current consumption during the ignition switch ON.
Specified value
0.3 ~ 0.5 A
Specified value
Notice
Test while at normal temperature and at idling state
by operating the engine.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-36
FUEL RAIL
1. Injector connector
2. Injector
6. Bolt
3. Fuel rail
7. Vacuum hose
8. O-ring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-37
3.2 ~ 3.6
3.7 ~ 4.2
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-38
1. Vacuum hose
4. O-ring
2. Circlip
5. O-ring
8. Fuel chamber
3. Valve
9. Spring chamber
5. Diaphragm
A. Valves closed
6. Compression spring
B. Valves opened
CHANGED BY
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AFFECTED VIN
When the fuel pressure goes up, the diaphragm forces the
compression spring (6) in the direction of compression. At
this moment, the valve (3) sticks to the diaphragm by the fuel
pressure, and the fuel return line (2) opens. The fuel over supplied returns to the fuel tank through the return line.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-39
The pressure difference between the fuel pressure and
the intake manifold is about 3.8 bars during the full load.
2. Intake manifold
A. Fuel pressure
B. Intake manifold negative pressure
LL. Idling
TL. Partial load
VL. Full load
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AFFECTED VIN
1F-40
INDUCTION SYSTEM
THROTTLE VALVE ACTUATOR
Ignition OFF
In the de-energized states the throttle valve position is
determined to be spring capsule.
Ignition ON
When the ignition S/W on the servo motor in the throttle
actuator is operated by the ECM. The throttle valve adopts
a position in line with the coolant temperature.
Closed Position
In the closed throttle position, the servo motor controls
engine speed by operating the throttle valve further (greater
mixture) or closing it further (reduced mixture), depending on coolant temperature and engine load. When this is
done, the throttle valve can be closed further by the servo
motor overcoming the force of the spring capsule (mechanical end stop). If the actuator is deenergized, the
throttle valve is resting against the spring capsule.
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AFFECTED VIN
Driving
When driving (part/full throttle), the servo motor controls
the throttle valve in line with the various load states and
according to the input signals from the pedal value sensor according to the input signals from the pedal value
sensor according to the position of the accelerator pedal.
The function of the EA (electronic accelerator) in the ECM
determines the opening angle of the throttle valve through
the throttle actuator. Further functions are;
Idle speed control
Cruise control
Reducing engine torque for ASR/ABS operation
Electronic accelerator emergency running
Storing faults
Data transfer through CAN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-41
Failur Code
Description
Trouble Area
104
105
108
109
116
Throttle actuator
learning control failure
119
121
123
125
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
Maintenance Hint
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-42
Failur Code
Description
Trouble Area
126
Maintenance Hint
127
185
Circuit Description
The ECM supplies a 5 volt reference signal and a ground to the TP sensor. The TP sensor sends a voltage signal back
to the ECM relative to the throttle plate opening. The voltage signal will vary from approximately 0.3 ~ 0.9 volts at closed
throttle, to over 4.0 ~ 4.6 volts at Wide Open Throttle (WOT).
The TP sensors serve for engine load control according to the drive pedal command. Load adjustments independent of
the drive pedal command can be implemented; such functions are, for instance, idle control, speed control, drive slip
control, load shock damping, and similar functions.
When the actuator current fails, the throttle valve is returned to emergency operating position by a spring. The throttle
valve position, thereby the actuator drive position check back is provided by two potentiometers. The motor positions the
throttle valve against the return spring force. Motor and return spring are two separate energy sources. Each of Them is
able to position the throttle valve in emergency position alone. Throttle valve position check back and monitoring is
provided by two actual value potentiometers connected to the engine control electronics.
TPS 1
TPS 2
Pedal Position
Specified Value
Closed
0.3 ~ 0.9V
Opened
1 4.0 ~ 4.6V
Closed
4.0 ~ 4.6V
Opened
0.3 ~ 0.9V
<10
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AFFECTED VIN
Specified Value
Ignition ON
0.8 ~ 2.3 v
Idling
1.0 ~ 2.5 v
(Coolant temperature is over 70 C)
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-43
1. Housing
4. Connector
2. Protector net
3. Electronic housing
6. Measuring port
The Hot Film Air Mass (HFM) sensor with recognition of flow direction related to pulsating flow is designed for recording
load on Engine Control Module (ECM) by measuring the output voltage proportional to the reference voltage of the ECM.
CHANGED BY
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AFFECTED VIN
1F-44
Under high fuel demands, the MAF sensor reads a high mass flow condition, such as Wide Open Throttle (WOT). The
ECM uses this information to enrich the mixture, thus increasing the fuel injector on-time, to provide the correct amount
of fuel. When decelerating, the mass flow decreases. This mass flow change is sensed by the MAF sensor and read by
the ECM, which then decreases the fuel injector on-time due to the low fuel demand conditions.
To facilitate the installation of the HFM in the intake passage, lubricating agents may be used. However, when lubricants
are used care must be taken to ensure that they do not enter the flow passage and cannot be sucked in with the air flow.
The following tables show the relationship between MAF and output voltage.
Mass Air Flow (kg/h)
Voltage (V)
Voltage (V)
0.95 ~ 1.05
250
3.51
10
1.28
370
3.93
15
1.41
480
4.23
30
1.71
640
4.56
60
2.16
800
4.82
120
2.76
R min.(
)
R nom. (
)
R max. (
)
-40
35,140
39,260
43,760
-20
12,660
13,850
15,120
5,119
5,499
5,829
20
2,290
2,420
2,551
40
1,096
1,166
1,238
60
565
609
654
80
312
340
370
100
184
202
222
120
114
127
141
130
91
102
114
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EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-45
Failur Code
Description
Trouble Area
Maintenance Hint
03
04
05
09
10
11
Circuit Description
The heated element on the MAF is a platinum film resistor (heater). It is located on a ceramic plate together with the other
elements in the bridge circuit. The temperature sensitive resistor (flow sensor) also included in the bridge. The separation
of heater and flow sensor facilitates design of the control circuitry. Saw cuts are employed to ensure thermal decoupling
between the heating element and the intake air temperature (IAT) sensor. The complete control circuitry is located on a
single layer. The voltage at the heater provides the index for the mass air flow. The MAFs electronic circuitry then converts
the voltage to a level suitable for processing in the ECM. This device does not need a burn off process to maintain its
measuring precision over an extended period. In recognition of the fact that most deposits collect on the sensor elements
leading edge, the essential thermal transfer elements are located downstream on the ceramic layer. The sensor element
is also design to ensure that deposits will not influence the flow pattern around the sensor.
The IAT sensor uses a thermistor to control the signal voltage to the ECM. The ECM supplies 5 volt reference and a
ground to the sensor. When the air is cold, the resistance is high; therefore the IAT signal voltage will be high. If the
intake air is warm, resistance is low; therefore the IAT signal voltage will be low.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-46
Specified Value
Ignition ON
0.9 ~ 1.1 v
Idling
1.3 ~ 1.7 v
(Coolant temperature is over 70 C)
Notice
If the measured value is not within the specified value, the possible cause may be in cable or MAF sensor
in itself. Perform the 5 volt power supply inspection procedures.
4.7 ~ 5.2 V
Notice
If the measured value is not within the specified value, the possible cause may be in cableor ECM coupling.
5. Measure the voltage between the ECM pin No. 105 and MAF sensor connecter terminal No. 4.
Specified value
4.7 ~ 5.2 V
Notice
If the measured value is not within the specified value, the possible cause may be in cableor ECM coupling.
11 ~ 14 V
Notice
If the measured value is not within the specified value, the possible cause may be in cable or Over Voltage
Protection Relay (OVPR).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-47
4. Connector
2. Metal housing
Engine Coolant Temperature (ECT) sensor detects coolant temperature and supplies information to the ECM. It is
composed of metal housing with two NTC resistor, 4 pin connector. The ECM provides a 5 volt signal to the ECT sensor
through a dropping resistor. When the engine is cold, the ECT sensor provides high resistance, which the ECM detects
as a high signal voltage. As the engine warms up, the sensor resistance becomes lower, and the signal voltage drops.
At normal engine operating temperature, the ECT signal will measure about 1.5 to 2.0 volts.
The ECM uses information about coolant temperature to make the necessary calculations for:
Fuel delivery
Ignition control
Knock sensor system
Idle speed
Torque converter clutch application
Canister purge
Cooling fan operation
Others
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-48
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Temperature (C)
)
Resistance (
Voltage (V)
-40
48,550
4.90
-30
27,000
4.82
-20
15,570
4.70
-10
9,450
4.52
5,890
4.43
10
3,790
3.96
20
2,500
3.57
30
1,692
3.14
40
1,170
2.70
50
826
2.26
60
594
1.86
70
434
1.51
80
322
1.22
90
243
0.98
100
185
0.78
110
143
0.63
120
111.6
0.50
130
88
0.40
140
71.2
0.33
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-49
Failur Code
Description
Trouble Area
00
Engine coolant
temperature sensor low
voltage
01
Engine coolant
temperature sensor
high voltage
Engine coolant
temperature sensor
plausibility
02
Engine coolant
temperature insufficient
for closed loop fuel
control
06
Maintenance Hint
Circuit Description
The ECT sensor uses a thermistor to control the signal voltage to the ECM. The ECM supplies a voltage on the signal
circuit to the sensor. When the engine coolant is cold, the resistance is high; therefore the ECT signal voltage will be high.
20
3.57
80
1.22
100
0.78
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-50
3. Turn the ignition switch to OFF position.
4. Disconnect the ECT sensor connector.
5. Turn the ignition switch to ON position.
6. Measure the resistance between the ECT sensor terminal pin No. 1 and No. 4.
Temperature (C)
20
2,500
80
322
100
185
Notice
Replace wiring and coolant temperature sensor if out of specified value.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-51
1. Accelerator pedal
4. 6-pin connector
5. Bolt
3. Bolts
The Acceleration Pedal Position (APP) sensor is mounted on the accelerator pedal assembly. The sensor is actually
two individual APP sensors and one housing. This sensor works with the Throttle Position (TP) sensor to provide input
to the Engine Control Module (ECM) regarding driver requested accelerator pedal and throttle angle at the throttle body.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-52
Failur Code
Description
Trouble Area
122
Acceleration pedal
position sensor signal
failure
160
Acceleration pedal
position 1 sensor low
voltage
161
Acceleration pedal
position sensor 1 high
voltage
162
Acceleration pedal
position sensor 2 low
voltage
163
Acceleration pedal
position sensor 2 high
voltage
164
Accelerator pedal
position sensor 1 not
plausible with
accelerator pedal
position sensor 2
167
Both setpoint
accelerator pedal
position sensor
defective
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Maintenance Hint
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-53
Circuit Description
The ECM supplies a 5 or 2.5 volt reference signal and a ground to the APP sensor 1or 2. The ECM calculates on these
signal lines. The APP sensor output changes as the accelerator pedal is moved. The output of the APP 1and APP2
sensor are low, about 0.4 ~ 0.7 volts and 0.2 ~ 0.35 volts respectively at the closed throttle position. As pushing the
accelerator pedal, the output increases so that the output voltages will be about 4.3 ~ 4.8 volts and 2.1 ~ 2.4 volts
individually when accelerating fully with the kick down, at Wide Open Throttle (WOT).
0.3 ~ 0.7
4.3 ~ 4.8
Notice
If measured value is not within the specified value, check the pedal valve sensor and the supply voltage to
APP 1 sensor.
0.1 ~ 0.4
2.1 ~ 2.5
Notice
If measured value is not within the specified value, check the pedal valve sensor and the supply voltage to
APP sensor 2.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-54
COOLING FAN
Failur Code
Description
Trouble Area
44
45
Maintenance Hint
Inspection the Engine Control
Module (ECM) pin 35 about short
circuit or open with bad contact
Inspection the power source
Inspection the cooling fan
Inspection the ECM
Circuit Description
Ignition voltage is supplied directly to the cooling fan relay coil. The ECM controls the relay by grounding the control
circuit. When the ECM is commanding a command ON, the voltage of the control circuit should be low (near 0 volt).
When the ECM is commanding the control circuit should be high (near battery voltage). If the fault detection circuit
senses a voltage other than what is expected, the fault line status will change causing the fault code to set.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-55
Failur Code
Description
228
Trouble Area
229
Maintenance Hint
Circuit Description
When the ECM detects that A/C has been requested, the ECM will activated the A/C clutch relay. When the relay has
been activated, voltage should be present at both the A/C clutch relay and A/C switch circuit at ECM.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-56
Failur Code
Description
Trouble Area
129
130
131
132
133
Cruise control
acceleration failure
134
Cruise control
deceleration failure
Maintenance Hint
Circuit Description
Cruise control is an automatic speed control system that maintain a desired driving speed without using the accelerator
pedal. The vehicle speed must be greater than 40 km/h to engage cruise control.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-57
RESONANCE FLAP
Failur Code
228
229
Description
Trouble Area
Maintenance Hint
Monitoring the actual operational
status and vehicle speed signal
through scan tool
Inspection the Engine Control
Module (ECM) pin 97 about short
circuit or open with bad contact
Inspection the power source short
circuit or open to resonance flap
Inspection the resonance flap
solenoid and hardware
Inspection the ECM
Circuit Description
A pneumatically actuated resonance flap is located on the intake manifold, and will be opened and closed by load, which
operates resonance flap according to engine and controlled by ECM and rpm.
Resonance flap is closed at idle/partial load (less than 3,800/rpm). The switch valve will be adjusted by ECM and
resonance flap will be closed. By increasing air flow passage through dividing intake air flow toward both air collection
housing. This leads to a significant increase in the torque in the lower speed range.
Resonance flap is open at full load (over 3,800/rpm). The switch valve will not be adjusted by ECM and resonance flap will
be open. The collected air in the air collection housing will not be divided and intake air passage will be shorten.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-58
Failur Code
Description
Trouble Area
Maintenance Hint
Monitoring the actual operational
status and vehicle speed signal
through scan tool
135
Circuit Description
The stop lamp switch is normally opened. When the ignition switch ON and brake ON, the battery voltage is supplied to
the ECM. A scan tool should display ON when brake pedal is depressed and should read OFF with brake pedal released.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-60
EXHAUST SYSTEM
CATALYTIC CONVERTER
The purpose of the catalytic converter is to convert the
three pollutants of carbon monoxide(CO), hydrocarbons
(HC) and oxides of nitrogen (NOx) contained in the exhaust of gasoline engines, into the harmless compounds
of water (H2O), carbon dioxide (CO2) and nitrogen (N2).
The catalytic converter contains a catalyst, a word coming from the Greek and which designates the element
essential for catalyst which triggers chemical reactions
without itself being consumed.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
N2 + O2
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-61
OXYGEN SENSOR
When the exhaust gas is rich (below 14.7 : 1), the voltage
output is high, above 450 mv. When the exhaust gas is
lean (above 14.7 : 1 air/fuel ratio), the sensors voltage
output is low, below 450 mv.
The ECM uses oxygen sensor information for:
Open loop / closed loop criteria
Ideal air / fuel ratio
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-62
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-63
Failur Code
Description
Trouble Area
80
89
82
Oxygen sensor no
activity detected
83
84
85
86
87
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
Maintenance Hint
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-64
Failur Code
Description
Trouble Area
Maintenance Hint
81
93
96
97
98
99
100
101
102
103
Circuit Description
In order to control emissions, a catalytic converter is used to covert harmful emissions into harmless water vapor and
carbon dioxide. The ECM has the ability to monitor this process by using a oxygen sensor. The oxygen sensor produces
and output signal which indicates the storage capacity of the catalyst. This in turn indicates the catalysts ability to
convert exhaust emission effectively. If the oxygen sensor pig tail wiring, connector, or terminal is damaged. Do not
attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly, it must have a clean air
reference provided to it. This clean air reference is obtained by way of the oxygen sensor wire(s). Any attempt to repair
the wires, connector, or terminal and degrade the oxygen sensor performance.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-65
0.2 ~ 1.0 V
Notice
If the measured value is not within the specified value, the possible cause may be in cable, oxygen sensor
or ECM.
11 ~ 14 V
Notice
If the measured value is not within the specified value, the possible cause may be in cable, oxygen sensor
or ECM.
0.2 ~ 2.0 A
Notice
If the measured value is not within the specified value, the possible cause may be in cable, oxygen sensor
or ECM.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-66
1.
2.
3.
4.
Cover
Plate
Connector
Flat pin
Vehicle side: No. 1-12
Engine side: No. 61-72
5. Pin
Vehicle side: No. 13-60
Engine side: No. 73-120
A. Vehicle side connector: Black
B. Engine side connector: Gray
The Engine Control Module (ECM), located inside the right side kick panel, is the control center of the fuel injection
system. It constantly looks at the information from various sensors and controls the systems that affect the vehicles
performance. Engine rpm and air mass are used to measure the air intake quantity resulting in fuel injection metering.
The ECM also performs the diagnostic functions of the system. It can recognize operational problems, store failure code(s)
which identify the problem areas to aid the technician in making repairs.
There are no serviceable parts in the ECM. The calibrations are stored in the ECM in the Programmable Read Only
Memory (PROM).
The ECM supplies either 5 or 12 volts to power the sensors or switches. This is done through resistance in the ECM
which are so high in value that a test light will not come ON when connected to the circuit. In some cases, even an
ordinary shop voltmeter will not give and accurate reading because its resistance is too low. You must use a digital
voltmeter with a 10 Mohm input impedance to get accurate voltage readings. The ECM controls output circuits such as
the ignition coils, the fuel injectors, the fuel pump relay, the intake manifold resonance flap, the camshaft actuator, the
canister purge valve, etc., by controlling the ground circuit.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-67
Failur Code
23
Description
CAN communication
failure: ASR/MSR
Trouble Area
Maintenance Hint
Inspection the ASR unit with CAN
connection
Inspection the Engine Control
Module (ECM) pin 38, 37 about short
circuit or open with bad contact
Inspection the ECM
24
CAN communication
failure: ABS
26
CAN communication
failure: TCU (A/T only)
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-68
Failur Code
27
Description
Trouble Area
Maintenance Hint
Inspection the TOD unit with CAN connection
Inspection the ECM pin 38, 37 about short
circuit or open with bad contact
Inspection the ECM
29
30
31
59
60
Circuit Description
The provision for communicating with the ECM is the Data Link Connector (DLC). It is located in the instrument panel
fuse block. The DLC is used to connect the scan tool. Battery power and ground is supplied for the scan tool through the
DLC. CAN line is used to communicate with the other module such as the Transmission Control Module (TCM) and
Transfer Case Control Unit (TCCU).
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-69
INTERNAL FAILURE
Failur Code
Description
Trouble Area
Maintenance Hint
Inspection the coding condition
through scan tool
Transmission coding
failure
21
136
142
Uncoded/unprogramed
ECM
137
143
144
145
146
ECM failure
(programming
checksum failure)
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-70
Description
110
Throttle actuator
learning data fault
117
120
Cruise control
interruption memory failure
138
Call Monitoring
139
140
186
ECM failure
(incompatible CPU)
187
188
189
190
231
232
233
234
235
236
237
238
Unusual throttle
controller monitoring data
comparison fault (CPU 2)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Trouble Area
Maintenance Hint
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-71
Failur Code
Description
239
240
Maintenance Hint
241
Unusual CPU
communication (CPU 2)
242
Unusual CPU
configuration (CPU 2)
243
244
245
246
247
248
249
250
251
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
Trouble Area
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-72
IMMOBILIZER
Failur Code
Description
Trouble Area
Maintenance Hint
D Inspection the Engine Control
Module (ECM) pin 13, 14 about
short circuit or open with bad contact
25
Communication with
transponder missing
Circuit Description
Immobilizer is a device disabling vehicle ignition unless a specific key is used and designed to help prevent vehicle theft.
Immobilizer is comprised of two devices, a key with encoded transponder and ECM with the same encoding of the
transponder. When a key is inserted into the hole to start vehicle and turned to ON, the ECM reads and decodes the
transponder code and, if the same, starts the engine, it is called immobilizer. It means immobilizer system disables
starting by stopping fuel supply if the code in the transponder does not match the code stored in ECM each other.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-73
25 Nm (18 lb-ft)
FUEL PUMP
Tools Required
A9922 0012A (661 589 00 46 00)
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-74
8. Using the fuel tank cap wrench 661 589 00 46 00, remove
the locking cap.
9. Remove the pump from the fuel tank.
Notice
Check the condition of the seal and replace if
necessary. Drain the fuel before removing the pump.
10. Perform an operational check of the fuel pump.
11. Installation should follow the removal procedure in the
reverse order.
FUEL FILTER
Removal and Installation Procedure
1. Disconnect the negative battery cable.
Caution
The fuel system is under pressure. To avoid fuel
spillage and the risk of personal injury or fire, it is
necessary to relieve the fuel system pressure before
disconnecting the fuel lines.
2. Relieve the fuel system pressure. Refer to Discharging
the Pressure in Fuel System in this section.
3. Disconnect the fuel lines from the fuel filter.
Installation
Tightening torque
28 Nm (21 lb-ft)
28 Nm (21 lb-ft)
Notice
Place the fuel pump pad. There may be a corrosion
due to the contact between the fuel filter and the
bracket.
5. Remove the fuel filter.
6. Install the fuel filter.
7. Perform a leak test of the fuel filter.
8. Installation should follow the removal procedure in the
reverse order.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-75
FUEL TANK
Removal and Installation Procedure
Caution
The fuel system is under pressure. To avoid fuel
spillage and the risk of personal injury or fire, it is
necessary to relieve the fuel system pressure before
disconnecting the fuel lines.
1. Relieve the fuel pressure. Refer to Discharging the
Pressure in Fuel System in this section.
2. Disconnect the negative battery cable.
3. Drain the fuel tank.
4. Disconnect the return line.
5. Disconnect the supply line.
6. Disconnect the fuel tank-to-canister hose from the fuel
tank.
7. Disconnect the fuel pump wiring connector.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-76
9. Unscrew the bolts and remove the fuel filler pipe from the
fuel filler opening.
10. Install the safety jack under the fuel tank and remove the
bolts (12mm x 4) from the fuel tank.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-77
11. Carefully lower the safety jack with the fuel tank.
Caution
Be careful not to drop the fuel tank while removing
it.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-78
25 Nm (18 lb-ft)
Caution
The fuel system is under pressure. To avoid fuel
spillage and the risk of personal injury or fire, it is
necessary to relieve the fuel system pressure before
disconnecting the fuel lines.
3. Relieve the fuel pressure in fuel supply system by
pressing the service valve.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-79
9 Nm (80 lb-ft)
23 Nm (17 lb-ft)
11. Remove the two left and two right bolts and one center
bolt of the fuel rail assembly from the intake manifold.
Installation
Tightening torque
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
25 Nm (18 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-80
Notice
Before removal, the fuel rail assembly may be cleaned
with as pray type cleaner, following package instructions.
Do not immerse the fuel rails in liquid cleaning solvent.
Use care in removing the fuel rail assembly to prevent
damage to the electrical connectors and injector spray
tips. Prevent dirt and other contaminants from entering
open lines and passages. Fittings should be capped and
holes plugged during service.
Important
If an injector becomes separated from the rail and remains
in the cylinder head, replace the injector O-ring seals and
the retaining clip.
12. Remove the injectors and the fuel rail carefully.
13. Remove the fuel injector retainer clips.
14. Remove the fuel injectors by pulling them down and out.
15. Discard the fuel injector O-rings.
16. Lubricate the new fuel injector O-rings with engine oil.
Install the new O-rings on the fuel injectors.
17. Perform a leak check of the fuel rail and fuel injectors.
18. Installation should follow the removal procedure in the
reverse order.
30 Nm (22 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-81
9 Nm (80 lb-ft)
12 Nm (106 lb-ft)
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-82
KNOCK SENSOR
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Disconnect the knock sensor electrical connector from
the intake manifold bracket.
3. Remove the knock sensor mounting bolt from the knock
sensor installed on the cylinder block.
Installation
Tightening torque
25 Nm (18 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-83
6 Nm (53 lb-ft)
OXYGEN SENSOR
Removal and Installation Procedure
1. Disconnect the negative battery cable.
Notice
The oxygen sensor uses a permanently attached
pigtail and connector. This pigtail should not be
removed from the oxygen sensor. Damage or removal
of the pigtail or the connector could affect proper
operation of the oxygen sensor. Do not drop the
oxygen sensor.
2. Disconnect the electrical connector.
3. Carefully remove the oxygen sensor from the exhaust pipe.
Installation
Tightening torque
55 Nm (41 lb-ft)
Important
A special anti-seize compound is used on the oxygen
sensor threads. This compound consists of a liquid
graphite and glass beads. The graphite will burn away,
but the glass beads will remain, making the sensor
easier to remove. New or serviced sensors will already have the compound applied to the threads. If a
sensor is removed from any engine and is to be reinstalled, the threads must have an anti-seize compound
applied before reinstallation.
4. Coat the threads of the oxygen sensor with an anti-seize
compound, if needed.
5. Installation should follow the removal procedure in the
reverse order.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-84
CANISTER
Removal and Installation Procedure
Caution
Canister and vacuum hoses contain fuel vapors. Do
not smoke in the area or permit an open flame.
1. Disconnect the fuel tank-to-canister hose form the
canister.
2. Disconnect the canister-to-purge control valve hose form
the canister.
3. Remove the canister mounting bolts.
Installation
Tightening torque
6 Nm (53 lb-ft)
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EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-85
10 Nm (89 lb-ft)
25 Nm (18 lb-ft)
25 Nm (18 lb-ft)
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-86
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-87
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-88
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-89
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-90
SPECIFICATIONS
ENGINE DATA DISPLAY TABLE
Parameter
Unit
Value
Engine rpm
rpm
Regular rpm
rpm
Engine load
18 ~ 25 %
Kg/h
16 ~ 25 Kg/h
TA
Spark advance
CA
CA (6 ~ 9CA)
Nm
Injection time
ms
3 ~ 5 ms
Battery voltage
Km/h
0 ~ 265 Km/h
Km/h
0 ~ 265 Km/h
0.4 ~ 4.8 V
0.2 ~ 2.4 V
Throttle position 1
0.3 ~ 4.6 V
Throttle position 2
0.3 ~ 4.6 V
0.8 ~ 1.2
Fuel integrator
Oxygen sensor
mv
100 ~ 900 mv
1=ON/0=OFF
1=ON/0=OFF
1=ON/0=OFF
1=ON/0=OFF
1=ON/0=OFF
1=ON/0=OFF
Knocking control
1=ON/0=OFF
Protect mission
1=ON/0=OFF
1=ON/0=OFF
Lambda function
1=ON/0=OFF
Catalyst heating
1=ON/0=OFF
1=ON/0=OFF
1=ON/0=OFF
Brake switch
1=ON/0=OFF
1=ON/0=OFF
CHANGED BY
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AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-91
Nm
Lb-Ft
Lb-In
10
89
53
30
22
10
89
10
89
53
28
21
25
18
25
18
23
17
38
28
80
25
18
Oxygen sensor
55
41
53
12
106
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-92
TEMPERATURE VS RESISTANCE
C
ECT Sensor
IAT Sensor
ohms ()
CHANGED BY
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AFFECTED VIN
130
266
88
102
120
248
111.6
127
110
230
143
159
100
212
202
202
90
194
261
261
80
176
340
340
70
158
452
452
60
140
609
609
50
122
835
835
40
113
1166
1166
30
86
1662
1662
20
68
2420
2420
10
50
3604
3604
32
5499
5499
-10
14
8609
8609
-20
-4
13850
13850
-30
-22
22960
22960
-40
-40
39260
39260
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-93
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1G-1
SECTION
00 1G
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1G-2
CATALYTIC CONVERTER
Notice
When you are inspecting or replacing exhaust system
components, make sure there is adequate clearance
from all points on the underbody to avoid possible
overheating of the floor panel and possible damage
to the passenger compartment insulation and trim
materials.
Notice
When jacking or lifting the vehicle from the body side
rails, be certain that the lift pads do not contact the
catalytic converter, as this could damage the catalytic
converter.
MUFFLER
Notice
Use of anything other than unleaded fuel will damage
the catalyst in the catalytic converter.
The catalytic converter are emission-control devices added
to the exhaust system to reduce pollutants from the exhaust pipes.
The oxidation catalyst is coated with a catalytic material
containing platinum and palladium, which reduces levels
of hydrocarbon (HC) and carbon monoxide (CO) from the
exhaust gas. The three-way catalyst has coatings which
contain platinum and rhodium, which additionally lower
the levels of oxides of nitrogen (NOx).
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1G-3
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1G-4
PURIFICATION OF CATALYTIC
CONVERTER
Adhesion of soluble organic fraction (SOF) below 180C
Purification of soluble organic fraction (SOF) over 180C
Chemical reaction formula
- SOF(HC)+O2
CO2+H2O
- 2CO+O2
2CO2
- 2C2H6+7O2
4CO2+6H20
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1G-5
RESONANCE FLAP
Function
A pneumatically actuated resonance flap (5) is located on the
intake manifold, and will be opened and closed by load, which
operates resonance flap according to engine and controlled
by ECU and rpm.
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AFFECTED VIN
1G-6
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
AIR CLEANER AND INTAKE AIR DUCT
Cover
Element
Housing
Specifications
Element Type
Dry-Element Type
* Initial cleaning: 5,000 km, Clean or change every 10,000 km as required.
However, change every 30,000 km.
Service Interval
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AFFECTED VIN
* If the vehicle is operated under severe condition (short distance driving, extensive
idling or driving in dusty condition): More frequent maintenance is required.
ENGINE INTAKE & EXHAUST
M162 GSL ENG SM - 2005.7
1G-7
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AFFECTED VIN
1G-8
1G-9
INTAKE MANIFOLD
Preceding Work: Removal of fuel rail
Removal of battery
Removal of canister
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
1G-10
RESONANCE FLAP
4. Vacuum hose
5. Resonance flap
3. O-ring
9 ~ 11 Nm
(80 ~ 97 lb-ft)
1G-11
EXHAUST LINE
2. Muffler
6. Hanger
7. Hanger
15. Screw
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AFFECTED VIN
1G-12
15 ~ 28 Nm
(11 ~ 21 lb-ft)
28 ~ 47 Nm
(21 ~ 35 lb-ft)
28 ~ 47 Nm
(21 ~ 35 lb-ft)
CHANGED BY
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1G-13
7. Remove the mounting hanger and tail exhaust pipe.
8. Check the muffler and pipes for holes, damage, open
seams, or other deterioration. Which could permit
exhaust fumes to seep into the passenger compartment
or the trunk.
9. Installation should follow the removal procedure in the
reverse order.
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1G-14
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Nm
Lb-Ft
Lb-In
15 ~ 28
11 ~ 21
28 ~ 47
21 ~ 35
22.5 ~ 27.5
16.6 ~ 20.3
22.5 ~ 27.5
16.6 ~ 20.3
28 ~ 47
21 ~ 35
9 ~ 11
80 ~ 97
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DI0A-1
SECTION
00 DI0A
GENERAL INFORMATION
Table of Contents
CLEANNESS ....................................... DI0A-2
STRUCTURE ...................................... DI0A-7
ENGINE CONTROLS ....................... DI0A-10
ECU related components ............. DI0A-10
Engine and sensors ...................... DI0A-11
Electrical components and pre heating
system .......................................... DI0A-12
INTAKE SYSTEM ............................. DI0A-13
Intake air flow chart ...................... DI0A-14
EXHAUST SYSTEM .......................... DI0A-15
GENERAL INFORMATION
DI ENG SM - 2004.9
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DI0A-2
CLEANNESS
Cleanness of DI Engine Fuel System and Service Procedures
The fuel system for DI engine consists of transfer (low pressure) line and high pressure line. Its highest pressure
reaches over 1600 bar. Some components in injector and HP pump are machined at the micrometer 100 m of
preciseness. The pressure regulation and injector operation are done by electric source from engine ECU.
Accordingly, if the internal valve is stucked due to foreign materials, injector remains open. Even in this case, the
HP pump still operates to supply high pressurized fuel. This increases the pressure to combustion chamber (over
250 bar) and may cause fatal damage to engine.
You can compare the thickness of injector nozzle hole and hair as shown in below figure (left side). The right side
figure shows the clearance between internal operating elements.
Diameter: 0.40 mm
Nozzle hole
Operating
clearance:
0.002 mm
Diameter:
2.0 mm
The core elements of fuel system has very high preciseness that is easily affected by dust or very small foreign
material. Therefore, make sure to keep the preliminary works and job procedures in next pages. If not, lots of
system problems and claims may arise.
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GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-3
Job procedures
1. Always keep the workshop and lift clean (especially, from dust).
2. Always keep the tools clean (from oil or foreign materials).
3. Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system.
Wash your hands and do not wear working gloves.
4. Follow the below procedures before starting service works for fuel system.
Visually check the leaks and vehicle appearance on the wiring harnesses
and connectors in engine compartment.
Locate the fault. If the cause is from fuel system (from priming pump to
injector, including return line), follow the step 1 through step 3 above.
5. If the problem is from HP pump, fuel supply line or injector, prepare the clean special tools and sealing caps
to perform the diagnosis for DI engine fuel system in DI10 DIAGNOSIS section in this manual. At this point,
thoroughly clean the related area in engine compartment.
Notice
GENERAL INFORMATION
DI ENG SM - 2004.9
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DI0A-4
6. Follow the job procedures. If you find a defective component, replace it with new one.
For safety reasons: check pressure is low before opening the HP systems (pipes)
Use special tools and torque wrench to perform the correct works.
Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail
and each injector should be replaced with new ones. The pipes should be tightened to
specified tightening torques during installation. Over or under torques out of specified
range may cause damages and leaks at connections. Once installed, the pipes have been
deformed according to the force during installtion, therefore they are not reusable.
The copper washer on injector should be replaced with new one. The injector holder bolt
should be tightened to specified tightening torque as well. If not, the injection point may be
deviated from correct position, and it may cause engine disorder.
Plug the disconnected parts with sealing caps, and remove the caps immediately
before replacing the components.
Common rail
IMV valve
Injection
pipe
Water separator
Water detection sensor
Priming
pump
Fuel filter
Injector
Cap position
Supply line
Return line
Fuel tank
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GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-5
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI0A-7
STRUCTURE
Front view
Rear view
7. Viscos clutch
9. Auto tensioner
6. Alternator
4. Idle pulley
GENERAL INFORMATION
DI ENG SM - 2004.9
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AFFECTED VIN
DI0A-8
Top view
25. Injector
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AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-9
Left side view
41. HP pump
GENERAL INFORMATION
DI ENG SM - 2004.9
modulator
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AFFECTED VIN
DI0A-10
ENGINE CONTROLS
ECU RELATED COMPONENTS
ECU/barometric sensor
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AFFECTED VIN
Fuel filter
(water detection sensor)
Main relay
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-11
Crankshaft position
sensor
Glow plug
Camshaft position
sensor
HP pump
GENERAL INFORMATION
DI ENG SM - 2004.9
Common rail
Coolant temperature
sensor
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AFFECTED VIN
DI0A-12
Battery
Fuse box
Alternator
Starter motor
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AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-13
INTAKE SYSTEM
HFM sensor
Intake manifold
Turbocharger
Intercooler
Inlet hose
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI0A-14
Intake manifold
Turbocharger
(compressor)
Engine
HFM sensor
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AFFECTED VIN
Intercooler
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-15
EXHAUST SYSTEM
Muffler
Turbocharger
GENERAL INFORMATION
DI ENG SM - 2004.9
Catalytic converter
Exhaust manifold
EGR valve
EGR pipe
Vacuum modulator
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AFFECTED VIN
DI0A-16
Catalytic converter
Exhaust pipe
Muffler
Ambient
air
Exhaust gas
Turbocharger
(turbine side)
EGR vacuum
modulator
To turbocharger
booster
Turbocharger
booster vacuum
modulator
Turbocharger booster
EGR valve
Exhaust manifold
EGR pipe
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AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-17
LUBRICATION SYSTEM
Oil dipstick
Oil separator
Oil pan
GENERAL INFORMATION
DI ENG SM - 2004.9
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AFFECTED VIN
DI0A-18
COOLING SYSTEM
CHANGED BY
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AFFECTED VIN
Coolant reservoir
Water pump
Radiator assembly
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-19
Oil cooler
Coolant reservoir
Intake manifold
Thermostat
Coolant outlet port
Water pump
Inner hose
Outlet hose
Cooling fan
Radiator
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI0A-20
FUEL SYSTEM
Injector
CHANGED BY
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AFFECTED VIN
HP pump
Common rail
Fuel filter
Priming pump
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-21
Common rail
IMV valve
High
pressure
pipe
Water separator
Fuel filter
Label
(C2I)
Priming pump
Water detection
sensor
Injector
Sensors
HFM sensor
Cam position sensor
ECU
Fuel tank
Components:
- High pressure fuel pump
- Fuel rail
- Fuel injectors
Supply line
Return line
ECU communication line
According to input signals from various sensors, engine ECU calculates drivers demand (position of the accelerator
pedal) and then controls overall operating performance of engine and vehicle on that time.
ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those
signals. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines injection order and ECU detects drivers pedal position (drivers demand) through electrical signal that is generated by variable resistance changes in accelerator pedal sensor. Air flow (hot film) sensor detects intake air volume and
sends the signals to ECU. Especially, the engine ECU controls the air-fuel ratio by recognizing instant air volume
changes from air flow sensor to decrease the emissions (EGR valve control). Furthermore, ECU uses signals from
coolant temperature sensor and air temperature sensor, booster pressure sensor and barometric sensor as compensation signal to respond to injection starting, pilot injection set values, various operations and variables.
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI0A-22
Explanation of Scheduled
Maintenance Services
The services listed in the maintenance schedule are further explained below. When the following maintenance
services are performed, make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle. Always use the proper fluid and lubricants.
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GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-23
Cautions on Inspection/Service
Notice
Note, Notice
While using this manual, there are a lot of Note or Notice
having below meaning.
Note
GENERAL INFORMATION
DI ENG SM - 2004.9
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DI0A-24
Electrical equipment
Electrical equipment should be handled more carefully.
Currently, the engine is equipped with a lot of electrical
equipments so there can be engine performance drops,
incomplete combustion and other abnormals due to short
and poor contact. Mechanics should well aware of vehicles
electrical equipment.
If have to work on the electrical equipment, be sure to
disconnect battery negative (-) terminal and position
the ignition switch to off if not required.
When replacing electrical equipment, use the same
genuine part and be sure to check whether ground or
connecting portions are correctly connected during
installation. If ground or connecting portion is loosened,
there can be vehicle fire or personal injury.
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AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-25
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI0A-26
8. Never reuse cotter pin, gasket, O-ring, oil seal, lock
washer and self-locking nut. Replace them with new.
If reused, normal functions cannot be maintained.
9. Align the disassembled parts in clean according to
disassembling order and group for easy assembling.
10. According to installing positions, the bolts and nuts have
different hardness and design. So be careful not to mix
removed bolts and nuts each other and align them
according installing positions.
11. To inspect and assemble, clean the parts.
12. Securely clean the parts that related with oil not to be
affected by viscosity of oil.
13. Coat oil or grease on the driving and sliding surfaces
before installing parts.
14. Use sealer or gasket to prevent leakage if necessary.
15. Damaged or not, never reuse removed gasket. Replace
with new and cautious on installing directions.
16. Tighten every bolt and nut with specified torque.
17. When service work is completed, check finally whether
the work is performed properly or the problem is solved.
18. If work on the fuel line between priming pump and injector
(including return line), be sure to cover the removed parts
with cap and be careful not to expose the connecting
passage and removed parts to external foreign materials
or dust. (Refer to cleanness.)
19. If remove high pressure fuel supply pipe between HP pump
and fuel rail and high pressure fuel pipe between fuel rail
and each injector, be sure to replace them with new.
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AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-27
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI0A-28
Rear Side
Using Jack
Front Jack Up Point
CHANGED BY
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AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-29
Lifting Positions
1. 4-post lift
As illustrated, position the vehicle on the 4-post lift securely and block the front and rear of each tire not to move during
working.
Notice
Warning
Be sure to use attachment during lifting to prevent the lift from contacting with body floor.
While lifting the vehicle, widen the lift floor as far as possible to stabilize between vehicle front and rear. When
fixing the lift floor, be careful not to contact with brake tube and fuel lines.
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI0A-30
4. Pull out the oil level indicator and look at the oil level
on it.
6. Push the indicator all the way back down into the
engine after taking the reading.
If you check the oil level when the oil is cold, do not run
the engine first. The cold oil will not drain back to the pan
fast enough to give a true oil level reading.
Headlamp Aim
Take note of the light pattern occasionally. Adjust the headlights if the beams seem improperly aimed.
AT LEAST MONTHLY
AT EACH FUEL FILL
A fluid loss in any (except windshield washer) system may
indicate a problem. Have the system inspected and repaired immediately.
Lamp Operation
Check the operation of the license plate lamp, the headlamps (including the high beams), the parking lamps, the
fog lamps, the taillamp, the brake lamps, the turn signals,
the backup lamps and the hazard warning flasher.
Fluid Leak Check
Periodically inspect the surface beneath the vehicle for
water, oil, fuel or other fluids, after the vehicle has been
parked for a while. Water dripping from the air conditioning
system after use is normal. If you notice fuel leaks or
fumes, find the cause and correct it at once.
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-31
AT LEAST ANNUALLY
Lap and Shoulder Belts Condition and
Operation
Inspect the belt system including: the webbing, the
buckles, the latch plates, the retractor, the guide loops
and the anchors.
Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints
must stay in the desired position.
GENERAL INFORMATION
DI ENG SM - 2004.9
Underbody Flushing
Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control.
At least every spring clean the underbody. First, loosen
the sediment packed in closed areas of the vehicle.
Then flush the underbody with plain water.
Engine Cooling System
Inspect the coolant and freeze protection fluid. If the
fluid is dirty or rusty, drain, flush and refill the engine
cooling system with new coolant. Keep the coolant at
the proper mixture in order to ensure proper freeze
protection, corrosion protection and engine operating
temperature. Inspect the hoses. Replace the cracked,
swollen, or deteriorated hoses. Tighten the clamps.
Clean the outside of the radiator and the air conditioning condenser. Wash the filler cap and the neck. Pressure test the cooling system and the cap in order to
help ensure proper operation.
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AFFECTED VIN
DI0A-32
Bolt*
M3 0.5
M4 0.7
M5 0.8
M6 1.0
M8 1.25
M10 1.25
M10 1.5
M12 1.25
M12 1.75
M14 1.5
M16 1.5
M18 1.5
M20 1.5
M22 0.5
M24 1.5
M24 2.0
Limit
9T
4T
0.5 Nm
7T
0.9 Nm
9T
1.3 Nm
4T
0.7 Nm
7T
1.2 Nm
17 Nm
(4.5 lb-in)
(8 lb-in)
(12 lb-in)
(6.3 lb-in)
(11 lb-in)
(15 lb-in)
1.2 Nm
2.0 Nm
3.0 Nm
1.6 Nm
2.6 Nm
4.0 Nm
(11 lb-in)
(18 lb-in)
(27 lb-in)
(14 lb-in)
(23 lb-in)
(36 lb-in)
2.4 Nm
4.0 Nm
5.6 Nm
3.1 Nm
5.2 Nm
7.6 Nm
(22 lb-in)
(36 lb-in)
(50 lb-in)
(28 lb-in)
(47 lb-in)
(68 lb-in)
4.0 Nm
6.7 Nm
9.7 Nm
5.4 Nm
9.0 Nm
12.7 Nm
(36 lb-in)
(60 lb-in)
(87 lb-in)
(49 lb-in)
(81 lb-in)
(114 lb-in)
8.6 Nm
15.7 Nm
22.5 Nm
12.7 Nm
20.6 Nm
30.4 Nm
(77 lb-in)
(12 lb-in)
(17 lb-in)
(9 lb-in)
(15.2 lb-in)
(22 lb-in)
18.6 Nm
32.3 Nm
46.0 Nm
25.5 Nm
42.1 Nm
60.8 Nm
(14 lb-in)
(24 lb-in)
(34 lb-in)
(19 lb-in)
(31 lb-in)
(31 lb-in)
18.6 Nm
30.4 Nm
44.1 Nm
24.5 Nm
41.2 Nm
58.8 Nm
(14 lb-in)
(22 lb-in)
(33 lb-in)
(18 lb-in)
(30 lb-in)
(44 lb-in)
34.3 Nm
56.8 Nm
82.3 Nm
45.0 Nm
75.5 Nm
107.8 Nm
(25 lb-in)
(42 lb-in)
(61 lb-in)
(33 lb-in)
(56 lb-in)
(80 lb-in)
32.3 Nm
53.9 Nm
77.4 Nm
43.1 Nm
71.5 Nm
98.0 Nm
(24 lb-in)
(40 lb-in)
(57 lb-in)
(32 lb-in)
(53 lb-in)
(73 lb-in)
54.0 Nm
89.2 Nm
127.4 Nm
71.6 Nm
117.6 Nm
166.6 Nm
(40 lb-in)
(66 lb-in)
(94 lb-in)
(53 lb-in)
(87 lb-in)
(123 lb-in)
81.3 Nm
107.8 Nm
196.0 Nm
107.8 Nm
186.2 Nm
264.6 Nm
(60 lb-in)
(80 lb-in)
(145 lb-in)
(80 lb-in)
(138 lb-in)
(196 lb-in)
117.6 Nm
196.0 Nm
284.2 Nm
156.8 Nm
264.6 Nm
372.4 Nm
(87 lb-in)
(145 lb-in)
(210 lb-in)
(116 lb-in)
(196 lb-in)
(276 lb-in)
166.6Nm
274.4 Nm
392.0 Nm
215.6 Nm
362.6 Nm
519.4 Nm
(123 lb-in)
(203 lb-in)
(290 lb-in)
(160 lb-in)
(268 lb-in)
(384 lb-in)
225.4Nm
372.4 Nm
529.2 Nm
294.0 Nm
490.0 Nm
705.6 Nm
(167 lb-in)
(276 lb-in)
(392 lb-in)
(218 lb-in)
(362 lb-in)
(522 lb-in)
284.2 Nm
480.2 Nm
686.0 Nm
382.2 Nm
637.0 Nm
921.2 Nm
(210 lb-in)
(355 lb-in)
(508 lb-in)
(283 lb-in)
(471 lb-in)
(682 lb-in)
274.4 Nm
460.6 Nm
666.4 Nm
372.4 Nm
617.4 Nm
891.8 Nm
(203 lb-in)
(341 lb-in)
(493 lb-in)
(276 lb-in)
(457 lb-in)
(660 lb-in)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-33
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI0A-34
BASIC SPECIFICATION
VEHICLE SPECIFICATIONS
Vehicle Dimension
(mm)
) : Optional item
CHANGED BY
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AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-35
SPECIFICATIONS
Systems
General
Items
Diesel (XDi)
Remark
5,125 (5,220)
1,915 (1,930)
( ): optional
item
1,820 (1,845)
2,750 (2,850)
Engine
5.6
200
Fuel
Diesel
80
Model
D27DT
5/18:1
2,696 cc
Total displacement
DOHC
Camshaft arrangement
Max. power
Max. torque
Injection timing
Idle speed
Water-cooled/forced circulation
Cooling system
Approx. 11.5
Coolant capacity
Lubrication
9.3
Type
Gear ratio
1st
4.315
2nd
2.475
rd
1.536
th
1.000
5th
0.807
Rev.
3.591
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI0A-36
SPECIFICATIONS (Contd)
Systems
Automatic
transmission
Items
Diesel (XDi)
Model
Electronic
Type
2.742
3.595
2.742
2nd
1.508
2.186
1.508
3rd
1.000
1.405
1.000
th
0.708
1.000
0.708
th
0.831
Rev. 1st
2.429
3.162
2.429
Rev. 2nd
1.926
Model
TOD
Type
Gear ratio
Clutch
( ): optional item
st
Gear ratio
Transfercase
Remark
1.000 : 1
Low
2.483 : 1
Type
Disc type
Power
steering
Front axle
Rear axle
Brake
Type
Steering angle
36 17'
Outer
32 40'
Build-up type
Semi-floating type
Build-up type
Tandem type
Booster type
Type
Vacuum booster
Inner
Disc
Outer
Drum (Disc)
Parking brake
Suspension
Front
Rear
Air
conditioner
Refrigerant
Electrical
CHANGED BY
AFFECTED VIN
R134a
Compressor type
EFFECTIVE DATE
Vane type
MF / 12 - 90
Diesel : 12 - 2.2, Gasoline : 12 - 1.8
Diesel
Gasoline
12 - 115
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-37
MAINTENANCE
Major Components and Service Interval
* Use only Ssangyong Genuine Parts.
Components
Engine
oil and
oil filter
Daily Weekly
Gasoline
engine
DI diesel
engine
Service Interval
Initial change: 10,000 km
Replace at every 15,000 km
Coolant
Remarks
More frequent maintenance is required if
the vehicle is operated under severe
condition.
Severe conditions?
- Frequent low-speed operation as in
stop-and-go traffic
- When most trips are less than 6 km (in
winter, less than 16 km)
- Driving in sandy, dusty, and salty road
- Driving in mountainous areas
- Extensive idling or high load operation
such as towing a trailer
Gasoline
engine
DI diesel
engine
DI diesel
engine
Replace at every 30,000 km (Drain the water from fuel filter at every 10,000 km)
Manual transmission
oil
Axle oil
Spark plug
(gasoline engine)
Water separator
(DI diesel engine)
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI0A-38
Lubrication Chart
Lubricant
Capacity
Classification
Quality
class**
DI Diesel
6.8 ~ 8.3 L
Quality
class**
7.0 ~ 9.0 L
Gasoline
DI Engine
MB sheet 325.0,
BASF GLYSANTIN G05-11,
Gasoline
11.3 ~ 11.5 L
Properly
1.1 L
8.0 L
1.4 L
Axle fluid
11.0 ~ 12.0 L
Engine coolant
(Antifreeze and soft water mixed***)
ACEA : B2, B3 or B4
MB sheet : 229.1/3 (preferable)
Viscosity
Engine oil
Front
1.3 ~ 1.4 L
Rear
1.7 L
Properly
Properly
ALVANIA EP#2
** In only case not available MB 229.1 or 229.3, API or ACEA oil may be accepted, however it would rather recommend
to shorten the change interval around 30%.
*** Mixture of antifreeze to water (demineralized)
- General region ; 50 % : 50 %
- Extremily coil region ; 60 % : 40 %
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-39
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER (VIN)
Vehicle identification number (VIN) is is on the right front
axle upper frame.
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 0
* K P T N 0 B 1 9 S Y P 0 0 0 0 0 0 *
Digit
0
: Nation - K
: Maker identification - P
: Vehicle type
T - Passenger car
: Restraint system
: Engine type
: Check digit
10
: Model year
4 - 2004
5 - 2005
6 - 2006
7 - 2007
8 - 2008
11
: Plant code
P - Pyungtaek plant
Certification Label
The certification label is affixed on the bottom of drivers side
B-pillar.
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI0A-40
MANUFACTURERS PLATE
1. Type Approval No.
2. Vehicle Identification No.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-41
Automatic
The transmisson label is affixed on the right area of transmission housing.
Transfer Case
The transfer case label is affixed on the transfer case housing.
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI0A-42
MANUAL DESCRIPTION
The contents of the manual consist of operational
principle of system, specifications, diagnosis, removal/
installation on vehicle, inspections, disassembly/
assembly of removed assembly, special tool usage.
Not providing simple removal/installation information
but focused on to describe much more functions, roles
and principles of system.
Every automotive term like part name on the manual
is the same in parts catalog, technical bulletin and
drawings to avoid confusion among them.
Abbreviation of small
group and page
Vehicle model
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI01-1
SECTION
00 DI01
ENGINE ASSEMBLY
Table of Contents
STRUCTURE AND FUNCTION DESCRIPTIONS ........ DI01-2
D27DT engine ........................................................ DI01-2
Engine performance curve ..................................... DI01-7
General diagnosis ................................................... DI01-9
DIAGNOSTIC INFORMATION AND PROCEDURE .. DI01-14
Oil leak diagnosis .................................................. DI01-14
Compression pressure test .................................. DI01-15
Cylinder pressure leakage test ............................ DI01-17
Tightening torque .................................................. DI01-18
REMOVAL AND INSTALLATION .............................. DI01-21
Engine mounting ................................................... DI01-21
Engine assembly - removal .................................. DI01-22
DISASSEMBLY AND REASSEMBLY ........................ DI01-34
Components and special tools ............................. DI01-34
Inspection before disassembly and reassembly .. DI01-35
Engine accessories .............................................. DI01-36
Engine overhaul .................................................... DI01-50
ENGINE ASSEMBLY
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-3
Engine Structure
Front View
Rear View
7. Viscos clutch
9. Auto tensioner
6. Alternator
ENGINE ASSEMBLY
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-4
Top View
25. Injector
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-5
ENGINE ASSEMBLY
DI ENG SM - 2004.9
modulator
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-6
Specifications
Description
Specification
D27DT / 5-cylinder
Engine
Cylinder
86.2
Stroke (mm)
92.4
Displacement (cc)
2696
Compression ratio
18:1
170/4,000
34.7/1,800
Idle speed
Valve
750 20 rpm
750 20 rpm
Intake
Exhaust
Camshaft
Type
Fuel system
Fuel type
Opens (BTDC)
16
Closes (ABDC)
33
Opens (BBDC)
46
Closes (ATDC)
21
DOHC
Low sulfur diesel
Vane pump in HP pump
Oil specification
Lubrication type
6.8 ~ 8.3
Oil capacity ( )
Cooling system
Cooling type
Thermostat: Fully
(Open: 100C)
Opening
temperature (C)
Type
Coolant capacity ( )
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
85
WAX pellet type
11.5
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-7
Torque [Nm]
Output [PS]
Speed [rpm]
ENGINE ASSEMBLY
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-8
Speed [rpm]
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-9
GENERAL DIAGNOSIS
Condition
Hard Starting
(With normal
cranking)
Decline of
Compression
Pressure
Malfunction of
Ignition System
Decline of
Compression
Pressure
Others
ENGINE ASSEMBLY
DI ENG SM - 2004.9
Correction
Faulty fuse.
Malfunction of
Ignition System
Malfunction of
Fuel System
Lack of Engine
Power
Probable Cause
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-10
Rough Engine
Idling
Others
Dragging brakes.
Decline of
Compression
Pressure
Malfunction of
Fuel System
Decline of
Compression
Pressure
Malfunction of
Ignition System
Others
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Correction
Malfunction of
Fuel System
Malfunction of
Ignition System
Engine Hesitate
(Upon pressing
accelerating
pedal, the engine
makes delayed
response This
situation is
remarkable when
cruising or
starting.)
Probable Cause
Others
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-11
Overheat
Malfunction of
Fuel System
Overheated
Engine
Malfunction of
Fuel System
Malfunction of
Ignition System
Others
Lack of coolant.
Refill coolant.
Refill oil.
Leakage of oil
Repair.
Malfunction of
Ignition System
Malfunction of
Cooling System
Malfunction of
Lubrication
System
Other
ENGINE ASSEMBLY
DI ENG SM - 2004.9
Correction
Decline of
Compression
Pressure
Others
Excessive
Detonation
(According to
the opening
range of Malfunction of
metallic is made
with abnormal
explosion )
Probable Cause
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-12
Excessive
Consumption of
Engine Oil
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Correction
Decline of
Compression
Pressure
Malfunction of
Fuel System
Malfunction of
Ignition System
Malfunction of
Cooling System
Others
Refill oil.
Leakage of
Engine Oil
Low Oil
Pressure
Probable Cause
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-13
DI ENG SM - 2004.9
Correction
Piston, Ring,
Cylinder Noise
Connecting Rod
Noise
Adjust or replace.
Valve Noise
Crankshaft Noise
ENGINE ASSEMBLY
Probable Cause
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-14
Gaskets
The fluid level/pressure is too high.
The crankcase ventilation system is malfunctioning.
The fasteners are tightened improperly or the threads
are dirty or damaged.
The flanges or the sealing surface is warped.
There are scratches, burrs or other damage to the
sealing surface.
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method
Seals
The fluid level/pressure is too high.
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-15
Before cranking the engine, make sure that the test wiring, tools and persons are keeping away from moving
components of engine (e.g., belt and cooling fan).
Park the vehicle on the level ground and apply the parking brake.
Do not allow anybody to be in front of the vehicle.
Specifications
Compression ratio
18 : 1
Test temperature
Compression pressure
32 bar
Minimum value
18 bar
ENGINE ASSEMBLY
DI ENG SM - 2004.9
Max. 3 bar
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-16
Measuring Procedure
Notice
Disconnect the fuel rail pressure sensor connector to cut off the fuel injection.
Discharge the combustion residues in the cylinders before testing the compression pressure.
Apply the parking brake before cranking the engine.
15 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-17
At whole engine
Max. 25 %
Max. 10 %
At piston ring
Max. 20 %
Notice
ENGINE ASSEMBLY
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-18
TIGHTENING TORQUE
NO.
Size
Quantity
Tightening Torque
Oil nozzle
M6 x 22
10 1
M11 x 62
12
M9 x 52
Rear cover
M6 x 20
10 1
Oil pump
M8 x 35SOC
25 2.5
M6 x 20
10
10 1
M6 x 16
10 1
M6 x 40
10 1
M6 x 60
10 1
M6 x 70
10 1
M8 x 80SOC
25 2.5
Flywheel
M10 x 30
Crankshaft hub
M18 x 50
M6 x 20
24
10 1
M6 x 35
10 1
M6 x 38
10 1
M6 x 40
25 2.5
M8 x 40
25 2.5
M14 x 1.5-8-1
65 5
M7 x 16
20 2 x 90 + 10
M8 x 25
M8 x 50
M12 x 177
11
M12 x 158
Step3: 3 x 90 + 10
M8 x 60
24
25 2.5
M8
10
15 1.5
25 2.5
90 10
1
2
3
8
9
10
Name
T.G.C.C
Oil pan
11
12
13
14
15
Camshaft cap
16
Stud bolt
17
M11 x 52
55 5
90 10
40 5
90 10
45 5
90 10
325 33
90 10
25 2.5
Step1: 20 Nm 2 Nm
Step2: 85 Nm 5 Nm
18
Chain tensioner
M22
65 5
19
M14
22 2.2
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-19
NO.
20
Name
Auto tensioner
Size
Quantity
Tightening Torque
M8 x 45(LOWER)
32 3
M12 x 90
82 6
21
M6 x 50
10 1
22
M6 x 12
10 1
23
M6 x 12
10 1
24
Alternator bracket
M8 x 32
25 2.5
25
Alternator
M10 x 90
46 4.6
26
M8 x 95
46 4.6
M8 x 25
25 2.5
assembly
M8 x 60
25 2.5
M6 x 14
10 1.0
bracket assembly
M8 x 16
25 2.5
M8 x 45
25 2.5
M8 x 130
25 2.5
27
28
29
Intake manifold
30
Bracket
M6 x 16
10 1.0
31
Knock sensor
M8 x 28
20 2.6
32
M8 x 16
12 1.7
33
M6 x 16
10 1.0
34
Exhauster manifold
M8
10
40 4
35
M8
25 2.5
36
32 3.2
37
Nut
M8
25 2.5
38
Combination bolt
M8 x 22
25 2.5
39
25 2.5
20 2.0
M6 x 16 (T/C side)
10 1.0
10 1.0
M8 x 22
25 2.5
M6 x 16
10 1.0
M8 x 22
35 2.0
M6 x 16
10 1.0
M8 x 16
25 2.5
M8
35 2.0
44
M5
15 3
45
Vacuum pump
M6 x 20
10 1.0
M6 x 25
10 1.0
M6 x 65
10 1.0
M6 x 85
10 1.0
M6 x 35
21
23 2.3
40
41
42
43
46
47
ENGINE ASSEMBLY
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-20
NO.
Name
Size
Quantity
Tightening Torque
M6 x 16SOC
10 1.0
48
Vacuum modulator
49
M6 x 16
10 1.0
50
M6 x 16
10 1.0
M8 x 35SOC
25 2.5
M8 x 50SOC
25 2.5
M8 x 55SOC
25 2.5
M8 x 35SOC
25 2.5
51
52
53
M6 x 60
54
M6 x 19
10 1.0
55
M6 x 16
10 1.0
56
M5 x 17
0.8 0.4
57
GAP
58
59
Wiring
60
61
62
63
64
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10 1.0
180 + 20
0.7 ~ 1.5
1
M6 x 16
10 1.0
M8 x 16
25 2.5
M8 x 40
25 2.5
M8 x 100
25 2.5
NUT
25 2.5
0.765 ~ 1.055
0.05 ~ 0.31
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI02-1
SECTION
00 DI02
ENGINE HOUSING
Table of Contents
CYLINDER HEAD/CYLINDER BLOCK ....................... DI02-2
Cylinder head .......................................................... DI02-2
Camshaft assembly .............................................. DI02-16
Timing chain assembly .......................................... DI02-24
Cylinder block ....................................................... DI02-28
CRANKSHAFT ........................................................... DI02-31
Arrangement of thrust washers and bearings ...... DI02-32
Torsional vibration damper ................................... DI02-37
Diassembly and reassembly ................................. DI02-38
FLYWHEEL ................................................................ DI02-41
Dual mass flywheel (DMF, Manual transmission
equipped vehicle) ................................................. DI02-41
PISTON AND CONNECTING ROD ............................ DI02-43
Piston ring ............................................................. DI02-44
Cylinder inner diameter and piston size ............... DI02-45
Disassembly and reassembly ............................... DI02-46
HIGH PRESSURE PUMP (HPP) ............................... DI02-50
Components locator ............................................. DI02-50
Disassembly and reassembly ............................... DI02-51
VACUUM PUMP ........................................................ DI02-56
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-2
System Characteristics
4-valve DOHC valve mechanism
Intake port
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Oil gallery: drilled and sealing with cap and screw plug
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-3
Test Procedures
1. Place the pressure plate on a flat-bed work bench.
60 Nm
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-4
142.4 mm
in longitudinal direction
0.08 mm
in transverse direction
0.0 mm
142.9 ~ 143.1 mm
within 0.1 mm
0.004 mm
Intake valve
0.1 ~ 0.7 mm
Exhaust valve
0.1 ~ 0.7 mm
Measurement
1. Measure the cylinder head height A.
Limit
Over 142.4 mm
Notice
2. Insert the valves into the valve guides and measure the
recesses.
Valve recess a
0.1 ~ 0.7 mm
Notice
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-5
Cylinder Head
- Disassembly and Reassembly
Disassembly
Preceding Works:
- Removal of fan belt
- Removal of fuel supply and return lines
- Removal of EGR related pipes and oil dipstick tube
- Removal of intake manifold mounting bracket
- Removal of injector fuel line and connector, and glow plug
connector
Notice
Plug the openings of injector holes and common
rail with the protective caps.
1. Remove the cylinder head cover.
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-6
4. Remove the chain tensioner.
6. Pull out the lock pins with a sliding hammer and remove
the upper guide rail.
Notice
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-7
8. Remove the cylinder head bolts according to the
numerical sequence.
M8 x 25
M8 x 50
M12 x 177
M12 x 158
:
:
:
:
2 EA
2 EA
11 EA
1 EA
Maximum Limit
177 mm
179 mm
158 mm
160 mm
ENGINE HOUSING
DI ENG SM - 2004.9
0.765 ~ 1.055 mm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-8
Reassembly
1. Install the cylinder head with the steel gasket.
Notice
Step 2 85 5.0 Nm
Step 3 270 (90 x 3) + 10
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-9
Exhaust: #1, #3, #6
Intake
25 Nm
Exhaust
25 Nm + 90
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-10
8. Fit the timing chain onto the camshaft sprockets and
install the upper guide rail.
Install the clamping guide rail pin.
Notice
Install the guide rail with slanted side facing
forward.
Be careful not to change the timing of HP pump
when fitting the timing chain.
25 2.5 Nm,
90 + 10
10 Nm
13. Install the intake manifold. Install the oil cooler with new
gasket.
Installation Notice
Tightening torque
25 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-11
14. Install the chain tensioner.
Installation Notice
Tightening torque
65 5 Nm
10 1.0 Nm
18. Check the mating surface of the #12 bearing cap and the
cylinder head for contacting.
19. Check if the O-ring is installed in the vacuum pump.
20. Install the vacuum pump with the key groove aligned.
21. Tighten the vacuum pump mounting bolts.
Installation Notice
Tightening torque
ENGINE HOUSING
DI ENG SM - 2004.9
10 1.0 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-12
22. Install the PCV valve assembly on the cylinder head.
Installation Notice
Tightening torque
10 1.0 Nm
23. Engage the engine oil hose and the PCV valve hose.
24. Remove the protective caps and install the new fuel supply
pipes.
Notice
To keep the cleanness and protect the components,
the fuel pipes should be replaced with new ones.
Be careful not to be mixed the fuel pipes because
the pipe appearance of #1 and #3 cylinders and #2
and #4 are same each other.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-13
Intake/Exhaust - Removal/Installation
1. Remove the cylinder head assembly.
3. Push the valve spring seat down with the lever and remove
the valve cotter, valve seat and valve spring.
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-14
Application
Pressure plate
(cylinder head pressure leakage
test)
Pressure plate
(intake camshaft pressure leakage
test
Pressure plate
(exhaust camshaft pressure leakage test)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-15
Name and Part Number
Application
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-16
CAMSHAFT ASSEMBLY
Preceding Work: Removal of cylinder head cover
Camshaft sprockets
Cylinder head
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Chain tensioner
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-17
Hall voltage
The camshaft position sensor uses hall-effect to set the camshaft position and metallic-magnetic-material sensor end is
attached on the camshaft and then rotates with it. If sensor protrusion passes camshaft position sensors semi-conductor wafer, magnetic field changes direction of electron on the semi-conductor wafer to the current flow direction that
passes through wafer from the right angle. When operation power is supplied from camshaft position sensor, camshaft
hall sensor generates signal voltage. The signal voltage will be 0V if protrusion and camshaft position sensor are near
and 5 V if apart.
ECU can recognize that the No. 1 cylinder is under compression stroke by using this voltage signal (hall voltage).
The rotating speed of camshaft is half of the crankshaft and controls engines intake and exhaust valves. By installing
sensor on the camshaft, can recognize specific cylinders status, compression stroke or exhaust stroke, by using
camshaft position when the piston is moving toward TDC (OT). Especially when started first, it is difficult to calculate the
stroke of a specific cylinder with only crankshaft position sensor.
Accordingly, camshaft position sensor is necessary to identify the cylinders correctly during initial starting. However,
when engine is started, ECU learns every cylinder of the engine with crankshaft position sensor signals so can run the
engine even though the camshaft position sensor is defective during engine running.
Pulse generation
Cam angle 6
0.2 ~ 1.8 mm
Tightening torque
10 ~ 14 Nm
Operating temperature
- 40 ~ 130C
Ground
Camshaft sensor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-18
Removal
Preceding Works:
- Removal of fan belt
- Removal of fuel supply and return lines
- Removal of intake manifold mounting bracket
- Removal of EGR pipe and oil dipstick tube
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-19
4. Mark on the intake camshaft sprocket and exhaust
camshaft sprocket for timing setting during installation.
Intake
Exhaust
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-20
Intake: #2, #4, #5
Exhaust: #8, #10, #11
* Do not remove the bolts at a time completely. Remove
them step by step evenly.
8. Remove the intake and exhaust camshafts from the
cylinder head.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-21
Installation
1. Install the HLA device and finger follower. Check the HLA
device with the diagnosis procedures before installation.
Notice
10
11
12
10
25 Nm
11
Exhaust
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
DI02-22
4. Install the intake and exhaust camshaft sprockets and
the timing chain.
Installation Notice
Tightening torque
25 Nm + 90 + 10
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
80 8.0 Nm
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-23
Application
HLA remover
Y99220152B
ENGINE HOUSING
DI ENG SM - 2004.9
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DI02-24
9. Crankshaft sprocket
5. HP pump sprocket
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ENGINE HOUSING
DI ENG SM - 2004.9
DI02-25
Chain
Chain type: Double Bush
Pitch: 9.525 mm
Load limits: 19,000 N
No. of links: 144 EA
Overall length: 1371.6 mm
Replace when the chain is extended by 0.5 % from overall length (Replace if extended by over 6.858 mm)
Chain tensioner
Check valve
The major function of tensioner is optimizing the movement of chain drive system by using spring constant and oil
pressure in the tensioner.
The tensioner performs function of adjusting chain tension to be always tight, not loose, while engine running. By doing
so, can reduce wears of each guide rail and sprocket.
Tightening torque
65 5.0 Nm
(Installed on the cylinder head)
Guide rail
Guide rail is used to optimize the movement of chain drive system like tensioner.
Guide rail can prevent chain slap when chain is extended and reduce chain wears.
Guide rail is needed especially when the distance between the sprockets are too long.
The material is plastic.
Location of guide rail
- Tensioner guide rail: Between crankshaft sprocket and exhaust camshaft sprocket
- Upper guide rail: Between exhaust camshaft sprocket and intake camshaft sprocket
- Clamping guide rail: Between intake camshaft sprocket and HP pump sprocket
- Lower guide rail: Between HP pump sprocket and crankshaft sprocket
ENGINE HOUSING
DI ENG SM - 2004.9
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DI02-26
Timing setting
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ENGINE HOUSING
DI ENG SM - 2004.9
DI02-27
ENGINE HOUSING
DI ENG SM - 2004.9
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DI02-28
CYLINDER BLOCK
System Characteristics
Rib design by considering strength against engine
vibrations and weight
Cambering type skirt design on case housing wall to
reduce the engine noise
Water jacket design to increase the cooling efficiency
of cylinder bore bridge
Deep head bolt thread to prevent the deformation at
cylinder bore surfaces
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Reinforcement of strength
- Main bearing housing / Main bearing cap
- Extended main bearing cap bolt
Reducing the noise, vibration and harshness (NVH)
- Minimize the vibration by adding external ribs
- Adding the ribs around oil pan mating surface
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-29
Knock Sensor
Two knock sensors are located on the cylinder block (intake manifold side).
To detect engine vibration under abnormal combustion, knock sensor has piezoelectric element fixed on the
vibration plate and this vibration plate is fixed on the base. If happens knocking, pistons or connecting rods
vibrate and occurs heavy sounds that hit metal. Knock sensor is used to detect those knockings caused by
abnormal combustions. It controls idling stabilities and turns on the engine warning light when detects injector
damages. And also controls pilot injection very precisely during MAP learning.
When knock sensor is defective, engine ECU corrects injection timing based on MAP values like engine speed,
intake air volume and coolant temperature.
Before checking the knock sensor unit, be sure to check the tightening torque of the sensor and connector
connecting conditions.
Insulating resistance
Min. 1M
Resonance frequency
25 kHz
Operating temperature
- 40 ~ 150C
26 8 mV/g (at 5 kHz)
Output voltage
22 ~ 37 mV/g (3 ~ 10 kHz)
22 ~ 57 mV/g (10 ~ 20 kHz)
Tightening torque
20 5 Nm
2. Nut
7. Piezo element
3. Disc spring
4. Weight
9. Body
5. Insulation disc
ENGINE HOUSING
DI ENG SM - 2004.9
10. Terminal
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DI02-30
Notice
The knock sensor should be tightened with the specified tightening torque. Otherwise, the engine output may
be decreased and the ENGINE CHECK warning lamp may come on. The internal resistance of the sensor is
approx. 4.7 k.
Ground
Knock sensor
Signal
Signal
Knock sensor
Ground
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ENGINE HOUSING
DI ENG SM - 2004.9
DI02-31
CRANKSHAFT
Preceding Works: Removal of end cover
Removal of pistons
Removal of crankshaft sprocket
5. Crankshaft
6. Crankshaft main bearing shells, lower
ENGINE HOUSING
DI ENG SM - 2004.9
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AFFECTED VIN
DI02-32
1. Crankshaft
Notice
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ENGINE HOUSING
DI ENG SM - 2004.9
DI02-33
Color
Crankshaft Journal
Blue
57.965 ~ 57.960
2.260 ~ 2.255
2.260 ~ 2.255
Yellow
57.960 ~ 57.955
2.265 ~ 2.260
2.265 ~ 2.260
Red
57.955 ~ 57.950
2.270 ~ 2.265
2.270 ~ 2.265
White
57.950 ~ 57.945
2.275 ~ 2.270
Violet
57.945 ~ 57.940
2.280 ~ 2.275
Crankshaft Bearing
Thrust Bearing
When new
0.027 ~ 0.051
0.026 ~ 0.068
Wear limit
Max. 0.070
Max. 0.080
When new
0.100 ~ 0.254
Wear limit
Max. 0.300
Bearing Clearance
(mm)
Description
Radial clearance
Axial clearance
24.500 ~ 24.533
2.15
24.600 ~ 24.633
2.20
24.70 ~ 24.733
2.25
24.900 ~ 24.933
2.35
25.000 ~ 25.033
2.40
Notice
Measure the crankshaft axial clearance and correct if necessary with appropriate thrust washers.
Thrust washers of the same thickness must be installed on both sides of the fit bearing.
ENGINE HOUSING
DI ENG SM - 2004.9
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DI02-34
Color
Blue
Yellow
Red
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Mark
Color
Blue
Yellow
Red
White
Violet
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-35
Permanent
magnet
Iron
coil
Standard
position
Ring gear
The crankshaft position sensor is located near to flywheel on the rear of cylinder block. It generates AC voltage between
increment type driven plate that fixed on flywheel inside. The sensor consists of soft iron core that winded copper wire
on permanent magnet and generates sign wave AC voltage when magnetism on the sensor wheel passes the sensor.
When the crankshaft rotates, + signal will be generated from near the front edge and - signal will be generated from
near the rear edge among teeth on the driven plate near to crankshaft position. The AC voltage increases as the engine
speed increases, however, no signal occurs from the 2-missing-tooth on the increment type driven plate. By using these
teeth, ECU recognizes TDC of No. 1 and 5 cylinders.
ECU converts the alternative signals into digital signals to recognize crankshaft position, piston position and engine
speed. The piston position that coupled with crankshaft is main factor in calculating injection timing. By analyzing the
reference position and camshaft position sensor, can recognize No. 1 cylinder and calculate the crankshaft speed.
<Drive plate>
a. Front edge
b. Rear edge
c. 2-missing-tooth
ENGINE HOUSING
DI ENG SM - 2004.9
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DI02-36
Ground
Signal
Crankshaft position
sensor
Drive plate
Output voltage
( 1 ~ 150 V)
1,090 15 %
0.3 ~ 1.5 mm
Operating temperature
- 40 ~ 150C
Tightening torque
6 ~ 8 Nm
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ENGINE HOUSING
DI ENG SM - 2004.9
DI02-37
Laser welding
Bearing
Pin
Cover
Hub
Bushing
Inertia ring
Pin
Silicone oil
System Description
Components: Hub, inertia ring, cover, bearing, bushing, silicone oil
Functions: The crankshaft pulley optimizes the drive system by reducing the amount of torsional vibration in crankshaft.
Conventional rubber damper is limited in changing materials (rubbers) to absorb vibration, but this crankshaft
pulley (viscous damper), using silicone oil, takes advantage of less changing viscosity according to the
temperature.
ENGINE HOUSING
DI ENG SM - 2004.9
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DI02-38
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ENGINE HOUSING
DI ENG SM - 2004.9
DI02-39
Crankshaft - Reassembly
1. Thoroughly clean the oil galleries and check the journal
section and bearings. Replace if necessary.
2. Coat the upper thrust washers with oil and insert into the
crankcase so that the oil grooves are facing the crank
webs (arrow).
3. Coat the lower thrust washers with oil and insert into the
crankcase so that the oil grooves are facing the crank
webs (arrow).
Notice
Notice
55 5 Nm + 90 + 10
ENGINE HOUSING
DI ENG SM - 2004.9
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DI02-40
6. Position the #1 piston at TDC and install the crankshaft.
7. Install the piston connecting rod journal to the crankshaft
journal and tighten the bolts.
8. Measure the crankshaft bearing axial clearance.
When new: 0.100 ~ 0.245 mm
When used: 0.300 mm
9. Rotate the crankshaft by hand and check whether it
rotates smoothly.
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ENGINE HOUSING
DI ENG SM - 2004.9
DI02-41
FLYWHEEL
DUAL MASS FLYWHEEL (DMF, MANUAL TRANSMISSION EQUIPPED VEHICLE)
Primary wheel
Ring gear
Primary wheel
Secondary
wheel
Plastic bushing
System Description
This flywheel is installed to the rear end of crankshaft and transfers the output from the engine to the power train
mechanism. When starting the engine, this drive the crank train mechanism initially by using the power from the start
motor. Also, DMF measure the crankshaft speed, sends the signals to ECU, and controls the ignition timing.
Conventional flywheel
ENGINE HOUSING
DI ENG SM - 2004.9
DMF
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DI02-42
Structure
Function and characteristics
When the output changes from the engine is high during
power stroke ( ): The damper absorbs the shocks to
reduce the changes to transmission.
When the output changes from the engine is low during
compression stroke ( ): The damper increases the torque
changes to clutch.
<Example of DMF operation>
Conventional system
DMFW
Engine
Engine
Transmission
Transmission
Speed [rpm]
Speed [rpm]
System Characteristics
Function
Filters irregularities of engine: The secondary flywheel
operates almost evenly so does not cause gear noises
The mass of the primary flywheel is less than
conventional flywheel so the engine irregularity
increases more (less pulsation absorbing effect)
Transmission protection function: Reduces the load to
powertrain (transmission) by blocking the irregularity
of engine
Characteristics of DMF
Reduced vibration noise from the powertrain by blocking
the torsional vibrations
Advantages of DMF
Improved torque response by using 3-stage type spring:
Strengthens the torque response in all ranges (low,
medium, and high speed) by applying respective spring
constant at each range.
Stable revolution of the primary and secondary wheel
by using planetary gear: Works as auxiliary damper
against spring changes
Less heat generation due to no direct friction against
spring surface: Plastic material is covered on the spring
outer surface
Increased durability by using plastic bushing (extends
the lifetime of grease)
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-43
3. Oil ring
Description
Cylinder bore diameter
Piston outer diameter (D1)
Clearance between bore and piston
Piston cooling gallery
Pin offset
Compression ratio
Length of piston pin
Material of top ring / coating
Tightening torque of connecting rod bolt
Permissible weight difference of connecting rod
D27 DT ENG
86.2 (0~0.018) mm
86.133
(0.009)
mm
74
Applied
0.15 mm (Thrust)
18 : 1
71.2 mm
Steel / Gas nitride
40 5.0 Nm, 90 + 10
4g
1.806 ~ 1.809 mm
1.809 ~ 1.812 mm
1.812 ~ 1.815 mm
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
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DI02-44
PISTON RING
1. No.1 compression ring
2. No.2 compression ring
3. Oil ring
5. Coil spring and oil control ring
6. Hook spring
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ENGINE HOUSING
DI ENG SM - 2004.9
DI02-45
(Unit : mm)
Engine
Code
Used piston
Cylinder Diameter
Piston Diameter
D27DT
A or X
86.200 ~ 86.206
86.124 ~ 86.130
A, B or X
86.206 ~ 86.212
86.129 ~ 86.137
B or X
86.212 ~ 86.218
86.136 ~ 86.142
+5
+5
86.250 ~ 86.260
86.167 ~ 86.181
+ 10
+ 10
86.300 ~ 86.310
86.217 ~ 86.231
ENGINE HOUSING
DI ENG SM - 2004.9
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DI02-46
0.20 ~ 0.35 mm
2nd groove
0.20 ~ 0.35 mm
3rd groove
0.20 ~ 0.40 mm
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AFFECTED VIN
0.075 ~ 0.119 mm
0.050 ~ 0.090 mm
0.040 ~ 0.080 mm
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-47
4. Fit the piston onto connecting rod so that the marking
on piston crown and locking slot are facing to straight
ahead direction.
Notice
ENGINE HOUSING
DI ENG SM - 2004.9
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DI02-48
10. Measure stretch shaft diameter of the connecting rod
bolts.
Limit C
7.1 mm
40 5.0 Nm,
90 + 10
0.5 ~ 1.5 mm
0.765 ~ 1.055 mm
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ENGINE HOUSING
DI ENG SM - 2004.9
DI02-49
Application
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI02-50
High pressure
line
Low pressure line
IMV connector
Inlet Metering
Valve (IMV)
High pressure
supply line
3. Plunger
9. Venting
5. Housing
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ENGINE HOUSING
DI ENG SM - 2004.9
DI02-51
ENGINE HOUSING
DI ENG SM - 2004.9
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DI02-52
3. Remove the cooling fan bracket assembly.
Notice
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AFFECTED VIN
64 5 Nm
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-53
8. While insert finger and push the chain guide backward
direction and turn the crankshaft pulley to ATDC 65 by
counter clockwise direction until feel the chain guide
inclined backward.
10. Remove the sprocket bolts and center nut and after
slightly lifted up the chain, remove the pump sprocket.
Installation Notice
Tightening torque
Nm
Sprocket bolt
20 Nm + 90
Center nut
65 5 Nm
ENGINE HOUSING
DI ENG SM - 2004.9
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DI02-54
12. Remove the HP pump mounting bracket.
Installation Notice
Tightening torque
24 2.4 Nm
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ENGINE HOUSING
DI ENG SM - 2004.9
DI02-55
Notice
* Tightening torque
Center nut
(M14 x 1.5 - 1EA)
Outer bolt
(M8 x 55 - 3EA)
Sprocket bolt
(M7 x 13 - 3EA)
ENGINE HOUSING
DI ENG SM - 2004.9
65 5.0 Nm
24 2.4 Nm
20 Nm 90
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AFFECTED VIN
DI02-56
VACUUM PUMP
Caution
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AFFECTED VIN
Within 190mmm
(torque: 4 ~ 12 Nm)
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-57
1. Unscrew the lower bolt (10mm) from the cooling fan shroud cover and remove the cover. Doing this eliminate the
interference between the cooling fan and shroud during lowering the engine.
ENGINE HOUSING
DI ENG SM - 2004.9
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AFFECTED VIN
DI02-58
2. Remove the FFH coolant inlet hose bracket nut and the engine ground. Move and attach them at front side of the
engine compartment to eliminate the interference between the engine and hoses during lifting up the engine.
3. Remove the upper engine mounting insulator nuts (19mm) at both sides.
Installation Notice
Tightening torque
LH
70 7.5 Nm
RH
4. Raise the main lift and unscrew the four bolts (arrows) and two fasteners (1) to remove the skid plate.
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ENGINE HOUSING
DI ENG SM - 2004.9
DI02-59
5. Place the rubber blocks under the oil pan (in front of the oil drain plug) and raise the engine with auxiliary lift.
Caution
The oil drain plug should be on the center point of the rubber block. Otherwise, the engine cannot be
raised properly due to the deviation of the center point of gravity.
6. Unscrew two engine mounting insulator bracket (RH) bolts and remove the bracket.
Installation Notice
Tightening torque
ENGINE HOUSING
DI ENG SM - 2004.9
25 2.5 Nm
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AFFECTED VIN
DI02-60
7. Unscrew the power steering hose and pipe mounting bracket bolt from the engine mounting insulator bracket (LH)
and remove the bracket.
8. Remove two engine mounting insulator bracket bolts.
Installation Notice
Tightening torque
25 2.5 Nm
Power steering hose and pipe mounting bracket bolt (12mm)
Mounting bolt
(14mm)
Mounting bolt
(14mm)
9. Raise the main lift and lower the engine with the auxiliary lift until the distance between the oil pan and the sub
frame No.2 crossmember is 20mm. Make sure that there is no interference between components. If the engine is
lowered beyond the specified distance, the interference between the transmission oil cooler pipe and the front axle
can be occurred.
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ENGINE HOUSING
DI ENG SM - 2004.9
DI02-61
10. Lower the main lift and remove the nut from brake booster vacuum hose.
11. Bring a torque wrench for vacuum pump and designated adaptor socket (special service tool).
within 190 mm
ENGINE HOUSING
DI ENG SM - 2004.9
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AFFECTED VIN
DI02-62
13. Install the vacuum pump with the specified tightening
torque.
Installation Notice
Tightening torque
10 1 Nm
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ENGINE HOUSING
DI ENG SM - 2004.9
DI03-1
SECTION
00 DI03
INTAKE SYSTEM
Table of Contents
AIR FLOWS ................................................................. DI03-2
INTAKE SYSTEM LAYOUT ......................................... DI03-3
Components locator ............................................... DI03-3
Tightening torque of intake system ........................ DI03-4
Air cleaner ............................................................... DI03-5
Air flow sensor
(hot film air mass sensor) ....................................... DI03-8
Intercooler ............................................................. DI03-12
Intake manifold assembly ..................................... DI03-16
INTAKE SYSTEM
DI ENG SM - 2004.9
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DI03-2
AIR FLOWS
Intake Valve
(in combustion chamber)
Intake Manifold
Air Cleaner
Turbo
Charger
Engine
HFM Sensor
Intercooler
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AFFECTED VIN
HFM
Sensor
Turbo
Charger
Intercooler
Intake
Manifold
Combustion
Chamber in
Engine
INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-3
INTAKE SYSTEM
DI ENG SM - 2004.9
Air cleaner
Intake manifold
HFM sensor
Intercooler
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AFFECTED VIN
DI03-4
There is a possibility that the clamps of intercooler and related intake hoses are disconnected by the pressure of turbo
charger, therefore it should be tightened with proper torque using torque wrench and ratchet.
Tightening torque
CHANGED BY
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AFFECTED VIN
5 ~ 6 Nm
INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-5
AIR CLEANER
Cover
Element
Housing
Specifications
Element Type
Dry-Element Type
* Initial cleaning: 5,000 km, Clean or change every 10,000 km as required.
However, change every 30,000 km.
Service Interval
INTAKE SYSTEM
DI ENG SM - 2004.9
* If the vehicle is operated under severe condition (short distance driving, extensive
idling or driving in dusty condition): More frequent maintenance is required.
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DI03-6
CHANGED BY
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INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-7
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DI03-8
Change history
inner tube added + grid (No.3)
added + sensing chip changed +
sensing section design changed
Results
Durability has enhanced 60
times (lab test results)
7. Hybrid
2. Cylinder housing
8. Sensor
3. Protection grid
9. Mounting plate
4. Hybrid cover
10. O-ring
6. Housing
Air flow sensor is locating on the air intake passage between air cleaner and intake manifold and measures air volume
flows to engine combustion chamber and intake air temperature.
And intake temperature sensor built-in the sensor detects intake temperature.
Internal circuit of the air flow sensor is being used to control the voltage value to control the temperature to maintain the
heating resistance (Rh) to 160C that is higher temperature than intake air temperature that is measured by resistance
(RI).
Temperature sensor of the heating resistance (Rh) is measured by resistance (Rs).
If temperature changes occur due to increasing/decreasing intake air volume, voltage of the heating resistance changes
to maintain the intake air temperature changes to set value (160C).
Control unit computes intake air volume based on voltage changes of heating resistance.
Intake air temperature is measured by NTC integrated in the sensor.
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INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-9
Intake air temperature sensor is a part of HFM sensor and a thermister and resister and detects air temperature
changes that flow into the engine. There occurs high resistance when temperature is low and low resistance when high
(NTC type).
ECU supplies 5 V to intake air temperature sensor and then measures voltage changes to determine the intake air
temperature. When air in the intake manifold is cold, the voltage is high and air is hot, the voltage is low.
The reason for using HFM sensor is that this sensor is most proper in controlling accurate air-fuel ratio to meet the legal
emission regulations. This sensor measures actual intake air mass into engine very accurately during specific instant
acceleration and deceleration, and determines engine loads and detects intake air pulsation and air flows.
Main functions of HFM sensor are:
Using for EGR feedback control
Using for turbocharger booster pressure control valve control
Using for fuel injecting compensation
CI type HFM sensor: The air flowing the sensor does not directs toward sensing section but flows along with lower wall
after passing protection grid to enhance durability of the sensor. Oil, water and dust less damage the sensor.
Air outlet
Air inlet
INTAKE SYSTEM
DI ENG SM - 2004.9
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AFFECTED VIN
DI03-10
Power supply
Intake air
flow
sensor
Ground
Ground
Signal
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INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-11
HFM sensor
4 ~ 5 Nm
INTAKE SYSTEM
DI ENG SM - 2004.9
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AFFECTED VIN
DI03-12
INTERCOOLER
The turbo charger is designed to improve the engine power by introducing more air (oxygen) into the engine. However,
the intake air is heated (100 ~ 110C) during the compression process in turbo charger compressor and the density is
lowered.
The intercooler is the device which cools (50 ~ 60C) the air entering the engine. Colder air has more oxygen molecules
than warm air. Thus cooler air gives more power and better fuel economy.
1. Intercooler
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INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-13
AQS sensor
Ambient temperature
sensor
Connector
[for air conditioner]
Receiver drier
Electric fans
INTAKE SYSTEM
DI ENG SM - 2004.9
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AFFECTED VIN
DI03-14
2. Remove the front end center member.
3. Remove the hood latch cable and remove the radiator support upper member.
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AFFECTED VIN
INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-15
4. Remove the intercooler inlet hose.
Tightening torque
Tightening torque
6 ~ 7 Nm
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AFFECTED VIN
DI03-16
System Characteristics
Shape that delivers the required capacity of compressed air from turbo charger to inlet port
Optimized EGR gas mixture in inlet chamber
Maximized intake efficiency with helical and tangential inlet port
- Improving the swirl ratio in low and mid operating range
- Improving the acceleration/fuel economy and reducing the maintenance in low and mid operating range
Integrated inlet port and coolant outlet port
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INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-17
Application
Installation of intake manifold
Y99220112B
INTAKE SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI03-18
INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-19
8. Remove the brackets and connectors from top section of
the engine.
- Vacuum hose bracket in turbo charger
- Booster pressure sensor
- Main wiring bracket
- Ground cable bracket
- Fuel pressure sensor connector
9. Unscrew the bolts and remove the vacuum modulator
bracket.
Installation Notice
Tightening torque
9.0 Nm
INTAKE SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI03-20
14. Remove the intake manifold mounting bolts.
Installation Notice
Tightening torque
25 2.5 Nm
M8 x 45: 6EA
M8 x 130: 6EA
15. Lift up the vehicle and remove the propeller shaft joint
bolts.
16. Unscrew the bolt in oil filter and remove the intake
manifold and gasket.
Notice
Replace the gasket with new one.
Make sure that the residual coolant in intake
manifold gets into the inside of inlet port.
17. Install in the reverse order of removal.
Notice
Replace the gasket with new one.
If replaced only gasket without any other service
operation, completely remove the coolant and other
contaminants from the engine before installation.
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INTAKE SYSTEM
DI ENG SM - 2004.9
DI04-1
SECTION
00 DI04
EXHAUST SYSTEM
Table of Contents
EXHAUST SYSTEM LAYOUT ..................................... DI04-2
Components locator ............................................... DI04-2
Exhaust gas flows ................................................... DI04-3
Turbo charger assembly ......................................... DI04-5
EGR VALVE AND VACUUM MODULATOR ............... DI04-26
EGR system .......................................................... DI04-26
EGR valve and turbo charger actuator
control vacuum circuit ........................................... DI04-27
EXHAUST SYSTEM AND MUFFLER ........................ DI04-35
Muffler ................................................................... DI04-35
System overview ................................................... DI04-36
EXHAUST SYSTEM
DI ENG SM - 2004.9
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DI04-2
Turbo charger
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Exhaust manifold
EGR valve
EGR pipe
Vacuum modulator
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-3
Exhaust
pipe
Muffler
Atmosphere
Exhaust gas
Turbo charger
(turbine side)
EGR vacuum
modulator
To turbo
charger booster
Turbo charger
booster vacuum
modulator
Turbo charger
booster
EGR valve
Exhaust manifold
Blow-by gas
EGR pipe
Engine
-Combustion
Chamber-
Exhaust
Manifold
Turbo
Charger
EGR Valve
EXHAUST SYSTEM
DI ENG SM - 2004.9
Exhaust
Muffler
Atmosphere
Intake
Manifold
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DI04-4
Exhaust Manifold
- Removal and Installation
1. Remove the two intake hoses from the turbo charger.
35 3.5 Nm
40 4.0 Nm
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-5
Turbine
Impeller
Intercooler
Intake
Exhaust
Intercooler
coolant
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DI04-6
1. Turbine housing
2. Turbine wheel
B. Air flow
3. Compressor housing
4. Compressor wheel
5. Center housing
7. Control link
8. Bypass flap
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-7
Impeller
Turbine
Impeller
Turbine shaft
Thrust collar
The radial type has the impeller plate arranged in straight line
at the center of shaft and, compared to the backward type, is
being widely used as it is simple, easy to manufacture and
appropriate for high speed rotation. As the impeller rotates in
the housing with the diffuser installed in it, the air receives
centrifugal force to be accelerated in the direction of housings
outer circumference and flows into the diffuser.
As surface of the passage increases, air flown into the diffuser transforms its speed energy into pressure energy and
flows into the intake manifold where the pressurized air is
supplied to cylinder each time the intake valve of cylinder opens
up. Therefore, the efficiency of compressor is determined by
the impeller and diffuser.
Floating bearing
Turbine
Impeller
Exhaust gas
Diffuser
Oil passage
Turbine
The turbine is wings installed at the exhaust end where, by the pressure of exhaust gas, it rotates the compressor and
performs the role of transforming heat energy of exhaust gas into torque energy. The radial type is used as the turbines
wings. Therefore, during operation of the engine, the turbine receives temperature of exhaust gas and it rotates in high
speed, it requires to have sufficient rigidity and heat resisting property.
During operation of the engine, exhaust gas discharged through the exhaust valve of each cylinder makes turbine rotate
by coming in contact with the turbines wings from the outer circumference within housing of the turbine and is exhausted through the exhaust manifold. At the same time, as the impeller is on the same shaft, it rotates.
Floating Bearing
Floating Bearing is a bearing, which supports the turbine shaft that rotates at about 10,000 to 15,000 rpm. It could be
rotated freely between the housing and the shaft as it gets lubricated by oil being supplied from the engine.
Notice
Stopping the engine immediately after driving at high speed stops oil from being supplied to the bearing and
may cause it to get burnt. Therefore, the engine must be stopped after cooling the turbo system by sufficiently
idling the engine.
EXHAUST SYSTEM
DI ENG SM - 2004.9
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DI04-8
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-9
EXHAUST SYSTEM
DI ENG SM - 2004.9
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DI04-10
- Oil Drain Pipe Defect
In case where oil flow from the turbo charger
sensor housing to the crank case is not smooth
would become the reason for leakage as oil builds
up within the center housing. Also, oil thickens
(sludge) at high temperature and becomes the
indirect reason of wheel hub section. In such case,
clogging and damage of the oil drain pipe and the
pressure of blow-by gas within the crank case
must be inspected.
- Damages from Foreign Materials
When the foreign materials get into the system,
it could induce inner damage as rotating balance
of the turbo charger gets out of alignment.
Inspection of Turbine
Thoroughly check the followings.
Notice
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-11
Path of Turbo Charger Defect
The following tries to understand the defects that can occur with vehicle installed with the turbo charger and to manage
the reasons of such defects.
1. In case where oil pan/oil pipe has been contaminated, oil filter is defected and where
adhesive of gaskets has been contaminated into the oil line.
Contamination of Oil
Journal Bearing
Damage or Wear
Clogging of Oil
Passage
Metal Contact
Rotor Wear
Seal Wear at
Exhaust System
Interference of
Turbine and Compressor Components
Oil Leakage
Abnormal Noise
EXHAUST SYSTEM
DI ENG SM - 2004.9
Lack of Power/Poor
Acceleration (Lack of
Turbo Charged Pressure)
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DI04-12
2. Oil Pump Defect: Rapid over-loaded driving after replacing oil filter and oil and clogging of oil
line.
Poor Oil Supply
Abnormal Noise
Lack of Power/Poor
Acceleration (Lack of
Turbo Charged Pressure)
Oil Leakage
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-13
3. Turbine Side: Inflow of foreign materials from engine
Compressor Side: such as air filter, muffler and nut
Inflow of Foreign Materials
Abnormal Noise
Oil Leakage
EXHAUST SYSTEM
DI ENG SM - 2004.9
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DI04-14
4. Defects caused by reasons other than that of the Turbo Charger.
No Problems in Turbo
Charger System
Misunderstanding of Oil
Leakage
<Mechanical
Malfunction>
Carbonization Caused By
High Temperature
Seal Wear
Oil Leakage
Inflow of Dust
Misunderstanding of Oil
Leakage
No Problems in Turbo
Charger System
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-15
How to Diagnose
The followings are cautions to take in handling defects of turbo charger, which must be fully aware of;
Cautions When Examining the Defects:
1. After stopping the engine, check whether the bolts on pipe connecting section are loose as well as the connecting
condition of vacuum port and modulator, which is connected to the actuator.
2. During idling of the engine, check for leakage in the connecting section of pipe (hoses and pipes, duct connections,
after the turbo charger) by applying soap water. The leakage condition in the engine block and turbine housing
opening can be determined by the occurrence of abnormal noise of exhaust.
3. By running the engine at idle speed, abnormal vibration and noise can be checked. Immediately stop the engine
when abnormal vibration and noise is detected and make thorough inspection whether the turbo charger shaft
wheel has any damages as well as checking the condition of connections between pipes.
4. In case where the noise of engine is louder than usual, there is possibility of dampness in the areas related with air
cleaner and engine or engine block and turbo charger. And it could affect the smooth supply of engine oil and
discharge.
5. Check for damp condition in exhaust gas when there is sign of thermal discoloration or discharge of carbon in
connecting area of the duct.
6. When the engine rotates or in case where there is change in noise level, check for clogging of air cleaner or air
cleaner duct or if there is any significant amount of dust in the compressor housing.
7. During the inspection of center housing, inspect inside of the housing by removing the oil drain pipe to check for
sludge generation and its attachment condition at shaft area or turbine side.
8. Inspect or replace the air cleaner when the compressor wheel is damaged by inflow of foreign materials.
9. Inspect both side of the turbo charger wheel after removing inlet and outlet pipe of the turbo charger.
- Is the rotation smooth when the rotor is rotated by hand?
- Is the movement of bearing normal?
- Inspect whether there has been any signs of interference between two wheels.
Notice
Its important not to drive the engine when the intake manifold hose has been removed.
EXHAUST SYSTEM
DI ENG SM - 2004.9
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DI04-16
Diagnosis and Measure
NO
YES
NO
YES
Reconnect Connections
NO
NO
NO
YES
Refer to Diagnosis
Table
NO
NO
YES
NO
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NO
Weakness of Engine
Function, Intake/Exhaust
Valve Damage, Timing
Defects of Each Valve
YES
Inspect and Repair
Related Components
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-17
Before Diagnosis
The base of making diagnosis on the EGR related system is the inspection on the connections of the vacuum hoses in
related system as the first priority. When abnormal condition occurs with the EGR system, the basic approach is, as
described in prior sentence, making detail inspections of vacuum circuits of each system before connecting the scan
tool or vacuum tester. It is necessary to manually check on the connections if there are any slacks or loose circuits even
if the visual inspection shows vacuum hose as being connected. If there are not any problems then the next inspection
area is the connections of the system connectors. Most problems with the occurrence of system malfunction are from
conditions of vacuum line and connector connections and the causes from the malfunction of mechanical mechanism is
actually very few.
For example, when there are no problems with basic components, lets assume that there is a vehicle having vacuum
leak from connection slack in the vacuum line between EGR vacuum modulator and EGR valve. This vehicle, due to the
driving condition or, according to the circumstances, smog or other conditions, could create customers complaint and
by connecting the scanning device could display as the malfunction of the EGR valves potentiometer.
As previously explained, this car has a separate controller to control the HUBER EGR and, in accordance with various
input element, the controller controls EGR valve by regulating the force of vacuum being applied to the EGR valve through
PWM control. At this time, the controller has to receive feedback whether the EGR valve operates correctly according to
the value sent to the EGR modulator and this role is performed by the EGR potentiometer located at top section of the
EGR valve.
In other word, the controller sent correct output value to the EGR vacuum modulator but, due to the leakage of vacuum,
signal of required value can not be received from the EGR potentiometer causing to display as malfunction of related
parts.
As a reference, the EGR valve of diesel vehicle (DI Engine) controlling from the engine ECU to EGR system has different
shape than the HUBER EGR valve because the EGR valves operation signal in the DI engine is performed by the HFM
sensor instead of the EGR potentiometer.
This principle is that when the EGR valve opens up to flow exhaust gas into the intake unit the amount of fresh air,
comparatively, will be reduced. The DI engine ECU receives feedback signal of change in amount of air being passed
through the HFM sensor according to the opening amount of the EGR valve.
EXHAUST SYSTEM
DI ENG SM - 2004.9
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DI04-18
The other big difference between the HUBER EGR and EGR controller for DI engine is that from two vacuum modulator,
one is same as being the modulator for EGR valve whereas the HUBER EGR systems the other modulator controls
ALDA of injection pump and the DI engines the other modulator controls waist gate of the turbo charger.
This difference is in accordance with the difference in fuel injection method where the IDI engine has mechanical
injection system and DI engine is capable of making electronically controlled fuel injection.
In other word, to reduce the amount of the fuel injection in no-load rapid acceleration mode, the IDI engines HUBER
EGR utilizes solenoid valve to disconnect the connection circuit between intake manifold and ALDA causing negative
pressure to occur in the vacuum modulator to reduce the amount of fuel injection. When DI engine, basing input signal
from the related sensors such as acceleration pedal sensor and engine RPM, recognizes that current mode is the noload rapid acceleration mode it reduces the amount of fuel injection by sending short electrical signal to the injector.
Therefore, disregarding the modulator for the EGR valve in DI engine, one must keep in mind that the other modulator is
used to control the booster pressure valve in turbo charger.
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-19
When Engine Exhaust Gas shows White Smog or
Blue Smog
NO
YES
NO
YES
Reconnection
NO
Clogging or Damage
between Air Cleaner and
Turbo
NO
YES
NO
YES
YES
Repair (overhaul)
Engine
NO
YES
Improper Viscosity of
Engine Oil Being Used
YES
NO
NO
Poor Oil Seal at Turbo Turbine
Side (trace of leakage in
housing and wheel)
YES
EXHAUST SYSTEM
DI ENG SM - 2004.9
NO
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DI04-20
Abnormal Noise from Turbo Charger System
Contamination or Clogging
of Air Cleaner
NO
YES
NO
YES
Clean or Replace If
required
Inspect or Replace
Connections
NO
NO
NO
NO
Check the Interference
between Rotating Turbo
Charger Components and
Housing
YES
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-21
Poor Rotation of the Turbo Charger
Compressor Wheel
Damages By Inflow of
Foreign Material
NO
YES
NO
YES
NO
Clogging of Compressor
by Dust
NO
Excessive Deposit of
Carbon or Combustion
Residues Inside of Turbine
Wheel by Oil Contamination
NO
YES
YES
YES
NO
YES
NO
Deterioration of Turbo
Charger Journal
YES
EXHAUST SYSTEM
DI ENG SM - 2004.9
NO
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DI04-22
Oil Leakage at Compressor in Turbo Charger
Contamination of Air
Cleaner Element
NO
YES
NO
YES
Clogging or Damage of
Pipe between Air Cleaner
and Turbo Charger
YES
Replace Damaged
Components after
Cleaning clogged Area
NO
Looseness in Connection
between Compressor
Outlet and Intake Manifold
NO
YES
NO
YES
NO
Deterioration or Damage
to Compressor Wheel
YES
Clean, Repair or Replace
Air Cleaner Element and
Turbo Charger
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NO
NO
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-23
Wear in Turbo Charger Inner Diameter and
Shaft Journal
NO
YES
NO
YES
YES
NO
Poor Oil Supply by
Clogging of Oil Supply
Pipe in Turbo Charger
NO
YES
Clean and Repair Damaged Components
NO
YES
Repair or Replace
Turbo Charger
NO
Poor Function of Engine
Oil Pump
YES
Inspect and Replace If
Required
EXHAUST SYSTEM
DI ENG SM - 2004.9
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DI04-24
25 2.5 Nm
2. Remove the vacuum hose and inlet hose from the turbo
charger.
Installation Notice
Tightening torque
6 ~ 7 Nm
25 2.5 Nm
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23 2.3 Nm
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-25
5. Remove the lower bolts at turbo charger oil return pipe.
Installation Notice
Tightening torque
25 2.5 Nm
32 3.2 Nm
8. Remove the bolts and nuts at the turbo charger and the
exhaust manifold.
Installation Notice
Tightening torque
25 2.5 Nm
EXHAUST SYSTEM
DI ENG SM - 2004.9
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DI04-26
Various sensor
Signals
1. EGR valve
2. Vacuum modulator
5. Intake manifold
3. Vacuum pump
6. HFM sensor
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-27
To turbo charger
actuator
Vacuum pump
EXHAUST SYSTEM
DI ENG SM - 2004.9
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DI04-28
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-29
Intercooler
Exhaust
manifold
Intake
manifold
EGR
valve
Regulated
vacuum
pressure
Modulator
Vacuum
pump
Duty
control
Feedback EGR
(Air Mass)
ECU
Improved target EGR
Pedal
signal
RPM
signal
EGR Valve
EGR valve recirculates some of exhaust gases to intake system to reduce toxic NOx from engine according to ECU
signals.
EGR valve opening point : -270 mmHg
EGR Modulator
According to ECU signals, the vacuum modulator drives EGR valve by controlling vacuum pressure that is generated by
vacuum pump with PWM type controls.
EXHAUST SYSTEM
DI ENG SM - 2004.9
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DI04-30
ATM
Plunger
Connector
Vacuum control
Diaphragm
Seat assembly
Spring
Atmospheric pressure
Plunger
Air flow
Vacuum is controlled according to relationship between chamber pressure (I) in rolling nipple cover and magnetic
force (II) in plunger.
According to ECU signals, the solenoid valve controls the vacuum pressure that is generated by vacuum pump (-900
20 mbar) with PWM type control and drives the mechanical EGR valve and turbo charger.
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-31
Operating principle: Balance between original vacuum pressure and magnetic force (see above figure)
Normal state (Fig. A): Original vacuum and seat section, 3 stoppers keep sealing
Duty up state (Fig. B): Original vacuum pressure is connected to inside of diaphragm chamber
Duty down state (Fig. C): Increased diaphragm chamber pressure is connected to atmosphere to compensate the
pressure.
Floating plunger
Stroke
(mm)
Max. Distance
1mm
DUTY 50%
Output C/V
Vacuum consumption: Compared to 50 % of duty, ON/OFF periods are most unstable and vacuum
consumption is most high.
Flowing
volume
Output Characteristics
EXHAUST SYSTEM
DI ENG SM - 2004.9
Up
Down
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DI04-32
Operating Conditions
Engine is running
Engine RPM is within a specified range. (EGR OFF under high RPM range)
Engine torque is within a specified range. (EGR OFF under high torque range)
Vehicle speed is within a specified range. (EGR OFF under high speed range)
Atmospheric pressure is within a specified range. (EGR OFF under high altitude and low atmospheric pressure)
Coolant temperature is within a specified range. (EGR OFF under high or low temperature)
EGR OFF under extended period of idling.
Control Logic
Main map: EGR volume is controlled based on intake air volume
Auxiliary map
- Coolant temperature (Coolant temperature sensor)
- Engine rpm (Crankshaft position sensor)
- Engine load (TPS): Detection of sharp acceleration
- Intake air temperature (HFM): Decreases when over 60C
- Atmospheric pressure (Barometric sensor): Compensation of altitude
Compensation value of auxiliary map will be increased/decreased based on main map then ECU calculates EGR
volume finally to regulate the vacuum duty that applies to the vacuum modulator to control EGR valve openings.
Shut-off Conditions
Engine rpm: over 2,950 rpm
Vehicle speed: over 105 km/h
Coolant temperature: over 100C or below 10C
Idle period: over 50 seconds
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-33
2. Unscrew the bolts and remove the EGR valve (2), EGR
valve #1 pipe (1) and gasket.
Installation Notice
Tightening torque
25 2.5 Nm
25 2.5 Nm
EXHAUST SYSTEM
DI ENG SM - 2004.9
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DI04-34
Vacuum Modulator
- Removal and Installation
1. Remove the vacuum hose from the vacuum modulator.
10 1.0 Nm
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-35
#3 Hanger
#2 Hanger
Muffler
Heat shield
#1 Hanger
Muffler
#1 Pipe
Muffler
Tail pipe
MUFFLER
The muffler is located at the middle of the exhaust pipe and reduces the pulse noise and the tail pipe noise by eliminating
the flowing resistance from the exhaust gas.
The important elements of the muffler are volume, construction and location.
EXHAUST SYSTEM
DI ENG SM - 2004.9
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DI04-36
SYSTEM OVERVIEW
Exhaust System
Check the complete exhaust system and the nearby body
areas and trunk lid for broken, damaged, missing or
mispositioned parts, open seams, holes, loose
connections, or other deterioration which could permit
exhaust fumes to seep into the trunk may be an indication
of a problem in one of these areas. Any defects should be
corrected immediately.
Notice
Muffler
Aside from the exhaust manifold connection, the exhaust
system uses a flange and seal joint design rather than a
slip joint coupling design with clamp and U-bolts. If hole,
open seams, or any deterioration is discovered upon inspection of the front muffler and pipe assembly, the complete assembly should be replaced. The same procedure
is applicable to the rear muffler assembly. Heat shields for
the front and rear muffler assembly and catalytic converter
protect the vehicle and the environment from the high temperatures that the exhaust system develops.
Heat Shield
The heat shield protects the vehicle and components from
the high heat generated from the exhaust system.
In this vehicle, the heat shield to block the heat from DOC
is installed to the underbody, and the heat shield to block
the heat from the rear muffler is installed to the underbody
between the fuel tank and the rear muffler.
Hanger
The hanger is to support the components.
Notice
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-37
Cover
Upper part of
converter
Insulation
Mat
Plate
Lower part of
converter
Monolith catalyst
Inlet gas
EXHAUST SYSTEM
DI ENG SM - 2004.9
Outlet gas
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DI04-38
Catalytic converter and temperature
Catalytic converter has the normal function of purification at a
range of the temperature. Because it has a weak point of decreasing of the purification rate in the condition of continuous
high temperature, it should keep the temperature range of 400
to 500C for normal condition. HC purification rate becomes
better according to the increase of temperature in the normal
range of temperature. CO purification rate becomes the best
near the temperature of 450C, and NOx does so near the
temperature of 400 to 500C.
Aldehide
Aromatic HC
Catalytic Material
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-39
Catalytic material supplies each CO and HC with O2 for
their oxidation : above 180C
Catalytic Material
Catalytic Material
Catalyzer
EXHAUST SYSTEM
DI ENG SM - 2004.9
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DI04-40
Exhaust Pipe
- Removal and Installation
1. Remove the upper bolts at turbo charger.
Notice
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-41
5. Remove the #3 hanger.
6. Remove the exhaust pipe.
7. Install in the reverse order of removal.
EXHAUST SYSTEM
DI ENG SM - 2004.9
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DI05-1
SECTION
00 DI05
LUBRICATION SYSTEM
Table of Contents
LUBRICATION SYSTEM ............................................. DI05-2
Lubrication system layout ....................................... DI05-3
Lubrication diagram ................................................ DI05-4
Specifications .......................................................... DI05-5
Engine oil change ................................................... DI05-9
Oil pump ................................................................ DI05-13
Oil spray nozzle ..................................................... DI05-15
Oil pan assembly .................................................. DI05-16
TROUBLE DIAGNOSIS ............................................. DI05-24
SPECIAL TOOLS AND EQUIPMENT ........................ DI05-25
LUBRICATION SYSTEM
DI ENG SM - 2004.9
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DI05-2
LUBRICATION SYSTEM
Cylinder head cover
Oil dipstick
Oil separator
Oil filter
Oil pump
Oil pan
Oil cooler
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LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-3
Cylinder head
Cylinder block
LUBRICATION SYSTEM
DI ENG SM - 2004.9
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DI05-4
LUBRICATION DIAGRAM
Chain lubrication
REF-Roller
Camshaft bearing
Vacuum pump
Oil tensioner
check valve
Return check valve
to cylinder head
Turbo charger
Connecting rod bearing Main bearing
Thrust bearing
Oil
filter
By-pass throttle
Contaminated oil
gallery
Oil pump
Relief valve
Oil cooler
Fuel tank
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LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-5
SPECIFICATIONS
Engine oil
Specification
Capacity
Service interval
Severe condition:
- When most trips include extended idling and/or frequent low-speed operation as in stop-and-go traffic.
- When most trips are less than 6 km (Operating when outside temperatures remain below freezing and when most
trips are less than 16 km)
- When operating in dusty, sandy and salty areas
- In hilly or moutainous terrain
- When doing frequent trailer towing
LUBRICATION SYSTEM
DI ENG SM - 2004.9
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DI05-6
Oil Pump
Engine
Oil
D27DT
MB SHEET
229.1/3
Oil Cooler
Oil cooler mounting bolt: M6 x 16: 4
Tightening torque
10 Nm
Replace two oil cooler gaskets with new ones when the
oil cooler has been removed.
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LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-7
to air duct
hose
Baffle plate
U-type oil
drain pipe
Baffle plate assembly: The baffle plates in cylinder head cover separates oil and gas from blow-by gas, and controls the
blow-by gas speed to send only gas to separator.
LUBRICATION SYSTEM
DI ENG SM - 2004.9
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AFFECTED VIN
DI05-8
Oil Separator
PCV valve
Outlet port (gas only)
(connected to air duct hose)
The first separation will happen when blow-by gas passes through baffle plates in cylinder head cover; then oil and gas
will be separated due to cyclone effect after entering the oil separator inlet port. Separated oil returns to oil pan via oil
drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that
opens/closes due to pressure differences between the intake side and crankcase.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-9
Water separation from the fuel filter should be performed when changing the engine oil.
25 2.5 Nm
Notice
The oil should not go above the upper mark on the dipstick. This would lead, for example, to increased oil
consumption, fouling of the spark plugs and excessive formation of carbon residue.
5. Close the oil filler cap and start the engine.
6. Stop the engine again and check the oil level. Add the engine oil if needed and check for the oil leaks.
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-10
Engine oil filter change
1. For changing procedures, refer to the Lubrication System section in this manual.
Lubricate the engine oil gasket with engine oil before installation.
Tighten it with the specified tightening torque.
Oil filter
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
25 2.5 Nm
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-11
23 2.3 Nm
4. Remove the oil cooler and filter assembly from the cylinder
block.
Notice
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-12
5. Install in the reverse order of removal.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-13
OIL PUMP
1. Oil pump
4. Guide pin
2. Plunger
3. Compression spring
Nm
M6 x 20 (24 EA)
10 1.0
M6 x 35 (2 EA)
10 1.0
M6 x 85 (2 EA)
10 1.0
M8 x 40 (4 EA)
25 2.5
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-14
35 3.5 Nm
3. Unscrew the bolt and remove the oil dipstick guide tube.
Installation Notice
Tightening torque
10 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-15
1. Fitting sleeve
a. Oil duct
Disassembly
1. Remove the oil pan or crankshaft.
2. Unscrew the bolts and remove the nozzle.
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-16
1. Oil pump
45. Washer
10. Bolt
46. Bolt
53. Bush
39. Spring
57. Bolt
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-17
BLANK
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-18
16cm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-19
4. Installing the engine bracket
Remove the existing engine mounting brackets and install the special service tools (temporary engine bracket) on the correct locations (dotted circles
in the figure) before removing the sub frame.
Engine mounting
bracket
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-20
Connections on the Sub Frame
1. Remove the high and low pressure pipes (A) of the steering
pump and lower arm shaft (B)
from the rear side of the sub
frame.
2. Remove the front brake caliper (D) and the wheel speed sensor (D).
(Attach the removed brake caliper and wheel speed sensor to the
vehicle after removing them.)
Suspension
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-21
2. Place each auxiliary lift under the front and rear side of the sub frame while taking care of the center point
of gravity. Mark on the mounting bolts of the sub frame, and remove the bolts (19mm x 6).
Installation Notice
Tightening torque
95 ~ 142 Nm
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-22
4. To prevent any damage, place the rubber blocks on the sub frame contact points in the 4-post lift before the sub
frame is lowered completely.
Rubber block installation points for front side of sub frame
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-23
5. Install the sub frame in the reverse order of removal. Make sure that the sub frame is securely seated on the
mounting holes.
6. Unscrew the oil pan bolts (10 mm) and remove the oil pan.
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-24
TROUBLE DIAGNOSIS
Cause
Symptom
Excessive oil
consumption
Action
Retighten
Retighten
Replace
Retighten
Retighten
Replace
Replace
Replace
Replace
Replace
Boring or replace
Adjust
Replace
Oil leaks
Repair
Check
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Improper viscosity
Retighten
Add
Replace
Replace
Replace or clean
Oil leaks
Repair
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-25
Application
103 589 02 09 00
Engine filter cap
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-1
SECTION
00 DI06
COOLING SYSTEM
Table of Contents
COOLING SYSTEM .................................................... DI06-2
ENGINE COOLING SYSTEM ...................................... DI06-3
Specifications ........................................................ DI06-12
INSPECTION AND REPAIR ....................................... DI06-13
Inspection .............................................................. DI06-13
REMOVAL AND INSTALLATION ............................... DI06-15
PREHEATING SYSTEM ............................................ DI06-32
Overview ............................................................... DI06-33
Preheating relay ................................................... DI06-33
Preheating system diagram .................................. DI06-34
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-2
COOLING SYSTEM
Coolant reservoir
FFH
Coolant temperature
sensor
Radiator
Water pump
Cooling fan
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-3
Cylinder head
Thermostat
Radiator
Heater
Water pump
Cylinder block
Oil cooler
(Heater line)
Coolant
reservoir
Engine
Cylinder head
Heater
Radiator
Thermostat
Water pump
EGR cooler
(henceforth)
Cylinder block
Oil cooler
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-4
Function Description
Intake Manifold
Cylinder Head
Cylinder head coolant outlet port is integrated into intake manifold. (in front of cylinder #1)
: Improved shape and gasket material to prevent coolant from leaking
From reservoir
From heater
In OM 600 engine, coolant inflows through the heater line rear section (cylinder #4 and #5) of cylinder head. However,
in D27DT engine, coolant inflows from cylinder block through oil cooler (refer to coolant flows layout in previous
page).
: It prevents cooling efficiency from decreasing due to coolant separation between cylinder #4 and #5.
In OM 600 engine, the cooling fan is installed with water pump, however, in case of D27DT engine, it is connected to
water pump with an additional pulley.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-5
Radiator
This vehicle has a lightweight tube-and-fin aluminum radiator.
Be careful not to damage the radiator core when servicing.
Water pump
The belt-driven centrifugal water pump consists of an impeller,
a drive shaft, and a belt pulley. The impeller is supported by a
completely sealed bearing.
The water pump is serviced as an assembly and, therefore,
cannot be disassembled.
Coolant reservoir
Notice
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-6
Thermostat
A wax pellet-type thermostat controls the flow of the engine
coolant through the engine cooling system. The thermostat is
mounted in the water pump housing. The thermostat stops
the flow of the engine coolant from the engine to the radiator
to provide faster warm-up, and to regulate the coolant
temperature. The thermostat remains closed while the engine
coolant is cold, preventing circulation of the engine coolant
through the radiator. At this point, the engine coolant is allowed to circulate only throughout the heater core to warm it
quickly and evenly. As the engine warms, the thermostat
opens. This allows the engine coolant to flow through the radiator where the heat is dissipated. This opening and closing
of the thermostat permits enough engine coolant to enter the
radiator to keep the engine within proper engine temperature
operating limits. The wax pellet in the thermostat is hermetically sealed in a metal case. The wax element of the thermostat expands when it is heated and contracts when it is cooled.
As the vehicle is driven and the engine warms, the engine
coolant temperature increases. When the engine coolant
reaches a specified temperature, the wax pellet element in
the thermostat expands and exerts pressure against the metal
case, forcing the valve open. This allows the engine coolant to
flow through the engine cooling system and cool the engine.
As the wax pellet cools, the contraction allows a spring to
close the valve.
The thermostat begins to open at 85C and is fully open at
100C. The thermostat closes at 85C.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Thermostat
Operating
Temperature (C)
Begins to open
85C
0.1 mm
Fully open
100C
8 mm
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-7
When closed (up to 85C)
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-8
Viscous fan clutch
9. Pin
2. Drive disc
10. Bi-metal
3. Flange
4. Seal ring
5. Needle bearing
6. Cooling fan
7. Oil scraper
8. Spring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-9
Scalding hot coolant and steam could be blown out under pressure, which could cause serious injury. Never
remove the coolant reservoir cap when the engine and radiator are hot.
Take precautions to prevent antifreeze coming in contact with the skin, eyes or vehicle body. If contact
happens, rinse affected areas immediately with plenty of water.
1. Place the vehicle on a level ground and check the coolant level through the coolant reservoir.
2. Add if needed. Change the coolant if necessary.
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-10
Temp.
Resistance
<Coolant Temperature Sensor>
Coolant temperature sensor is a NTC resister that sends coolant temperature to ECU.
NTC resister has characteristics that if the engine temperature rises, the resistance lowers so the ECU detects lowering
signal voltages.
If the fuel injected into the engine through injector has more turbulence, then combusts very well. However, if engine temperature is too low, the fuel injected as foggy state forms big compounds causing incomplete combustion. So the sensor detects
coolant temperature and changes coolant temperature changes into voltage then sends to ECU to increase the fuel volume
during cold start for better starting. And detects engine overheating for fuel volume reduction to protect the engine.
ECU functions as below with coolant temperature sensor signals.
When engine is cold, controls fuel volume to correct idle speed
When engine is overheated, controls electrical fan and A/C compressor to protect the engine
Sends information for emission control
Temperature
NTC 1 Resistance ( )
NTC 2 Resistance ( )
20
2,550
6,062
50
826
1,800
80
321
638
120
123
200
Signal
Auto amp
Ground
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-11
Trouble Diagnosis
Symptom
Low coolant
level
Excessively
high coolant
temperature
Cause
Action
Leaks in radiator
Replace radiator
Replace heater
Replace hose
Replace gasket
Retighten
Add coolant
Defective thermostat
Replace thermostat
Defective radiator
Replace radiator
Clogged coolant passages in cylinder head or cylinder block Clean coolant passages
Excessively
low coolant
temperature
COOLING SYSTEM
DI ENG SM - 2004.9
Replace thermostat
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-12
SPECIFICATIONS
Description
Cooling system
Type
Coolant
Capacity
Thermostat
Type
Water pump
DI
85
DI
100
DI
83
Stroke
DI
mm
min. 8
Electric
Blades
Diameter
Coolant reservoir
Specification
11.3
Type
Cooling fan
Unit
5
mm
320 (2)
91
88
95
92
psi
270
Kg/cm2
1.2 ~ 1.5
Kg/cm2
0.1
Turbo centrifugal
mm
72.3
Type
Impeller diameter
Impeller blades
Radiator
10
-
Down-flow
Core width
mm
701
Core height
mm
372
Core thickness
mm
18
Kcal/h
45,000
Type
3.33 ~ 3.78
0.32 ~ 0.35
Anti-freeze agent
Type
ALUTEC-P78
50 : 50
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-13
Thermostat
Immerse the thermostat into the water. Heat the water and
check the valve opening temperature.
Valve opening temperature
COOLING SYSTEM
DI ENG SM - 2004.9
Temperature gauge
DI Engine: 85 2C
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-14
Terminal B
Terminal A
(for coolant temp.)
Terminal B
(for glow plug)
0.4 / 79C
23.8 / 115C
24.8 / -20C
3.25 / 20C
Thermostat
1. Immerse the thermostat into the oil. Heat the oil until it
reaches the specified temperature and check if the
coolant temperature switch is turned OFF.
Coolant temperature at
point A
113 3C
Coolant temperature at
point B
116C
Notice
Use only engine oil for this inspection. Stir the oil
during heating it. Never heat the oil over required
temperature.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-15
1. Thermostat housing
4. Belt pulley
5. Bolt ................................................................... 10 Nm
3. Bolt ................................................................... 10 Nm
6. Water pump
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-16
2. Unscrew the bolts and remove the EGR pipe and bracket.
Installation Notice
Tightening torque
23 2.3 Nm
10 Nm
10 Nm
Notice
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-17
Thermostat
Preceding Works:
-
Draining of coolant
Removal of V-belt
Removal of cooling fan
Removal of intake duct (air cleaner to turbo charger)
5. Thermostat
6. Seal
3. Connector
7. Coolant hose
4. Bolt ............................................................. 10 Nm
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-18
1. Unscrew the bolts and remove the thermostat housing.
Installation Notice
Tightening torque
10 1.0 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-19
46 4.6 Nm
25 2.5 Nm
10 1.0 Nm
Notice
Be careful not to damage the O-ring in coolant outlet
pipe (cylinder head side).
Remove the gasket residues from the sealing
surface and replace the gasket with new one.
5. Install in the reverse order of removal.
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-20
Radiator
Components of Radiator Module
Related Components (Assembly): Intercooler, Electric Fans, Condenser, Radiator
Preceding Work:
- Disconnection of negative battery cable
- Removal of front bumper assembly
- Discharge of refrigerant
- Draining of engine coolant
Removal Procedure
Intercooler
Radiator
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Electric Fans
Condenser
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-21
The clamp in the intake system related with intercooler may be moved out of its location due to the pressure from the
turbo charger when the proper tightening torque is not achieved. Always tighten the clamps to the specified value with a
torque wrench or ratchet wrench.
Tightening torque
COOLING SYSTEM
DI ENG SM - 2004.9
6 ~ 7 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-22
Intercooler Assembly
1. Disconnect all wiring harnesses and related connectors from the front side of radiator assembly.
AQS sensor
Ambient temperature
sensor
Connector
[for air conditioner]
Receiver drier
Electric fans
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-23
2. Remove the front end center member.
3. Remove the hood latch cable and remove the radiator support upper member.
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-24
4. Remove the intercooler inlet hose.
Tightening torque
Tightening torque
6 ~ 7 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-25
Electric Fans
1. Disconnect the electric fan connectors.
2. Unscrew the bolts at both sides and remove the electric fan assemblies.
Appearance
Front view
COOLING SYSTEM
DI ENG SM - 2004.9
Rear view
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-26
Condenser Assembly
Appearance
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-27
Fan Shroud
COOLING SYSTEM
DI ENG SM - 2004.9
) at bottom of the fan shroud and remove the fan shroud by pulling up the clip at the opposite
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-28
Fan Clutch
Unscrew the bolts with the fan clutch pulley locked by a special tool and remove the fan clutch.
Appearance
Front view
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Rear view
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-29
Fan Belt
Remove the fan belt with the tensioning shock absorber depressed (counter-clockwise direction).
Idle pulley
Auto temsioner pulley
Alternator pulley
Air conditioner
comperessor pulley
TVD (Torsional
Vibration Damper)
COOLING SYSTEM
DI ENG SM - 2004.9
Auto tensioner
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-30
Coolant Reservoir
1. Drain the coolant.
2. Remove the hoses.
7 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-31
3. Remove the drain plug and seal in the cylinder block and
drain the coolant.
4. Replace the seal with new one and install the drain plug.
Installation Notice
Tightening torque
30 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-32
PREHEATING SYSTEM
ECU
Glow plug
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Preheating relay
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-33
OVERVIEW
Glow plug is installed on the cylinder head (combustion chamber) in the D27DT preheating control unit system. Cold
starting performance has improved and exhaust gas during cold starting has reduced.
ECU receives coolant temperature and engine speed to control; after monitoring the engine preheating/after heating and
glow plug diagnosis function, the fault contents will be delivered to ECU.
Engine preheating/after heating functions
Preheating relay activation by ECU controls
- Senses engine temperature and controls the preheating/after heating time
- Glow indicator
K-LINE for information exchanges between preheating unit and ECU
- Transmits preheating unit self-diagnosis results to ECU
- Transmits glow plug diagnosis results and operating status to ECU
PREHEATING RELAY
Structure
K-LINE #1
(ECU 34)
IG1
Power terminal
Glow plug
control signal
(ECU 113)
Ground terminal
B+main wire
(12V)
Glow plug
terminal
Y220_06069
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-33
OVERVIEW
Glow plug is installed on the cylinder head (combustion chamber) in the D27DT preheating control unit system. Cold
starting performance has improved and exhaust gas during cold starting has reduced.
ECU receives coolant temperature and engine speed to control; after monitoring the engine preheating/after heating and
glow plug diagnosis function, the fault contents will be delivered to ECU.
Engine preheating/after heating functions
Preheating relay activation by ECU controls
- Senses engine temperature and controls the preheating/after heating time
- Glow indicator
K-LINE for information exchanges between preheating unit and ECU
- Transmits preheating unit self-diagnosis results to ECU
- Transmits glow plug diagnosis results and operating status to ECU
PREHEATING RELAY
Structure
K-LINE #1
(ECU 34)
IG1
Power terminal
Glow plug
control signal
(ECU 113)
Ground terminal
B+main wire
(12V)
Glow plug
terminal
Y220_06069
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-34
Coolant
temperature
sensor
Specifications
Description
Specification
Rated voltage
DC 12 V
DC 8 ~ 15 V
Operating range
- 40 ~ + 100C
Over 6.5 V
Over 1.5 V
11.3
Voltage drop
Parasitic current
MAX 1mA
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-35
Function
Preheating system controls and checks following functions and operating conditions.
Pre-Heating
The power will be supplied to the glow plugs by ECU controls when the power is supplied to the IG terminal from
the battery and there are normal communications with ECU within 2 seconds. The surface of glow plug will be
heated up to 850C very quickly to aid combustion by vaporizing air-fuel mixture during compression stroke.
Preheating time is controlled by ECU.
After-heating
When the engine is started, after-heating starts by ECU controls. The idle rpm will be increased to reduce toxic
smoke, pollutants and noises.
After-heating time is controlled by ECU.
Checking glow plugs
Check each glow plug for short in circuit
Check each glow plug for open in circuit due to overvoltage
Check glow plug for short to ground
Forceful relay shut-down
When glow plug is shorted to ground
K-Line communication
ECU sends the results to preheating time control relay through K-Line to start communication.
Preheating time control relay sends messages including self-diagnosis data for glow plugs to ECU.
Glow plug makes communication only as response to demand.
When power is supplied, ECU starts self-diagnosis within 2 seconds.
Under the following conditions, communication error occurs.
- When there is no response from glow plug module within 2 seconds
- When an error is detected in checksum
- Less byte is received
Error code of P1720 - Pre heating control communication fail will be reported.
Operating time
Preheating
Afterheating
Glow
Indicator
Coolant Temp.
-35 C
-25 C
-20 C
-10 C
0 C
10 C
20 C
Operating Time
31 sec
22 sec
19 sec
17 sec
14 sec
0 sec
0 sec
Operating
Conditions
IG: ON
Coolant Temp.
-30 C
-20 C
-10 C
0 C
10 C
20 C
35 C
Operating Time
115 sec
80 sec
30 sec
19 sec
11 sec
11 sec
0 sec
B+ : below 15.2V
-30 C
-25 C
-20 C
-10 C
0 C
10 C
20 C
Operating Time
18 sec
16 sec
10 sec
5 sec
2 sec
0 sec
0 sec
Operating
Conditions
IG: ON
COOLING SYSTEM
DI ENG SM - 2004.9
Release
When engine cranking
Conditions
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-1
SECTION
00 DI07
FUEL SYSTEM
Table of Contents
CAUTIONS FOR DI ENGINE ....................................... DI07-2
FUEL SYSTEM ............................................................ DI07-6
Fuel injection system .............................................. DI07-6
Fuel transfer line ................................................... DI07-12
Inlet metering valve (IMV) ..................................... DI07-19
High fuel pressure line .......................................... DI07-22
Injector .................................................................. DI07-35
REMOVAL AND INSTALLATION OF FUEL TANK .... DI07-49
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-2
DI Engine
Comparatively conventional diesel engines, DI engine controls the fuel injection and timing electrically, delivers high
power and reduces less emission.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-3
Priming Pump
The priming pump installed in fuel pump is the device to fill the fuel into the fuel filter. When the vehicle is under the
conditions as below, press the priming pump until it becomes rigid before starting the engine.
WARNING
1. Fuel filter
3. Priming pump
4. Water separator
Notice
When replaced the fuel filter or drained the water from fuel filter, press the priming pump until it becomes
rigid before starting the engine.
The water drain from fuel filter should be performed whenever changing the engine oil.
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-4
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-5
1. Place the water container under the fuel filter & water
separator.
2. Disconnect the connector under the drain plug of the water
separator.
3. Turn both drain plugs to A direction to drain the water.
4. Wait until a certain amount of fuel gets out from the port,
then turn the both drain plugs to B direction to tighten it.
Notice
1. Fuel filter
3. Water separator
4. Drain plug
2. Priming pump
5. Connector
WARNING
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-6
FUEL SYSTEM
FUEL INJECTION SYSTEM
Electronic Control of Fuel System
Fuel pressure sensor
High pressure pump
Common rail
IMV valve
Low and high
pressure pump
Fuel temperature
sensor
Injection
pipe
Water separator
Fuel filter
Priming
pump
Water detection
sensor
Injectors
Sensors
HFM sensor
Cam position sensor
Fuel tank
ECU
System composition
- High pressure fuel pump - Fuel rail
- Fuel injector
Supply line
Return line
ECU connecting line
According to input signals from various sensors, engine ECU calculates drivers demand (position of the accelerator
pedal) and then controls overall operating performance of engine and vehicle on that time.
ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those
signals. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines injection order and ECU detects drivers pedal position (drivers demand) through electrical signal that is generated by variable resistance changes in accelerator pedal sensor. Air flow (hot film) sensor detects intake air volume and
sends the signals to ECU. Especially, the engine ECU controls the air-fuel ratio by recognizing instant air volume
changes from air flow sensor to decrease the emissions (EGR valve control). Furthermore, ECU uses signals from
coolant temperature sensor and air temperature sensor, booster pressure sensor and atmospheric pressure sensor as
compensation signal to respond to injection starting, pilot injection set values, various operations and variables.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-7
Common rail
Injector
Priming pump
Fuel pump
(High pressure pump, transfer pump)
Fuel filter
Fuel route
Fuel tank
Priming pump
Fuel filter
Transfer
pump
Injector
Common rail
High pressure
pump
Fuel pressure
regulation valve
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-8
Pressure limiter
(High pressure)
Transfer pump
Return
valve
Inlet
valve
below 2 bar
below - 0.3 bar
Venturi
Common rail
Up to
1050 bar
* At IMV full open
Injector
Priming pump
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Return line
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-9
Fuel tank
Fuel tank is made of anti-corrosion material and its allowable
pressure is 2 times of operating pressure (more than 0.3 bar).
It has protective cap and safety valve to prevent excessive
pressure building. Also, it has structure to prevent fuel from
leaking in shocks, slopes and corners and to supply fuel
smoothly.
Priming pump
If fuel runs out during driving or air gets into fuel line after fuel
filter replacement, it may cause poor engine starting or damage to each component. Therefore, the hand priming pump is
installed to bleed air from transfer line.
When the vehicle is under the conditions as below, press the
priming pump until it becomes rigid before starting the engine.
- After run out of fuel
- After draining the water from fuel filter
- After replacing the fuel filter
Press the priming pump until it becomes rigid before starting
the engine.
Fuel filter
It requires more purified fuel supply than conventional diesel
engine. If there are foreign materials in the fuel, fuel system
including pump components, delivery valve and injector nozzles
may be damaged.
Fuel filter purifies fuel before it reaches to high pressure pump
to help proper operations in high pressure pump. And more, it
separates water from fuel to prevent water from getting into
FIE system (high pressure line).
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-10
Transfer pump
The transfer pump is included in the housing of the high pressure pump. The transfer pump is the volumetric blade type
pump. To deliver the continuously required fuel volume, the
pump transfers fuel from the fuel tank to high pressure pump.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-11
High pressure pipe (fuel pipe)
Fuel line transfers high pressure fuel. Accordingly, it is made
of steel to endure intermittent high frequency pressure changes
that occur under maximum system pressure and injection
stops. Injection lines between rail and injectors are all in the
same length; it means the lengths between the rail and each
injector are the same and the differences in length are compensated by each bending.
No. 5 cylinder
Injectors
The fuel injection device is composed of electrical solenoid
valve, needle and nozzle and controlled by engine ECU. The
injector nozzle opens when solenoid valve is activated to directly inject the fuel into combustion chamber in engine. When
injector nozzle is open, remaining fuel after injection returns
to fuel tank through return line.
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-12
from HP pump
to fuel tank
to HP pump
from fuel tank
Water Sensor
Capacity: 120 cm
Fuel filter
3
Drain plug
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-13
Change Interval: 30,000 km
Water separation and storage function
Function: It separates the condensation water from diesel fuel to prevent the water from getting into FIE system, and
results in protection of FIE system. (manual drain)
Water storage capacity: 120 cc
Water sensor: light if over 39 cc
Water drain interval: When changing engine oil or every 20,000 km
Water sensor
It is integrated in the filter and sends signal to ECU when water level reaches at a specified value (over 39 cc) in the filter
to let the driver drain the water.
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-14
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-15
Sedimentor bowl
Cylindrical mesh
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-16
Priming Pump
If fuel runs out during driving or air gets into fuel line after fuel
filter replacement, it may cause poor engine starting or damage to each component. Therefore, the hand priming pump is
installed to fill filter.
to fuel filter
Notice
When the fuel filter is replaced, the fuel in the fuel tank should be transferred to the filter by using priming
pump. So never transfer the fuel in the fuel tank to the filter by driving HP pump with cranking the engine.
Pump
Ventury
Injector
The fuel transfer line is the line between fuel tank and HP pump inlet port. The pressure on this line affects the
lifetime of fuel filter.
Temperature of fuel transfer line
- HP pump inlet temperature is less than 80C.
- The temperature of fuel pump inlet is up to 80C.
And, diesel fuel has lubrication effects due to its viscosity. Thus, the fuel is also used for pump lubrication.
However, this lubrication performance drops as the temperature rises. Accordingly, when the fuel temperature is
over 50C, 100% of fuel is returned to fuel tank to cool down the temperature and then increase the lubrication
effects of fuel and prevent heat damage on each section of high fuel pressure line.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-17
Transfer Pump
Description
The transfer pump is the device to provide sufficient fuel to high fuel pressure line and is mechanical type feed pump that
is driven by timing chain linked to crankshaft. This mechanical type feed pump is subject to air inflow, therefore, a hand
priming pump is installed to fill fuel in Low fuel pressure(LP) circuit.
The transfer pump is included in the housing of the HP pump. The transfer pump is the volumetric blade type pump and
consists of the following components:
A rotor turned by the shaft of the HP pump. The connection is provided by splines.
An eccentric liner fixed to the housing of the HP pump by 6 Torx bolts. The liner is positioned by two off-set pins in
order to prevent any assembly errors.
Four blades set at 90. Each blade is held against the liner by a coil spring.
The inlet and outlet orifice.
Transfer pump
HP pump
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-18
Principle of operation
Housing
Rotor
OUT
Blade
Chamber
Consider the chamber between the rotor, the liner and two successive blades (refer to above figure).
When the chamber is in position 1, the volume of the chamber is minimal. The changes in volume according to the
angle of rotation of the rotor are small.
The rotor makes a quarter turn clockwise. The previous chamber is now in position 2.
The inlet orifice is uncovered. The volume contained in the chamber quickly rises. The pressure inside the chamber
drops sharply. Fuel is drawn into the chamber.
The rotor continues to rotate. It is now in position 3. The inlet and outlet orifices are now sealed off. The volume area
controlled by the rotor, the liner and the two blades is at the maximum. The changes in volume according to the
angle of rotation of the rotor are small.
The rotor continues to rotate. It is finally in position 4. The outlet orifice is uncovered. The volume area controlled by
the rotor, the liner and the blades decreases quickly. The pressure inside the chamber rises sharply. The fuel is
expelled under pressure. The depression caused by the transfer pumps rotation is sufficient to draw in diesel fuel
through the filter. The transfer pump is driven by the shaft of the HP pump, transfer pressure thus rises with engine
speed. A regulating valve allows the transfer pressure to be maintained at a practically constant level (about 6 bar)
throughout the whole range of engine operations by returning some of the fuel to the pump inlet.
Fuel
pressure
(bar)
6 bar
Volume controlled
5.6 cm3/revolution
Flow
Intake capacity
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-19
IMV effect
without IMV
with IMV
Torque (Nm)
Rail pressure = 80 bar
FUEL SYSTEM
DI ENG SM - 2004.9
Fuel temperature at
system backleak
without IMV
with IMV
Fuel Temp.(C)
Torque (Nm)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-20
Composition of IMV
The IMV is located on the hydraulic head of the pump. It is fed with fuel by the transfer pump via two radial holes. A
cylindrical filter is fitted over the feed orifices of the IMV. This makes it possible to protect not only the LP actuator, but
also all the components of the injection system located downstream of the IMV.
The IMV consists of the following components:
A piston held in the fully open position by a spring.
A piston filter located at inlet.
Two O-rings ensuring pressure tightness between the hydraulic head and the body of the IMV.
A body provided with two radial inlet holes and an axial outlet hole.
Coil
Transfer pump
Solenoid
Fuel
Filter
Spring
Piston
High pressure
Outlet hole
O-ring
Fuel
Transfer pump
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AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-21
Principle of Operation
The LP actuator is used to proportion the amount of fuel sent to the pumping element of the HP pump in such a way that
the pressure measured by the HP sensor is equal to the pressure demand sent out by the ECU. At each point of
operation, it is necessary to have:
Flow introduced into the HP pump = Injected flow + Injector backleak flow + injector control flow
The IMV is normally open when it is not being supplied with fuel. It cannot therefore be used as a safety device to shut
down the engine if required.
The IMV is controlled by current. The flow/current law is represented below.
Flow (I/hr)
Current (mA)
Specifications
Piston stroke
1.4 mm
Diameter of holes
3.4 mm
Coil resistance
Power supply
Battery voltage (It is prohibited to supply the IMV directly at the battery voltage
during the diagnostic test)
Max. current
1A
Weight
260 g
Operating temperature
Fluid temperature
Control logic
Normally open without power (The flow decreases as the current rises).
ECU determines the value of the current to be sent to the IMV according to:
Engine speed
Flow demand
Rail pressure demand
Measured rail pressure
FUEL SYSTEM
DI ENG SM - 2004.9
E
C
Inlet Metering
Valve (IMV)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-22
Fuel supply
Specifications
Maximum operating pressure: 1600 150 bar
Max. Overpressure: 2100 bar
Maximum sealing pressure: when using a plug instead of PRV, no leaks around pump outlet port (when applying
2500 bar of constant pressure)
Operating temperature: Continuously operating within temperature range of -30C ~ 120C in engine compartment
Inflowing fuel temperature: The maximum inflowing fuel temperature is 85C (continuously able to operate)
Pump inlet pressure: Relative pressure Min. - 0.48 bar (to end of filters lifetime)
Driving torque: 15 Nm / 1600 bar
Gear ratio (engine: pump): 0.625
Lubrication:
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AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-23
Principle of operation
During the filling phase, the rollers are kept in contact with the cam by means of coil springs mounted on either side
of each shoe. The transfer pressure is sufficient to open the inlet valve and to move the pumping plungers apart.
Thus, the dead volume between the two plungers fills with fuel.
When the diametrically opposite rollers simultaneously encounter the leading edge of the cam, the plungers are
pushed towards each other.
As soon as the pressure becomes higher than the transfer pressure, the inlet valve closes. When the pressure
becomes higher than the pressure inside the rail, the delivery valve opens. Consequently, the fuel is pumped under
pressure into the rail.
During the input phase, transfer pressure pushes back the inlet valve. Fuel enters the body of the pumping element.
The valve closes as soon as the pressure in the pumping element becomes higher than the transfer pressure.
During the input phase, the ball of the delivery valve is subject to the rail pressure on its outer face and to the transfer
pressure on its inner face. Thus the ball rests on its seat, ensuring the pressure tightness of the body of the pumping
element. When the pressure in the element becomes higher than the pressure in the rail, the ball is unbalanced and
it opens. Fuel is then pumped into the rail at high pressure.
Roller
Plunger
<Fuel input>
<Pressurize>
This high pressure pump generates the driving torque with low peak torque to maintain the stress to driving components.
This torque is smaller than that of conventional injection pump, thus, only a small load will be applied to pump. The
required power to drive pump is determined by set pressure for rail and pump speed (delivery flow). Note that the fuel
leakage or defective pressure control valve may affect the engine output.
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-24
Inlet valve and delivery valve
During the input phase, transfer pressure pushes back the inlet valve. Fuel enters the body of the pumping element.
Under the effect of the transfer pressure, the two plungers are forced apart. When the rollers simultaneously encounter
the leading edge of the cam, pressure suddenly rises in the body. Of the pumping element. The valve closes as soon as
the pressure in the pumping element becomes higher than the transfer pressure. During the input phase, the ball of the
delivery valve is subject to the rail pressure on its outer face and to the transfer pressure on its inner face. Thus the ball
rests on its seat, ensuring the pressure tightness of the body of the pumping element. When the two diametrically
opposite rollers encounter the leading edges of the cam, the plungers are forced together and pressure quickly rises in
the body of the pumping element. When the pressure in the element becomes higher than the pressure in the rail, the
ball is unbalanced and it opens. The spring calibration is negligible compared with the pressure forces. Fuel is then
pumped into the rail at high pressure.
<Inlet valve>
<Delivery valve>
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AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-25
IMV open
Venturi
to common rail
Fuel supply
to fuel tank
Backleak
Transfer pump
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-26
When do not need high fuel pressure (deceleration)
IMV close
Venturi
to common rail
Fuel supply
to fuel tank
Backleak
Transfer pump
The fuel is sent to the high pressure side (hydraulic head) and compressed by the plunger. And, goes into the common
rail through the high pressure pipe.
The IMV installed in the high pressure side (hydraulic head) of HP pump precisely controls the fuel amount and delivers
the rail pressure feedback same as required amount.
The IMV is controlled by ECU.
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-27
<Transfer Pump>
IMV valve
Drive shaft
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-28
Inlet valve
Temperature sensor
Delivery valve
<Hydraulic Head>
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AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-29
Description
The high pressure accumulator reserves the high pressure fuel. Simultaneously, the pressure changes due to the
delivery from HP pump and the fuel injection is diminished by rail volume. This high pressure accumulator is commonly
used in all cylinders. Even when a large amount of fuel leaks, the common rail maintains its internal pressure. This
ensures that the injection pressure can be maintained from when the injector opens.
Function
Relieve the pressure pulsation
Provide pressure information to ECU (fuel pressure sensor)
Specifications
Material: Forged Steel
Dimension: - Volume: 22 1cc
- Length: Max. 397.7 mm
- Outer diameter: 25.3 mm
Fuel pressure sensor Integrated type
- Sensor input voltage: 5 0.1V
- Sensor output signal voltage: - 4.055 0.125 V @ 1600 15 bar
- 0.5 0.04 V @ 0 bar
Operating pressure range
- Normal condition: 0 ~ 1600 bar
- Max. Overpressure: 2100 bar
Ambient temperature: - available within -40C ~ 125C
- Spontaneous max. temperature after engine stops: 140C (acceptable against total 15 hours)
Fluid temperature: -40 ~ 100C under normal operating conditions
Removal and installation: 10 times without any damage
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-30
No. 1
No. 2
No. 3
No. 4
No. 5
HP pipe
Injector
Fuel rail
Fuel pressure sensor
HP pump
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AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-31
40 10 Nm
Notice
40 10 Nm
Notice
25 2.5 Nm
Notice
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-32
Fuel pressure sensor on the center of common rail detects instant fuel pressure changes and then sends to ECU. When
received these signals, ECU uses them to control fuel volume and injection time.
The fuel in the rail reaches to sensor diaphragm via blind hole in the pressure sensor and the pressure signal converts to
electrical signal. The signal measured by sensor will be amplified to input to ECU.
This piezo element type sensor changes pressure into electrical signal. Accordingly, when the shape of diaphragm
changes, electrical resistance in the layers on the diaphragm changes then can measure 0.5 ~ 5 V.
Sensor input voltage: 5 0.1 V
Output signal voltage of sensor
- 4.055 0.125 V: 1600 15bar
- 0.5 0.04 V: 0 bar
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EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-33
Pressure
Physical
changes
Sensing area
Amplifier
Converts to
electric signal
Electrically
amplyfying
signal
Upper area
Output
voltage
Lower area
Pressure (P)
<Sensor voltage>
Piezo resistance
Ground
SIG
REF 5V
Pressure sensor
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-34
Temperature
Resistance
Fuel temperature sensor is a NTC resistor that sends fuel temperature to ECU.
In case of NTC resistor, the resistance lowers if engine temperature rises so the ECU detects lowering signal voltages.
Fuel temperature sensor is installed on the fuel return line to correct pressure after measuring fuel temperature. 5V is
supplied to the sensor and voltage drop by temperature is delivered to ECU to measure the fuel temperature through
analog-digital converter (ADC).
Notice
Signal
Ground
HFM Sensor
- Refer to Intake System
Knock Sensor
- Refer to Engine Assembly
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-35
INJECTOR
The C2I labels including injector characteristics are attached in each injector. These C2I values should be input to ECU
by using SCAN-100 when replacing the ECU or injectors.
Special cautions:
1. Plug the openings of hoses and pipes with the sealing caps.
2. Replace the copper washer with new one plus injector holder bolt & washer.
3. Tighten the injector holder bolts with the specified tightening torque.
4. Be careful not to drop the injector.
Specifications
Length:
C2I label
Bobbin
C2I value
Control valve
Cap nut
Adaptor plate
Nozzle body
Washer
Nozzle needle
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-36
The maximum injection pressures are approximately 1,600 bar. The forces to be overcome in order to lift the needle of
the injector are therefore very large. Because of this, it is impossible to directly control the injector by using an electromagnetic actuator, unless very high currents are used, which would be incompatible with the reaction times required for
the multiple injections. The injector is therefore indirectly controlled by means of a valve controlling the pressurizing or
discharging of the control chamber located above the needle:
When the needle is required to lift (at the start of injection): the valve is opened in order to discharge the control
chamber into the back leak circuit.
When the needle has to close (at the end of injection): the valve closes again so that pressure is re-established in
the control chamber.
Valve
In order to guarantee response time and minimum energy
consumption:
Valve
Contact
making seal
Volume
under
high
pressure
Valve
Depressurization grooves
Spill
orifice
Volume under
vacuum
Spacer
INO inlet
irifice
SPO spill
orifice
Spacer
The spacer is situated underneath the valve support. It integrates the control chamber and the three calibrated orifice
which allow operation of the injector. These orifices are:
The injector supply orifice (Nozzle Path Orifice: NPO)
The control chamber discharge orifice (Spill Orifice: SPO)
The control chamber filling orifice (Inlet Orifice: INO)
NOP nozzle
path orifice
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EFFECTIVE DATE
AFFECTED VIN
Control
chamber
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-37
Principle of Operation
Ff
Ff= =pressure * space
(Ff
rail * S)
(Ff==PPrail
S)
Fo = pressure * space
Fo ==Prail * S)
(Fo
(Fo = Prail
A)
Valve closed
Valve opens
Valve open
Valve closes
Valve closed
Needle closed
Needle closed
Needle opens
Needle open
Needle closed
No injection
No injection
Start of injection
End of injection
No injection
Injector at rest
The valve is closed. The control chamber is subject to the rail
pressure.
The pressure force applied by the fuel onto the needle is:
Ff = S * Prail
The needle is closed and hence there is no fluid circulation
through the NPO orifice. While static, the nozzle produces no
pressure drop. The cone of the needle is therefore subject to
the rail pressure. The force applied by the fuel to the needle is:
Fo = A * Prail
Since Ff > Fo, the needle is held in the closed position. There
is no injection.
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EFFECTIVE DATE
AFFECTED VIN
DI07-38
Start of injection
As soon as Ff < Fo, or in other words:
Pcontrol < Prail * A/S
The needle lifts and injection begins. As long as the valve is open, the injectors needle remains lifted. When injection
begins, fuel circulation is established to feed the injector. The passage of the fuel through the inlet orifice of the injector
(similar to a nozzle) leads to a pressure drop which depends on the rail pressure.
When the rail pressure is at its highest (1600 bar), this pressure drop exceeds 100 bar. The pressure applied to the cone
of the needle (the injection pressure) is therefore lower than the rail pressure.
End of injection
As soon as the solenoid valve is de-energized, the valve closes and the control chamber is filled. Since the needle is
open, the thrust section areas situated on either side of the needle is therefore to apply different pressures to each of
these faces. The pressure in the control chamber cannot exceed the rail pressure, so it is therefore necessary to limit
the pressure applied to the needles cone. This pressure limitation is achieved by the NPO orifice which produces a
pressure drop when fuel is passing through it.
Prail * S
(Prail -
P) * S
When static, this pressure drop is zero. When the pressure in the control chamber becomes higher than the pressure
applied to the needles cone, the injection stops.
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EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-39
Injecting Process
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-40
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-41
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-42
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-43
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-44
Fuel pressure
Fuel pressure
Minimum operating pressure: start injection over 100 bar
Maximum operating pressure: 1,600 bar (max. operating pressure in normal conditions)
Max overpressure: 2,100 bar
Main injection
Pilot injection
Opening Delay
10%
signal
amplitude
Injection rate
Injector drive pulse
10%
signal
amplitude
Time (
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-45
Injector control
Current
Peak pull current
= 22.0 A
Through pull
current = 7.5 A
Time
Pull-in period
Hold period
Joule Effect: The principle that the heat produced by an electric current is equal to the product of the resistance
of the conductor, the square of the current, and the time for which it flows.
I: current (A)
R: resistance ()
T: time (sec)
H: calori (cal)
Heat capacity (H) = 0.24 I 2RT
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-46
Fuel Injection
Other than conventional diesel engine, common diesel engine use two steps injection as follows:
Pilot Injection
Main Injection
In above two step injection, the fuel injection volume and injection timing is calibrated according to fuel pressure and fuel
temperature.
Pilot injection
Before starting main injection, a small amount of fuel is injected to help proper combustion. This injection is for reducing
the engine noise and vibration.
Angle of crankshaft
<Characteristic curve of discharge without pilot injection>
In other words, it makes the pressure increase in combustion chamber during combustion smooth to reduce the engine
noise and vibration (suppressing the surging). Basic values for pilot injection are adjusted according to the coolant
temperature and intake air pressure.
Angle of crankshaft
<Characteristic curve of discharge with pilot injection>
Main injection
Actual output from engine is achieved by main injection.
Pressure
The main injection determines the pilot injection has been occurred, then calculates the injection volume. Accelerator
pedal sensor, engine rpm, coolant temperature, intake air temperature and atmospheric pressure are basic date to
calculate the fuel injection volume in main injection.
1. Pilot injection
2. Main injection
1a. Ignition pressure with pilot injection
2a. Ignition pressure without pilot injection
Angle of crankshaft
<Characteristic curve of combustion chamber pressure during pilot injection>
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-47
40 10 Nm
180 10
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-48
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-49
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-50
Components Locator
Fuel
return line
Fuel
supply line
Wiring
Ventilation tube
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EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-51
1. Disconnect the fuel supply hose, fuel return hose, FFH supply pipe and connector.
2. Unscrew the bolts and remove the fuel filler pipe from the fuel filler opening.
3. Install the safety jack under the fuel tank and remove the bolts (12mm x 4) from the fuel tank.
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-52
4. Carefully lower the safety jack with the fuel tank.
Caution
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AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-53
5. Remove the sender gauge assembly from the removed fuel tank.
(1) Disconnect the connector from the fuel tank cap.
(2) Remove the fuel hose (FFH fuel pump, Fuel supply)
FUEL SYSTEM
DI ENG SM - 2004.9
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AFFECTED VIN
DI07-54
(4) Remove the fuel sender gauge assembly from the fuel
tank.
6. Always check the gauge operating conditions when replacing the components or repairing the system.
Caution
The fuel system (fuel tank) related operation may cause a fire. Always prepare the fire-fighting equipment
before starting the fuel system related operation.
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AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI08-1
SECTION
00 DI08
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DI08-2
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Camshaft position
sensor
Fuel filter
(water sensor)
Preheating relay
Accelerator pedal
sensor
Main relay
DI08-3
TOP VIEW
Injectors (5)
Booster pressure
sensor
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AFFECTED VIN
DI08-4
SIDE VIEW
Coolant temperature
sensor
CHANGED BY
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AFFECTED VIN
Fuel pressure
regulating valve
Crankshaft position
sensor
DI08-5
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AFFECTED VIN
DI08-6
Pin No.
Description
Pin No.
Description
Engine ground
40
Engine ground
41
42
43
44
45
46
47
48
10
49
11
50
12
ABD signal
51
52
13
53
15
54
CAN- H1
16
55
14
17
56
18
57
19
58
20
59
21
60
22
61
Preheater #1
23
62
Preheater #2
63
24
25
64
26
65
27
28
Engine ground
66
Engine ground
67
29
68
30
69
31
70
32
71
72
33
34
K-LINE #1
73
35
K-LINE #2
74
36
75
37
IG 1
76
38
77
78
Trip computer
39
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DI08-7
Pin No.
Description
Pin No.
Description
79
A/C relay
101
80
102
81
103
82
104
83
105
84
106
85
107
Blower switch
86
108
87
109
88
Engine ground
110
111
112
Immobilizer
91
113
92
114
Injector #1
93
115
Injector #4
94
116
Injector #3
89
90
95
117
96
EGR valve
118
97
119
98
120
Injector #5
121
Injector #2
99
100
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DI08-8
ECU InputsOutputs
Inputs
Control
Output
Injector
EGR system
Immobilizer
Warning lights
(Water warning light, glow plug indica-
Accelerator sensor
K - line
CAN communication
Self-diagnosis
compressor)
DI08-9
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DI08-10
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DI08-11
Flow demand
IMV current
Open
Engine speed
IMV
Current
Rail pressure
demand
Error
PIG
governor
Correction
Measured rail
pressure
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DI08-12
DI08-13
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DI08-14
Drivers request
Cruise control
Flow limit
Speed limiter
Overflow
Driver Demand
The driver demand is the translation of the pedal position into the fuel demand. It is calculated as a function of the pedal
position and of the engine speed. The driver demand is filtered in order to limit the hesitations caused by rapid changes
of the pedal position. A mapping determines the maximum fuel which can be injected as a function of the driver demand
and the rail pressure. Since the flow is proportional to the injection time and to the square root of the injection pressure,
it is necessary to limit the flow according to the pressure in order to avoid extending the injection for too long into the
engine cycle. The system compares the driver demand with this limit and chooses the smaller of the 2 values. The driver
demand is then corrected according to the coolant temperature. This correction is added to the driver demand.
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DI08-15
Flow Limitation
The flow limitation strategy is based on the following strategies:
The flow limitation depending on the filling of the engine with air is determined according to the engine speed and the
air flow. This limitation allows smoke emissions to be reduced during stabilized running.
The flow limitation depending on the atmospheric pressure is determined according to the engine speed and the
atmospheric pressure. It allows smoke emissions to be reduced when driving at altitude.
The full load flow curve is determined according to the gear engaged and the engine speed. It allows the maximum
torque delivered by the engine to be limited.
A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are
detected by the system. In this case, and depending on the gravity of the fault, the system activates:
- Reduced fuel logic 1: Guarantees 75 % of the performance without limiting the engine speed.
- Reduced fuel logic 2: Guarantees 50 % of the performance with the engine speed limited to 3,000 rpm.
- Reduce fuel logic 3: Limits the engine speed to 2,000 rpm.
The system chooses the lowest of all these values.
A correction depending on the coolant temperature is added to the flow limitation. This correction makes it possible to
reduce the mechanical stresses while the engine is warming up. The correction is determined according to the coolant
temperature, the engine speed and the time which has passed since starting.
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DI08-16
Accelerometer Strategy
Resetting the pilot injection
The accelerometer is used to reset the pilot injection flow in closed loop for each injector. This method allows the
correction of any injector deviations over a period of time. The principle of use of the accelerometer is based on the
detection of the combustion noises.
The sensor is positioned in such a way as to receive the maximum signal for all the cylinders. The raw signals from the
accelerometer are processed to obtain a variable which quantifies the intensity of the combustion. This variable, known
as the ratio, consists of the ratio between the intensity of the background noise and the combustion noise.
A first window is used to establish the background noise level of the accelerometer signal for each cylinder. This
window must therefore be positioned at a moment when there cannot be any combustion.
The second window is used to measure the intensity of the pilot combustion. Its position is such that only the
combustion noises produced by the pilot injection are measured . It is therefore placed just before the main injection.
The accelerometer does not allow any evaluation of the quantity injected. However, the pulse value will be measured
when the injector starts injection and this pulse value is called the MDP (Minimum Drive Pulse). On the basis of this
information, it is possible to efficiently correct the pilot flows. The pilot injection resetting principle therefore consists of
determining the MDP, in other words the pulse corresponding to the start of the increase in value of the ratio (increase
of vibration due to fuel combustion).
Cylinder pressure
Needle lift
Ratio
No pilot injection
No injection
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DI08-17
This is done periodically under certain operating conditions. When the resetting is finished, the new minimum pulse
value replaces the value obtained during the previous resetting. The first MDP value is provided by the C2I. Each
resetting then allows the closed loop of the MDP to be updated according to the deviation of the injector.
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DI08-18
Delivery (mm3/st)
It is function between pulse and rail pressure and fuel injection curve is called injector characteristics curve having the
following shape.
Common rail injectors are very accurate components. They are able to inject fuel delivery between 0.5 to 100 mg/str
under pressure varying from 150 to 1600 bar.
This high level of accuracy requires very low machining tolerances (few
).
Nevertheless, due to the machining dispersion, the loss of charge through the functional orifices, the friction between
moving parts and electromagnetic field level are different from one injector to the other. So, the difference of fuel delivery
for the same pressure and the same pulse can reach 5 mg/str from one injector to the other. It is impossible to control
efficiently the engine with such a dispersion between the different injectors. It is necessary to add a correction that
allows injecting the demanded fuel delivery whatever the initial hydraulic characteristics of the injector is. The method
consists in correcting the pulse that is applied to the injector with an offset that depends on the initial hydraulic map of
the injector. So, the pulse should be corrected according to characteristics of each injector.
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DI08-19
C2I is composed of models on these characteristics of injectors.
C2I consists of 16-digit; composed of numbers from 1 to 9 and alphabets from A to F. ECU remembers C2I, characteristics of each injector, to make the most optimal fuel injection.
When replacing the injector, C2I code on the top of new injector should be input into ECU because the ECU is
remembering the injectors C2I value. If C2I is not input, engine power drops and occurs irregular combustion.
When ECU is replaced, C2I code of every injector should be input. If not, cannot accelerate the vehicle even when
the accelerator pedal is depressed.
C2I Number
(16 digits)
C2I
value
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DI08-20
Learning Conditions
Coolant temperature
> 75C
Vehicle speed
Engine speed
Battery voltage
Fuel temperature
5 seconds
Trouble Codes
Trouble code
Description
P1171
P1172
P1173
P1174
P1175
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Diagnosis
DI08-21
OTHER COMPONENTS
Accelerator Pedal Sensor
Accelerator pedal sensor changes accelerator pedal position into electrical signal and then sends to ECU to let know
the drivers demand. There are 2 sensors in the accelerator pedal sensor. Accelerator pedal No.1 (ACC 1) sensor signal
determines fuel injection volume and injection timing during driving, and accelerator pedal No. 2 (ACC 2) sensor signal
compares whether the No. 1 sensor signal value is correct.
If accelerator pedal No. 1 and 2 sensors are defective, ECU remembers defect code, and acceleration responses are
getting bad and engine rpm hardly increases.
Notice
When depressing the accelerator pedal and brake pedal simultaneously while driving, the acceleration response
will be diminished abruptly and cannot drive with over 70 km/h even though depressing the accelerator pedal
to its end. At this time, the trouble code of P-1124 Accelerator pedal sensor stuck is stored into ECU. If
depressing the accelerator pedal over 3 times, it will be resumed to normal condition.
* For detailed information, refer to Diagnosis section in this manual.
Signal 1
Ground
Signal 2
Ground
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DI08-22
Temp.
Resistance
Coolant temperature sensor is a NTC resister that sends coolant temperature to ECU.
NTC resister has characteristics that if the engine temperature rises, the resistance lowers so the ECU detects lowering
signal voltages.
If the fuel injected into the engine through injector has more turbulence, then combusts very well. However, if engine
temperature is too low, the fuel injected as foggy state forms big compounds causing incomplete combustion. So the
sensor detects coolant temperature and changes coolant temperature changes into voltage then sends to ECU to
increase the fuel volume during cold start for better starting. And detects engine overheating for fuel volume reduction to
protect the engine.
ECU functions as below with coolant temperature sensor signals.
When engine is cold, controls fuel volume to correct idle speed.
When engine is overheated, controls electrical fan and A/C compressor to protect the engine.
Sends information for emission control.
Temperature (C)
)
NTC 1 Resistance (
)
NTC 1 Resistance (
20
2,550
6,062
50
826
1,800
80
321
638
120
123
200
Signal
Auto amp
Ground
DI08-23
Boost pressure sensor uses piezo element and uses only 3 terminals out of 6.
It sets fuel injection timing and corrects fuel injection volume according to atmospheric pressure.
Output voltage calculation
VO = VS x ( P x 0.004 - 0.04)
VO : Output voltage
VS : Supply voltage
P : Applying voltage
Voltage (V)
Pressure (bar)
20 ~ 250 KPa
- 40 ~ 110C
- 40 ~ 125C
4.85 ~ 5.35 V
Responsibility
Tightening torque
TR
7ms
10 Nm
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DI08-24
Ground
REF 5V
SIG
Function
- Limits idle control correction duty range
- Controls cooling fan
- Cuts fuel injection if exceeds max. speed
ABS
or
ESP control unit
CAN communication
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DI08-25
Other switches
Brake switch
Brake switch detects brake pedal operations and then sends to engine ECU. It has dual structure with 2 combined
switches and there are brake switch 1 and 2. When these 2 signals are input, engine ECU recognizes as normal brake
signals. These switch signals are related with accelerator pedal sensor operations and used to control the fuel volume
during braking. It means there are no problems in operating accelerator pedal when the brake pedal is operated but the
fuel volume reduces if operates brake pedal while the accelerator pedal is depressed.
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DI09-1
SECTION
00 DI09
ELECTRIC DEVICES
AND SENSORS
Table of Contents
ELECTRIC DEVICES AND SENSORS ........................ DI09-2
Sensors in engine compartment ............................. DI09-2
Electric devices in engine compartment ................. DI09-3
Specifications .......................................................... DI09-4
Circuit diagram of preheating system ..................... DI09-5
Circuit diagram of starting and alternator .............. DI09-6
TROUBLE DIAGNOSIS ............................................... DI09-7
General ................................................................... DI09-7
Alternator ................................................................ DI09-9
Starter ................................................................... DI09-11
Preheating system ................................................ DI09-13
Preheating time relay ............................................ DI09-15
Glow plug .............................................................. DI09-16
SPECIAL TOOLS AND EQUIPMENT ........................ DI09-18
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DI09-2
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Booster pressure
sensor
Camshaft position
sensor
Coolant temperature
sensor
Crankshaft position
sensor
Fuel temperature
sensor
Knock sensor
DI09-3
Alternator
Glow plug
Capacity
PTC equipped vehicle
: 12V - 140A
FFH equipped vehicle
: 12V - 115A
Starter
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DI09-4
SPECIFICATIONS
Description
Starter
Unit
Specification
WP220
Kw
2.2
160
rpm
4500
rpm/A
1700/430
Brush length
mm
18
Armature diameter
mm
55
Armature run-out
mm
0.1
mm
21.7
NP37
V/A
Type
Output power
No load test @ 12 volts
Drive pinion speed at no load
Drive pinion speed at load
Alternator
Type
Output voltage / current
Regulating voltage
14.6
mm
12.5
mm
MF
Capacity
AH
12V - 90AH
Rupture capatity
RC
160
Type
Seized type
Rated voltage
11.5
Circuit connection
Parallel
sec
Max. 60 ~ 90
Brush
Length
Quantity
Wear limit
Battery
Glow plug
Type
Preheating time
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DI09-5
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DI09-6
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DI09-7
TROUBLE DIAGNOSIS
GENERAL
Condition
No crank
Battery discharge
Probable Cause
Correction
Ground short.
Replace alternator
Repair wiring
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DI09-8
Symptom
Hard engine starting
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Cause
Action
DI09-9
ALTERNATOR
1. Viscous clutch
3. Alternator
2. Bolt ............................................................. 45 Nm
4. Plug connection
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DI09-10
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DI09-11
STARTER
1. Starter
3. Nut .................................................................... 15 Nm
2. Washer
4. Bolt ................................................................... 48 Nm
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DI09-12
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DI09-13
PREHEATING SYSTEM
General
Glow plug is installed on the cylinder head (combustion chamber) in the D27DT preheating control unit system. Cold
starting performance has improved and exhaust gas during cold starting has reduced.
ECU receives coolant temperature and engine speed to control; after monitoring the engine preheating/after heating and
glow plug diagnosis function, the fault contents will be delivered to ECU.
Engine preheating/after heating functions
Preheating relay activation by ECU controls
- Senses engine temperature and controls the preheating/after heating time
- Preheating warning light
K-LINE for information exchanges between preheating unit and ECU
- Transmits preheating unit self-diagnosis results to ECU
- Transmits glow plug diagnosis results and operating status to ECU
Coolant
temperature
sensor
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DI09-14
Function
Preheating system controls and checks following functions and operating conditions.
Pre-heating
: The power will be supplied to the glow plugs by ECU controls when the power is supplied to the IG terminal from
the battery and there are normal communications with ECU. The surface of glow plug will be heated up to 850C
very quickly to aid combustion by vaporizing air-fuel mixture during compression stroke.
Preheating time is controlled by ECU.
While engine starting
: Help to warm up engine
After-heating
: When the engine is started, after-heating starts by ECU controls. The idle rpm will be increased to reduce toxic
smoke, pollutants and noises.
After-heating time is controlled by ECU.
Checking glow plugs
- Check each glow plug for short in circuit
- Check each glow plug for open in circuit due to overvoltage
- Check glow plug for short to ground
Forceful relay shut-down
- When glow plug is shorted to ground
K-Line communication
- ECU sends the results to preheating time control relay through K-Line to start communication.
- Preheating time control relay sends messages including self-diagnosis data for glow plugs to ECU.
- Glow plug makes communication only as response to demand.
- The ECU will attempt to read the diagnostic information 2 seconds after power up.
- Under the following conditions, communication error occurs.
When there is no response from glow plug module within 50 milli-second after request of ECU.
When an error is detected in checksum
Less byte is received
Error code of Pre heating control communication fail will be reported.
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DI09-15
K-LINE #1
(ECU 34)
IG1 power
terminal
B+ main
wire (12V)
Glow plug terminal
#1 ~ #5
Specifications
Description
Specification
Rated voltage
DC 12 V
DC 8 ~ 15 V
Operating range
- 40 ~ + 100C
Over 6.5 V
Over 1.5 V
11.3
Voltage drop
Parasitic current
Max. 1mA
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DI09-16
GLOW PLUG
Cylinder type glow plug is inserted into the cylinder and composed of heating pin and housing.
There are heating coil and control coil in the heating pin and
those coils located inside of ceramic cover turn ON or OFF
the internal switch.
Purposes of use
- Preheating before engine starting
- During engine starting
- After-heating after engine starting
Specifications
Description
Specification
Rated voltage
11 0.1 V
Current consumption
Preheating time
Initial current I
T
850C
intial
< 30.0 A
= 5 1.5 sec.
900 C
Tightening torque
15 + 3 Nm
Trouble Code
Refer to Diagnosis section in this manual.
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DI09-17
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DI09-18
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AFFECTED VIN
Application
Removal of glow plug
DI10-1
SECTION
00 DI10
DIAGNOSIS
Table of Contents
SCAN-100 OPERATING PROCEDURES D27DT ENGINE ........................................................... DI10-3
TROUBLE DIAGNOSIS TABLE ................................. DI10-25
FUEL SYSTEM DIAGNOSIS ................................... DI10-179
DIAGNOSIS
DI ENG SM - 2004.9
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DI10-3
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI10-4
CHANGED BY
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AFFECTED VIN
in MAIN MENU
in VEHICLE
in CONTROL UNIT
DIAGNOSIS
DI ENG SM - 2004.9
DI10-5
DIAGNOSIS
DI ENG SM - 2004.9
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AFFECTED VIN
DI10-6
FUNCTION SELECTION
Check the Trouble Code
Preceding work: Perform the Entering Diagnosis Procedures
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AFFECTED VIN
if you press
if you press
DIAGNOSIS
DI ENG SM - 2004.9
DI10-7
in FUNCTION
key
Note
DIAGNOSIS
DI ENG SM - 2004.9
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AFFECTED VIN
DI10-8
Actuator Check
Preceding Work: Perform the Entering Diagnosis Procedures
in FUNCTION
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AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-9
4. If you want to operate the glow plug relay, press
DIAGNOSIS
DI ENG SM - 2004.9
key in
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AFFECTED VIN
DI10-10
in
CHANGED BY
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AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-11
4. If the trouble has been change to H (History trouble code)
code, press
key to go back to FUNCTION
SELECTION screen. In this screen, select 4] TROUBLE
.
CODE CLEAR and press
DIAGNOSIS
DI ENG SM - 2004.9
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AFFECTED VIN
DI10-12
ECU Identification
Preceding Work: Perform the Entering Diagnosis Procedures
in
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AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-13
Note
The C2I value of replacing injector is recorded in
the label.
C2I coding number: 16 digits (ex, B1 B9 D4 1B 43
C6 0E 4F)
DIAGNOSIS
DI ENG SM - 2004.9
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AFFECTED VIN
DI10-14
3-1. If you enter the invalid C2I value of the relevant injector,
the message as shown in figure appears with alarm sound.
Note
3-2. If you enter the valid C2I value of the relevant injector, the
message as shown in figure appears with alarm sound.
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EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-15
Leak Detection
Preceding Work: Perform the Entering Diagnosis Procedures
Note
This item is for checking the high fuel pressure after the
IMV supply line of HP pump in DI engine fuel system. If
you still suspect that the fuel pressure system is defective
even after no trouble is detected, perform the fuel pressure
test again by using a fuel pressure tool kit.
in
DIAGNOSIS
DI ENG SM - 2004.9
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AFFECTED VIN
DI10-16
Variant Coding
Preceding Work: Perform the Entering Diagnosis Procedures
in
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AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-17
4. If you need to change the variant coding, press
6. If you press
, the message as shown in figure
appears. And, then VARIANT CODING screen is
displayed.
DIAGNOSIS
DI ENG SM - 2004.9
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AFFECTED VIN
DI10-18
ECU Replace
Preceding Work: Perform the Entering Diagnosis Procedures
1. Select 0] ECU REPLACE and press
FUNCTION SELECTION screen.
in
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AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-19
, the message as shown in figure 1 (system
4. If you turn the ignition switch to ON position and press
initialization) appears, and then MULTI CALIBRATION screen (figure 2) is displayed.
figure 1
figure 2
DIAGNOSIS
DI ENG SM - 2004.9
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AFFECTED VIN
DI10-20
7. If the multi calibration is completed successfully, ECU
REPLACE (STEP 5) screen is displayed.
Backup data:
- Multi calibration value
- VIN value
- Variant code value
- Injector (C2I) value
9. Press
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AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-21
11. If the password is valid, an immobilizer coding is started.
12. If you want to code for additional keys, remove the first
key from key switch and insert the second key. Turn it
to ON position and press
to proceed.
.
14. When the immobilizer coding is completed, press
The completion message as shown in figure appears.
DIAGNOSIS
DI ENG SM - 2004.9
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AFFECTED VIN
DI10-22
15. When you turn the ignition key to OFF position, the
message screen as shown in figure is displayed. Wait
for 15 seconds and turn the ignition key to ON position.
16. Press
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AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-23
DIAGNOSIS
DI ENG SM - 2004.9
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AFFECTED VIN
DI10-24
3. Enter the current rail pressure value and press [ENTER]
to reset the offset value.
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AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-25
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
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DI10-26
INDEX OF DTC
P0102 Low HFM Sensor Signal (Circuit Open) .......... DI10-29
...................................................................... DI10-42
...................................................................... DI10-42
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DIAGNOSIS
DI ENG SM - 2004.9
DI10-27
P0202
P0204
P0205
P0203
P1201
P1202
P1204
P1171
P1205
P1172
P1203
P1174
P0182
P1175
P0183
P1173
P0180
P1252
P1678
P1120
P1679
P1121
P1680
P1122
P0113
P0112
P0110
Intake Air Temperature Circuit Malfunction Source Power Problem .................................. DI10-57
P1530
P1531
P1532
P1124
P1534
P0122
P1535
P1536
P1254
P1253
P1257
P1259
P0123
P0120
P0222
P0223
P1258
P1256
P1123
P0220
P0192
P0193
P0190
P1191
P0255
P0191
P0251
P1192
P0253
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-28
Fuel Rail Pressure Sensor Initial Signal Fault -
P0671
P0672
P1190
P0673
P0215
P0674
P1500
P0675
P0642
P1671
P0643
P1672
P0641
P1673
P0652
P1674
P0653
P1675
P0651
P0700
P0698
P1540
P0699
P1541
P0697
P1542
P0245
P0246
P1149
P1634
P0606
P1635
P1607
P1600
P1601
P1602
P1631
P1614
P1632
P1615
P1633
P1616
P0633
P1606
P1636
P1620
P1621
P1622
P1603
P1604
P1605
P1148
P0400
P1235
P1608
P0335
P1170
P1676
P1677
P1193
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
P1630
DIAGNOSIS
DI ENG SM - 2004.9
DI10-29
Trouble
Help
P0102
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-30
DTC
Trouble
P0100
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P0344
P0341
P0219
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-31
DTC
Trouble
Help
P0336
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
P1107
35 Kpa: 1.0 V
55 Kpa: 2.0 V
80 Kpa: 3.0 V
35 Kpa: 1.0 V
55 Kpa: 2.0 V
80 Kpa: 3.0 V
35 Kpa: 1.0 V
55 Kpa: 2.0 V
80 Kpa: 3.0 V
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-32
DTC
P0562
Trouble
Low Battery Voltage
Help
- Malfunction in recognition of system
source voltage (Lower than threshold).
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-33
DTC
Trouble
Help
P0109
- Out of signal range about boost pressure sensor at Ignition key-On and Engine Stop (Lower than specified values).
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
- Out of signal range about boost pressure sensor at Ignition key-On and Engine Stop (Higher than specified
values).
- Check the supply voltage to sensor.
- Actual boost pressure vs. Output
voltages.
Raw Signal Range: 0.545 ~ 2.490 bar
0.4 bar: 0.6120 V
1.4 bar: 2.6520 V
2.4 bar: 4.6920 V
- Check the sensor wiring harness for
ECU pin #99 and #100 (open, poor
contact).
- Visually check sensor and replace if
required.
- Replace the ECU if required.
- Check whether existing or not about
turbo boosting control malfunction
(P1235) simultaneously.
- If there is turbo boost control fault,
Should be checked followings also;
Leakage before turbo system
Vacuum pump malfunction
Waste gate solenoid valve
Turbo charger system defect or
malfunction itself
Air inlet restriction
Exhaust system restriction
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-34
DTC
Trouble
Help
P0107
- Out of signal range about boost pressure sensor at Engine running condition (Lower than specified values).
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
- Out of signal range about boost pressure sensor at Engine running condition (Higher than specified values).
- Check the supply voltage to sensor.
- Actual boost pressure vs. Output voltages
Raw Signal Range: 0.545~2.490 bar
0.4 bar: 0.6120 V
1.4 bar: 2.6520 V
2.4 bar: 4.6920 V
- Check the sensor wiring harness for
ECU pin #99 and #100 (open, poor
contact).
- Visually check sensor and replace if
required.
- Replace the ECU if required.
- Check whether existing or not about
turbo boosting control malfunction
(P1235) simultaneously.
- If there is turbo boost control fault,
Should be checked followings also;
Leakage before turbo system
Vacuum pump malfunction
Waste gate solenoid valve
Turbo charger system defect or
malfunction itself
Air inlet restriction
Exhaust system restriction
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-35
DTC
Trouble
Help
P0105
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-36
DTC
Trouble
Help
P1109
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-37
DTC
P1572
Trouble
Brake Lamp Signal Fault
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
P1571
P1286
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-38
DTC
Trouble
Help
P1287
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P1289
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-39
DTC
Trouble
Help
P1292
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
P1294
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-40
DTC
Trouble
Help
P1295
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P1291
P0704
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-41
Trouble
Help
DTC
P1115
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-42
DTC
Trouble
Help
P0117
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P0685
P1405
P1406
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-43
DTC
Trouble
P1480
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
P1481
P1482
P1526
P1527
P1528
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-44
DTC
Trouble
Help
P0325
Accelerometer #1 (Knock
Sensor) Malfunction
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
Accelerometer #2 (Knock
Sensor) Malfunction
P1611
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-45
DTC
Trouble
Help
P1612
- Malfunction of injector (#1, #4, #3) circuit (High): Short to Ground or to Battery.
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
- Operating voltage: 6 ~ 18 V
- Check the injector bank #1: Short and
poor contact
- Check if the trouble recurs with the injectors removed and the ignition key OFF.
If recurred, check the injector and
ECU wiring harness.
- Check if the trouble recurs while installing the injectors one by one with
the ignition key ON.
If recurred, replace the injector (perform
C2I coding after replacement).
Check the other injectors with same
manner.
- Check the ECU wiring harness.
- Replace the ECU if required.
P1618
P1619
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-46
DTC
Trouble
Help
P0263
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P0272
P0275
P0269
P0201
P0202
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-47
DTC
P0204
Trouble
Injector #4 Circuit Open
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
P0205
P0203
P1201
P1202
P1204
P1205
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-48
DTC
P1203
Trouble
Injector #3 Circuit Short
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Help
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P0182
-20C: 21.873
-10C: 12.462
0C: 7.355
10C: 4.481
20C: 2.812
25C: 2.252
30C: 1.814
40C: 1.199
50C: 0.811
70C: 0.394
90C: 0.206
120C: 0.087
- Recovery values when fuel temperature sensor failure: 95C
- Check the supply voltage to sensor.
- Check the wiring harness for open,
short and poor contact.
ECU pin: #109, #110
- Check the ECU wiring and replace the
ECU if required.
P0183
-20C: 21.873
-10C: 12.462
0C: 7.355
10C: 4.481
20C: 2.812
25C: 2.252
30C: 1.814
40C: 1.199
50C: 0.811
70C: 0.394
90C: 0.206
120C: 0.087
- Recovery values when fuel temperature sensor failure: 95C
- Check the supply voltage to sensor.
- Check the wiring harness for open,
short and poor contact.
ECU pin: #109, #110
- Check the ECU wiring and replace the
ECU if required.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-49
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
DTC
Trouble
Help
P0180
Delayed
Engine
Stop
Immediately
Engine
Stop
-20C: 21.873
-10C: 12.462
0C: 7.355
10C: 4.481
20C: 2.812
25C: 2.252
30C: 1.814
40C: 1.199
50C: 0.811
70C: 0.394
90C: 0.206
120C: 0.087
- Recovery values when fuel temperature sensor failure: 95C
- Check the supply voltage to sensor.
- Check the wiring harness for open,
short and poor contact.
ECU pin: #109, #110
- Check the ECU wiring and replace the
ECU if required.
P1678
P1679
P1680
P1530
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-50
DTC
Trouble
P1531
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P1532
P1534
P1535
P1536
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-51
DTC
Trouble
P1254
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
P1253
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-52
DTC
Trouble
Help
P1256
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P1257
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-53
DTC
Trouble
Help
P1258
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
P1259
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-54
DTC
Trouble
Help
P1191
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P0251
P0253
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-55
DTC
Trouble
Help
P0113
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-56
DTC
Trouble
Help
P0112
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-57
DTC
Trouble
Help
P0110
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
P1172
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-58
DTC
Trouble
P1174
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P1175
P1173
P1252
P1120
DIAGNOSIS
DI ENG SM - 2004.9
DI10-59
DTC
Trouble
Help
P1121
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P1123
P1124
P0122
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-60
DTC
Trouble
P0120
Help
- The 5 V supply voltage is faulty.
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P0222
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-61
DTC
Trouble
Help
P0192
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-62
DTC
Trouble
P0191
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Help
- The rail pressure drop is too high.
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P1192
90 bar
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-63
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
DTC
Trouble
Help
P1190
Delayed
Engine
Stop
Immediately
Engine
Stop
90 bar
P1500
P0642
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-64
DTC
Trouble
Help
P0643
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
Supply voltage: 5 V
- Check the supply voltage to each sensor
Supply voltage (5 V): accelerator
pedal sensor 1, HFM sensor, rail
pressure sensor, booster pressure
sensor, cam sensor
- Check the wiring harnesses.
- Replace the ECU if required.
P0641
P0652
Supply voltage: 5 V
- Check the supply voltage to each sensor
Supply voltage (5 V): accelerator
pedal sensor 1, HFM sensor, rail
pressure sensor, booster pressure
sensor, cam sensor
- Check the wiring harnesses.
- Replace the ECU if required.
P0653
P0651
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-65
DTC
Trouble
Help
P0698
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
P0697
P0245
P1607
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-66
DTC
P1600
Help
Trouble
ECU Shut Down Fault
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P1601
ECU Fault
P1602
ECU Fault
P1614
ECU Fault
ECU Fault
ECU Fault
ECU Fault
ECU Fault
ECU Fault
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-67
P1603
Help
Trouble
DTC
ECU Fault
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
O
P1604
ECU Fault
P1605
ECU Fault
P1148
Accelerometer (Knock
Sensor) Learning Fault
P0400
P1235
ECU Fault
P0335
No Crank Signals
- Refer to P0372.
P1170
- Refer to P0372.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-68
DTC
Trouble
Help
P1676
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P0671
P0672
P0673
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-69
DTC
Trouble
P0674
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
P0675
P1671
P1672
P1673
P1674
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-70
DTC
Trouble
P1675
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
P0700
P1540
P1541
P1542
P1149
P1634
P1635
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-71
DTC
Trouble
Help
P1630
- The invalid key is inserted or no communication between transponder and immobilizer (no response from transponder).
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
P1632
P1633
- No key coding.
- Perform the immobilizer coding again.
- Check the ECU wiring harness.
Check the ECU pin #34 for open and
short.
- Check the immobilizer unit for open and
short or check the supply voltage.
- Check the immobilizer antenna and
transponder for damage.
- Replace the ECU if required.
P0633
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-72
DTC
Trouble
P1636
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-73
INDEX OF DTC
HMF sensor Signal Fault (Electric Failure) .......... DI10-77
P0102 ............................................................ DI10-77
P0103 ............................................................ DI10-77
P0100 ............................................................ DI10-77
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-74
Condenser Fan Driving Signal Fault (Type 2) ..... DI10-105
P1526 .......................................................... DI10-105
P1527 .......................................................... DI10-105
P1528 .......................................................... DI10-105
#1 Accelerometer Malfunction
(Idling Signal/Too Small Noise Ratio) ................. DI10-106
P0325 .......................................................... DI10-106
#2 Accelerometer Malfunction
(Idling Signal/Too Small Noise Ratio) ................. DI10-107
P0330 .......................................................... DI10-107
Injector Bank 1 Malfunction
(Short to Ground or B+) ..................................... DI10-108
P1611 .......................................................... DI10-108
P1612 .......................................................... DI10-108
Injector Bank 2 Malfunction
(Short to Ground or B+) ..................................... DI10-110
P1618 .......................................................... DI10-110
P1619 .......................................................... DI10-110
Cylinder Balancing Fault (Injector #1) =
Clogged Air Intake System ................................ DI10-112
P0263 .......................................................... DI10-112
Cylinder Balancing Fault (Injector #2) =
Clogged Air Intake System ................................ DI10-113
P0266 .......................................................... DI10-113
Cylinder Balancing Fault (Injector #4) =
Clogged Air Intake System ................................ DI10-114
P0272 .......................................................... DI10-114
Cylinder Balancing Fault (Injector #5) =
Clogged Air Intake System ................................ DI10-115
P0275 .......................................................... DI10-115
Cylinder Balancing Fault (Injector #3) =
Clogged Air Intake System ................................ DI10-116
P0269 .......................................................... DI10-116
Open Circuit (Injector #1) ................................... DI10-117
P0201 .......................................................... DI10-117
Open Circuit (Injector #2) ................................... DI10-118
P0202 .......................................................... DI10-118
Open Circuit (Injector #4) ................................... DI10-119
P0204 .......................................................... DI10-119
Open Circuit (Injector #5) ................................... DI10-120
P0205 .......................................................... DI10-120
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-75
IMV Operation Fault (Electrical Fault) ................ DI10-137
P0255 .......................................................... DI10-137
P0251 .......................................................... DI10-137
P0253 .......................................................... DI10-137
Intake Air Temperature Sensor Fault
(Electric Fault) .................................................. DI10-138
P0112 .......................................................... DI10-138
P0113 .......................................................... DI10-138
P0110 .......................................................... DI10-138
MDP Fault (Injector #1) ..................................... DI10-139
P1171 .......................................................... DI10-139
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-76
ECU Non-Volatile Memory Fault ........................ DI10-163
P1614 .......................................................... DI10-163
P1615 .......................................................... DI10-163
P1616 .......................................................... DI10-163
P1606 .......................................................... DI10-163
P1620 .......................................................... DI10-163
P1621 .......................................................... DI10-163
P1622 .......................................................... DI10-163
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-77
Symptom
P0102
Low Signal
MIL ON
P0103
High Signal
P0100
Supply Voltage
Diagnosis Procedures
Read DTC
YES
NO
Wiring Problem?
NO
YES
Repair or
replace
NO
Wiring Problem?
Resistance Problem?
NO
YES
Replace
sensor
Replace ECU
Wiring Problem?
YES
Repair or
replace
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-78
Symptom
Diagnosis Procedures
Check sensor wiring and
connector
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
Check sensor
NO
Sensor Problem?
YES
Replace
sensor
NO
YES
Replace cam
wheel
NO
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO
Anmormal Signal?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair or
replace
DIAGNOSIS
DI ENG SM - 2004.9
DI10-79
Symptom
MIL ON
Diagnosis Procedures
Check sensor wiring
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
Check sensor
Sensor Problem?
YES
YES
Repair wiring
NO
Replace
sensor
Check cam installation
NO
Wiring Problem?
YES
YES
NO
Repair or
replace
Replace ECU
NO
Anmormal Signal?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Repair wiring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace cam
wheel
DI10-80
Symptom
Diagnosis Procedures
Check sensor wiring
Wiring Problem?
YES
Repair or
replace
Trouble Continues?
YES
NO
Replace APS
wheel
NO
YES
Repair or
replace
Trouble Continues?
YES
Replace ECU
NO
NO
YES
Repair wiring
NO
Trouble Continues?
YES
Replace VR
sensor
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-81
Symptom
MIL ON
Diagnosis Procedures
Check sensor wiring
Wiring Problem?
YES
Repair or
replace
Trouble Continues?
YES
NO
Replace APS
wheel
NO
YES
Repair or
replace
Trouble Continues?
YES
NO
NO
YES
Repair wiring
NO
Trouble Continues?
YES
Replace VR
sensor
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-82
Symptom
MIL ON
Diagnosis Procedures
Check sensor wiring
Wiring Problem?
YES
Repair or
replace
Trouble Continues?
NO
YES
Replace APS
wheel
NO
YES
Repair or
replace
Trouble Continues?
NO
YES
Replace ECU
NO
YES
Repair wiring
NO
Trouble Continues?
YES
Replace VR
sensor
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-83
Low Signal
P1108
High Signal
P1105
Supply Voltage
Symptom
Diagnosis Procedures
Replace ECU
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-84
Symptom
P0562
Low Signal
Not operatable.
P0563
High Signal
P0560
Supply Voltage
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-85
Diagnosis Procedures
Key ON and check battery
voltage
Battery Problem?
YES
Charge
battery
NO
YES
YES
Repair or
replace
Replace ECU
NO
Wiring Problem?
YES
Repair or
replace
NO
High Resistance
DIAGNOSIS
DI ENG SM - 2004.9
YES
Repair ECU
ground
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-86
Low
P0106
High
Symptom
Diagnosis Procedures
1. Diagnosis Procedures (Boost Pressure)
Read DTC
YES
NO
Repiar Completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-87
YES
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-88
Low
P0108
High
P0105
Supply Voltage
P1106
GRAD
Symptom
Diagnosis Procedures
1. Diagnosis Procedures (Boost Pressure)
Read DTC
YES
NO
Repiar Completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-89
YES
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-90
Symptom
Diagnosis Procedures
1. Diagnosis Procedures (Boost Pressure)
Read DTC
YES
NO
Repiar Completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-91
YES
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-92
Symptom
MIL ON
Unable Cruise Control
Diagnosis Procedures
Check switch wiring
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair or
replace
NO
YES
Check wiring
and fuse
NO
Wiring Problem?
YES
Repair wiring
Switch Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Replace
switch
Replace ECU
DIAGNOSIS
DI ENG SM - 2004.9
DI10-93
Symptom
P1572
MIL ON
P1571
MIL ON
Diagnosis Procedures
Check switch wiring
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair or
replace
NO
YES
Check wiring
and fuse
NO
Wiring Problem?
YES
Switch Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Replace
switch
Replace ECU
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-94
Symptom
P1286
Low
P1287
High
MIL ON
Unable Dynamic Leak of Injector #1
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Read DTC
Low Fault?
YES
NO
Refer to
injector circuit
malfunction
(open) tree
Read DTC
High Fault?
NO
YES
Refer to
injector circuit
malfunction
(short) tree
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-95
Symptom
P1288
Low
P1289
High
MIL ON
Unable Dynamic Leak of Injector #2
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Read DTC
Low Fault?
YES
NO
Refer to
injector circuit
malfunction
(open) tree
Read DTC
Highs Fault?
NO
YES
Refer to
injector circuit
malfunction
(short) tree
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-96
Symptom
P1292
Low
P1293
High
MIL ON
Unable Dynamic Leak of Injector #4
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Read DTC
Low Fault?
YES
NO
Refer to
injector circuit
malfunction
(open) tree
Read DTC
High Fault?
NO
YES
Refer to
injector circuit
malfunction
(short) tree
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-97
Symptom
P1294
Low
P1295
High
MIL ON
Unable Dynamic Leak of Injector #5
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Read DTC
Low Fault?
YES
NO
Refer to
injector circuit
malfunction
(open) tree
Read DTC
High Fault?
NO
YES
Refer to
injector circuit
malfunction
(short) tree
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-98
Symptom
P1290
Low
P1291
High
MIL ON
Unable Dynamic Leak of Injector #3
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Read DTC
Low Fault?
YES
NO
Refer to
injector circuit
malfunction
(open) tree
Read DTC
High Fault?
NO
YES
Refer to
injector circuit
malfunction
(short) tree
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-99
Symptom
Diagnosis Procedures
Check switch wiring
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair or
replace
NO
YES
Check wiring
and fuse
NO
Wiring Problem?
YES
YES
Replace switch
Replace ECU
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-100
Symptom
Diagnosis Procedures
Read DTC
YES
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
Resistance Problem?
YES
Replace
sensor
Replace ECU
NO
Wiring Problem?
YES
Repair or
replace
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-101
Symptom
P0117
Low
P0118
High
P0115
Supply Voltage
Diagnosis Procedures
Read DTC
YES
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Resistance Problem?
YES
Replace
sensor
Replace ECU
NO
Wiring Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Repair or
replace
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-102
Symptom
Diagnosis Procedures
Check relay wiring
Wiring Problem?
YES
Repair or
replace
NO
NO
Wiring Problem?
YES
Repair or
replace
NO
YES
Replace ECU
NO
Repiar Completed
Wiring Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair wiring
DIAGNOSIS
DI ENG SM - 2004.9
DI10-103
Symptom
P1405
MIL ON
P1406
Diagnosis Procedures
Check actuator wiring
NO
Wiring Problem?
YES
Repair or
replace
Replace actuator
NO
Trouble Continues?
YES
Resistance Problem?
YES
Replace
actuator
Repiar Completed
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-104
Symptom
P1480
Open Circuit
P1481
Short Circuit
MIL ON
P1482
Short to Ground
Diagnosis Procedures
Check relay wiring
NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO
YES
Replace ECU
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-105
Symptom
P1526
Open Circuit
P1527
Short Circuit
MIL ON
P1528
Short to Ground
Diagnosis Procedures
Check relay wiring
NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO
YES
Replace ECU
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-106
#1 Accelerometer Malfunction
(Idling Signal/Too Small Noise Ratio)
Trouble Code and Symptom
Trouble Code
P0325
Symptom
MIL ON
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Caution: Check the sensing
value of coolant temp., intake
air temp., fuel temp. barometric pressure. Incorrect default
values of theses sensors may
cause wrong diagnosis.
Check accelerometer wiring
and tightening torque, especially shield ground.
NO
Wiring Problem?
YES
Repair or
replace
Replace accelerometer
(knock sensor)
NO
Trouble Continues?
Wiring Problem?
YES
YES
Replace ECU
NO
Repair or
replace
Repiar Completed
NO
Wiring Problem?
YES
Repair wiring
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-107
#2 Accelerometer Malfunction
(Idling Signal/Too Small Noise Ratio)
Trouble Code and Symptom
Trouble Code
P0330
Symptom
MIL ON
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Caution: Check the sensing
value of coolant temp., intake
air temp., fuel temp. barometric pressure. Incorrect default
values of theses sensors
may cause wrong diagnosis.
Check accelerometer wiring
and tightening torque,
especially shield ground.
NO
Wiring Problem?
YES
Repair or
replace
Replace accelerometer
(knock sensor)
NO
Trouble Continues?
Wiring Problem?
YES
YES
NO
Repair or
replace
Repiar Completed
NO
Wiring Problem?
YES
Repair wiring
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-108
Symptom
P1611
P1612
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-109
Diagnosis Procedures
1. Fuel Injection Bank 1/2
YES
Repair or
replace
NO
Repair or
replace
NO
Trouble Continues?
YES
Wiring Problem?
YES
Refer to check
injector wiring
YES
Repair wiring
NO
Replace ECU
NO
Trouble Recurred?
NO
YES
Replace the
injector - Enter
new injector
C2I into ECU
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-110
Symptom
P1618
P1619
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-111
Diagnosis Procedures
1. Fuel Injection Bank 1/2
Injector - short
YES
Repair or
replace
NO
Repair or
replace
NO
Trouble Continues?
YES
Wiring Problem?
YES
Refer to check
injector wiring
YES
Repair wiring
NO
Replace ECU
NO
Trouble Recurred?
NO
YES
Replace the
injector - Enter
new injector
C2I into ECU
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-112
Symptom
MIL ON
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Read DTC
NO
YES
Circuit Open:
Wiring problem
NO
YES
Repair or
replace
YES
Repair air
intake system
and check
EGR
NO
YES
Repair or
replace
NO
Valve Problem?
YES
Repair or
replace valve
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-113
Symptom
MIL ON
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Read DTC
NO
YES
Circuit Open:
Wiring problem
NO
YES
YES
Repair or
replace
NO
YES
Repair or
replace
NO
Valve Problem?
YES
Repair or
replace valve
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair air
intake system
and check
EGR
DI10-114
Symptom
MIL ON
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Read DTC
NO
YES
Circuit Open:
Wiring problem
NO
YES
Repair or
replace
YES
Repair air
intake system
and check
EGR
NO
YES
Repair or
replace
NO
Valve Problem?
YES
Repair or
replace valve
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-115
Symptom
MIL ON
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Read DTC
NO
YES
Circuit Open:
Wiring problem
NO
YES
YES
Repair or
replace
NO
YES
Repair or
replace
NO
Valve Problem?
YES
Repair or
replace valve
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair air
intake system
and check
EGR
DI10-116
Symptom
MIL ON
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Read DTC
NO
YES
Circuit Open:
Wiring problem
NO
YES
Repair or
replace
YES
Repair air
intake system
and check
EGR
NO
YES
Repair or
replace
NO
Valve Problem?
YES
Repair or
replace valve
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-117
Symptom
Diagnosis Procedures
Key OFF and check injector
wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO
NO
DIAGNOSIS
DI ENG SM - 2004.9
YES
Replace
injector
and enter new
injector C2I
value into ECU
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-118
Symptom
Diagnosis Procedures
Key OFF and check injector
wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair or
replace
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Replace
injector
and enter new
injector C2I
value into ECU
DIAGNOSIS
DI ENG SM - 2004.9
DI10-119
Symptom
Diagnosis Procedures
Key OFF and check injector
wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO
NO
DIAGNOSIS
DI ENG SM - 2004.9
YES
Replace
injector
and enter new
injector C2I
value into ECU
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-120
Symptom
Diagnosis Procedures
Key OFF and check injector
wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair or
replace
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Replace
injector
and enter new
injector C2I
value into ECU
DIAGNOSIS
DI ENG SM - 2004.9
DI10-121
Symptom
Diagnosis Procedures
Key OFF and check injector
wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO
NO
DIAGNOSIS
DI ENG SM - 2004.9
YES
Replace
injector
and enter new
injector C2I
value into ECU
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-122
Symptom
Diagnosis Procedures
Key OFF and check injector
wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
YES
NO
Replace
injector
and enter new
injector C2I
value into ECU
Replace ECU
Wiring Problem?
YES
Repair or
replace
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-123
Symptom
Diagnosis Procedures
Key OFF and check injector
wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
YES
NO
Replace
injector
and enter new
injector C2I
value into ECU
Replace ECU
Wiring Problem?
YES
Repair or
replace
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-124
Symptom
Diagnosis Procedures
Key OFF and check injector
wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
YES
NO
Replace
injector
and enter new
injector C2I
value into ECU
Replace ECU
Wiring Problem?
YES
Repair or
replace
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-125
Symptom
Diagnosis Procedures
Key OFF and check injector
wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
YES
NO
Replace
injector
and enter new
injector C2I
value into ECU
Replace ECU
Wiring Problem?
YES
Repair or
replace
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-126
Symptom
Diagnosis Procedures
Key OFF and check injector
wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
YES
NO
Replace
injector
and enter new
injector C2I
value into ECU
Replace ECU
Wiring Problem?
YES
Repair or
replace
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-127
Low
P0183
High
P0180
Supply Voltage
Symptom
Diagnosis Procedures
Read DTC
YES
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Resistance Problem?
YES
Replace
sensor
Replace ECU
NO
Wiring Problem?
YES
Repair or
replace
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-128
Symptom
P1678
Open Circuit
MIL ON
P1679
Short Circuit
P1680
Short to Ground
Diagnosis Procedures
Check glow plug box wiring
NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO
Trouble Continues?
YES
Replace ECU
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-129
Open Circuit
P1531
Short to +Batt
P1532
Short to Ground
Symptom
Unable Heater Operation
Diagnosis Procedures
Check relay wiring
NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO
YES
Replace ECU
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-130
Open Circuit
P1535
Short to +Batt
P1536
Short to Ground
Symptom
Unable Heater Operation
Diagnosis Procedures
Check relay wiring
NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO
YES
Replace ECU
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-131
Symptom
P1254
Maximum Value
P1253
Minimum Value
MIL ON
Unable Dynamic Leak of Injector #1
Unable Dynamic Leak of Injector #2
Unable Dynamic Leak of Injector #4
Unable Dynamic Leak of Injector #5
Unable Dynamic Leak of Injector #3
Unable Cylinder Balancing
Unable Accelerometer Learning Strategy
Diagnosis Procedures
1. Rail Pressure Control
Read DTC
YES
Refer to IMV
diagnosis
NO
YES
YES
Repair or
replace
YES
NO
Replace ECU
DIAGNOSIS
DI ENG SM - 2004.9
Repair or
replace
NO
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-132
Fuel Exhausted?
Add fuel
Cause Found?
YES
Add fuel
NO
NO
YES
Repair or
replace
NO
YES
NO
Install a
container to
H/P pump
venturi.
Remove
venturi return
lines. Fill fuel
with hand
pump.
Different Specification?
YES
Replace filter
with new one
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-133
Symptom
P1256
P1257
MIL ON
P1258
P1259
Diagnosis Procedures
1. Diagnosis Procedures (Rail Pressure Control)
Read DTC
YES
Refer to IMV
diagnosis
NO
YES
YES
Repair or
replace
YES
NO
Replace ECU
DIAGNOSIS
DI ENG SM - 2004.9
Repair or
replace
NO
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-134
Fuel Exhausted?
YES
Add fuel
NO
Different Specification?
Visually check transfer fuel
system (fuel leaks, installation)
YES
Replace filter
with new one
NO
YES
Repair or
replace
Repiar Completed
NO
YES
NO
Install a
container to
H/P pump
venturi.
Remove
venturi return
lines. Fill fuel
with hand
pump.
Cause Found?
YES
Repair or
replace
NO
DIAGNOSIS
DI ENG SM - 2004.9
DI10-135
Symptom
Diagnosis Procedures
1. Diagnosis Procedures (Rail Pressure Control)
Read DTC
YES
Refer to IMV
diagnosis
NO
YES
YES
Repair or
replace
YES
NO
Replace ECU
DIAGNOSIS
DI ENG SM - 2004.9
Repair or
replace
NO
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-136
Fuel Exhausted?
YES
Add fuel
NO
Different Specification?
Visually check transfer fuel
system (fuel leaks, installation)
YES
Replace filter
with new one
NO
YES
Repair or
replace
NO
YES
NO
Install a
container to
H/P pump
venturi.
Remove
venturi return
lines. Fill fuel
with hand
pump.
Cause Found?
YES
Repair or
replace
NO
DIAGNOSIS
DI ENG SM - 2004.9
DI10-137
Symptom
P0255
Open Circuit
P0251
Short Circuit
P0253
Short to Ground
Diagnosis Procedures
Check IMV wiring
NO
Wiring Problem?
YES
NO
Resistance Problem?
YES
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO
Wiring Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Repair wiring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace H/P
pump and IMV
DI10-138
High
P0113
Low
P0110
Supply Voltage
Symptom
MIL ON
Diagnosis Procedures
Read DTC
YES
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
Resistance Problem?
YES
Replace
sensor
Replace ECU
NO
Wiring Problem?
YES
Repair or
replace
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-139
Symptom
Unable Accelerometer Decoding
MIL ON
Unable Pilot and Post Injection
Unable Dynamic Leak of Injector #1
Torque Limit For Injector Drift
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Enter the injector data into
ECU after replacing injector
Symptom
Unable Accelerometer Decoding
MIL ON
Unable Pilot and Post Injection
Unable Dynamic Leak of Injector #2
Torque Limit For Injector Drift
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Enter the injector data into
ECU after replacing injector
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-140
Symptom
Unable Accelerometer Decoding
MIL ON
Unable Pilot and Post Injection
Unable Dynamic Leak of Injector #4
Torque Limit For Injector Drift
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Enter the injector data into
ECU after replacing injector
Symptom
Unable Accelerometer Decoding
MIL ON
Unable Pilot and Post Injection
Unable Dynamic Leak of Injector #5
Torque Limit For Injector Drift
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Enter the injector data into
ECU after replacing injector
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-141
Symptom
Unable Accelerometer Decoding
MIL ON
Unable Pilot and Post Injection
Unable Dynamic Leak of Injector #3
Torque Limit For Injector Drift
Unable Accelerometer Learning Strategy
Diagnosis Procedures
Enter the injector data into
ECU after replacing injector
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-142
Symptom
Diagnosis Procedures
1. Diagnosis Procedures (Rail Pressure Control)
Read DTC
NO
YES
Refer to
IMV diagnosis
NO
YES
Repair or
replace
YES
Repair or
replace
NO
Replace ECU
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair or
replace
DIAGNOSIS
DI ENG SM - 2004.9
DI10-143
Fuel Exhausted?
YES
Add fuel
NO
Different Specification?
Visually check transfer fuel
system (fuel leaks, installation)
YES
NO
YES
Repair or
replace
Repiar Completed
NO
YES
Install a
container to
H/P pump
venturi.
Remove
venturi return
lines. Fill fuel
with hand
pump.
Cause Found?
YES
Repair or
replace
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace filter
with new one
DI10-144
Symptom
P1120
P1121
Diagnosis Procedures
Read DTC
YES
NO
Wiring Problem?
YES
YES
Replace
sensor
Repair or
replace
NO
NO
Wiring Problem?
YES
Repair wiring
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Replace ECU
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-145
Symptom
MIL ON
Diagnosis Procedures
Read DTC
YES
NO
Wiring Problem?
YES
YES
Replace
sensor
Repair or
replace
NO
NO
Wiring Problem?
YES
Repair wiring
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-146
Symptom
MIL ON
Diagnosis Procedures
Read DTC
YES
NO
Wiring Problem?
YES
YES
Replace
sensor
Repair or
replace
NO
NO
Wiring Problem?
YES
Repair wiring
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Replace ECU
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-147
Symptom
Diagnosis Procedures
Read DTC
NO
YES
NO
Repair or
replace brake
switch.
Wiring Problem?
Check if accelerator pedal is
normal
YES
Repair or
replace
NO
YES
NO
YES
Repair wiring
NO
YES
Repair or
replace
Trouble Continues?
NO
NO
Wiring Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
YES
Repair or
replace
Repiar Completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-148
Symptom
P0122
Low
MIL ON
P0123
High
P0120
Supply Voltage
Diagnosis Procedures
Read DTC
YES
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Replace ECU
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-149
Symptom
P0222
Low
MIL ON
P0223
High
P0220
Supply Voltage
Diagnosis Procedures
Read DTC
YES
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-150
Symptom
P0192
Low
P0193
High
P0190
Supply Voltage
P0191
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-151
Diagnosis Procedures
Read DTC
YES
NO
Wiring Problem?
NO
YES
Repair or
replace
NO
Trouble Continues?
Wiring Problem?
NO
YES
Repair or
replace
NO
Wiring Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Repair wiring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-152
Symptom
P1192
Low
P1193
High
P1190
Supply Voltage
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-153
Diagnosis Procedures
Check sensor wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Trouble Continues?
YES
Wiring Problem?
YES
Repair or
replace
Repair completed
NO
Wiring Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Repair wiring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace rail
and sensor
DI10-154
Symptom
MIL ON
Diagnosis Procedures
Check relay wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair or
replace
NO
YES
Replace ECU
NO
Repair completed
Wiring Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair wiring
DIAGNOSIS
DI ENG SM - 2004.9
DI10-155
Symptom
Diagnosis Procedures
Check vehicle conditions
NO
Automatic Transmission
Equipped?
YES
NO
Recognize
vehicle speed
through CAN.
Check CAN
and
transmission.
Wiring Problem?
YES
NO
YES
NO
Trouble Continues?
YES
Wiring Problem?
YES
Repair or
replace
Repair completed
NO
Wiring Problem?
DIAGNOSIS
DI ENG SM - 2004.9
Replace gear
box target
YES
Repair or
replace
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-156
Low
P0643
High
P0641
Supply Voltage
Symptom
Unable Cruise Control
Diagnosis Procedures
Supply Voltage 1 (5V):
Accelerator Pedal Sensor 1
Supply Voltage 2 (5V): HFM
sensor, Rail pressure
sensor, Boost pressure
sensor and Cam sensor
Supply Voltage (2.5 V): Accelerator Pedal Sensor 2
Read DTC
YES
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-157
Low
P0653
High
P0651
Supply Voltage
Symptom
Diagnosis Procedures
Supply Voltage 1 (5 V):
Accelerator Pedal Sensor 1
Supply Voltage 2 (5 V): HFM
sensor, Rail pressure
sensor, Boost pressure
sensor and Cam sensor
Supply Voltage (2.5 V): Accelerator Pedal Sensor 2
Read DTC
YES
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-158
Low
P0699
High
P0697
Supply Voltage
Symptom
Unable Cruise Control
Diagnosis Procedures
Supply Voltage 1 (5 V):
Accelerator Pedal Sensor 1
Supply Voltage 2 (5 V): HFM
sensor, Rail pressure
sensor, Boost pressure
sensor and Cam sensor
Supply Voltage (2.5 V):
Accelerator Pedal Sensor 2
Read DTC
YES
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-159
Symptom
P0245
Short to GND
P0246
Short Circuit to B+
Diagnosis Procedures
Check actuator wiring
NO
Wiring Problem?
YES
Repair or
replace
Replace actuator
NO
Trouble Continues?
YES
Resistance Problem?
YES
Replace
actuator
Repair completed
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-160
Symptom
Diagnosis Procedures
Read DTC
YES
Check body
ground wiring
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-161
Symptom
Diagnosis Procedures
Read DTC
YES
Check body
ground wiring
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-162
P1601
P1602
Symptom
Diagnosis Procedures
Read DTC
YES
Check body
ground wiring
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-163
Symptom
P1614
MDP
P1615
Tele-Coding
P1616
Watchdog
P1606
CAN
P1620
ECU Malfunction
P1621
ECU Malfunction
P1622
ECU Malfunction
MIL ON
Diagnosis Procedures
Read DTC
YES
Check body
ground wiring
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-164
Symptom
P1603
Code Integrity
P1604
Code Integrity
P1605
Code Integrity
Diagnosis Procedures
Read DTC
YES
Check body
ground wiring
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-165
Symptom
Diagnosis Procedures
Read DTC
NO
YES
Refer to
Accelerometer (Knock
Sensor)
Diagnosis
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-166
Symptom
Diagnosis Procedures
Read DTC
YES
Check
sensors and
EGR system
NO
Repair completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-167
Symptom
Diagnosis Procedures
1. Diagnosis Procedures(Boost Pressure)
Read DTC
NO
YES
Refer to
Diagnosis
Tree Check
sensor(1)
Repair completed
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-168
YES
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair or
replace
NO
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Replace ECU
Wiring Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair or
replace
DIAGNOSIS
DI ENG SM - 2004.9
DI10-169
TBD
Trouble Code and Symptom
Trouble Code
P1608
Symptom
ECU Malfunction
Diagnosis Procedures
Read DTC
YES
Check body
ground wiring
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-170
No Crank Signal
Symptom
No Crank Signal
MIL ON
Diagnosis Procedures
Check sensor wiring
Wiring Problem?
YES
Repair or
replace
Trouble Continues?
YES
NO
Replace APS
wheel
NO
YES
Repair or
replace
Trouble Continues?
YES
Replace ECU
NO
NO
Wiring Problem?
Repair completed
YES
Repair wiring
NO
Trouble Continues?
YES
Replace VR
sensor
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-171
Symptom
MIL ON
Diagnosis Procedures
Read DTC
YES
Refer to IMV
diagnosis
NO
Read DTC
NO
YES
Repair or
replace
NO
YES
NO
YES
Repair or
replace
Replace ECU
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-172
Communication
P1677
Controller
Symptom
Diagnosis Procedures
Read DTC
NO
YES
NO
Communication problem
between ECU
and glow plug
box. Check
related wirings.
Wiring Problem?
YES
Repair wiring
Wiring Problem?
YES
Repair or
replace
NO
Trouble Continues?
Check glow plug and wiring
(Resistance: below 1 )
Problems?
YES
Replace ECU
NO
YES
NO
Repair or
replace glow
plug
Repair completed
Wiring Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair or
replace
DIAGNOSIS
DI ENG SM - 2004.9
DI10-173
Glow Plug #1
P0672
Glow Plug #2
P0673
Glow Plug #3
P0674
Glow Plug #4
P0675
Glow Plug #5
Symptom
Diagnosis Procedures
Read DTC
NO
YES
NO
Communication problem
between ECU
and glow plug
box. Check
related wirings.
Wiring Problem?
YES
Repair wiring
Wiring Problem?
YES
Repair or
replace
NO
Trouble Continues?
Check glow plug and wiring
(Resistance: below 1 )
NO
Repair completed
Problems?
YES
NO
Repair or
replace glow
plug
Wiring Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Repair or
replace
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-174
Glow Plug #1
P1672
Glow Plug #2
P1673
Glow Plug #3
P1674
Glow Plug #4
P1675
Glow Plug #5
Symptom
Diagnosis Procedures
Read DTC
NO
YES
NO
Communication problem
between ECU
and glow plug
box. Check
related wirings.
Wiring Problem?
YES
Repair wiring
Wiring Problem?
YES
Repair or
replace
NO
Trouble Continues?
Check glow plug and wiring
(Resistance: below 1 )
Replace ECU
NO
Repair completed
Problems?
YES
NO
Repair or
replace glow
plug
Wiring Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair or
replace
DIAGNOSIS
DI ENG SM - 2004.9
DI10-175
Symptom
Diagnosis Procedures
Check ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO
Communication problem
continues
YES
Repair or
replace
(Replace TCU)
NO
Repair completed
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-176
Symptom
P1540
Open Circuit
P1541
Short to +Batt
P1542
Short to Ground
Diagnosis Procedures
Check vehicle condition
(above fault is related to A/C
system)
NO
YES
NO
Wiring Problem?
Wiring Problem?
YES
Repair wiring
NO
YES
Repair or
replace
NO
A/C Problem?
YES
Check sensor
Repair or
replace
NO
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Replace ECU
Wiring Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair or
replace
Repair completed
DIAGNOSIS
DI ENG SM - 2004.9
DI10-177
Symptom
Diagnosis Procedures
Remove fuel filter
NO
YES
Repair
completed
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
NO
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO
Resistance Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Replace
coolant
temperature
sensor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-178
Immobilizer Malfunction
Trouble Code and Symptom
Trouble Code
P1634
Symptom
Immobilizer Malfunction
MIL ON
Immobilizer Warning Light ON
P4335
P1630
P1631
P1632
P1633
P0633
P1636
Diagnosis Procedures
Check immobilizer unit
and ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
YES
Repair
completed
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-179
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-180
Transfer fuel
pressure regulator
IMV
High pressure
pump
Transfer pump
Supply
valve
Suction
valve
Below 2 bar
Below -0.3 bar
Venturi
Common rail
Up to
1050 bar
Injectors
Fuel filter
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Return line
DIAGNOSIS
DI ENG SM - 2004.9
DI10-181
target pressure/volume
Fuel injection
volume
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-182
Pressure/volume loss
Injector back
leak volume
Pump capacity
Fuel injection
volume
Pressure/volume
consumption
Pressure/volume
build up
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-183
Pressure/volume loss
Injector back
leak volume
Pump capacity
Fuel injection
volume
Pressure/volume
consumption
Pressure/volume
build up
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-184
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-185
Prerequisite
1. Check the connections in fuel supply lines.
2. Check the fuel level in fuel tank.
3. Check if the air exists in fuel supply lines (air bubbles in fuel supply lines or fuel with air bubbles).
4. Check the fuel supply lines for leaks (transfer and high pressure).
5. Check if the specified fuel is used.
6. Check the fuel filter for contamination and abnormality.
No
No
DTC Detected?
Yes
Fuel system
related DTC:
P1252, P1253,
P1254...P0251
no
Notice
If more than one DTC have been detected, check the wiring
harness for open or short first.
Check the transfer fuel system and fuel filter before
proceeding the high pressure fuel system check in next page.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-186
No Abnormality
in Initial Check?
No
Yes
No
Method 2
Yes
No
Yes
Yes
No
DIAGNOSIS
DI ENG SM - 2004.9
DI10-187
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-188
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-189
3. Disconnect the key connector for connecting the priming pump to fuel filter and install both connectors of the
special tool to the fuel pump and the priming pump hoses.
4. Start the engine and visually check the transfer line for clogged and air bubbles while running the engine at idle
speed.
5. If the fuel flows are not smooth or air bubbles are found in fuel lines, locate the leaking area and correct it.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-190
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-191
4. Crank the engine twice with 5 seconds of interval.
5. Check if the back leak volume meets the specification.
Specified value
Below 20 cm
Note
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-192
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Below 38 ml
DIAGNOSIS
DI ENG SM - 2004.9
DI10-193
40 Nm
3. Install the opposite end of the closed rail into the fuel rail
for test.
Specified value
40 Nm
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-194
5. Connect the digital tester connector into the sensor
connector of fuel rail for test.
6. Disconnect the IMV connector and the fuel rail pressure
sensor connector.
7. Check if the measured value on the digital tester meets
the specified value.
Specified value
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-195
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-196
4) If there are not any troubled conditions in TEST
CONDITION screen, press ENTER.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
2A
Windshield
heated glass unit Sensor cluster (ESP) Air bag unit (SDM)
STICS
ICM
module
Sun sensor
PAS unit
Navigation unit
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
TV antenna
amplifier
Engine ECU
TCU
ELECTRICAL SYSTEM
STAVIC - 2004.09
TCCU
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2A
Horn
Receiver drier
AQS sensor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
Sub condenser
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2A
Power button
Mode button
SEEK button Up
SEEK button Down
Mute button
Volume button Up
Volume button Down
Window switches
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
Hazard switch
Multi meter
Front room lamp switch
ESPOFF
Passenger seat
warmer switch
Passengers window
switch
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2A
Tweeter speaker
Center speaker
Center speaker
AV head unit
Audio remote
control switches
GPS antenna
Center speaker
(RH)
AV head unit
Center
DVD changer s p e a k e r
Center speaker
(LH)
Front tweeter
speaker (LH)
Front speaker (LH)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
DVD changer
Rearview camera
Rear monitor
Tuner/Amplifier/Navigation unit
Tuner
DSP integrated
amplifier
Navigation unit
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
11
2. COMPONENTS LOCATOR
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
2A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
13
Capacity
Usage
Fuse NO.
Capacity
Usage
Ef9
20A
AV System
60A
ABS, ABS/ESP
Ef10
30A
Glass HTD
SB3
30A
Ef11
15A
SB4
30A
Ef12
15A
Seat Warmer
SB5
30A
20A
Sun Roof
Ef14
20A
4WD (TOD)
SB1
120A/140A
SB2
Condenser Fan
SB6
50A
SB7
30A
SB8
30A
Blower (FRT)
SB9
30A
Ef15
20A
SB10
30A
Ef16
10A
SB11
30A
Ef17
10A
Ef1
10A
Ef18
7.5A
Illumination
Ef2
15A
Ef19
15A
ENG ECU
Ef3
15A
DRL
Ef20
15A
Ef4
10A
Horn
Ef21
15A
Ef5
15A
ENG SNR 1
Ef22
15A
RR Blower
Ef6
20A
Ef23
20A
Ef7
30A
ABS, ABS/ESP
Ef24
20A
Ef8
15A
Ef25
15A
Buzzer
Ef26
15A
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
2A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
15
RK STICS
ICM box
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
2A
Front view
Relay 15
(rear fog lamp)
Relay 3
(seat warmer, LH)
Relay 1 (spare 2)
Relay 4
(seat warmer, RH)
Relay 2
(O 2 sensor: gasoline)
Relay 9
(horn relay)
Relay 5
(wiper INT-LOW)
Relay 6
(wiper HIGH)
Relay 8
(door lock relay)
Relay 14
(flasher unit)
Relay 7
(power socket)
Relay 10
(front cigarette lighter
and power socket)
Relay 13
(theft deterrent relay)
Relay 11
(door unlock)
Relay 12
(drivers door unlock)
Buzzer 1
(Back sonar)
Buzzer 2
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
17
Rear view
Relay 3
(spare 2)
Relay 1
Relay 4
Relay 2
Relay 9
Relay 5
Relay 8
Relay 15
Relay 6
Relay 7
Relay 12
Relay 13
Relay 11
Buzzer 2
ELECTRICAL SYSTEM
STAVIC - 2004.09
Relay 10
Relay 14
Buzzer 1
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
2A
! " #
! " # $
! "
' ! ! ! !! !"
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
&
'
% & '
# $ % &
!# !$ !% !& !' "
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
19
This circuit is supplied the power through the relevant fuse and STICS. The supplied power magnetize the switch to
supply the power to the appropriate system.
To inspect this circuit, turn the switch on and check if the voltage from ICM box is within specified range. After then,
check the output through the ICM box.
Checking the condition of the relevant component in the system should be done before doing this inspection.
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
2A
The rain sensing system in this vehicle has a different control logic compared to conventional rain sensing system. In the
conventional rain sensing system, the rain sensor unit controls the wipers directly. However, in this vehicle, the rain
sensor communicates the data with STICS, and the STICS controls the wiper motor.
Signals from STICS to rain sensor unit contain the information that there is no rain under the current mode based on
following conditions;
- Washer switch is operating,
- Operating under MIST mode, or
- The multifunction wiper switch is in AUTO mode.
For more details, refer to the Rain Sensing Wiper section in this manual.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
21
The relay and unit that controls the hazard warning flasher and turn
signal lamp is also installed in the ICM box as illustrated. Also, the
theft deterrent relay that operates the hazard warning flasher and the
theft deterrent horn is installed.
This vehicle has two separate horns in the engine compartment; a
horn (see figure) located in front of the battery is used for theft deterrent warning and beep sound during the operation of doors by remote
control key.
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
2A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
23
Tailgate Heated Glass, Outside Rearview Mirror Heated Glass (controlled by STICS)
1. The outside rearview mirror heated glass operates for 12 minutes when turning on the defogger switch while the
engine is running.
2. If the defogger switch is pressed again during the operation, the operation stops.
3. If the defogger switch is pressed again within 10 minutes after completion of the first operation, the defogger
system operates for 6 minutes just for once.
4. The defogger is not available when the ignition switch is in OFF position or the alternator is not running.
Defogger switch
Back sonar
buzzer
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
2A
4. Unscrew the connector mounting nuts from the back of the ICM box and disconnect the connector A and B.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
25
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
2A
2) W/H Main
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
27
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
2A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
29
5) W/H Air-con
Front air-con
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30
2A
Rear air-con
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
31
6) W/H Door
Front door
Rear door
ELECTRICAL SYSTEM
STAVIC - 2004.09
Tailgate door
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
32
2A
7) W/H Roof
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
33
8) W/H Seat
Drivers
Passengers
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MEMO
................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
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................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
2A
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2A
Windshield
heated glass unit Sensor cluster (ESP) Air bag unit (SDM)
STICS
ICM
module
Sun sensor
PAS unit
Navigation unit
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
TV antenna
amplifier
Engine ECU
TCU
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
TCCU
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2A
Horn
Receiver drier
AQS sensor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
Sub condenser
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2A
Power button
Mode button
SEEK button Up
SEEK button Down
Mute button
Volume button Up
Volume button Down
Window switches
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
Hazard switch
Multi meter
Front room lamp switch
Refogger switch
ESPOFF
Passenger seat
warmer switch
Passengers window
switch
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2A
Tweeter speaker
Center speaker
Center speaker
AV head unit
Audio remote
control switches
GPS antenna
Center speaker
(RH)
AV head unit
Center
DVD changer s p e a k e r
Center speaker
(LH)
Front tweeter
speaker (LH)
Front speaker (LH)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
DVD changer
Rearview camera
Rear monitor
Tuner/Amplifier/Navigation unit
Tuner
DSP integrated
amplifier
Navigation unit
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
11
2. COMPONENTS LOCATOR
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
2A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
13
Capacity
Usage
Fuse NO.
Capacity
Usage
Ef9
20A
AV System
60A
ABS, ABS/ESP
Ef10
30A
Glass HTD
SB3
30A
Ef11
15A
SB4
30A
Ef12
15A
Seat Warmer
SB5
30A
20A
Sun Roof
Ef14
20A
4WD (TOD)
SB1
120A/140A
SB2
Condenser Fan
SB6
50A
SB7
30A
SB8
30A
Blower (FRT)
SB9
30A
Ef15
20A
SB10
30A
Ef16
10A
SB11
30A
Ef17
10A
Ef1
10A
Ef18
7.5A
Illumination
Ef2
15A
Ef19
15A
ENG ECU
Ef3
15A
DRL
Ef20
15A
Ef4
10A
Horn
Ef21
15A
Ef5
15A
ENG SNR 1
Ef22
15A
RR Blower
Ef6
20A
Ef23
20A
Ef7
30A
ABS, ABS/ESP
Ef24
20A
Ef8
15A
Ef25
15A
Buzzer
Ef26
15A
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
2A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
15
RK STICS
ICM box
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
2A
Front view
Relay 15
(rear fog lamp)
Relay 3
(seat warmer, LH)
Relay 1 (spare 2)
Relay 4
(seat warmer, RH)
Relay 2
(O 2 sensor: gasoline)
Relay 9
(horn relay)
Relay 5
(wiper INT-LOW)
Relay 6
(wiper HIGH)
Relay 8
(door lock relay)
Relay 14
(flasher unit)
Relay 7
(power socket)
Relay 10
(front cigarette lighter
and power socket)
Relay 13
(theft deterrent relay)
Relay 11
(door unlock)
Relay 12
(drivers door unlock)
Buzzer 1
(Back sonar)
Buzzer 2
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
17
Rear view
Relay 3
(spare 2)
Relay 1
Relay 4
Relay 2
Relay 9
Relay 5
Relay 8
Relay 15
Relay 6
Relay 7
Relay 12
Relay 13
Relay 11
Buzzer 2
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
Relay 10
Relay 14
Buzzer 1
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
2A
1 2 3 4
13 14 15 16
21 22 23 24
29 30 31 32 33 34
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
9 10 11 12
17 18 19 20
25 26 27 28
35 36 37 38 39 40
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
19
This circuit is supplied the power through the relevant fuse and STICS. The supplied power magnetize the switch to
supply the power to the appropriate system.
To inspect this circuit, turn the switch on and check if the voltage from ICM box is within specified range. After then,
check the output through the ICM box.
Checking the condition of the relevant component in the system should be done before doing this inspection.
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
2A
The rain sensing system in this vehicle has a different control logic compared to conventional rain sensing system. In the
conventional rain sensing system, the rain sensor unit controls the wipers directly. However, in this vehicle, the rain
sensor communicates the data with STICS, and the STICS controls the wiper motor.
Signals from STICS to rain sensor unit contain the information that there is no rain under the current mode based on
following conditions;
- Washer switch is operating,
- Operating under MIST mode, or
- The multifunction wiper switch is in AUTO mode.
For more details, refer to the Rain Sensing Wiper section in this manual.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
21
The relay and unit that controls the hazard warning flasher and turn
signal lamp is also installed in the ICM box as illustrated. Also, the
theft deterrent relay that operates the hazard warning flasher and the
theft deterrent horn is installed.
This vehicle has two separate horns in the engine compartment; a
horn (see figure) located in front of the battery is used for theft deterrent warning and beep sound during the operation of doors by remote
control key.
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
2A
Back sonar
buzzer
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
23
4. Unscrew the connector mounting nuts from the back of the ICM box and disconnect the connector A and B.
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
2A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
25
2) W/H Main
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
2A
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EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
27
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
2A
5) W/H Air-con
Front air-con
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
29
Rear air-con
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30
2A
6) W/H Door
Front door
Rear door
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Tailgate door
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
31
7) W/H Roof
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
32
2A
8) W/H Seat
Drivers
Passengers
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2B
Coolant
temperature
gauge
RPM gage
Speedometer
Fuel level
gauge
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
Indicator Display
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
Connector B
Connector A
1. Immobilizer indicator
2. Glow indicator
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
The tachometer indicates engine speed in revolutions per minute. Multiply 1,000 to the current number, then it will be the
current number of engine revolutions.
Under the normal engine operating temperature, the proper idling speed is 700~800 rpm. The red zone (danger rpm
range) starts from 4,500 rpm.
1. Connect the tachometer for tune-up test and start the engine.
2. Eliminate the hysteresis by tapping the tachometer.
3. Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive.
Specification (VIN=13 0.1V, Temperature: 25C)
Description
Engine speed (rpm)
700
1000
2000
3000
4000
5000
6000
Tolerance (rpm)
+50
+100
+125
+150
+150
-100
-100
-125
-150
-150
If the tachometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in
tachometer. If there is a difference between actual engine speed (rpm) and reading from tachometer, connect a scanner
and then compare the value on tachometer with the reading from scanner.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
Speedometer
The speedometer indicates the vehicle speed by calculating the signals from the rear right wheel speed sensor through
ABS or ESP unit.
If the speedometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in
speedometer. However, these symptoms also could be appeared when the tire has uneven wear, different tire inflation
pressures or different tire specifications.
Perform the speedometer test regarding the tolerance as described. However, it is not similar simple work in field due to
lack of measuring conditions such as test equipment and preciseness.
1. Check the allowable tolerance of the speedometer and operations of the trip odometer by using a tester.
2. Check if the speedometer pointer is shaking and the abnormal noise sounds.
3. Eliminate the hysteresis by tapping the speedometer.
[Notice]
The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range.
20
40
(60)
80
100
120
140
(160)
(180)
Tolerance (Km/h)
+4
+5.5
+7
+9
+10.5
+12.5
+14.5
+16
+18
+2
+2.5
+3.5
+4
+6
+7.5
+8.5
+10
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
The fuel level gauge displays the resistance value of the float on the fuel sender in the fuel tank through a pointer. Note
that this vehicle doesnt have a service hole for checking the fuel sender connector in the fuel tank.
The fuel sender and its connector can be checked and replaced only when the fuel tank is removed. The power supply
and resistance value should be measured at the connector in front of the fuel sender (refer to wiring diagram).
When the power supply and output resistance are normal, the float operation by fuel level may be defective; if so, replace
the fuel sender.
Tolerance and resistance value by indicating angle
Tolerance and resistance value by indicating angle
Scale
Indicating angle ()
Full
(3/4)
1/2
(1/4)
Full (LFW)
40
20
- 20
- 40
Tolerance ()
+4~0
2.5
2.5
+ 1.5
Resistance()
38 1
67 1
99.5 1
247 1
260 1
This table shows the tolerance and resistance value changes by fuel level in normal conditions. Therefore, the differences that can be occurred by the road conditions and fuel fluctuations are ignored.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2B
40o
0o
-40o
The coolant temperature gauge displays the coolant temperature with a pointer. The angle of pointer that changes by
coolant temperature is as shown below.
Tolerance and resistance value by indicating angle
Indicating angle
Tolerance
Coolant temperature
- 40 (H)
0C (1/2)
+40(C)
2.5
+0C
+5C
- 5C
+1C
70C ~ 110C
Over 125C
40C
20C :
2449
5 %
50C :
826
5 %
80C :
321
5 %
100C :
112
5 %
When the resistance value by coolant temperature is within the specified range, check thermostat, water pump, radiator
related coolant circuit for normal operation. Also, check the wiring harnesses and connectors for proper connection.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
11
Reset button
* Press and hold (over 1 sec.)
Trip odometer TRIP A and TRIP B will be reset to 0. (However, only the corresponding driving
range will be set to 0.)
* Press shortly (between 0.1 ~ 1 sec.)
The mode changes in order as shown in the figure.
ODO
TRIP A
TRIP B
Increment: 0.1 km
Increment: 0.1 km
Increment: 1 km
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AFFECTED VIN
12
2B
This indicator indicates the operating conditions of immobilizer system. This indicator
comes on when the ignition key is communicating with the engine control unit (during
engine starting) and goes out after starting
the engine. If this indicator blinks, it may indicate that there is something wrong in the immobilizer system.
The indicator comes on when the Winter mode (W) switch near the gear selector lever is pressed. Use this mode
to drive off smoothly under icy and slippery road. In this mode, the vehicle
drives off with second gear in forward
and reverse driving.
Driving gears
Immobilizer Indicator
2B
13
Defogger Indicator
[NOTE]
The vehicle equipped with ABS
performs self-diagnosis on the system
when the engine is started and drives
off. During the diagnosis, brake pedal
vibration and noise may be apparent
when the driving motors discharges
the hydraulic pressure from the
internal hydraulic device. This means
the ABS is properly functioning.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
2B
2. Pull out the front cup holder, disconnect the cigarette connector and the power socket connector, and remove the
front cup holder.
3. Carefully pry off the chrome coated cover from the selector lever cover, unscrew the screws and remove the
selector lever cover.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
15
4. Carefully pull out the center speakers and disconnect the connectors.
5. Remove the screws and take out the front cover from the instrument panel.
6. Disconnect all switch connectors including TRIP switch connector (2) during removal of the front cover.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
2B
7. Unscrew four screws and pull out the meter cluster housing.
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AFFECTED VIN
2B
17
Indicator Display
1. Remove the indicator display cover.
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MEMO
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2B
2B - Cluster / Warning
& Indicator Panel (2005 ~)
Table of Contents
METER CLUSTER / INDICATOR DISPLAY ...... 2B-3
1. Appearance ................................................................. 2B-3
2. Connectors and circuit diagram ................................... 2B-4
3. Descriptions of indicator display .................................. 2B-6
4. Function description and inspection of meter cluster ... 2B-7
5. Warning & indicator panel ......................................... 2B-12
6. Removal and installation of meter cluster and indicator
display ...................................................................... 2B-14
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AFFECTED VIN
2B
Coolant
temperature
gauge
RPM gage
Speedometer
Fuel level
gauge
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
The tachometer indicates engine speed in revolutions per minute. Multiply 1,000 to the current number, then it will be the
current number of engine revolutions.
Under the normal engine operating temperature, the proper idling speed is 700~800 rpm. The red zone (danger rpm
range) starts from 4,500 rpm.
1. Connect the tachometer for tune-up test and start the engine.
2. Eliminate the hysteresis by tapping the tachometer.
3. Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive.
Specification (VIN=13 0.1V, Temperature: 25C)
Description
Engine speed (rpm)
700
1000
2000
3000
4000
5000
6000
Tolerance (rpm)
+50
+100
+125
+150
+150
-100
-100
-125
-150
-150
If the tachometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in
tachometer. If there is a difference between actual engine speed (rpm) and reading from tachometer, connect a scanner
and then compare the value on tachometer with the reading from scanner.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
Speedometer
The speedometer indicates the vehicle speed by calculating the signals from the rear right wheel speed sensor through
ABS or ESP unit.
If the speedometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in
speedometer. However, these symptoms also could be appeared when the tire has uneven wear, different tire inflation
pressures or different tire specifications.
Perform the speedometer test regarding the tolerance as described. However, it is not similar simple work in field due to
lack of measuring conditions such as test equipment and preciseness.
1. Check the allowable tolerance of the speedometer and operations of the trip odometer by using a tester.
2. Check if the speedometer pointer is shaking and the abnormal noise sounds.
3. Eliminate the hysteresis by tapping the speedometer.
[Notice]
The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range.
20
40
(60)
80
100
120
140
(160)
(180)
Tolerance (Km/h)
+4
+5.5
+7
+9
+10.5
+12.5
+14.5
+16
+18
+2
+2.5
+3.5
+4
+6
+7.5
+8.5
+10
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
The fuel level gauge displays the resistance value of the float on the fuel sender in the fuel tank through a pointer. Note
that this vehicle doesnt have a service hole for checking the fuel sender connector in the fuel tank.
The fuel sender and its connector can be checked and replaced only when the fuel tank is removed. The power supply
and resistance value should be measured at the connector in front of the fuel sender (refer to wiring diagram).
When the power supply and output resistance are normal, the float operation by fuel level may be defective; if so, replace
the fuel sender.
Tolerance and resistance value by indicating angle
Tolerance and resistance value by indicating angle
Scale
Indicating angle ()
Full
(3/4)
1/2
(1/4)
Full (LFW)
40
20
- 20
- 40
Tolerance ()
+4~0
2.5
2.5
+ 1.5
Resistance()
38 1
67 1
99.5 1
247 1
260 1
This table shows the tolerance and resistance value changes by fuel level in normal conditions. Therefore, the differences that can be occurred by the road conditions and fuel fluctuations are ignored.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2B
40o
0o
-40o
The coolant temperature gauge displays the coolant temperature with a pointer. The angle of pointer that changes by
coolant temperature is as shown below.
Tolerance and resistance value by indicating angle
Indicating angle
Tolerance
Coolant temperature
- 40 (H)
0C (1/2)
+40(C)
2.5
+0C
+5C
- 5C
+1C
70C ~ 110C
Over 125C
40C
20C :
2449 5 %
50C :
826
5 %
80C :
321
5 %
100C :
112
5 %
When the resistance value by coolant temperature is within the specified range, check thermostat, water pump, radiator
related coolant circuit for normal operation. Also, check the wiring harnesses and connectors for proper connection.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
11
Reset button
* Press and hold (over 1 sec.)
Trip odometer TRIP A and TRIP B will be reset to 0. (However, only the corresponding driving
range will be set to 0.)
* Press shortly (between 0.1 ~ 1 sec.)
The mode changes in order as shown in the figure.
ODO
TRIP A
TRIP B
Increment: 0.1 km
Increment: 0.1 km
Increment: 1 km
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
2B
This indicator indicates the operating conditions of immobilizer system. This indicator
comes on when the ignition key is communicating with the engine control unit (during
engine starting) and goes out after starting
the engine. If this indicator blinks, it may indicate that there is something wrong in the immobilizer system.
The indicator comes on when the Winter mode (W) switch near the gear selector lever is pressed. Use this mode
to drive off smoothly under icy and slippery road. In this mode, the vehicle
drives off with second gear in forward
and reverse driving.
2 3 4 5
Driving gears
Immobilizer Indicator
When the ignition is switched on, this warning light comes on and should go out. This
warning light comes on when the parking
brake is applied and/or the brake fluid level is
lower than specified level. If the vehicle is
driven for over 2 seconds (over 10 km/h) while
the parking brake is applied, the parking brake
warning light comes on and warning buzzer
sounds.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
Defogger Indicator
13
This warning light comes on when the ignition switch is turned to ON and goes out
if the engine is in normal condition. If the
light stays on or comes on while driving,
some of engine control components including sensors and devices are defective.
When this warning light comes on, the
vehicle operates in safety mode to maintain minimum driving conditions and to prevent the system from being damaged. In
this mode, the engine driving force may
be decreased or the engine may stall. For
more details, refer to Engine section in
this manual.
This light comes on when a door or tailgate is either opened or not closed
completely. If you drive over 10 km/h of
vehicle speed without closing the door,
the warning light blinks.
[NOTE]
The vehicle equipped with ABS
performs self-diagnosis on the system
when the engine is started and drives
off. During the diagnosis, brake pedal
vibration and noise may be apparent
when the driving motors discharges
the hydraulic pressure from the
internal hydraulic device. This means
the ABS is properly functioning.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
2B
2. Pull out the front cup holder, disconnect the cigarette connector and the power socket connector, and remove the
front cup holder.
3. Carefully pry off the chrome coated cover from the selector lever cover, unscrew the screws and remove the
selector lever cover.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
15
4. Carefully pull out the center speakers and disconnect the connectors.
5. Remove the screws and take out the front cover from the instrument panel.
6. Disconnect all switch connectors including TRIP switch connector (2) during removal of the front cover.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
2B
7. Unscrew four screws and pull out the meter cluster housing.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
17
Indicator Display
1. Remove the indicator display cover.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2C
1. COMPONENTS LOCATOR
Air bag ECU
RK STICS
Installed under the battery. This
horn works only for the theft deterrent function, panic function, and
remote starting.
Diagnosis connector
ICM module
REKES
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2C
2. TRANSMITTER CODING
Coding process:
1. Remove the ignition key from key hole.
2. Connect the No. 3 terminal (REKES coding) and No. 16 terminal (battery+) on the diagnosis connector with a
jumper cable.
3. Press any button on the remote control key shortly. (approx. 0.5 sec.)
4. When the coding is successful, turn signal lamps blink once and warning horn sounds once.
5. If the coding has failed, repeat 1 to 4 steps.
IG1
Ground
Signal ground
CAN_High
ECU
ABS
Air bag
10
TGS
11
TCU
12
13
TCCU
14
CAN_Low
15
16
Battery+
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
3. DESCRIPTIONS
Below table shows the major differences compared to the previous vehicle model before year 2004. For whole functions
and details, refer to corresponding section.
Item
RK STICS
Door lock
The door unlock output is sent to all doors once for 0.5 seconds when the LOCK
signal is inputted into unit within 0.5 seconds after closing the drivers or
passengers door. This is regardless of key in or key out. It is to prevent the
doors from locking due to impact when the door is closed.
Previously, G-sensor in STICS outputs auto door unlock signal if the vehicle
collides over 15 km/h of vehicle speed. However, the air bag system is installed
in this vehicle as a basic equipment. When a collision, the Auto Door Unlock
function is activated by using a collision signal from the air bag module.
1. When receiving the unlock signal from remote control key with the door
closed, the front room lamp comes on for 30 seconds.
2. When receiving the unlock signal again during the time lagging operation,
another 30 seconds will be extended from unlock point.
The power window can be operated for 30 seconds after removing the ignition
key from key switch. This lagging operation stops when closing the door.
When the vehicle speed signal is inputted with the parking brake applied, the
warning light blinks and the chime buzzer in ICM box continuously sounds for 0.
6 seconds with 0.3 seconds of pausing time (when driving over 10 km/h of vehicle
speed for more than 2 seconds).
1. Turns on or off the tail lamp relay according to the tail lamp switch
operations.
2. The tail lamp relay is turned off (auto-cut) when removing the ignition key
and opening and closing the door while the tail lamp switch is turned on.
The hazard warning relay in ICM box outputs when the remote control key is
operated or the theft deterrent alarm is activated. At this time, separate warning
horn sounds.
1. The theft deterrent horn sounds for 27 seconds when receiving the panic
signal from the remote control key.
2. The panic alarm is turned off when receiving any signal from the remote
control key during the panic alarm operation.
3. This function works under armed mode.
1. The headlamp control supplies the power to headlamp relay for 20 seconds and
turns off when receiving the escort signal from the remote control key with the
ignition key off (if the escort signal is inputted again, it will be extended once for
20 seconds). However, the power supply and output is activated only when the
vehicle is in armed mode activated by remote control key.
2. The headlamp relay output is turned off immediately after receiving the
remote control lock signal during its operation (however, signals other than
lock signal from remote control key will be ignored).
3. The headlamp relay output is immediately turned off when the key is turned
to ON position during its operation (this function is also activated under
remote starting).
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2C
NO.
Description
Status
NO.
Description
Status
Output
38
Hood switch
Input
Output
39
Input
Output
40
Output
Coding
41
Input
Door lock
Output
42
Input
ALT_D
Input
43
Tailgate switch
Input
Output
44
Input
Ground
45
Input
Headlamp relay
Output
46
Input
10
Door unlock
Output
47
Input/Output
11
Input
48
Input
12
Output
49
Washer switch
Input
13
Output
50
Input
14
Output
51
Output
15
Output
52
Intermittent volume
Input
16
V+
53
Output
17
54
Headlamp relay
Output
18
Ground
19
Output
56
20
Output
57
21
IGN 2
Input
58
22
IGN 1
Input
59
23
Output
60
24
Input
61
25
Input
62
26
Input
63
27
Input
64
28
Input
65
29
Input
66
Input/Output
67
Output
68
Input
69
30
31
32
Output
55
33
Input
70
34
Output
71
35
Input
72
36
Input
73
37
Input
74
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
5. SPECIFICATIONS
1) Electrical Performance
Item
Requirement
Remark
Rated voltage
DC 12 V
Operating voltage
DC 9~16 V
Operating temperature
-30C ~ +80C
Reserved temperature
-40C ~ +85C
95%
Resistible voltage
24 V
Insulating resistance
current leaks.
the insulation.
below 4.0 mA
below 1.2 V
Pin no. 8 and 2, 3, 5, 7, 10, 12, 13, 15, 19, 20, 23, 40, 47,
below 2.0 V
51, 53, 54
Parasitic current
Voltage drop
3) Time Tolerance
1. If not indicated, time tolerance will be 10%.
However, if less than 500 ms, time tolerance will be 50 ms.
2. The time indicated in each function does not include chattering processing time from switch input changing point.
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2C
RK Stics
1
IGN 1
IGN 2
ALT_D
OPEN = GND
OPEN = GND
BAT = Battery
Tailgate switch
OPEN = GND
ON = GND
10
ON = GND
11
12
16
Hood switch
OPEN = GND
17
Tailgate switch
ON = GND
18
Defogger switch
ON = GND
19
20
ON = GND (applied)
21
Washer switch
ON = GND
22
Intermittent switch
ON = GND
23
Intermittent volume
24
ON = GND
25
26
27
ON = GND
28
Collision sensor
29
Speed sensor
30
Coding
ON = BAT
31
Diagnosis (K-Line)
13
communication)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
6. FUNCTIONS OF RK STICS
1) Wiper Control
Wiper MIST and Washer Coupled Wiper
1. The wiper relay is turned on 0.3 seconds (T1) after turning ON the washer switch for 0.2 ~ 0.59 seconds (T2) with
the ignition key ON, and it is turned off when the parking terminal is turned off.
2. The wiper relay is turned on 0.3 seconds (T1) after turning ON the washer switch over 0.6 seconds (T2) with the
ignition key ON, and it is turned on three times immediately after turning off the washer switch.
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2C
3. If the washer operating signal is inputted while the wipers are operating in intermittent or AUTO mode, the system
stores the previous intermittent interval and operates the washer coupled wiper. After then, the wiper operation
returns back to intermittent or AUTO mode with the stored operating interval.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
T4: 3 cycles
RK STICS
STAVIC - 2004.09
2C
11
1. System layout
This vehicle has a different wiper control logic compared to other models. As shown in the system diagram, the rain
sensor unit does not control wiper directly. The rain sensor unit sends infrared rays signal through LED and then
receives it with photo diode and then sends the returned signal to STICS and the STICS controls the wipers directly.
For more details, refer to rain sensing wiper section in this manual.
Multi-function (wiper)
switch
Rain
sensor
RESTICS
Wiper LO
Wiper HI
Wiper motor
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
2C
T1: 1 cycle
SENSITIVITY
RAIN SENSOR
Rain Detected
OFF
WIPER RELAY
LO
ON
OFF
T1: 1 cycle
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AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
13
IGN (Operation)
GND (Stop)
2) When the parking terminal is fixed to IGN (HIGH), the wiper system outputs the operating signal of current sensitivity
for 2 seconds, then continuously outputs the parking signal of current sensitivity
* The wiper motor runs only when the rain sensor requires.
IGN (Operation)
GND (Stop)
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
2C
SENSITIVITY
RAIN SENSOR
Malfunction signal (1): Yes
Malfunction signal (1): No
WIPER RELAY
ON
LO
OFF
T1: 1 cycle
2) The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from
4 during receiving the malfunction signal (2) from the rain sensor (while the ignition key is in ON position and the
wiper switch is in AUTO position).
SENSITIVITY
RAIN SENSOR
Malfunction signal (1): Yes
Malfunction signal (1): No
WIPER RELAY
ON
LO
OFF
T1: 1 cycle
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EFFECTIVE DATE
AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
15
3) The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from
1 during receiving the malfunction signal (3) from the rain sensor (while the ignition key is in ON position and the
wiper switch is in AUTO position). Also, the wiper relay (LO) is turned on and the wiper motor runs one cycle when
the wiper sensitivity is changed to 2 from 1 during receiving the ground fixed or IGN fixed signal from the rain
sensor.
SENSITIVITY
RAIN SENSOR
Malfunction signal (1): Yes
Malfunction signal (1): No
WIPER RELAY
ON
LO
OFF
T1: 1 cycle
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AFFECTED VIN
16
2C
Pause time
(sec.)
[Notice]
(1) Wiper MIST and washer coupled wiper
1) When turning on the washer switch while the wiper relay is operating.
- If the wiper relay ON request time is shorter than the remained ON time, it is disregarded.
(2) Speed sensitive INT (intermittent) wiper
1) The wiper relay continues to output for remaining ON time even when the INT switch is turned off.
2) IGN 2 switch ON, INT switch OFF: resume the intermittent time when turning ON
3) IGN 2 switch OFF, INT switch ON: resume the intermittent time when turning ON
(3) Controls when the wiper motor parking is defective
- The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while the wiper relay is
ON (INT switch = ON or Washer switch = ON) (The output stops immediately after turning off the switch)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
17
CHIME BUZZER
Key Reminder
1. This function does not work if the vehicle speed is over 3 km/h.
2. The system outputs UNLOCK for 5 seconds (T2) from 0.5 seconds after the drivers door is opened and the door
lock switch is changed to LOCK (while the ignition key is in ignition switch).
3. The system outputs UNLOCK for 5 seconds (T2) when the door lock switch is changed to LOCK from UNLOCK
and the drivers door is closed within 0.5 seconds (T1) (while the ignition key is in ignition switch).
T1: 0.5s
T2: 5s
[Note]
Operating conditions for (*1) and (*2)
(*1): Drivers door is opened and drivers door lock switch is turned to LOCK
(*2): Passengers door is opened and passengers door lock switch is turned to LOCK
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
2C
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
19
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
2C
VEHICLE SPEED
OVER V1
BELOW V1
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AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
21
FASTEN
UNFASTEN
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
2C
VEHICLE SPEED
OVER V1
BELOW V2
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EFFECTIVE DATE
AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
23
4. The front room lamp comes on for 30 seconds (T3) when receiving the
unlock signal from the remote control key while the door is closed.
5. The front room lamp output period is extended by 30 seconds (T3) when receiving the unlock signal from the remote
control key again during output.
6. When a door is opened during its extended period, the lamp stays on. If closed, operates as in step 2.
7. The room lamp output stops immediately after receiving the lock signal from drivers door and passengers door
lock switch while the drivers door and passengers door are closed.
RECEIVE
NO SIGNAL
OUTPUT
RK STICS
STAVIC - 2004.09
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AFFECTED VIN
24
2C
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
25
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
2C
AUTO CUT
CHANGED BY
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AFFECTED VIN
AUTO CUT
RK STICS
STAVIC - 2004.09
2C
27
OVER 9V
BELOW 9V
REAR DEFOGGER
SWITCH
REAR DEFOGGER
RELAY
T1: 12 min.
T2: 10 min.
T3: 6 min.
This vehicle has the windshield heated glass and the tailgate and outside rearview mirror heated glass. The heater relay
in the ICM box controls the tailgate and outside rearview mirror heated glass and its fuse (15A) is located in the engine
compartment fuse box.
Defogger switch
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
2C
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
29
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30
2C
NO SIGNAL
CHANGED BY
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AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
31
VEHICLE
SPEED
OVER 50 KM/H
BELOW 50 KM/H
LOCK OUTPUT
5 times
RK STICS
STAVIC - 2004.09
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EFFECTIVE DATE
AFFECTED VIN
32
2C
ING SW(*1)
ON
OFF
ON
OFF
UNLOCK
RELAY
ON
OFF
[Notice]
(1) The Unlock control by air bag signal prevails over any LOCK or UNLOCK control by other functions.
(2) The LOCK/UNLOCK request by other functions will be ignored after/during the output of UNLOCK by the air bag.
However, the door lock is controlled by other functions when IGN1 SW is OFF and IGN2 SW is OFF.
(3) If the door lock system outputs LOCK and UNLOCK simultaneously, only the LOCK output can be activated.
(4) Even though the LOCK/UNLOCK output is requested, the door lock system cannot output LOCK/UNLOCK when all
door lock switches are locked/unlocked.
Also, even though the UNLOCK output for the drivers door is requested, the door lock system cannot output UNLOCK
when the drivers door is unlocked.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
33
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
34
2C
CHANGED BY
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AFFECTED VIN
Specification:
CR 2032
Quantity:
1 ea
RK STICS
STAVIC - 2004.09
2C
35
Receiver
1. Operating requirements
- IGN key = OUT (removed)
2. Code registration requirement
- After connecting the B+ to external coding terminal (applying battery voltage)
RK STICS
STAVIC - 2004.09
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EFFECTIVE DATE
AFFECTED VIN
36
2C
Tx SIGNAL
NO SIGNAL
ENTRANCE
DOOR SW
ENTRANCE
DOOR
LOCK SW
OPERATION
ARMED MODE
OTHERS
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AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
37
4) Warning operation
1. The theft deterrent horn and hazard warning flasher output is ON for T3 (27 seconds) with the interval of T2 (1
second).
5) Warning cancellation requirements
1. Cancels warning by using any signal from the remote control key (LOCK, UNLOCK, START, STOP, PANIC,
CHECK) during warning operation.
2. Cancels warning after 27 seconds (remaining period) while the ignition key is turned to ON position.
WARNING
REQUIREMENTS
ESTABLISHED
WARNING
CANCELLATION
ESTABLISHED
THEFT
DETERRENT
STATE
WARNING
RK STICS
STAVIC - 2004.09
NO ESTABLISHED
NO ESTABLISHED
ARMED
NORMAL
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AFFECTED VIN
38
2C
REMOTE
CONTROL KEY
PANIC SIGNAL
THEFT
DETERRENT
WARNING
OTHERS
MODE
HORN
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AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
39
RK STICS
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
40
2C
Diagnostic Procedures
2. Select RK STICS.
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AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
Code
41
Descriptions
Help
01
This DTC is set when the unit didnt receive the contact signal of door
lock actuator after the unit has sent the LOCK signal to the door lock
relay (while the auto door lock is activated and the vehicle speed is
over 50 km/h).
02
This DTC is set when the unit didnt receive the contact signal of door
lock actuator after the unit has sent the LOCK signal to the door lock
relay by the remote control key or knob.
03
This DTC is set when the unit didnt receive the contact signal of door
unlock actuator after the unit has sent the LOCK signal to the door
unlock relay by the remote control key or knob.
04
This DTC is set when the unit didnt receive the contact signal of door
unlock actuator after the unit has sent the LOCK signal to the door
unlock relay by the remote control key. (When the function that opens
drivers door only is not operating)
05
This DTC is set when the wiper stop signal cannot be detected during
the wiper relay operation.
06
07
This DTC is set when more than 3 km/h of vehicle speed is detected
from the vehicle speed signal input area while the ignition key is in
ON position and ALT D is LOW.
08
09
This DTC is set when the door ajar warning light comes on while the
vehicle speed is over 3 km/h.
10
This DTC is set whenever the collision signal is entered into the collision sensor while the ignition key is in OFF position
11
This DTC is set when the STICS sends the door unlock signal and its
feedback value is normal.
12
This DTC is set when more than 200 km/h of vehicle speed is detected.
13
This DTC is set when the brake warning light comes on while the
vehicle speed is over 3 km/h.
14
15
16
17
RK STICS
STAVIC - 2004.09
42
2C
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AFFECTED VIN
RK STICS
STAVIC - 2004.09
2D
1. COMPONENTS
Multifunction wiper switch:
AUTO and sensitivity control
AUTO
STICS
ICM box
The wiper related relays are
installed in ICM box.
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AFFECTED VIN
2D
Front
Rain sensor
unit
Housing and
receiver lens
Receiver lens
The receiver lens guides the
reflected infrared rays from
windshield to photodiode.
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AFFECTED VIN
2D
Multifunction switch
Wiper
relay (LO)
STICS
Wiper
motor
Wiper relay
(HI)
Washer motor
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AFFECTED VIN
2D
Operation mode
low speed. The wiper blade returns to parking position if the switch
returns to the original position. The rain sensor ignores inputs during
parking signal periods.
The wiper motor rotates in low speed until it returns to parking position.
AUTO 1
SLOW
(Low sensitivity)
(Low/medium sensitivity)
AUTO 3
(Medium sensitivity)
AUTO 4
(Medium/High sensitivity)
AUTO 5
(High sensitivity)
FAST
Washer switch
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AFFECTED VIN
2D
6. DIAGNOSIS PROCEDURES
CHANGED BY
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10
2D
7. TROUBLESHOOTING
1. The wiper should not operate one cycle when turning the wiper switch to AUTO from OFF position
or Ig S/W (Ig2) while the wiper switch is in AUTO position.
1) When Ig2 with the wiper switch AUTO position, the wiper operates one cycle to remind a driver that the wiper
switch is in AUTO position.
2) When the wiper switch is turned to AUTO from OFF, the wiper operates one cycle. It always operates one cycle
for the initial operation, however, the wiper does not operate afterwards to prevent the wiper blade wear if not raining
when turning the wiper switch to AUTO from OFF. However, the wiper operates up to 5 minutes after rain stops.
If this function does not occur, check No. 1 pin. If the pin is normal, check the wiper relay related terminals in ICM
box.
Check whether the variable resistance knob on the wiper switch is set in FAST. The FAST is the highest stage
of sensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to low sensitivity.
1) Check the wiper blade for wear. If the wiper blade cannot wipe the glass uniformly and clearly, this problem could
be occurred. In this case, replace the wiper blade with new one.
2) Check whether the variable resistance knob on the wiper switch is set in FAST. The FAST is the highest stage
of sensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to low sensitivity.
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AFFECTED VIN
2D
11
Check whether the variable resistance knob on the wiper switch is set in FAST or SLOW.
Notify that the customer can select the sensitivity by selecting the variable resistance value. And, select a proper
stage.
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12
2D
Service hole
2. Pull of the rain sensor unit from the windshield glass and disconnect the rain sensor connector.
CHANGED BY
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AFFECTED VIN
2E
INTERIOR SWITCHES
Audio remote control switch
Mute button
Volume button - Up
Volume button - Down
Window switch
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
Multi-meter
Defogger switch
Front room lamp
operation
Passengers seat
warmer switch
Multifunction switch
Window switch
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2E
SWITCHES
1. CENTER SWITCH
Seat Warmer Switch
The seat warmer relay is installed in ICM box and the seat heated wire is installed in the drivers and passengers seat.
When the seat warmer switch is operated, the seat cushion and seatback gets warm. If the temperature of seat surface
gets 40 5C, the thermistor cuts or connects the power to heated wire to maintain the temperature to the specified
level.
The is no control switch and unit to control the temperature of the seat surface temperature.
Passengers seat
warmer switch
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
[Notice]
The temperature of seat surface should be increased over 20C within 3 minutes after turning on the switch while a person
(height: 175 5 cm, weight: 75 5 kg).
[Notice]
- Do not place anything sharp on the seat.
- When cleaning the seats, do not use organic solvents such as benzene or thinner.
- Do not use this function when the engine is not running. The battery could be discharged.
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2E
Fog lamp
The fog lamp with indicator comes on when pressing the fog lamp switch while the light switch is ON. It goes off
when pressing the switch again.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
The hazard warning indicators on the indicator display, both turn signal lamps, and both side repeaters blink when
pressing the hazard warning flasher switch.
ICM box
Flasher unit
Left side
lamps
SWITCH
STAVIC - 2004.09
Right side
lamps
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2E
Defogger Switch
The windshield, tailgate glass, and outside rearview mirrors have heated wire. STICS controls the defogger relay in the
engine room fuse and relay box.
Defogger indicator
STICS
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
Circuit Diagram
The defogger switch is connected to STICS. The STICS controls the tailgate windshield and outside rearview mirror
heated glass according to the switch operations while the engine is running.
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2E
Tailgate Heated Glass, Windshield Galss and Outside Rearview Mirror Heated Glass (controlled
by STICS)
1. The outside rearview mirror heated glass operates for 12 minutes when turning on the defogger switch while the
engine is running.
2. If the defogger switch is pressed again during the operation, the operation stops.
3. If the defogger switch is pressed again within T2 (10 minutes) after completion of the first operation (T1), the
defogger system operates for 6 minutes just for once.
4. The defogger is not available when the ignition switch is in OFF position or the alternator is not running.
OVER 9 V
BELOW 9 V
T1: 12 min.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
T3: 6 min.
SWITCH
STAVIC - 2004.09
2E
11
ESPOFF Switch
If the driving wheels are slipping on the snowy or icy road, the engine rpm may not be increased even when depressing
the accelerator pedal, and accordingly, the vehicle may not be started off. In this case, stop the ESP function by
pressing the ESPOFF switch. When the ESPOFF switch is pressed, the ESP function stops and the vehicle is driven
independently from the sensor outputs. However, the ABS function is still activated.
ICM box
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
2E
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
13
2. Pull out the front cup holder, disconnect the cigarette connector and the power socket connector, and remove the
front cup holder.
3. Carefully pry off the chrome coated cover from the selector lever cover, unscrew the screws and remove the
selector lever cover.
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
2E
4. Carefully pull out the center speakers and disconnect the connectors.
5. Remove the screws and take out the front cover from the instrument panel.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
15
7. Remove the center switch cover and pull out the switches from it.
SWITCH
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
16
2E
Driving mode
4H 4L
Changing requirement
Vehicle is stationary.
Selected gear
Neutral
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
17
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
2E
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EFFECTIVE DATE
AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
19
POWER
Turns on and off the audio system.
MODE
Changes the audio mode in order as below:
MUTE
SEEK
SEEK
In radio mode
- Press briefly: Manual searching for a station.
VOLUME
VOLUME
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
2E
Audio
switches
Tail
lamp
relay
Pin number
Descriptions
31
Audio signal
32
Audio ground
33
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
21
3. Unscrew the bolts and disconnect the remote control switch connector.
SWITCH
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
22
2E
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
23
[Note]
The mirrors can be folded/unfolded for 30 seconds
after turning the ignition key to OFF position.
Manual folding or unfolding the outside rearview
mirrors may cause a malfunction of the mirror
folding system.
Window lock
switch
If this switch is pressed,
all door windows are
operated only by drivers
door window switches.
When the front of the switch is lightly pressed (stage 1), the
window will be lowered while the switch is pressed. When
pressed to its end (stage 2), the window will open automatically until it is fully opened. The window stops during its
operation when pressing the switch (stage 1) again or pulling
up the switch.
The other window can be operated only while the appropriate
switch is activated.
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
2E
* Abbreviations
CHANGED BY
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
25
Front Left
Front Right
Rear Left
Rear Right
Door Lock
SWITCH
STAVIC - 2004.09
11
12
14
LOCK
10
UNLOCK
Illumination
ILL
Power
B+
B+ (S)
13
E(-)
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AFFECTED VIN
26
2E
3. Pry off the door lever cover and remove the mounting screws.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
27
5. Unscrew the bolts and remove the door grip from the removed door trim.
6. Unscrew the bolts and remove the outside rearview mirror switch from the door grip.
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
2E
Driver side
Passenger side
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
29
MULTIFUNCTION SWITCH
1. MULTIFUNCTION SWITCH
Steering wheel
Steering wheel
angular sensor
Light switch
Wiper/washer
switch
Specifications
Descriptions
Multifunction
switch
Specifications
Rated voltage
DC 12V
Light switch
Dimmer and passing switch
Turn signal switch
Wiper switch
-30C ~ +80C
Turn on: 1 A (relay load)
Hi/Low/Passing: 0.3 A (relay load)
6.6 0.5 A (lamp load)
Low: 5 A, Hi: 7 A (motor load)
AUTO: 0.22 0.05 A (relay load)
Fixed: max. 28 A (motor load)
Washer switch
Intermittent wiper switch
MIST switch
SWITCH
STAVIC - 2004.09
4 A (motor load)
Max. 25 mmA
5 A (motor load)
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AFFECTED VIN
30
2E
CHANGED BY
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
31
Connector A
1. Connector A
Pin number
11
56 7
10
2. Connector A
15
14 16
STAVIC - 2004.09
Descriptions
10
11
Descriptions
Pin number
22 21 17 20
18 19
SWITCH
Connector B
14
15
16
S: Wiper stop
17
18
19
20
21
22
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AFFECTED VIN
32
2E
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
33
2. Put an installation mark on the steering wheel and nut and remove the steering wheel.
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
34
2E
5. Disconnect the multifunction switch connector. Unscrew the screws from the air bag contact coil, and remove the
air bag contact coil assembly.
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EFFECTIVE DATE
AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
35
6. Disconnect the steering wheel angular sensor connector. Unscrew the screws and remove the multifunction switch
assembly.
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
36
2E
Specifications
Description
Auto light sensor unit
Specifications
Operating voltage
Load
9 ~ 16V
Max. 200 mA (relay load)
Operating temperature
-30C ~ +85C
Storage temperature
-40C ~ +120C
Location
Headlamp
relay
Tail lamp
relay
Ignition switch
Battery
12V
Control
circuit
Headlamp
switch
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Tail lamp
switch
SWITCH
STAVIC - 2004.09
2E
37
Headlamp ON condition
ON
30.5 5(LUX)
8.9 3(LUX)
OFF
60.5 5(LUX)
17.2 3(LUX)
3 1 second
Brightness
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
38
2E
Operational Characteristics
IGN SW
Within ON range
AUTO light SW
Tail lamp
Headlamp
However, the tail lamp and headlamp should be within ON and OFF ranges.
T1: 3 1.0 sec T2: 500 100 msec
Inspection
Position the multifunction switch to AUTO position and cover
the auto light sensor on the instrument panel (passenger side)
with a cloth to block the light coming from outside and then
check the auto light functions.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
39
Wiper blade
assembly
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
40
2E
Specifications
Descriptions
Motor
Specifications
Rated voltage
DC 12 V 0.3 V
Test voltage
DC 13.5 V 0.3 V
DC 10 ~ 15 V
Below DC 8 V
Over 1 m
Insulating voltage
Restraint test
Torque
Over 1.1 Km
Voltage
Below 14 A
-40C ~ +80C
DC 12 V
Rated voltage
DC 9 ~ 16 V
-30C ~ +80C
-40C ~ +90C
Over 1 m
Insulating voltage
Below 0.5 V
Voltage drop
Test voltage
Maximum 10 A
Circuit Diagram
Relay 1
Voltage
controller
Relay 2
Wiper motor
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EFFECTIVE DATE
AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
41
Components Locator
Wiper blade
Wiper linkage
Wiper motor
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
42
2E
and remove the wiper blade assembly, and remove the hood cowl
B. Cowl grill
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
3. Disconnect B motor connector
43
. Unscrew two mounting bolts and two nuts and remove the wiper motor.
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
44
2E
Components Locator
CHANGED BY
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
45
1. Motor connector
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MEMO
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2E
2E - Switch (2005 ~)
Table of Contents
INTERIOR SWITCHES ...................................... 2E-2
SWITCHES ........................................................ 2E-4
1. Center switch .............................................................. 2E-4
SWITCH
RODIUS/STAVIC - 2005.07
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EFFECTIVE DATE
AFFECTED VIN
2E
INTERIOR SWITCHES
Audio remote control switch
Mute button
Volume button - Up
Volume button - Down
Window switch
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EFFECTIVE DATE
AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
Multi-meter
Defogger switch
Front room lamp
operation
Passengers seat
warmer switch
Multifunction switch
Window switch
SWITCH
RODIUS/STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2E
SWITCHES
1. CENTER SWITCH
Seat Warmer Switch
The seat warmer relay is installed in ICM box and the seat heated wire is installed in the drivers and passengers seat.
When the seat warmer switch is operated, the seat cushion and seatback gets warm. If the temperature of seat surface
gets 40 5C, the thermistor cuts or connects the power to heated wire to maintain the temperature to the specified
level.
The is no control switch and unit to control the temperature of the seat surface temperature.
Passengers seat
warmer switch
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EFFECTIVE DATE
AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
[Notice]
The temperature of seat surface should be increased over 20C within 3 minutes after turning on the switch while a person
(height: 175 5 cm, weight: 75 5 kg).
[Notice]
- Do not place anything sharp on the seat.
- When cleaning the seats, do not use organic solvents such as benzene or thinner.
- Do not use this function when the engine is not running. The battery could be discharged.
SWITCH
RODIUS/STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2E
Fog lamp
The fog lamp with indicator comes on when pressing the fog lamp switch while the light switch is ON. It goes off
when pressing the switch again.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
The hazard warning indicators on the indicator display, both turn signal lamps, and both side repeaters blink when
pressing the hazard warning flasher switch.
ICM box
Flasher unit
Left side
lamps
SWITCH
RODIUS/STAVIC - 2005.07
Right side
lamps
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2E
Defogger Switch
The windshield, tailgate glass, and outside rearview mirrors have heated wire. STICS controls the defogger relay in the
engine room fuse and relay box.
Defogger indicator
STICS
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EFFECTIVE DATE
AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
Circuit Diagram
The defogger switch is connected to STICS. The STICS controls the tailgate heated glass windshield glass and
outside rearview mirror heated glass according to the switch operations while the engine is running.
SWITCH
RODIUS/STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2E
Tailgate Heated Glass, Windshield Glass and Outside Rearview Mirror Heated Glass (controlled by
STICS)
1. Defogger relay operates for 12 minutes when turning on the defogger switch while the engine is running.
2. If the defogger switch is pressed again during the operation, the operation stops.
3. If the defogger switch is pressed again within T2 (10 minutes) after completion of the first operation (T1), the
defogger system operates for 6 minutes just for once.
4. The defogger is not available when the ignition switch is in OFF position or the alternator is not running.
OVER 9 V
BELOW 9 V
DEFOG SW
DEFOG
RELAY
T1: 12 min.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
T3: 6 min.
SWITCH
RODIUS/STAVIC - 2005.07
2E
11
ESPOFF Switch
If the driving wheels are slipping on the snowy or icy road, the engine rpm may not be increased even when depressing
the accelerator pedal, and accordingly, the vehicle may not be started off. In this case, stop the ESP function by
pressing the ESPOFF switch. When the ESPOFF switch is pressed, the ESP function stops and the vehicle is driven
independently from the sensor outputs. However, the ABS function is still activated.
ICM box
SWITCH
RODIUS/STAVIC - 2005.07
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EFFECTIVE DATE
AFFECTED VIN
12
2E
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
13
2. Pull out the front cup holder, disconnect the cigarette connector and the power socket connector, and remove the
front cup holder.
3. Carefully pry off the chrome coated cover from the selector lever cover, unscrew the screws and remove the
selector lever cover.
SWITCH
RODIUS/STAVIC - 2005.07
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EFFECTIVE DATE
AFFECTED VIN
14
2E
4. Carefully pull out the center speakers and disconnect the connectors.
5. Remove the screws and take out the front cover from the instrument panel.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
15
7. Remove the center switch cover and pull out the switches from it.
SWITCH
RODIUS/STAVIC - 2005.07
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EFFECTIVE DATE
AFFECTED VIN
16
2E
TOD
P/Time
TOD
Gear
Vehicle
speed
TOD
4H 2H 4L
4H 4L
Stationary
4WD
HIGH
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EFFECTIVE DATE
AFFECTED VIN
P/Time
2E
17
SWITCH
RODIUS/STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
2E
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
19
POWER
Turns on and off the audio system.
MODE
Changes the audio mode in order as below:
MUTE
SEEK
SEEK
In radio mode
- Press briefly: Manual searching for a station.
VOLUME
VOLUME
SWITCH
RODIUS/STAVIC - 2005.07
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EFFECTIVE DATE
AFFECTED VIN
20
2E
POWER ON/OFF
Audio
switches
Tail
lamp
relay
Pin number
Descriptions
31
Audio signal
32
Audio ground
33
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AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
21
3. Unscrew the bolts and disconnect the remote control switch connector.
SWITCH
RODIUS/STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
2E
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
23
[Note]
The mirrors can be folded/unfolded for 30 seconds
after turning the ignition key to OFF position.
Manual folding or unfolding the outside rearview
mirrors may cause a malfunction of the mirror
folding system.
Window lock
switch
If this switch is pressed,
all door windows are
operated only by drivers
door window switches.
When the front of the switch is lightly pressed (stage 1), the
window will be lowered while the switch is pressed. When
pressed to its end (stage 2), the window will open automatically until it is fully opened. The window stops during its
operation when pressing the switch (stage 1) again or pulling
up the switch.
The other window can be operated only while the appropriate
switch is activated.
SWITCH
RODIUS/STAVIC - 2005.07
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EFFECTIVE DATE
AFFECTED VIN
24
2E
* Abbreviations
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
25
Front Left
Front Right
Rear Left
Rear Right
Door Lock
SWITCH
RODIUS/STAVIC - 2005.07
11
12
14
LOCK
10
UNLOCK
Illumination
ILL
Power
B+
B+ (S)
13
E(-)
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AFFECTED VIN
26
2E
3. Pry off the door lever cover and remove the mounting screws.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
27
5. Unscrew the bolts and remove the door grip from the removed door trim.
6. Unscrew the bolts and remove the outside rearview mirror switch from the door grip.
SWITCH
RODIUS/STAVIC - 2005.07
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EFFECTIVE DATE
AFFECTED VIN
28
2E
Driver side
Switch
Passenger side
Switch
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AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
29
MULTIFUNCTION SWITCH
1. MULTIFUNCTION SWITCH
Steering wheel
Steering wheel
angular sensor
Light switch
Wiper/washer
switch
Specifications
Descriptions
Multifunction
switch
Specifications
Rated voltage
DC 12V
Light switch
Dimmer and passing switch
Turn signal switch
Wiper switch
-30C ~ +80C
Turn on: 1 A (relay load)
Hi/Low/Passing: 0.3 A (relay load)
6.6 0.5 A (lamp load)
Low: 5 A, Hi: 7 A (motor load)
AUTO: 0.22 0.05 A (relay load)
Fixed: max. 28 A (motor load)
Washer switch
Intermittent wiper switch
MIST switch
SWITCH
RODIUS/STAVIC - 2005.07
4 A (motor load)
Max. 25 mmA
5 A (motor load)
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EFFECTIVE DATE
AFFECTED VIN
30
2E
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
31
Connector A
1. Connector A
Pin number
11
56 7
10
2. Connector A
15
14 16
RODIUS/STAVIC - 2005.07
Descriptions
10
11
Descriptions
Pin number
22 21 17 20
18 19
SWITCH
Connector B
14
15
16
S: Wiper stop
17
18
19
20
21
22
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EFFECTIVE DATE
AFFECTED VIN
2E
39
Wiper blade
assembly
SWITCH
RODIUS/STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
40
2E
Specifications
Descriptions
Motor
Specifications
Rated voltage
DC 12 V 0.3 V
Test voltage
DC 13.5 V 0.3 V
DC 10 ~ 15 V
Below DC 8 V
Over 1 m
Insulating voltage
Restraint test
Torque
Over 1.1 Km
Voltage
Below 14 A
-40C ~ +80C
DC 12 V
Rated voltage
DC 9 ~ 16 V
-30C ~ +80C
-40C ~ +90C
Over 1 m
Insulating voltage
Below 0.5 V
Voltage drop
Test voltage
Maximum 10 A
Circuit Diagram
Relay 1
Voltage
controller
Relay 2
Wiper motor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
41
Components Locator
Wiper blade
Wiper linkage
Wiper motor
SWITCH
RODIUS/STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
42
2E
and remove the wiper blade assembly, and remove the hood cowl
B. Cowl grill
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
3. Disconnect B motor connector
43
. Unscrew two mounting bolts and two nuts and remove the wiper motor.
SWITCH
RODIUS/STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
44
2E
Components Locator
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
RODIUS/STAVIC - 2005.07
2E
1. Release the wiper arm cap
45
1. Motor connector
SWITCH
RODIUS/STAVIC - 2005.07
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EFFECTIVE DATE
AFFECTED VIN
2F
MULTI-METER
1. LOCATION
MULTIMETER
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2F
2. CIRCUIT DIAGRAM
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EFFECTIVE DATE
AFFECTED VIN
MULTIMETER
STAVIC - 2004.09
2F
3. DISPLAY MODE
Mode changing sequence:
[Altitude, Direction]
[Driving time]
[Battery voltage]
[Average speed]
[Note]
MULTIMETER
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2F
AM (PM)
Hour
Minute
Day
Month
Year
[Note]
- A day of the week is automatically changed according to the adjusted date, month, and year.
- An intercalary is automatically calculated.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MULTIMETER
STAVIC - 2004.09
2F
Direction
NE
45
90
SE
135
180
SW
225
270
NW
315
[Note]
This function is available only when the vehicle speed is over 2.8 km/h.
2. Turning Calibration
This operation is needed to calibrate the indication tolerance between the actual direction and the indicated direction
at current vehicle location.
Turning calibration conditions
- when the multi-meter is installed in the vehicle.
- when the battery is replaced.
Turning calibration procedure
1. When pressing the MODE and UP button simultaneously for more than 1 second, the current direction flashes.
2. Turn the vehicle over 1 complete circle within 128 seconds slowly, then the calibration will be accomplished.
3. When the calibration is finished, the vehicles new direction will be indicated.
[Note]
The turning calibration process is automatically canceled if the vehicle is not turned within 120 seconds after calibration
mode started.
MULTIMETER
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2F
Altimeter
1. Absolute Altimeter
0 m above the sea level is equivalent to 1013.25 hpa and the altimeter convert the difference between this pressure and
atmospheric pressure to absolute altitude. Its Indication range is -200 m to 2,800 m.
Current altitude
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MULTIMETER
STAVIC - 2004.09
2F
2. Relative Altimeter
It indicates the specific areas relative altitude based on the current altitude of the vehicle (current altitude is indicated
to 0 m).
Barometer
It indicates the current atmospheric pressure in range from 720 hpa to 1045 hpa by 1 hpa.
MULTIMETER
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2F
Flashing interval
stays ON
below 40 km/h
1 second
below 60 km/h
0.8 seconds
below 80 km/h
0.5 seconds
0.3 seconds
0.2 seconds
4) Driving Time
- It indicates the driving time from start up to now.
- It can be reset to 0 when turning the ignition key to OFF
position or pressing UP or DOWN button for a specific
period of time.
- Indication range: 0:00 ~ 23:59
5) Average Speed
- It indicates the average vehicle speed from start up to
now.
- It can be reset to 0 km/h when turning the ignition key to
OFF position or pressing UP or DOWN button for a
specific period of time.
- Indication range: 0 ~ 120 km/h
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MULTIMETER
STAVIC - 2004.09
2F
11
[Note]
The display returns back to previous mode screen when
placing the selector lever to other positions.
Display changes according to the distance between rear bumper and rear obstacle
Rear center
Rear right
sensor
sensor
All displaying bars are displayed when the distance between rear bumper and obstacle is over 120 cm.
The number of displaying bars is decreased and the alarm interval becomes faster as the obstacle approaches.
MULTIMETER
STAVIC - 2004.09
Step
Distance
Step 1
80 ~ 120 cm
Step 2
50 ~ 80 cm
Step 3
below 50 cm
Display
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AFFECTED VIN
12
2F
7) Battery Mode
- The screen shows fully charged battery when the battery voltage is over 12 V.
- It indicates the current battery voltage by 0.1 V.
- When the battery voltage goes below 9 V, current display is changed to battery voltage mode and LOW VOLTAGE
message flashes.
Charging level
Battery voltabe
Charging Level
Battery voltage
Indication
Over 12.0 V
(fully charged)
11.9 ~ 11.0 V
10.9 ~ 10.0 V
9.9 ~ 9.0 V
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MULTIMETER
STAVIC - 2004.09
2F
13
3. Unscrew three screws from the back of the overhead console and remove the multi-meter.
MULTIMETER
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2G
AV SYSTEM
1-DIN head unit equipped with cassette deck and radio is installed as a factory installed item and 2-DIN head unit
equipped with extra CD player (with MP3) and equalizer is installed as an optional item. There are 6 speakers in basic
and it can be 12 including tweeter if equipped with DVD system.
6-CD changer and 8-DVD changer can be installed as an extra item. DVD changer is available for the vehicle equipped
with DVD head unit and can play audio CD, video CD, MP3 CD and DVD CD.
Followings are AV systems and will be described based on the vehicle equipped with DVD system.
Rear speaker
CD changer
Tweeter
Head unit
Rear speaker
DVD changer
TV antenna module
Radio antenna module
GPS antenna
AV head unit
Rearview camera
Rear monitor
(DVD)
Rear center
speaker
Amplifier/tuner/navigation unit
with built-in DSP function
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
2G
Tweeter speaker
Center speaker
Center speaker
AV head unit
Audio remote
control switch
Front tweeter
speaker (RH)
GPS antenna
Subwoofer with
built-in amplifier
Center speaker
(RH)
AV head unit
DVD changer
Center speaker
(LH)
Subwoofer with built-in amplifier
Front tweeter
speaker (LH)
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
Center speake
2G
DVD changer
er
Rear monitor
Tuner/amplifier/navigation unit
Tuner
Navigation unit
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
2G
DVD changer
Rearview camera
Even though the AV head unit is turned off, the rearview display always appears when placing the gear
selector lever to R position. The reverse driving
signal is prior to all other video signals.
Send
Receive
Tuner
TV sound (TV antenna, LH)
TV sound (TV antenna, RH)
Send
TV video data
Sound communication line
(Bus line)
AV head unit
(with built-in EGA 6.5 monitor)
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
GPS satellite
Rear monitor
Video signal
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
2G
DVD NAVI
Rearview camera
Audio signal
(Video signal)
AV head unit
AVC-LAN
(EGA/6.5)
Roof monitor (7)
DVD changer
OPTIC
TX
OPTIC
TX
(Video signal)
Tuner unit
OPTIC
RX
5.1 channel
power amplifier
OPTIC
RX
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
Appearance
Front view of head unit
Touch-screen panel
When cleaning the touch screen, turn off the system and clean
the surface with a dry and soft cloth. Never use any coarse
cloth, hard cloth, chemical agent, volatile cleaning solvent
(alcohol, benzene, thinner) for cleaning the touch screen.
[Notice]
Do not apply excessive force to adjust, open, and close the monitor. Do not impede the automatic
movement of the unit.
Tape deck
Reset button
Forceful operation or impeding the
movement of AV system may
cause unstable operations. When
the system operation is unstable,
push the reset button with a sharp
object like a ball-point pen to initialize the system.
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
10
2G
Disc size
Play time
approx. 133 minutes (SS/SL)
approx. 242 minutes (SS/DL)
DVD video
Video CD
5 (12 cm)
approx. 74 minutes
Audio CD
5 (12 cm)
approx. 74 minutes
CD-ROM
5 (12 cm)
DL = Double layer
DVD head unit and DVD changer cannot play following discs.
DVD-R
DVD-RAM
DVD-ROM
DVD-Audio
CD-G
Mixed CD (Date)
Active Audio (Date)
VSD
Multi-section disc
DVD with region code other than (3) or (ALL)
Bulk CD-R or CD-RW that their quality cannot be secured may not be recognized.
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
11
MODE
Changes AV mode and turns on/off the Mode
display with Power ON. The display returns back
to previous screen when pressing Mode button
over 2 seconds in NAVI mode.
VOL
DESTINATION
This button is used for setting
Destination in NAVI mode.
Volume Up/Down
MENU
AV MODE: Controls the display, tone and
menu with Power ON.
NAVI MODE: Displays menus in NAVI
mode.
To control the display, volume and others,
press and hold the button for over 2
seconds.
OPEN / CLOSE
Moves the monitor to fully open or close position.
When pressing this button, the monitor moves to
fully open position if it is not in fully open position,
and moves to previously stored tilting position if it
is in fully open position.
TILT
Moves the monitor to desired tilting position while
pushing this button.
UP button is not available when the fully close
position.
The down tilting angle can be precisely adjusted by
using Down button within a specified range. If it
reaches to its end, no more movement can be done.
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
12
2G
Descriptions of Terminals
Connector A (26-pin)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
BUS 1 output
BUS 1 input
BUS 1 ground
TV LHTV RHRemote control ground
S-Remote control
V-ground
TV-Video
IlluminationReverse signal
ACC+
Battery+
BUS 2 output
BUS 2 input
BUS 2 ground
TV LH+
TV RH+
Ground
R-Remote control
Remote control ground
VSYNC
Illumination +
Parking signal
Ground
Speed pulse
Connector B (20-pin)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
M. Ground
Rearview camera battery output
Rearview camera Vground
Rearview camera video
Navigation voice
Navigation Vground
Navigation CSYNC
Navigation Gi
Remote control optic sensor ground
Remote control optic sensor signal
Amp mute
Amp ON
Amp voice ON
Amp ground
Navigation voice output
Navigation voice ON
Navigation voice BI
Navigation GI
Connector C (16-pin)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
RVSYNC
RSYNC
Vground
R-G
RGB ground
R-Mode 1
Ground
Mute
Video
Power ON
N.C.
R-SSW
R-B
R-R
R-Mode 2
-
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
13
Specifications
System
Radio/TV
Function
- Manual preset: FM1 (6), FM2 (6), AM (6), TV1 (6), TV2 (6)
- Manual channel up/down
- Seek up/down
- BSM (AM/FM), auto memory (TV)
- Local/DX (use with BSM: -20db)
Tape
- Program/Play
- FF (fast forwarding)/REW (rewinding)
- DOLBY B-NR
- AUTO METAL
- Repeat
- Back-up eject function
- Auto power when tape is inserted
DVD player
Key input
NAVI display
Display OFF
- If the display disturbs the driving conditions at night, possible to turn off just display.
- Cancellation of display OFF
* Screen touching
* Power key input
* NAVI key input
* MODE and MENU key input
Audio OFF
Sliding memory
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
14
2G
EQ control
: Up/down in FADER/BALANCE
POSITION control
* POS: Changes in order of ALL F/R F/L REAR ALL
* Finish: Changes to start page of each mode.
* Previous: Changes to basic control display
* Can control if in DSP ON
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
15
DTS-DVD
Recently, it is using as music format for DVD titles. Dolby Digital or PCM type is poplar for DVD-VIDEO, but DTS
function is increasing for high-end AMP or players. In case of DTS, level of sound division and every details are recorded
(DVD title) and has 1/3 of compression ratio compared with Dolby Digital 5.1. So a title, having large capacity, that
formatted by DTS function cannot record other supplement and subtitles.
However, it is very sensitive to sound so people accustomed to 5.1 channel prefer DTS titles.
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
16
2G
Tuner
A tuner filters and cuts unnecessary signals among
received signals and then precisely adjusts input
signals. Installed tuner has following functions.
Connecting terminal of the tuner receives amplified
signals from each TV antenna module locating rear
quarter glass that receives TV signals from glass
antenna and then inputs to left and right channel.
AM/FM radio module on the roof panel rear end receives amplified signals from glass antenna and then
transmits to tuner input (1 channel).
TV antenna module RH
TV antenna module LH
2 channels
2 channels
DVD Navigation
Navigation unit in this vehicle transmits huge amount of data on the
DVD CD directly to AV head unit, without via tuner and AMP. It has
3D view function for roads and buildings and supporting data. GPS
antenna to receive/send vehicle position from/to satellite is located
behind the Instrument panel.
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
17
Appearance
Connector
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
18
2G
Rear monitor
Front monitor
Monitor Control
Rear monitor Brightness / Tint / Color control dial
OPEN switch
When pressing the OPEN button, the power is supplied and the rear monitor slide down by approx. 25.
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
19
Location
Opening angle
When pressing the OPEN button, the power is supplied and the rear monitor slide down by approx. 25. After then,
manually adjust the monitor to desired angle. Its angle can be adjusted by 100.
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
20
2G
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
21
Tuner
1. Disconnect four TV antenna terminals, main connector
and radio antenna connector.
Main connector
TV antenna
Radio antenna
[Tuner unit]
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
22
2G
Main connector
DVD Navigation
Preceding work: Removal of Tuner/Amplifier deck
Unscrew the bracket bolts (2 x 2), disconnect the rear amplifier connector, and remove the navigation unit.
[Notice]
Make sure to remove the tuner/amplifier deck before
disconnecting the connector.
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
23
Rear Monitor
1. Unscrew four fixing bolts (10 mm) with the rear monitor
lowered.
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
24
2G
Subwoofer Speaker
Preceding work: Removal of passengers seat
Remove four bracket bolts and disconnect the connector and terminals.
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
25
3. Unscrew the bolts from the removed door trim and remove the tweeter speaker.
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
26
2G
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
27
3. Unscrew the screws from the removed front center speaker assembly and remove the front center
speaker.
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
28
2G
2. Disconnect the tweeter speaker connector from the removed instrument panel, unscrew the screws and
remove the tweeter speaker.
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
29
Preceding works:
Removal of luggage room lamp,Removal of third
and fourth row seats, Removal of rear quarter upper
and lower trims, Removal of rear headlining
1
TV antenna connections
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
MEMO
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................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
2H
Front monitor
ICM box
Rearview camera
When selecting R position while A/V system is in use:
The video mode in front A/V system is changed to rearview monitoring mode. However, the audio mode stays on.
The video mode in front A/V system resumes when
shifting out from R position.
The audio and video mode in rear A/V system are not
changed.
When selecting R position while A/V system is not in use:
Both monitors are automatically turned on to display rearview.
Both monitors are automatically turned off when shifting
out from R position.
Rearview camera
The rearview camera sends the rearview to the monitor by using wide angle
lens.
PAS unit
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2H
2. SYSTEM CONTROL
Parking Aid Unit
Send
Generates sensor
12 V
driving signals
Back
Regulator
sonar
Signal transmitter
AMP
& BPF
GND
Receive
Reverse driving
(supplies power)
Buzzer
(ICM box)
Back sonar
sensor
(LH)
Back sonar
sensor
(Center)
Back sonar
sensor
(RH)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2H
Multi-meter
Parking aid
buzzer
PAS unit
Right sensor
Left sensor
Center sensor
Tuner
Amplifier with
built-in DSP
Navigation unit
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2H
4. COMPONENT SPECIFICATIONS
The parking aid system emits the supersonic wave signals from the sensors on the rear bumper with a specific interval
and detects the reflected signals from obstacles while the gear selector lever is in R position.
The number of displaying bars is decreased and the alarm interval becomes faster as the obstacle approaches. This
supplementary system is to secure the safety distance for parking.
Descriptions
Value
Value
Operating temperature
-30C ~ +80C
DC 9 V ~ 16 V
Storage temperature
-40C ~ +85C
Unit
Below 100 mA
Relative humidity
Sensor
Below 20 mA (each)
Rated voltage
DC 12 V
Operating voltage
Current
consumption
Descriptions
Weight
Over 5 M
95%RH max
Unit
Sensor
Min. 100 at 50 5 cm
Min. 60 at 50 5 cm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2H
3) Alarm interval
Alarm interval and display changes according to the distance as below:
While reversing, if obstacles are within stage 1, the warning beep sounds with long intervals. If within stage 2, the
warning beep sounds with short intervals and if within stage 3, the warning beep sounds continuously.
Stage
L, C, R sensor
Interval (msec)
Remark
65
65
1
81 ~ 120 cm
Beep
195
195
65
65
2
65
65
Beep
Beep
Beep
51 ~ 80 cm
25 ~ 50 cm
Beep
Troubleshooting of Sensor
When the power is applied (gear selector lever is in R position), the sensor will be diagnosed once. If found any failure
due to open circuit to sensor or communication error, warning buzzer sounds for 3 seconds and the data on failed
sensor transmits to the instrument panel to light up the corresponding LED. If normal, the warning buzzer sounds only
for 65 ms.
1) Whenever the power is applied, the diagnosis mode is initiated.
2) Sensor failure conditions (conditions for warning beep due to failure)
(a) Sensor failure conditions (conditions for warning beep due to failure)
(b) Open in sending circuit
(c) Open in receiving circuit
(d) Open in power circuit (+, -)
Back sonar (RH)
* Warning beeps
300ms
300ms
When failed
65ms
65ms
When normal
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2H
* Note that the display does not show everything in the rear area.
Always check nobody, especially animals and children, is behind the vehicle.
* Normal precautions when reversing should be maintained.
1. The parking aid system is just a supplemental device to help your parking operation.
2. Always keep the safety precautions.
3. Do not press or shock the sensors by hitting or high-pressure water gun while washing, or the sensors will be
damaged.
4. If the system is in normal operating conditions, a short beep sounds when the gear selector lever is moved into R
position with the ignition key ON.
5. If the system is in abnormal operating conditions, a beep sounds for 3 seconds when the gear selector lever is
moved into R position with the ignition key ON or engine running. However, it is also occurred when the obstacle
is within 50 cm from the rear bumper.
The parking aid system will not work or improperly work under following cases:
1) Certain obstacles that sensors can not detect
- Wires, ropes, chains.
- Cotton, sponge, clothes, snow that absorb ultrasonic waves.
- Obstacles lower than the bumper.
2) Not defective but improperly working
- When the sensing portion is frozen.
- When the sensing portion is covered by rain, water drops, snow or mud.
- When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles).
- When a high-power radio is turned on.
3) Narrowed sensing area
- When the sensing portion is partially covered by snow or mud.
- Surrounding temperature of sensor is too high (approx. over 80C) or too low (approx. below -30C)
4) Not defective but may occur improper working
- When driving on the rough roads, gravel road, hill and grass.
- When the bumper height is changed due to the heavy load.
- When the sensing portion is frozen.
- When the sensing portion is covered by rain, water drops, snow or mud.
- When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles).
- When a high-power radio is turned on.
- When some accessories are attached in detecting ranges
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2H
5) Circuit Diagram
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2H
2. Remove the sensor cover and sensor while pushing and turning the sensor cover.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2H
11
PAS unit
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
2H
REARVIEW CAMERA
This is a supplementary parking aid system to display the rearview when the gear selector lever is moved into R
position.
R position
Rearview camera
Power supply
in R position
Front monitor
Rear monitor
The audio and video mode in rear A/V system are not changed when selecting R position while A/V system is in use.
[Notice]
The real distance is different from what you see in monitor because the camera uses wide-angle lens.
Note that the display does not show everything in the rear area.
Keep the camera lens clean with a lens cleaner.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2H
13
General
When selecting R position while A/V system is in use:
The video mode in front A/V system is changed to rearview monitoring mode. However, the audio mode stays on.
The video mode in front A/V system resumes when shifting out from R position.
The audio and video mode in rear A/V system are not changed.
When selecting R position while A/V system is not in use:
Both monitors are automatically turned on to display rearview.
Both monitors are automatically turned off when shifting out from R position.
Auto mode
* Automatic operating mode
When selecting R position while A/V system is not in use (Ignition switch ON, engine running):
Both monitors are automatically turned on to display rearview.
Both monitors are automatically turned off when shifting out from R position.
When selecting R position while A/V system is in use (Ignition switch ON, engine running):
The video mode in front A/V system is changed to rearview monitoring mode. However, the audio mode stays on.
The video mode in front A/V system resumes when shifting out from R position.
The audio and video mode in rear A/V system are not changed.
[Notice]
The real distance is different from what you see in monitor because the camera uses wide-angle lens.
Note that the display does not show everything in the rear area.
Keep the camera lens clean with a lens cleaner.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
2H
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2I
EXTERIOR LAMPS
1. LOCATIONS OF EXTERIOR LAMPS
Front Lamps
Headlamp
Tail lamp:
one at each side (12V - 5W)
Low beam:
one at each side (12V - 55W)
High beam:
one at each side (12V - 55W)
Tail lamp
Connector
3
4
Headlamp
(High beam)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Headlamp
(Low beam)
LAMP
STAVIC - 2004.09
2I
Rear Lamps
High mounted stop lamp
: center 1 (12V 5W)
Rear lamp
Stop lamp
Tail lamp
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2I
- spare tire and OVM tools loaded (unlade all other loads)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
No.1 adjustment:
No.2 adjustment:
No.3 adjustment:
No.4 adjustment:
Direction A - Up
Direction C - Left
Direction E - Up
Direction G - Left
Direction B - Down
Direction D - Right
Direction F - Down
Direction H - Right
LAMP
STAVIC - 2004.09
2I
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2I
2. Run the engine with approx. 2,000 rpm and turn on the
headlamp. At this moment, the focus of the headlamp
should aim the A point.
(Unit: mm)
Allowable focusing
area
Allowable focusing
area
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
1. Down
Knob
Fog lamp
1 - Clockwise
Down
Knob
2 - Counterclockwise
Fog lamp
Up
Knob
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2I
Connector
Bulb
Lamp cover
Lamp cover
1. Headlamp assembly
Bulb
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
1) Headlamp Assembly
Preceding work: Disconnection of negative battery cable
The headlamp assembly consists of position lamp, headlamp low beam, headlamp high beam, and front turn signal lamp.
1. Remove two bolts on the lamp housing.
2. Remove one bolt in engine compartment, disconnect two connectors, and remove the lamp assembly.
[Notice]
If the cover rubber ring is worn, replace it with new one.
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2I
Remove
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
11
2. Remove the tail lamp/turn signal lamp bulbs from the headlamp assembly and install new bulb with same
specifications.
Tail lamp bulb assembly
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
2I
Lamp
Bulb connector
Mounting screws
Bulb
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
13
Bulb connector
Lamp assembly
Bulb assembly
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
2I
Adhesive area
Adhesive area
Adhesive area
Lamp
Mounting screw
Mounting screw
Lamp cover
2. Unscrew the screws from the high mounted stop lamp, disconnect the lamp connector, and remove the lamp assembly.
Tailgate spoilera
Rearview camera
High mounted stop lamp bulb
Rearview camera cover
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
15
Bulb connector
Bulb
Lamp
License plate
lamp assembly
Fog lamp /
Back-up lamp
3. Remove the tail lamp (back-up lamp) assembly and pull out the bulb from the removed tail lamp assembly.
Bulb connector
Bulb connector
Tail lamp
(back-up lamp)
/ Fog lamp
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
2I
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
17
3. Remove the bulb connector by rotating it counterclockwise from the removed tailgate lamp assembly. Pull out the
bulb from the bulb connector and install the new bulb with same specifications.
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
2I
INTERIOR LAMPS
1. LOCATIONS OF INTERIOR LAMPS
1. Front room lamp
: one at both sides (12V 5W)
Front room lamp switch
(coupled operation with door)
The front room lamps (1, 2) are turned on when pushing the lamp
body regardless of the positions of front room lamp coupled switch.
Press the lamp body again to turn off.
Front room lamps (drivers and passengers) are turned on when
opening one of front doors with this switch (A) pressed in.
Rear room lamps are turned on and off when the switch (1) is
pressed in and out.
Four rear room lamps are turned on when opening a rear door
with this switch pressed in. The rear room lamps are turned off
when closing the door.
LAMP
STAVIC - 2004.09
2I
19
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
2I
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
21
4. Interior room lamp assembly 5. Front room lamp assembly 6. Center console lamp assembly
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
2I
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
23
Bulb
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
2I
2. Disconnect the lamp connector (1), unscrew the screws from the removed room lamp assembly, and remove the
lamp.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
25
4. Remove the bulb from the removed front room lamp. Install in the reverse order of removal.
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
2I
Remove the lamp cover (1) and pull out the bulb (2).
[Notice]
1. Be careful not to damage the lamp cover when removing it.
2. Replace the bulb with new one with same specifications.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
3A
FATC
Manual air
conditioner
It changes sun load coming through front
windshield into current to input to FATC
controller.
Blower high
speed relay
Mode door
actuator
Air conditioner
wiring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Thermo AMP
Power transistor
3A
Receiver drier
Condenser right
Condenser
Detects A/C AUTO switch position, coolant temperature, engine condition and driving condition to control the air conditioner.
Sub-condenser
right wheel front
Blower motor
Power transistor
Rear
Air mix door
actuator
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
3A
2. VENTILATION SYSTEM
1) Locations of Vents
Front Ventilation
Rear ventilation
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
3A
2) Ventilation Modes
* Vent mode
* Bi-level mode
* Floor mode
* Defrost mode
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
3A
Mode motor
Air source
selection motor
High speed relay
Blower motor
(FATC, manual)
Interior temperature
sensor (interior
humidity sensor)
C211B A/C wiring
Air mix
motor
A/C control
panel (FATC)
A/C control
panel (manual)
Thermo amp
(FATC, manual)
Components
Air conditioner filter
Evaporator
Blower
motor
Blower high
speed relay
Heater core
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
3A
C305 A/C
wiring
(RR)
Components
Roof air conditioner duct
Blower motor
Air mixer door actuator
Evaporator
Mixer door
Heater core
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
3A
- When pressing this switch, the outside temperature measured by ambient temperature
sensor comes on for 5 seconds and then
returns back to preset temperature.
Fan control switch in rear seats: can control the rear fan speed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
3A
A/C switch: When pressing this switch, the air conditioner operates in manual mode and A/C ON indicator comes
on.
AQS system
- Air Quality System (AQS) changes the air source selection to
recirculation mode when polluted air is detected through AQS
sensor. The air source selection returns back to fresh air intake
mode after a specified period or the polluted air is disappeared
(refer to AQS and ambient temperature sensor).
Defroster switch
MODE switch
- By depressing this switch, the airflow mode is changed.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
3A
Fan switch
18
32
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
3A
11
Defroster switch
A/C switch
Operates air conditioner by turning on blower motor and compressor.
Mode switch
Vent mode
The air flows towards face and
the indicator comes on.
Floor mode
The air flows towards floor and
the indicator comes on.
Bi-level mode
The air flows towards face and
floor and the indicator comes on.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
3A
Malfunction
Remark
Code
Malfunction
Remark
Normal
25
Defective AQS
25
10
11
12
13
14
15
Self Diagnosis
1. Set the temperature to 26C with the temperature control switch (AUTO), and press the OFF switch 3 times within
3 seconds after temperature setting while the AUTO switch is pressed.
AUTO switch
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
3A
13
2. At this moment, the air conditioner controller performs the self diagnosis procedures.
3. The Micro computer integrated in controller displays the defect codes in turns on the VFD after performing self
diagnosis. Below figure shows the defect code caused by disconnecting the interior temperature sensor/humidity
temperature sensor connector.
Defect code ON
Defect code ON
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Current setting
temperature blinks
- If the setting temperature starts to blink, the self diagnosis starts to check the conditions of defective sensor.
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6. SYSTEM DIAGRAM
User
Control
Setting
temperature
Power
transistor
Blower high
speed relay
Ambient
temperature
Duct
temperature
Environments
Interior
temperature
Sun loads
Air
conditioner
controller
AQS sensor
Vehicle
information
Temperature control
Mode motor
Air source
selection motor
Vehicle
speed
Wiper
operation
Engine ECM
Compressor control
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2) Front blower, motor (mode/air source selection), inside air/humidity, outside air/AQS sensor
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Inspection
If the active incar sensor defect code (DTC 1) and the humidity sensor defect code (DTC 10) are set, check as below:
[Humidity sensor]
1. Apply 5 V to terminal No. 1 and 3 on the humidity
sensor connector.
2. Connect the positive (+) probe of a tester on No. 2
terminal and the negative (-) probe on No. 3 terminal,
and measure the output voltage while the voltage is
applied.
(output voltage: approx. 0.8 ~ 3.4 V)
3. Check whether the output voltage is changed when
blowing into the inlet of the sensor. If there is a voltage
change, the sensor is in normal condition. However,
if the voltage is not changed, replace the humidity
sensor.
4. In addition, if the output voltage is extremely high or
low even in the specified range, replace the humidity
sensor.
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AQS sensor
Connector
Manual Mode
To change the AQS mode to Manual mode from AUTO mode, use
the MODE switch or the fan speed control dial. In Manual mode, the
AUTO symbol on the display is disappeared. When pressing the
AQS and air source selection switch, the mode is changed in order
of AQS LED ON, AQS LED OFF (fresh air), and air source LED ON
(recirculation).
The figure shows that the mode has been changed to the recirculation mode from fresh air mode under AQS mode (AQS LED ON)
after detecting the polluted outside air.
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2) AQS Operation
The AQS operates under air conditioner AUTO mode or when the AQS switch is pressed under manual mode. It requires
preheating time (for seconds) for operation and the module and sensor are integrated.
(However, it operates only when the DEF (defroster) switch on the air conditioner switch panel is not pressed in.)
1. Self diagnosis and preheating process during initial operation of A/C controller (AUTO mode)
1. When the air conditioner controller is operated in AUTO
mode during its initial operation, the air source is changed
to the recirculation mode and AQS LED comes on.
(This is the self diagnosis and preheating process for
AQS.)
2. After completing the above process, the AQS LED is
turned off and the air source is automatically changed to
the fresh air mode.
[Note]
If the AQS switch is pressed in, the AQS function works
regardless of air conditioner controller operation.
2. AQS operation (AQS switch is pressed in): detecting the polluted outside air
1. When pressing the AQS switch, the LED on the AQS
switch is turned on and the AQS function is activated.
2. When the polluted outside air is detected, the AQS
operates and converts the air source to recirculation mode
automatically. At this moment, the recirculation mode
indicator comes on in the display.
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5. IGN2
4. Ground
[AQS sensor]
1. Measure the voltage value of AQS.
(between connector terminal No. 3 and 4.)
2. If the measured voltage is out of 0.1 to 4.8 V, replace
the AQS.
3. If the measured voltage is out of the specified range,
replace the AQS. If it is within the specified range,
check as below.
4. Turn the ignition key to ON position.
5. Measure the voltage between terminal B9 and B15
on the air conditioner controller.
6. If the voltage value cannot be measured, check the
circuit for open. If the measured value is within the
specified range, replace the FATC controller.
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2. Disconnect the AQS sensor connector, unscrew two bolts (10 mm) and remove the AQS sensor assembly.
(Install in the reverse order of removal.)
AQS sensor
Ambient temperature
sensor
Connector
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Inspection
If the duct temperature sensor defect code (DTC 3) is set, check as below.
1. Remove the duct temperature sensor and measure the resistance between terminals on the sensor connector.
(standard: approx. 25C, 2.2 k)
In addition, if the resistance is extremely high or, replace the sensor.
2. If the measured value is out of the specified range, replace the duct temperature sensor. If the measured value is
within the specified range, check as below.
3. Turn the ignition switch to ON position and measure the voltage to duct temperature sensor from the FATC controller
connector.
(standard: approx. 2 V at 25C)
4. If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified
range, replace the FATC controller.
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2) Power Transistor
The power transistor controls the fan speed. It controls the blower motor operating speed without stages by changing
the current value to the base of power transistor when receiving the fan control signal from FATC.
Inspection
If the power transistor defect code (DTC 6) is appeared, check as below.
1. Turn the ignition switch to ON position.
2. Measure the voltage between terminals while changing the fan speed from stage 1 to stage 6.
3. The specified voltage value in each stage:
Stage
Stage 1
Stage 2
Stage 3
Stage 4
Stage 5
Stage 6
Blower (V)
4.5
6.0
7.5
9.0
11
Max. HI
4. If the voltage is out of specified value, check the circuit for open. If the circuit is in normal condition, replace the
power transistor.
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Inspection
Terminal arrangement
Circuit diagram
If the intake door mode on FATC is different from the actual intake door mode, check as below.
1. Turn the ignition switch to ON position.
2. Measure the voltage between each terminal (P1 through P5)and positive (+) terminal in respective mode.
(If the voltage is changed from 0 V to 12 V after selecting the mode, it is normal.)
3. If the voltage value is out of the specified value, check the related circuits for open.
4. If the circuits are in normal condition, replace the FATC.
5. If the voltage is within the specified value, replace the mode door actuator assembly.
6. Connect the positive (+) and negative (-) cables of temporary power supply to the door mode actuator. And, connect
the negative cable to each terminal (P1 through P5) to check its operation.
(If it operates as shown in above figure, it is normal.)
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Inspection
Circuit diagram
Terminal arrangement
If the intake door mode on FATC is different from the actual intake door mode, check as below.
1. Turn the ignition switch to ON position.
2. Measure the voltage between terminal P1 and P2 (approx. 12 V) and terminal a and b (approx. 5V).
3. If the voltage value is out of the specified value, check the related circuits for open.
4. If the circuits are in normal condition, replace the air door actuator assembly.
5. If the voltage is within the specified value, replace the mode door actuator assembly.
6. Connect the positive (+) and negative (-) cables of temporary power supply to the air door actuator. And, connect
the cable to each terminal (P1 and P2) in turn to check the motor operation and terminal output.
Air source
Mode
Bc resistance
Fresh air
P1 (-), P2 (+)
below 300
Recirculation
P1 (+), P2 (-)
over 2.4 k
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Inspection
Circuit diagram
Terminal arrangement
Mode
Bc resistance
Cool
P1 (-), P2 (+)
below 300
Hot
P1 (+), P2 (-)
over 2.4 k
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6) Thermo AMP
The thermo AMP outputs the compressor ON or OFF signal to ECU to prevent evaporator from freezing. The sensing part
of the thermistor is the evaporator fin contact type.
3A
37
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39
Thermo AMP
The thermo AMP is installed on the
heater core inside of air conditioner
module.
Make sure that the parts (2) of air door actuator is securely
seated when installing it.
Power transistor
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Tightening torque: 10 ~ 15 Nm
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, unscrew the mounting screws and remove the heater unit assembly.
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2. Remove the rear air conditioner module assembly with the sequence as below:
1) Remove the heater hose/pipe
5) Unscrew the lower mounting screw and remove the rear air conditioner module assembly.
Tightening torque: 10 ~ 15 Nm
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4. Install in the reverse order of removal. Make sure that no air leaks on the connections of heater and cooler duct.
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3. Disconnect the receiver drier connector
assembly.
49
and remove the condenser mounting bolts. Remove the condenser
Detailed of A
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5. Unscrew the lower mounting bolt and remove the receiver drier. The O-rings on the pipes should be replaced with
new ones. (Tightening torque: 20 ~ 30 Nm)
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5) Compressor Assembly
Preceding works: 1. Disconnection of negative battery cable and removal of fan belt
2. Collection of air conditioner refrigerant (dispose the wasted refrigerant to designated place)
1. Remove the two air conditioner pipe flange bolts
(At this moment, the sealing washer on the pipe flange bolt should be removed. And, it should be replaced with new
one during installation)
B. Connector
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6) Sub condenser
Preceding works: 1. Disconnection of negative battery cable and removal of fan belt
2. Collection of air conditioner refrigerant (dispose the wasted refrigerant to designated place)
1. Remove the wheel cover, disconnect the sub condenser connector
2. Unscrew four mounting bolts
Install in the reverse order of removal. Tightening torque of A/C pipe mounting bolt: 10 ~ 15 Nm
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Sub condenser
Fan cover bracket
Fan
Protective mesh
Fan motor
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Diagnostic connector
FFH assembly
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3. SYSTEM LAYOUT
FFH Overview
1. FFH assembly
2. Water pump & bracket
A. FFH assembly
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1. Jacket
2. Jacket cover
4. Combustion chamber
22. O-ring
6. Heat exchanger
7. Controller
28. O-ring
exchanger)
17. O-ring
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4. FFH SPECIFICATION
Heater
D 5 S-H
Heating medium
Coolant
in operation
5000 W
2300 W
0.63
0.28
35 W
11 W
at start
100 W
after-running
12 W
12 V
Rated voltage
Operating range
Lower voltage limit: An undervoltage protection
device in the controller switches the heaters off at
approx. 10 volt.
Upper voltage limit: An overvoltage protection device
in the controller switches the heaters off at approx.
15 volt.
15 V
up to 2.5 bar overpressure
300 L/H
In the main fuel tank
Fuel
Tolerable ambient temperature
10 V
operation
storage
Weight
(with controller, water pump and fuel pump)
-40C ~ 80C
-40C ~ 125C (2h for 125C)
approx. 2.7 kg
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Above graph shows the FFH control process while the FFH is operating.
The control element is coolant as shown in the graph.
The FFH is operated in HI mode (high output: approx. 5000 W) until the coolant temperature reaches at 80C and starts
to be operated in LO mode (low output: approx. 2300 W) from 81C.
When the coolant temperature reaches at approx. 85C, FFH stops its operation until the operating conditions will be
met again.
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Rear
Water pump
Engine
Fan
Heater module
Front
Heater
Blower fan
Heater module
Heating system
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Circuit Diagram
The FFH has various sensors in FFH unit, and the FFH unit is connected to the water pump, the fuel circulation pump
and the ambient temperature sensor (switch) that provides important signals for the initial and repeat operations.
For diagnosis, remove the FFH system connector and install the scan tool. Currently, the K-Line that is connected to
the diagnostic connector is not available.
FFH & PTC
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5. The fuel pump does not start when the glow plug is
defect or electrical lead to the dosing pump is
interrupted.
6. The fan motor speed is monitored continuously.
If the fan motor does not start up, is blocked or if the
speed falls below 40% of the nominal speed, the
heater is switched off in fault mode after 60 seconds.
7. It is possible to diagnose the system by connecting
the diagnostic device to controller. For details, refer
to the Diagnosis Procedures section.
[Emergency shutdown]
If an emergency shutdown -EMERGENCY OFF- is
necessary during operation, proceed as follows;
Pull the fuse (Ef6: 20A) out.
Disconnect the heater from the battery.
12 V
9 V ~ 15 V
16 W
800 l/h
-40C ~ 135C
0.28 kg
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Function Diagram
Control stage
small
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6. FFH ASSEMBLY
[Notice]
There is no need to disassemble the FFH unit for repair. This section is to show the internal components of the FFH unit.
Jacket cover
- The O-rings are installed between jacket cover and two
coolant hoses.
- The coolant hoses should be connected to right side.
1. Jacket
2. Jacket cover
3. Cable harness cover
Resistance (Ohm)
2. Mounting spring
Temperature (C)
Specified value
Temperature [C]
Resistance []
10
20
30
40
50
60
70
80
90
100
110
120
8.06
5.33
3.60
2.48
1.75
1.25
0.91
0.67
0.50
0.38
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Surface sensor
The surface sensor and cable harness make up one
component.
1. Surface sensor
2. Mounting spring
Resistance (Ohm)
Temperature (C)
Specified value
Temperature [C]
Resistance []
10
20
30
40
50
60
70
80
90
100
110
120
8.90
6.20
4.41
3.19
2.34
1.75
1.32
1.02
0.79
0.62
Controller
The surface heater and cable harness make up one
component.
3. Combustion chamber housing
4. Surface sensor assembly
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Glow plug
1. Glow plug
2. Combustion chamber with flame pipe
Flame sensor
1. Flame sensor
2. Graphite bush
3. Bush
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Resistance (Ohm)
Temperature (C)
Specified value
Temperature [C]
-50
Resistance []
803 1000 1022 1062 1097 1194 1309 1347 1385 1498 1573 1758 1941 2120 2297 2470
10
20
30
50
80
90
100
130
150
200
250
300
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400
18
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Combustion chamber
1. Combustion chamber
2. Heat exchanger
3. Jacket
4. O-ring
5. Seal - combustion chamber / heat exchanger
Heat exchanger
1. Jacket
2. Heat exchanger
3. Combustion chamber with flame tube
4. Seal - combustion chamber / heat exchanger
5. O-ring (for heat exchanger)
Heat exchanger
1. Heat exchanger
2. Jacket
3. Stopper
4. Groove (bottom of heat exchanger)
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Fuel Pump
4. Fuel pump
3. Fuel supply hose
Fuel Tank
10 1.0 Nm
FFH
[Notice]
Cap the fuel supply hose to prevent oil leakage
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3. Connector pin
4. Connector
2. Holder
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FFH Assembly
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10 1.0 Nm
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(10mm - 2EA)
1. FFH Mounting
bolt (10mm - 6EA)
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Picture B
Picture A
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8. TROUBLE DIAGNOSIS
1. FFH Heater Trouble Diagnosis Precedure
When Faults Occur, First Check
Faulty wiring?
(short circuits, interruptions)
Visual check for
-
corroded contacts
defect fuses
damaged electrical leads, links and connections
damaged exhaust and combustion air guidance
Controller Lock
The controller is locked when the following faults occur:
Overheating
If FFH overheats 10 times in succession, error code 015 appears and the controller is locked.
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SCAN100 Diagnosis
1. Vehicle
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Trouble Description
Remedies
No faults
10
Check alternator
11
14
Difference in temperature values between surface sensor and control overheating sensor is too large. (Prerequisite for this trouble
code display is that the heater is in operation and the water temperature at the overheating sensor has reached min. 80C)
Check cooling system
Check the temperature sensor and overheating sensor, replace
if necessary
15
16
Difference evaluation 2
If the surface sensor has a far higher temperature value than the control overheating sensor, then the system proceeds with a fault shutdown.
17
20
21
22
25
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Trouble
Code
30
Trouble Description
Remedies
31
32
34
47
48
49
50
During start (no flame formed yet), the flame sensor reports
temperature value too high for too long
51
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Trouble
Code
52
29
Trouble Description
Safety time exceeded
Remedies
Check exhaust and combustion air system
Check fuel quantity and fuel supply
Clean or replace sieve used in fitting of fuel pump
53
54
56
Warning
In the case of flame aborted in power, large and small
stage and with still tolerable start attempts, the heater proceeds
with a new start or with subsequent start repeat. If the new
start or start repeat is successful, the trouble code display goes
off.
Fault(because no more start attempt allowed )
Check exhaust and combustion air system
Check fuel quantity and fuel supply
Check flame sensor - see trouble code 64 and 65
60
61
64
71
72
74
Replace controller
87
Replace controller
88
Replace controller
89
CAN error
90
Replace controller
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Trouble
Code
Trouble Description
Remedies
91
Replace controller
92
ROM error
Replace controller
93
RAM error
Replace controller
94
95
Replace controller
96
Replace controller
97
Resonator/quartz faulty,
wrong processor cycle
Replace controller
98
Replace controller
99
EEPROM error
Replace controller
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Low coolant
level
Abnormally
high coolant
temperature
Abnormally
loow coolant
temperature
Causes
Remedies
Coolant leakage
Add coolant
excessive anti-freezer
Defective themostat
Change thermostat
Defective radiator
Change radiator
Defective thermostat
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Engine ECU
PTC Assembly
PTC Relay
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2. PTC COMPONENTS
Radiator Element
Frame
Connector
Spring clip
PTC-Ceramic
Characteristics of PTC
P.T.C Heater
Heating type
Heating efficiency
Excellent
Element
Weight
approx. 500g
Durability
Excellent
Safety
Excellent
Advantages
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Circit Diagram
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GENERAL INFORMATION
OVERVIEW
2WD
4WD
7202700600
722 600 0
377900
722 600 0
Blank
DC Variant Number
Serial Number
Transmission Type
2. Bar Code:
A/T Serial #
A/T Variant
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STRUCTURE
1. Torque converter
7. Disc brake B3
13. Freewheel F2
2. Oil pump
8. Disc clutch C3
3. Input shaft
9. Disc brake B2
16. Freewheel F1
5. Disc clutch C1
6. Disc clutch C2
4. Disc brake B1
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4-LOW mode
Note
1. Based on DI Engine + A/T equipped vehicle
specifications
Gear ratio
1st gear: 3.595
2nd gear: 2.185
3rd gear: 1.405
4th gear: 1.000
5th gear: 0.831
4. FAST OFF
When abruptly releasing the accelerator pedal, the
transmission remains at 4th gear other than 4 4
shift (when slowly releasing the accelerator pedal, the
transmission is shifted to 5th gear).
5. Dynamic shift range
When operating the accelerator pedal, the 4 3 shift
is completed by kick-down signal after completion of
4 4 shift.
When promptly operating the accelerator pedal, the 4
3 shift is done in shaded arae.
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SPECIFICATIONS
Item
W5A330 (300)
W5A580 (400)
330 Nm
580 Nm
78 kg
78 kg
270 mm
270 mm
Yes
Yes
1st
3.951
3.595
2nd
2.423
2.186
3rd
1.486
1.405
4th
1.000
1.000
5th
0.833
0.831
3.147/1.93
3.167/1.926
Input torque
Weight (including ATF)
Diameter (Torque converter)
Lockup function
Gear ratios
2WD (4WD)
Fuchs ATF 3353
Fluid specification
approx. 8
P.R.N.D
D+/D-
Mechanical
Electrical
P.R.N.D
Lever position
4, 3, 2, 1
CAN
Resistance: R, D
0.5 ~ 2.5 k
Resistance: P, N
20 k
TCU
EGS 52
3.8 0.2
Resistance
(25C)
Operating distance
0.2 mm
Operating current
1.5 ~ 2 A
5.0 0.2
Resistance
(23C)
Operating distance
0.6 mm
Operating current
0~1A
Resistance
(25C)
Operating distance
Operating current
Operating range
RPM sensor
Resistance
Operating voltage
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2.5 0.2
0.2 mm
1.5 ~ 2.0 A
3rd to 5th gears
HALL type
6V
Switch contact
ON (D, R position )
Switch contact
4A
7
Item
W5A330 (300)
Mode switch
W5A580 (400)
W (Winter)
S (Standard)
One-way clutch
F1, F2
Friction plates
C1, B1, B3
C2, C3, B2
3, 4, 3
4, 4, 4
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AFFECTED VIN
4A
POWER FLOW
Sectional View
Shifting elements
Gear
C1
C2
C3
B1
B2
3)
3)
5
P/N
1)
P/N
2)
2)
F1
F2
z
z
3)
z
z
R 1)
B3
z
z
3)
3)
4A
Engine torque
9
Torque
converter
lockup
clutch
Flywheel
Torque
converter
Automatic
transmission
Multiple disc
clutch
Multiple disc
brake
Final drive
gear
Output
torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
4A
Input
Output
A. Engine speed
F. Mounting elements
P. Impeller
T. Turbine wheel
L. Stator
C1
C2
C3
B1
B2
3)
3)
B3
F1
F2
Lockup clutch
3) Overrun
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
11
Output
A. Engine speed
E. Mounting elements
P. Impeller
T. Turbine wheel
L. Stator
C1
C2
C3
z
3)
B1
B2
B3
F1
3) Overrun
F2
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
4A
Input
Output
D. Mounting elements
P. Impeller
A. Engine speed
T. Turbine wheel
L. Stator
C1
C2
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
C3
B1
B2
B3
F1
F2
4A
13
Output
T. Turbine wheel
L. Stator
A. Engine speed
P. Impeller
C1
C2
C3
B1
B2
B3
F1
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
F2
14
4A
Output
A. Engine speed
F. Mounting elements
P. Impeller
T. Turbine wheel
L. Stator
C1
C2
C3
B1
3)
B2
B3
F1
F2
3) Overrun
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
15
Input
Output
E. Mounting elements
A. Engine speed
F. Mounting elements
P. Impeller
T. Turbine wheel
L. Stator
C1
R (S)
C2
C3
B1
3)
B2
B3
F1
3) Overrun
DC 5-SPEED AUTOMATIC TRANSMISSION
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
F2
16
4A
Input
Output
A. Engine speed
E. Mounting elements
P. Impeller
T. Turbine wheel
L. Stator
C1
R (W)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
C2
C3
z
B1
B2
B3
F1
F2
4A
17
R: Reverse driving
Conversion between Standard and Winter switch changes the reverse gear ratio but must be operated before the
selector lever is moved. Pressing on the Winter switch allows to have effective driving when driving on the slippery road
surface and, also, possible to have smooth driving in reverse as it starts in 2nd gear.
1234D
-D+
1234D
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AFFECTED VIN
18
4A
TORQUE CONVERTER
Function (4WD)
Torque converter is installed between engine and automatic transmission. It consists of pump impeller, turbine and
stator. The pump impeller is welded at converter housing and the converter housing is bolted at the drive plate.
The torque converter converts the mechanical energy from engine to hydraulic energy, and the turbine connected to
transmission input shaft converts this hydraulic energy to mechanical energy again. The stator between pump and
turbine increases the output torque from turbine by converting the flowing direction.
The stator has a torque converter area that changes the flowing direction and a fluid coupling area where the stator
rotates. And, the lockup clutch integrated in torque converter prevents the power from losing and reduces fuel consumption.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
19
below 6.5 mm
* Torque converter
P/NO
2 EA
Engine
E23/E28/E32/D27DT
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AFFECTED VIN
20
4A
LOCKUP CLUTCH
1. Impeller wheel
2. Turbine wheel
11. Piston
3. Stator wheel
4. Stator shaft
B : Slipping
7. Converter cover
8. One-way clutch
9. Input shaft
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
21
Lockup clutch
Torque converter
output
Torque converter
input
Transmission
lubrication points
Oil sump
drain
Oil cooler
Working
pressure
Oil sump drain
Lubrication pressure
Shift valve
pressure
Lockup clutch regulating valve controls the lockup clutch in torque converter and distributes the lubricating oil to the
friction parts. TCU generates the lockup clutch control pressure by duty controlling the lockup solenoid valve, and this
pressure is applied to the lockup clutch regulating valve to engage, disengage and slip the lockup clutch. When the
lockup clutch control pressure is increased, the lockup clutch regulating valve moves up and the working pressure is
applied to lockup clutch. In its regulating position (slipping, torque converter lockup clutch pressurized), a reduced
volume of lubricating oil flows through the annular passage bypassing the torque converter and passing direct through
the oil cooler into the transmission. The rest of the lubricating oil is directed via the throttle a into the torque converter
in order to cool the torque converter lockup clutch.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
4A
Ring gear
Pinion gear
Sun gear
Output
Input
Locked
Relatively high
step-down ratio
Relatively low
step-down ratio
Locked
Input
Output
Output
4A
23
MULTIPLE-DISC CLUTCH
1. Input shaft
C2a. Piston C2
C3a. Piston C3
C1a. Piston C1
Location
Three multiple-disc clutches, the front, middle and rear multiple-disc clutches K1, K2 and K3, are located in the planetary gear sets in the transmission housing.
Funtion and description
A multiple-disc clutch consists of a number of internally toothed discs (10) on an internally toothed disc carrier and
externally toothed discs (9) on an externally toothed disc carrier.
If the piston (C1a) on multiple-disc clutch K1 is subjected to oil pressure, it presses the internal and external discs of the
disc set together. The sun gear (V1) is locked with the planet carrier (V3) via the externally toothed disc carrier (C1b) and
the internally toothed disc carrier (C1c). The front planetary gear set is thus locked and turns as a closed unit. If the
multiple-disc clutch C2 is actuated via the piston (C2a), the piston compresses the disc set. The ring gear (V4) of the
front planetary gear set is locked with the ring gear (M4) of the middle planetary gear set via the externally toothed disc
carrier (K2b) and the middle planet carrier (M3) on which the internally toothed discs are seated. Ring gear (V4) and ring
gear (M4) turn at the same speed as the input shaft (1). If the multiple-disc clutch C3 is actuated via the piston (C3a), the
piston compresses the disc set. The sun gear (M1) of the middle planetary gear set is locked with the sun gear (H1) of
the rear planetary gear set via the externally toothed disc carrier (C3b) and the internally toothed disc carrier (C3c). Sun
gear (M1) and sun gear (H1) turn at the same speed.
DC 5-SPEED AUTOMATIC TRANSMISSION
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
4A
FREEWHEEL
1. Outer race
A. Rotation direction A
2. Inner race
B. Rotation direction B
3. Locking elements
Location
Freewheels are installed in the front planetary gear set between the sun gear and the stator shaft, and in the rear
planetary gear set between the sun gear and the intermediate shaft.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
25
1. Cap
4. Leaf spring
CHANGED BY
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AFFECTED VIN
26
4A
1. Leaf spring
7. Solenoid valve
2. Contact spring
3. Conductor track
4. O-ring
8. Solenoid valve
5. O-ring
6. Shift plate
Function
The plastic Electric Hydraulic Control Unit (EHU) is installed on the top of valve body. RPM sensor, start lock-out switch
and oil temperature sensors are integrated in EHU.
The 13-pin connector is connected to automatic transmission via PCB.
Three up/downshift solenoid valves are installed on the top of hydraulic control unit.
The solenoid valves are sealed with two O-rings against the valve body. The solenoid valves are pressed against the valve
body by the leaf springs.
CHANGED BY
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AFFECTED VIN
4A
27
1.5 ~ 2.0 A
Operating distance
0.2 mm
Resistance
I (Current)
2.5A
1.5A
60mA
T (Time)
Circuit diagram
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
4A
Modulating Pressure (MP) and Shift Pressure (SP) Control Solenoid Valve
Solenoid valve
1. Leaf spring
2. Shift plate
3. Strainer
Function
These valves control the modulating pressure and the shift
pressure by applying appropriate electric current to solenoid valves according to driving condition of engine and
transmission.
Working Current
0 ~ 1.0 A
Operating distance
0.6 mm
Resistance
5 0.2 (25C)
When the electric current from TCU is high/low, the regulated pressure decreases/increases.
Regulated
pressure
Regulated pressure
Drain line
Drain line
CHANGED BY
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AFFECTED VIN
Line pressure
4A
29
Circuit diagram
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30
4A
1. Leaf spring
3. Shift plate
2. O-ring
Function
This valve activates and releases the lockup clutch by
adjusting the current to solenoid valve according to engine
throttle opening value and output shaft speed. The lockup
clutch operates in 3rd, 4th and 5th gear with steps to reduce shift shocks.
Working Current
1.5 ~ 2.0 A
Operating distance
0.2 mm
Resistance
Operating range
3, 4, 5 shift
Circuit diagram
Lockup S/V
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
31
Speed Sensor
Speed
sensor (n3)
1. Leaf spring
Speed
sensor (n2)
3. Pulse ring
2. Valve body
Function
The speed sensors are fixed to the shell of the hydraulic control unit via the contact tabs. A leaf spring, which rests
against the valve body, presses the speed sensors against the transmission housing. This ensures a precise distance
between speed sensors and impulse rings. speed sensor (n3) detects the speed of the front sun gear and speed sensor
(n2) detects the speed of the front planetary carrier. If the speed sensor is defective, the transmission is operated in
emergency driving mode. Below table shows the detection of speed sensor.
Gear
N2
N3
2
3
4
5
R (S mode)
R (W mode)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
32
4A
Circuit diagram
Speed
sensor
n3
CHANGED BY
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AFFECTED VIN
Speed
sensor
n2
4A
33
Function
The oil temperature sensor is installed in hydraulic control unit and is connected in series with the starter lock-out
contact.
This means that the temperature signal is transferred to TCU when the starter lock-out contact is closed.
The oil temperature has a considerable effect on the shifting time and therefore the shift quality. By measuring the oil
temperature, shift operations can be optimized in all temperature ranges.
Circuit diagram
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
34
4A
1. Plunger
3. Reed contact
2. Permanent magnet
Function
The starter lock-out contact is installed beside oil temperature sensor and is actuated by a cam rail, which is located on
the latching plate.
In the selector lever positions P and N, the permanent magnet is moved away from the reed contact. This opens the
reed contact and the transmission control module receives an electrical signal. The transmission control module activates the starter lock-out relay module. This closes the electrical circuit to the starter in selector lever positions P and
N via the starter lock-out relay module. In other words, when the selector lever is in driving positions, the contact is
closed and the starter cannot be operated.
Circuit diagram
Ignition switch 50
Start lock-out contact
AD converter
Starter
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
35
Kick-down Control
Function
When the throttle valve is partially opened, the shifting point gets faster. When the throttle valve is widely opened,
shifting point is delayed because the system needs low speed gear with bigger driving force.
Kick-down control is a system that enables to get bigger driving force as the down shift occurs by suddenly increasing
the throttle openings during constant driving. It has no separate kick-down switch where the down shift operates when
a certain point (about 1 second) lapses after opening of full throttle. The signal recognition allows to send control signal
to TCU from engine ECU via CAN communication.
Circuit diagram
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
36
4A
Mode Switch
Function
The mode switch is installed beside the selector lever and it has two modes of S mode (Standard
Mode) and W mode (Winter Mode).
- S mode is used in normal driving (starts off with 1st gear). TCU (Transmission Control Unit)
provides pleasant driving by changing the shifting pattern according to the driving habits
(downhill gripping: approx. 11 ~ 13.5 %)
- When W mode is selected, the Winter mode indicator in meter cluster comes on, and the
vehicle starts off with 2nd gear to achieve smooth starting on the icy or slippery road.
In winter mode, the up shift becomes faster and the down shift becomes slower for improving fuel consumption. The W
mode is automatically changed to S mode in full throttle or kick-down operation. The vehicle can starts off with 2nd
reverse gear (gear ratio: 1.92 ~ 1.93) when the W mode is selected. It is very useful on icy and slippery road. However,
in this case, the W switch should be selected before placing the selector lever to R position.
Even though W mode is selected, the vehicle starts off with 1st gear in following:
When the system recognizes the mode switch operation, the selector lever control unit sends the control signal TCU via
CAN communication.
1. When the selector lever is in 1 position.
2. When fully depressing the accelerator pedal or when starting off with kick-down condition.
Circuit diagram
Instrument panel
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
37
12
1. Selector lever
7. Locking lever
5. Mode switch
6. Locking disc
Function
Reverse (R) lock system is a safety system that prevents the selector lever from shifting to P or R position by
activating the solenoid valve when the selector lever unit determines that the vehicle speed exceeds 10 km/h by checking the speed signal from wheel speed sensor via CAN communication.
Parking (P) lock system uses the signals from brake switch other than conventional cable system to shift to other
positions. The wiring harness for detecting brake switch operation is connected to selector lever control unit.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
38
4A
Circuit diagram
Brake switch
1. Locking disc
2. Cam (P lock)
8. Locking lever
3. Cam (R lock)
4. Selector lever
5. Base body
6. Mode switch
CHANGED BY
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AFFECTED VIN
4A
39
2. Cam (P lock)
8. Locking lever
3. Cam (R lock)
4. Selector lever
5. Base body
6. Mode switch
1. Detent plate
2. Spring
5. Guide sleeve
3. Cone
CHANGED BY
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AFFECTED VIN
40
4A
Terminals
Pin No.
Use For
CAN HI
CAN LO
Self diagnosis
Tail lamp
10
Back-up lamp
Ground
CHANGED BY
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AFFECTED VIN
Remark
4A
41
Circuit diagram
Ignition switch
Ignition switch
Self diagnostic 10
Brake switch
Selector lever
control unit
Backup lamp
Instrument panel,
HECU, ECU
CHANGED BY
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AFFECTED VIN
42
4A
Selected gear
Shifted status
Coolant temperature
Automatic transmission
Downshift
Kick-down status
TCU
Driving conditions
Meshed gear
Odometer (I/P)
ATF Temperature
Circuit diagram
Self diagnostic 11
Instrument panel
CHANGED BY
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AFFECTED VIN
4A
43
TCU
TCCU
Function
TCU controls the gear groups according to the driving conditions. It receives the driving data from many sensors and
switches as input signals. It is also connected with ECU, HECU, instrument panel and selector lever control unit.
1. Shifting Method
Basic shift operation includes up-shift and down-shift for all gear groups. Shift control unit determines driving
resistance, accelerator pedal position, vehicle speed and some parameters (road surface condition, up hill and
down hill gradients, trailer driving conditions, catalytic converter conditions, driving habits and automatic transmission
oil temperature) to select a shift gear.
2. Down Shift
When engine speed increases excessively, the down shift does not occur.
3. Engine RPM Adjustment
During shifting, the engine torque is reduced to optimize the shift operation by delaying the ignition time.
4. Lock-Up Clutch Control
The lockup clutch in torque converter is activated in 3rd, 4th and 5th gear and operates in sequence via PWM
solenoid valve.
5. Others
The transmission is automatically controlled to compensate durability and wear.
The shift control values such as shifting point, shifting time, pressure during shifting, and lockup clutch control are
permanently saved and the diagnosis is partially available.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
44
4A
M/P S/V
36
S/P S/V
37
Engine
control
38
14
D 15
16
Engine torque
reduction
I 13
HECU
Sol.
valve
Sensor fround
33
Sensor
A
Posi. Identifi. signal WO
Start signal
Starter
relay
Selector
angle
N2 speed
12
N3 speed
35
T/M
I/P
Diagnosis
Diag.
Conn.
Mileage
29
Parttime
TOD
25, 27
30
CHANGED BY
AFFECTED VIN
IGN1
Power
ground
TCCU
EFFECTIVE DATE
4A
45
Electrical defect
If an electrical defective occurs in transmission during driving, current shift gear position is held.
A. Shut off of various solenoid valves
B. Internal pressure in transmission increases (shift shock gets bigger when changing selector lever due to
maximized MP and SP)
C. Lockup clutch is released
If the shift operation cannot be activated, the driver must reset the system as follows:
A. Stop the vehicle and place the selector lever to P position.
B. Wait for 10 seconds after stopping the engine (release hydraulic pressure)
C. Start the engine.
D. Place the selector lever to D or R position.
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AFFECTED VIN
46
4A
Connector A
Connector B
Connector A
Connector B
Pin No.
Description
Connected to
Diagnostic
Starter relay
12
RPM sensor N2
13
14
15
16
17
29
30
Ground
33
34
35
RPM sensor N3
36
37
38
CAN Low
CAN High
CHANGED BY
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AFFECTED VIN
4A
47
OTHER FUNCTIONS
OIL LEVEL CONTROL
Function
This is the function that closes the opening between oil chamber and planetary gear set chamber, so that the gear set
does not splash in oil if the oil level rises.
The lubricating oil flowing continuously out of the gear sets returns through the opening (2) into the oil chamber. If the oil
level rises, the oil forces the float (1) against the housing.
The float separates the oil chamber from the gear set chamber. The lubricating oil which escapes further from the gear
sets is thrown against the housing wall by the rotating parts and flows now through the upper opening (arrow) back into
the oil chamber.
Reduction of power losses and prevention of fluid loss from the transmission at high fluid level.
1. Float
A. Oil chamber
2. Opening
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
48
4A
Lock pin
Lock pin
Cap
Approx. 8
Fuchs ATF 3353 or Shell ATF 3353
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
49
1. Range lever
D. D range
2. Shift rod
P. P range
3. Selector lever
A. Disengage the shift rod from range lever and place the range lever at D position.
B. Place the selector lever at D position.
C. Insert the shift rod into range lever and tighten nut.
[Notice]
Lock the selector lever so that it will not move.
D. Check if the indication lamp in meter cluster indicates correct gear position while moving the selector lever to P,
R, N, and D position.
E. Check if the engine can be started at selector lever P or N position.
DC 5-SPEED AUTOMATIC TRANSMISSION
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
50
4A
CIRCUIT DIAGRAM
Starter, Selector Lever, CAN Communication
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
51
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
52
4A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
53
in MAIN
in VEHICLE
in CONTROL UNIT
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
54
4A
in FUNCTION
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
55
Procedure
1. Vehicle selection
CHANGED BY
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AFFECTED VIN
56
5. Select Yes
4A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
57
Defectives
Faulty TCU internal watchdog test
Action
- Self-diagnosis with IGN ON.
- Cycle the IGN switch from OFF to ON. Check and replace TCU if the
trouble still exists.
P2001
P2002
- Self-diagnosis.
- Cycle the IGN switch from OFF to ON. Check and replace TCU if the
trouble still exists.
- Cycle the IGN switch from OFF to ON. Check and replace TCU if the
trouble still exists.
P2003
P2004
- Self-diagnosis.
- Self-diagnosis.
- Cycle the IGN switch from OFF to ON. Check and replace TCU if the
trouble still exists.
- Cycle the IGN switch from OFF to ON. Check and replace TCU if the
trouble still exists.
P2005
P2006
P2007
P2008
P200A
P200B
P200C
P2010
- Self-diagnosis.
- Check harness contact.
- Self-diagnosis.
- Check harness contact.
- Self-diagnosis with IGN ON.
- When the TCU coding is not exist.
- Check again after TCU coding.
P2011
P2012
P2013
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AFFECTED VIN
58
4A
Trouble
Code
Defectives
Action
Defective 1-2, 4-5 shift solenoid valve - When 1-2 or 4-5 shift solenoid valve is defective.
P2100
- Measure the resistance of 1-2 or 4-5 shift solenoid valve (turn the IGN
OFF, then and disconnect TCU connector).
TCU connector terminals: B12, B3
Specified value: 3.8 0.2
- Triggered emergency mode when the defective is detected.
Fixed at 2nd gear in D range.
- Check the related harness for open, short and contact.
1-2, 4-5 shift solenoid valve - short
P2101
P2102
P2103
P2104
P2105
CHANGED BY
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AFFECTED VIN
4A
59
Trouble
Code
Defectives
Action
P2106
- Measure the resistance of lockup clutch solenoid valve (turn the IGN
OFF, then disconnect TCU connector).
TCU connector terminals: B9, B3
Specified value: 2.5 0.2
- Triggered emergency mode when the defective is detected.
Fixed at 2nd gear in D range.
- Check the related harness for open, short and contact.
P2107
P2108
- Measure the resistance of shift pressure solenoid valve (turn the IGN
OFF, then disconnect TCU connector).
TCU connector terminals: B4, B3
Specified value: 5.0 0.2
- Triggered emergency mode when the defective is detected.
Electrical error: Fixed at 2nd gear in D range.
- Check the related harness for open, short and contact.
P2200
- When the rpm sensor N2 detects 0 rpm of front sun gear speed.
- Check the related harness for open, short and contact.
TCU connector terminal B6: rectangular wave signal
B8: signal ground
B13: 6V
P2203
- When the rpm sensor N3 detects 0 rpm of planetary gear carrier speed.
- Check the related harness for open, short and contact.
TCU connector terminal B6: rectangular wave signal
B8: signal ground
B13: 6V
P220A
P2220
P2221
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
60
4A
Trouble
Code
P2222
Defectives
Action
Abnormal oil temperature sensor signal - Turn the IGN OFF, then disconnect TCU connector.
- Selector lever position: R or D
- Measure the resistance of oil temperature sensor.
TCU connector terminals: B7, B8
- Check the related harness for open, short and contact.
P2300
P2301
P2310
P2311
P2312
P2313
P2315
CAN: Faulty instrument panel commu- - Check CAN communication line H and L.
nication
- Check instrument cluster.
P2317
P2331
P2332
P2333
P2335
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
Trouble
Code
P2337
61
Defectives
Action
- Check CAN communication line H and L.
- Check TCCU/TOD unit.
- Check the related harness for open, short and contact.
P2400
P2401
P2402
P2403
P2404
P2405
P2406
P2407
P2408
CAN: No minimum engine torque signal - Check CAN communication line H and L.
- Check engine ECU.
- Check the related harness for open, short and contact.
P2409
CAN: No maxmum engine torque signal - Check CAN communication line H and L.
- Check engine ECU.
- Check the related harness for open, short and contact.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
62
Trouble
Code
P240A
4A
Defectives
CAN: No engine rpm signal
Action
- Check CAN communication line H and L.
- Check engine ECU.
- Check the related harness for open, short and contact.
P240B
P240C
P240D
P2500
- Cycle the IGN switch from OFF to ON. Check A/T system again after a
certain period of driving.
- If the trouble still exists, replace A/T assembly.
- To protect transmission, any shift is not available.
P2501
P2503
P220B
P2510
- Check the hydraulic lines for leaks (valve No.22 in valve body).
P2520
- Check ECU.
P2502
P2600
P2601
P2602
P2603
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
63
HYDRAULIC SYSTEM
STRUCTURE OF VALVE BODY
Torque converter
Oil pump
Input shaft
B1 C1 C2 B3 C3 B2
Output shaft
Lockup clutch
1. Shift housing
2. 1-2/4-5 command valve
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
64
4A
HYDRAULIC CIRCUIT
M/P S/V
S/P S/V
1-2/4-5 shift
S/V
3-4
shift
S/V
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
65
1. Selector valve
6. Command valve
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
66
4A
Oil Pressure
Modulating pressure
control solenoid valve
7. Oil pump
8. Drain
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
67
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
68
4A
Shift Groups
The hydraulic control range (including shift elements), which is responsible for the pressure distribution before, during
and after a gear change, is designated a shift group.
The hydraulic system consists of 3 shift groups.
A shift group can be in two phases.
Shift phase
Stationary phase
In the shift phase, a change takes place in one shift group of the engaged clutch/brake. The other two shift groups are
then in the stationary phase.
Shift group C1/B1 (gear change 1-2/4-5) is responsible for the up/down shifts 1-2/2-1 and 4-5/5-4.
It includes:
Clutch C1
Brake B1
Command valve
Holding pressure shift valve
1-2/4-5 shift solenoid valve
Pressure overlap control valve
1-2/4-5 shift solenoid valve
Shift group C2/C3 (gear change 2-3) is responsible for the up/down shifts 2-3/3-2.
It includes:
Clutch C2
Clutch C3
Command valve
Holding pressure shift valve
2-3 shift solenoid valve
Pressure overlap control valve
2-3 shift solenoid valve
Shift group C3/B2 (gear change 3-4) is responsible for the up/down shifts 3-4/4-3 and the engagement process.
It includes:
Clutch C3, 3-4 pressure overlap control valve
Brake B2, 3-4 shift solenoid valve
Brake B3
Command valve
Holding pressure shift valve
3-4 shift solenoid valve
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
75
valve B2
Rear Section
1. Dowel pin
4. Filter
5. Plastic valve
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
76
4A
Left Section
1.
2.
3.
4.
5.
6.
7.
Shift housing
1-2/4-5 command valve
1-2/4-5 holding pressure shift valve
1-2/4-5 shift pressure shift valve
1-2/4-5 overlap control valve
Shift pressure control valve
Regulating pressure control valve
8.
9.
10.
11.
12.
13.
Right Section
1. Valve housing
2. Selector valve
3. 2-3 overlap control valve
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
77
8 Nm
14 Nm
1. Bolts (29)
4. Shift housing
2. Valve housing
5. Leaf spring
3. Sealing plate
[Notice]
Check the valves for damage, and replace if necessary.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
78
4A
4WD
2WD
2WD
2. Plug connector
2. Drain plug
3. Oil line
3. Union bolt
4. Shield
4. Shield
5. Bolts
5. Plug connector
7. Union plugs
7. Transmission assembly
8. Drain plug
8. Shift rod
9. Oil line
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
79
Check point
Make sure that the oil cooler pipe hose is not twisted, oil cooler pipe (radiator side) is not clogged. If it is contaminated with foreign materials, thoroughly clean before replacing transmission assembly (This work is necessary
when removing and installing the radiator).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
80
4A
1. Remove the front and rear propeller shaft from the transfer
case.
Bolt
No
Tightening torque
M17
81 ~ 89 Nm
M14
70 ~ 80 Nm
Front
Rear
Oil draining
If necessary, drain the oil. However, when removing or installing the transmission without any other processes, just add oil
excluding drainage.
Installation Notice
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14 Nm
4A
81
2. Disconnect T/C motor connector, T/M plug connector, T/M shift lever, air bleeder hose and other attachments.
1. T/C motor connector (1) & plug connector (2).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
82
4A
3. Remove T/M oil return pipe (A), supply pipe (B), oil filler pipe (C) from T/M.
A. Oil return pipe
* Transmission Assembly
[Notice]
1. Collect the dropping oil from removed pipes in the oil collecter and seal the pipes with caps.
2. Be careful not to contaminate the body and work space.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
83
4. For easier removal, unscrew the stabilizer mounting bolts (B) and put it down to the sub frame.
5. Support the transmission with hydraulic jack.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
84
4A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
85
7. Unscrew the T/M insulator bracket bolts and remove the bracket.
8. Unscrew the transfer case mounting bolts (12 mm - 11 EA) and remove the T/C from the T/M.
Tightening torque
20 ~ 25 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
86
4A
9. Remove the torque converter hole cover and unscrew torque converter bolts one by one as rotating the engine crank
shaft clockwise. (14 mm - 6 EA)
20 ~ 25 Nm
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
87
10. Unscrew the mission housing bolts and drop the transmission slowly with hydraulic jack (17 mm - 8EA, Tightening
torque: 50 - 60 Nm)
[Notice]
Be careful not to drop the torque converter
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
88
4A
[Notice]
Place the selector lever at P position when removing
installing selector lever and wire cable.
A. Shift rod
: Remove the shift rod pin (1) and separate the shift
rod from selector lever
4A
89
C3 assembly
Input shaft
Output shaft
B1 C1 C2
B3 C3 B2
C2 assembly
Parking lock gear
F2 Intermediate shaft
Center planetary gear
F1
Stator shaft
B3 assembly
Lockup clutch
Valve body
Housing assembly
C1 assembly
B2 assembly
B1 assembly
Oil pump
Output flange
Adaptor plug
(transmission wiring connection)
Torque converter
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
90
4A
Friction Disc
Transmission
Friction Disc
C1
C2
C3
B1
B2
B3
Numbers
Single
Dual
Single
Single
Dual
Dual
face
face
face
face
face
face
Single
Dual
Single
Single
Dual
Dual
face
face
face
face
face
face
W5A300
Type
(G32D: 4WD)
W5A400
Numbers
(D27DT: 4WD)
Type
Remark
Tightening Torque
No.
Description
Tightening
Torque (Nm)
Remark
14
Heaxgon, 5 mm
12 ~ 14
7~8
30 ~ 38
Oil pan
T 30
20
36 ~ 44
20
42
10
Converter housing/engine
50 ~ 60
11
20
T 45
12
Valve body
T 30
13
T 30
14
Solenoid valve
15
200
12-Angle, each 30 mm
16
B2 housing bolt
16
T 45
17
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
91
5. Valve body
1. Guide bush
5-3. Pin
2. Drain plug
3. Bolts
5-5. Bolts
5-11. Screw
4. Oil filter
5-12. Screw
5. Valve body
5-13. Bolts
6. Oil pan
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
92
4A
Preceding work:
Install the transmission on the fixture stand.
[Note]
2. Unscrew the oil pan bolts and remove the oil pan (6).
Installation Notice
Tightening torque
8 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
93
8 Nm
5-2. Unscrew the bolts on solenoid valve and remove the leaf
springs.
Installation Notice
Tightening torque
8 Nm
[Notice]
The socket bolts do not have same length. Be careful not to
mix up.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
94
4A
[Notice]
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
95
Transmission housing
30 ~ 35 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
96
4A
200 Nm
6. Remove the snap ring with snap ring pliers and remove
the washer.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
97
20 Nm
[Note]
Slightly turn the transmission housing to left and right
direction to make the removal process easier.
[Notice]
Apply loctite to the bolts from T/C housing to T/M. (15EA)
No loctite to the bolts from T/M to T/C housing. (2EA)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
98
4A
Clutch C2
Clutch C1
Brake B1
Oil pump
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
99
16 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
100
4A
8 Nm
20 Nm
[Notice]
Install two bolts on the opposite side of oil pump housing
and tap the surface of oil pump with plastic hammer to
remove it from converter housing.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
101
5-2. Check the radial seal ring (3), and replace if necessary.
5-3. Replace the O-ring (4) with new one.
[Notice]
Lubricate the pump gears (1, 2) before installation.
Place the pump gear (2) into pump housing and install the
pump gear (1) onto the pump housing chamber.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
102
4A
Brake B2
Brake B3
Snap ring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
103
16 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
104
4A
8 Nm
[Notice]
Check the sealing ring for damage.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
105
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
106
4A
Clutch C1
Clutch C2
Clutch C3
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
107
Clutch C2
Clutch C3
24. Clutch C3
2. Piston
26. Piston
4. Return spring
5. Spring plate
6. Snap ring
16. Piston
8. Snap ring
9. Snap ring
Clutch C1
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
108
4A
Multi-disc brake B1
Multi-disc brake B2
Multi-disc brake B1
Multi-disc brake B2
1. Disc brake B1
8. Disc carrier B2
2. Piston
9. Sealing ring
3. Return spring
4. Snap ring
11. Piston in B2
18. O-ring
5. Cushion spring
7. Snap ring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
109
2. Needle bearing
13. O-ring
3. Teflon ring
4. Thrust washer
15. Freewheel
6. Shim
7. Snap ring
18. Shim
9. Thrust washer
10. Clutch C3
11. Rear hollow shaft
C. Oil outlet port in clutch C3
D. Oil inlet port in clutch C3
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
110
4A
49.90 mm
Distance b
49.00 mm
Difference
0.90 mm
Axial play E
0.40 mm
Shim size
0.50 mm
0.3 ~ 0.5 mm
[Notice]
Select a proper thickness of shim:
0.2, 0.3, 0.4, 0.5 mm
2. Install a shim.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
111
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
112
4A
(Figure 1)
6b
6c
6f
6h
69
70a
70b
70c
L
(2) Procedure
(Figure 2)
1. Soak new discs into ATF for one hour before installation.
2. Install the brake B1 discs with the order as shown in
(Figure 1).
3. Install the compressor (078) on external discs (70c) and
apply the 1200N of force to the disc pack. This force is
applied on the marking ring point (small arrow in figure
2). Do not apply excessive force.
4. Determine the clearance (L) at three points between
external disc (70c) and snap ring (6h) with feeler gauge.
The snap ring (6h) should be contacted to top of the
external disc carrier (6b) during installation.
5 adjust the clearance with proper snap rings if needed.
- 2 : 2.2 ~ 2.6 mm
- 3 : 2.4 ~ 2.8 mm
- 4 : 2.6 ~ 3.0 mm
- 2.3 ~ 2.7 mm
- 2.7 ~ 3.1 mm
- 3.0 ~ 3.4 mm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
113
(Figure 1)
14a
27
134a
134b
134c
134d
134e
144a
L
(2) Procedure
(Figure 2)
1. Soak new discs into ATF for one hour before installation.
2. Install the brake B2 discs with the order as shown in
(Figure 1).
3. Install the compressor (078) on external discs (134a) and
apply the 1200N of force to the disc pack. This force is
applied on the marking ring point (small arrow in figure
2). Do not apply excessive force.
4. Determine the clearance (L) at three points between
external disc (134a) and snap ring (144a) with feeler gauge.
The snap ring (144a) should be contacted to top of the
external disc carrier (14a) during installation.
5. adjust the clearance with proper snap rings if needed.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
114
4A
(Figure 1)
2
14a
133a
133b
133c
133d
133e
133f
L
(2) Procedure
(Figure 2)
1. Soak new discs into ATF for one hour before installation.
2. Install the brake B3 discs with the order as shown in
(Figure 1).
3. Determine the clearance (L) at three points between
external disc (133c) and snap ring (133a) with feeler gauge.
The snap ring (133a) should be contacted to top of the
external disc carrier (133c) during installation.
4. Adjust the clearance with proper snap rings if needed.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
115
(Figure 1)
83a
86
86b
89a
89b
89c
89d
90
L
(2) Procedure
1. Soak new discs into ATF for one hour before installation.
(Figure 2)
- 3 : 2.4 ~ 2.8 mm
- 4 : 2.6 ~ 3.0 mm
- 5 : 2.8 ~ 3.2 mm
- 6 : 2.9 ~ 3.3 mm
- 2.7 ~ 3.1 mm
- 3.0 ~ 3.4 mm
- 3.3 ~ 3.7 mm
- 3.6 ~ 4.0 mm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
116
4A
(Figure 1)
100a
101
105a
105b
105c
105d
106
107
L
(2) Procedure
(Figure 2)
1. Soak new discs into ATF for one hour before installation.
2. Install the brake C2 discs with the order as shown in
(Figure 1).
3. Install the compressor (078) on external discs (105c) and
apply the 1200N of force to the disc pack. This force is
applied on the marking ring point (small arrow in figure
2). Do not apply excessive force.
4. Determine the clearance (L) at three points between
external disc (105c) and snap ring (106) with feeler gauge.
The snap ring (106) should be contacted to top of the
external disc carrier (83a) during installation.
5. adjust the clearance with proper snap rings if needed.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
117
(Figure 1)
37
41a
41b
41c
44a
44c
44g
44h
L
(2) Procedure
(Figure 2)
1. Soak new discs into ATF for one hour before installation.
2. Install the brake C3 discs with the order as shown in
(Figure 1).
3. Install the compressor (078) on external discs (41a) and
apply the 1200N of force to the disc pack. This force is
applied on the marking ring point (small arrow in figure
2). Do not apply excessive force.
4. Determine the clearance (L) at three points between
external disc (41a) and snap ring (44g) with feeler gauge.
The snap ring (44g) should be contacted to top of the
external disc carrier (44a) during installation.
5. adjust the clearance with proper snap rings if needed.
- 3 : 2.3 ~ 2.7 mm
- 4 : 2.4 ~ 2.8 mm
- 5 : 2.5 ~ 2.9 mm
- 2.3 ~ 2.7 mm
- 2.4 ~ 2.8 mm
- 2.5 ~ 2.9 mm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
118
4A
[Notice]
Component
2.4 - 2.8 mm
2.7 - 3.1 mm
2.6 - 3.0 mm
3.0 - 3.4 mm
2.8 - 3.2 mm
3.3 - 3.7 mm
2.9 - 3.3 mm
3.6 - 4.0 mm
C1
C2
C3
B1
B2
B3
2.3 - 2.7 mm
2.4 - 2.8 mm
2.5 - 2.9 mm
2.7 - 3.1 mm
2.3 - 2.7 mm
2.3 - 2.7 mm
2.4 - 2.8 mm
2.4 - 2.8 mm
2.5 - 2.9 mm
2.5 - 2.9 mm
2.2 - 2.6 mm
2.3 - 2.7 mm
2.4 - 2.8 mm
2.7 - 3.1 mm
2.6 - 3.0 mm
3.0 - 3.4 mm
1.9 - 2.3 mm
2.0 - 2.5 mm
2.0 - 2.4 mm
1.0 - 1.4 mm
1.0 - 1.4 mm
1.0 - 1.4 mm
[Notice]
1) Approximately 1,200 Nm must be applied to keep the piston
down (B1, B2, C1, C2, C3)
2) 10 Nm is to be applied for B3
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
722.6
Shift member
119
Circlip thickness
in mm
C1
C2
C3
B1
B2
B3
Clearance spec.
in mm
# frictions/spec
2.6
140 994 87 40
2.9
140 994 88 40
3.2
140 994 89 40
3.5
140 994 29 35
3.8
140 994 30 35
2.3
140 994 92 40
2.6
140 994 93 40
2.9
140 994 94 40
3.2
140 994 32 35
3.5
140 994 33 35
2.0
140 994 99 40
2.3
140 994 10 35
2.6
140 994 11 35
2.9
140 994 35 35
3.2
140 994 36 35
2.6
140 994 87 40
2.9
140 994 88 40
3.2
140 994 89 40
3.5
140 994 29 35
3.8
140 994 30 35
2.9
140 994 63 35
3.2
140 994 62 35
3.5
140 994 61 35
3.8
140 994 60 35
4.1
140 994 59 35
3.2
140 994 15 35
3.5
140 994 16 35
3.8
140 994 17 35
4.1
140 994 41 35
4.4
140 994 42 35
4.7
140 994 43 35
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
120
4A
Application
Removal and installation of torque converter
Handle
W 116 589 06 59 00
Assembly stand
W 140 589 12 15 00
Arbor
W 001 589 50 33 00
Puller
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
121
Application
Fixing automatic transmission
Fixing plate
W 140 589 06 34 00
Collet chuck
W 140 589 13 43 00
Piston puller
W 126 589 02 09 00
Socket
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
122
4A
Name and Part Number
128 589 04 31 00
Measuring bridge
W 208 589 00 21 00
Application
Measuring the clearance between ball
bearing and parking lock gear
Compressor
W 140 589 15 21 00
Pipstick guage
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
123
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MEMO
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4B
GENERAL INFORMATION
1. OVERVIEW
4WD
2WD
1. TSM54/52 transmission is designed to link the gear ratio, installation dimensions and shapes with current T5
transmission and BTRA automatic transmission. It provides maximum drivability by the optimized engine torque
and gear ratio.
2. TSM54/52 transmission uses linkage type shift elements directly connected to the transmission. It prevent the
transmission from shifting to the reverse gear from 5th gear when shifting to reverse gear. It also prevents the break
and wear.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4B
Features
3. All gears use the helical type and high strength
materials.
[Notice]
The helical type gear provides less noise.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4B
2. SPECIFICATIONS
General Specifications
Description
DI ENGINE
Length
(mm)
(mm)
81
Input torque
(kgxm)
Semi-remote
1st gear
4.315
2nd gear
2.475
3rd gear
1.536
4th gear
1.000
5th gear
0.807
Reverse gear
3.591
Specification
Transmission fluid
Capacity
Change interval
( )
Tightening Torque
Description
Tightening Torque
4 ~ 5 kgfxm
39.22 ~ 49.03 Nm
3 ~ 4 kgfxm
29.42 ~ 39.22 Nm
41.18 ~ 55.89 Nm
16.67 ~ 25.48 Nm
7 ~ 10 kgfxm
68.6 ~ 98 Nm
3.92 ~ 5.88 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4B
3. SYSTEM COMPONENTS
Gear Combinations
1st gear
2nd gear
Input gear
Input shaft
Output shaft
5th gear
Counter shaft
3rd gear
4th gear
Transmission adaptor
Interlock plate
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4B
Sectional View
4WD
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4B
1. Transmission front housing
3. Front cover
6. Sealing
7. Pin
8. Input shaft
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4B
2WD
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10
4B
3. Front cover
6. Sealing
7. Pin
8. Input shaft
37. Bearing
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4B
11
Rear view
8. Interlock bolt
(tightening torque: 40 ~ 50 Nm)
9. Shift lever
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12
4B
Offset lever
5. Apply Loctite DRI LOC 200
10. Apply Loctite 5900
7. TGS bushing
9. TGS pin
4. Stopper plate
5. Air vent
(tightening torque: 30 ~ 40 Nm)
6. Lock washer
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4B
13
Power Flows
1st gear
Counter shaft
4th
gear
3rd
gear
2nd
gear
1st Reverse
gear
gear
5th
gear
4th
gear
3rd
gear
2nd
gear
1st Reverse
gear
gear
5th
gear
2nd gear
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14
4B
4th
gear
3rd
gear
2nd
gear
1st Reverse
gear
gear
5th
gear
4th gear
4th
gear
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AFFECTED VIN
3rd
gear
2nd
gear
1st Reverse
gear
gear
5th
gear
4B
15
4th
gear
3rd
gear
2nd
gear
1st Reverse
gear
gear
5th
gear
Reverse gear
Reverse
gear
4th
gear
3rd
gear
2nd
gear
1st Reverse
gear
idler
gear
5th
gear
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16
4B
4. SHIFTING MECHANISM
Interlock System
Interlock system prevents the gears from meshing over two sets.
Interlock bolt
Interlock plate
1/2
(3/4 & 5/R lock)
3/4
(1/2 & 5/R lock)
5/R
(1/2 & 3/4 lock)
Neutral
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5/R select
5/R shift
4B
17
1. Offset lever
3. Shift shaft
2. Shift lever
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18
4B
Detent pin
Adaptor - T/M
3 & 4 Rall
Set ball
Hub spline
Sleeve spline
Offset lever
Offset plate
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4B
19
Synchronizer
Composition
It consists of synchronizer hub, sleeve, ring, key and spring (1/2, 5/R, and 3/4 synchronizer are different from each
other).
- 3/4 and 5/R shift: Single cone type
- 1/2 shift: Double cone type - Improving the capacity to bigger engine torque of 1/2 shift (added synchronizer inner
cone and middle cone)
Single cone type
1/2 shift
1/2 shift
3/4 shift
3/4 shift
5/R shift
5/R shift
1. Synchronizer sleeve
2. Synchronizer hub
3. Synchronizer ring
4. Synchronizer key
[Notice]
Be careful not to mix up the 1/2 shift synchronizer sleeve with 3/4 or 5/R shift synchronizer sleeve.
The 3/4 synchronizer hub also different from 1/2 and 5/R synchronizer hub (different oil gallery).
TSM54/52 MANUAL TRANSMISSION
STAVIC - 2004.09
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20
4B
Synchronizer element
A cone or sleeve that slides to and fro on the transmission main shaft and makes the gears rotate at the same speed to
prevent clash when the gears are about to mesh. Whenever a vehicle is rolling, the transmission main shaft is turning
and the clutch gear is spinning. Even though the clutch is disengaged, the clutch gear continues to spin until friction
slows it down or stops it. Thus when the driver shifts into another gear he is trying to mesh gears that may be moving at
different speeds. By using synchronizers, the possibility of broken or damaged teeth is reduced and shifting effort is
lowered.
[1st step]
Sleeve
Synchronizer ring
Gear spline area
Projected area
Synchronizer key
Spline area of sleeve
Spline area of synchronizer ring
[2nd step]
Sleeve
Synchronizer ring
Gear spline area
Synchronizer key
Spline area of sleeve
[3rd step]
Sleeve
Synchronizer key
Spline area of sleeve
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4B
21
Bearing
The needle bearings are introduced to each gear and the taper roller bearings are used for input and counter shaft in
transmission housing.
Taper roller bearing
Needle bearing
[Notice]
Use the following spacers to adjust the end play (A or B) between input shaft and counter shaft.
(Specified range of end play: 0.05 ~ 0.1 mm)
For input shaft: 0.75 ~ 1.45 mm (15 spacers with increment of 50 m)
For output shaft: 0.4 ~ 1.45 mm (10 spacers with increment of 50 m)
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22
4B
Input shaft
Thrust ring 1
3/4
synchronizer
1/2
synchronizer
Output shaft
Thrust washer
Counter gear assembly
Head set
gear
3rd
gear
2nd
gear
1st
gear
Reverse
gear
5th
gear
Lubrication
Transmission oil: ATF DEXRON II or III
Initial installation for taper roller bearing and needle roller bearing, lubrication for shift rail: MoS2 Grease
Oil level
Installation Notice
Sealant on oil drain screw during installation: Loctite DRI LOC 200
Tightening torque: 40 ~ 50 Nm
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4B
23
2WD
4WD
[Notice]
Sealant on oil drain screw during installation: Loctite DRI LOC 200
Tightening torque: 40 ~ 50 Nm
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24
4B
Cause
Action
ing
shaft binding.
Damaged synchronizer.
Damaged gear(s).
necessary.
Transmission locked in
or damaged parts.
one gear
or rail.
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4B
25
Symptom
Transmission locked in
Cause
Worn or damaged synchronizer.
Action
Check worn or damaged synchronizer parts
and replace if necessary.
one gear
Worn or damaged gears.
Transmission noise
Tighten as specified.
Realign correctly.
shaft alignment.
Noisy transmission bearing.
Noisy gears.
Transmission leakage
Tighten as specified.
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26
4B
Diagnosis Table
Applicatio
1 Shift Hop-out
2 Shift Gear Crash
3 Shift Block-out
4 Hard Shift
5 Noise in Reverse Gear
6 Noise in 5th Gear
7 Noise in 4th Gear
8 Noise in 3rd Gear
9 Noise in 2nd Gear
10 Noise in 1st Gear
11 Noise in All Speeds
12 Leak at Transmission Rear Part
13 Leak at Transmission Center Part
14 Leak at Transmission Front
Possible Faulty Part
Transmission Case
Extension Housing
Shift Cover / Shift Shaft
Shift Control Lever
Input Bearing Retainer
Input Gear Set
3rd Speed Gear Set
2nd Speed Gear Set
Reverse Speed Gear Set
1st Speed Gear Set
5th Speed Gear Set
Clutch Housing and Release Derive
Crankshaft Pilot Bushing and Release Bearing
Input Bearing
Main Shaft Input Bearing
Main Shaft Thrust Bearing
3rd Speed Gear Bearing
2nd Speed Gear Bearing
1st Speed Gear Bearing
Reverse Idler Gear Bushing
Counter Shaft Front Bearing
Counter Shaft Rear Bearing
Counter Shaft Thrust Bearing
5th Speed Drive Gear Bearing
Slip Yoke Bushing
Slip Yoke Seal
Speedometer Drive / Driven Gears
Speedometer Driven Gear Housing
Input Shaft Seal
1 - 2 Synchronizer Assembly
3 - 4 Synchronizer Assembly
5th Synchronizer Assembly
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4B
27
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28
4B
ON-VEHICLE SERVICE
1. OIL CHECK/CHANGE
[Notice]
Do not check or change the oil Immediately after driving off.
It may cause serious hurt.
Place the vehicle on the flat and even ground and stop the
engine. After 5 minutes, check the oil level.
1. Remove the oil level plug (1) and check the oil level.
[Notice]
If the oil level is up to the bottom line of plug hole, it is OK.
2. If needed, add the oil through the oil level plug hole (1).
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4B
29
Transfer case
Mounting insulator
Propeller shaft - Front
T/M assembly
2WD
Propeller shaft - Rear
Mounting insulator
T/M assembly
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30
4B
Tightening torque
70 ~ 90 Nm
[Notice]
IIf the oil should be changed, remove the oil drain plug in
transmission housing and fully drain the oil. And, retighten
the plug.
Installation Notice
Tightening torque
40 ~ 50 Nm
3. Unscrew extension bar - sem remote mounting nut (1) and remove a pin (A) which connects the shifting lever and
extension rod.
Tightening torque
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AFFECTED VIN
70 ~ 90 Nm
4B
31
5. Disconnect the back up lamp switch connector and air bleeder hose from the T/M assembly.
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32
4B
6. Disconnect the clutch oil hose (Fix the hose with a tool to prevent oil leakage) at A marked position.
7. For easier work, unscrew three T/M housing bolts (1) and disconnect stabilizer bar from link (A) to have the
stabilizer bar down to sub frame.
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4B
33
8. Securely support the T/M with a hydraulic jack and then, remove center cross member.
50 ~ 60 Nm
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34
4B
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4B
35
T/M ASSEMBLY
1. ASSEMBLY OVERVIEW
Top Cover Assembly
7. Pin
2. Nut
8. Joint housing
14. Bolt
9. Offset lever
5. Snap ring
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36
4B
1. Front cover
10. Bolt
2. Spacer
3. T/M housing
4. Filler plug
29. Spacer
6. Drain plug
7. Adaptor
16. Bearing
8. Clutch cylinder
9. Pipe
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4B
37
Gear Assembly
6. Main shaft
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AFFECTED VIN
38
4B
2. DISASSEMBLY
Preceding work: 1. Drain the T/M oil.
2. Remove the T/M from vehicle.
1. Remove the T/M top cover assembly.
CHANGED BY
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AFFECTED VIN
4B
39
CHANGED BY
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AFFECTED VIN
40
4B
7. Pull the counter gear (5th gear) retainer ring out from the
ring groove with a ring pliers.
[Notice]
Be careful not to stiffen the retainer ring.
8. Spread the retainer ring and remove the counter 5th gear
with a puller.
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AFFECTED VIN
4B
41
10. Remove the 5th gear retainer ring with a ring pliers.
12. Remove the 5th gear and pull out the spring pin.
[Notice]
Be careful not to lose or mix the spring pins.
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AFFECTED VIN
42
4B
15. Remove 5/R gear retainer ring from the shaft with a ring
pliers.
[Notice]
Store the ring with the relevant gear to prevent incorrect
installation.
CHANGED BY
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AFFECTED VIN
4B
43
CHANGED BY
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AFFECTED VIN
44
4B
23. Remove the shift rail and shift fork. Place the output shaft
and counter gear on the special tool.
24. Place the output shaft assembly with the 1st gear facing
down and remove the intermediate taper roller bearing
with a special tool.
[Notice]
To prevent the bearing damage, securely seat the special
tool before removing the intermediate taper roller bearing
that is pressed in.
Do not use general bearing puller.
CHANGED BY
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AFFECTED VIN
4B
45
27. Loose the 1/2 gear and hub and double synchronizer
sleeve with a press.
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46
4B
30. Remove the inner race and 1st gear from 1st gear, and
remove the needle bearing from the shaft.
[Notice]
Store the disassembled gears by relevant components.
Synchronizer
under ring
Synchronizer
intermediate
cone
Synchronizer
outer ring
Synchronizer
outer ring
Synchronizer
intermediate
cone
Synchronizer
under ring
32. Remove the 1/2 gear synchronizer hub along with double
synchronizer sleeve.
CHANGED BY
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AFFECTED VIN
4B
47
CHANGED BY
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AFFECTED VIN
48
4B
CHANGED BY
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AFFECTED VIN
4B
49
CHANGED BY
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AFFECTED VIN
50
4B
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AFFECTED VIN
4B
51
4. REASSEMBLY
1. Install the 2nd gear needle bearing.
[Notice]
The 1st/2nd/3rd gear needle bearings have one bearing row
and the sizes of them are same. The reverse needle bearing
has two bearing rows. The 5th needle bearing is smaller than
others and consists of two bearings.
Groove
No step
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AFFECTED VIN
52
4B
CHANGED BY
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AFFECTED VIN
4B
53
11. Place the output shaft assembly with the 1st gear facing
downward and install the 3rd gear.
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54
4B
CHANGED BY
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AFFECTED VIN
4B
55
17. Install the input shaft along with the 4th synchronizer
ring. Place the input shaft to face downward on the work
bench.
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AFFECTED VIN
56
4B
19. Place the counter gear on the work bench with the same
manner.
CHANGED BY
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4B
57
CHANGED BY
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AFFECTED VIN
58
4B
CHANGED BY
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AFFECTED VIN
4B
59
CHANGED BY
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AFFECTED VIN
60
4B
34. Install the thrust washer (t= 5.0) while aligning the key
grooves.
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AFFECTED VIN
4B
38. Install the inner shift lever and interlock plate in the 3/4
gear shift rail.
61
Interlock plate
[Notice]
The spring pin for locking the inner shift lever is small (6 x
22) and its slot should face to the shaft.
39. Install the 3/4 hear shift rail in the transmission adaptor.
41. Install the 3/4 shift fork and shift rail while aligning the
grooves.
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AFFECTED VIN
62
4B
42. Install the 1/2 gear shift rail in the transmission adaptor.
43. Partially engage the 1/2 shift fork to the shift rail.
44. Install the shift lug on the 1/2 shift rail. Install the reverse
lock spring, reverse lock plate and reverse lock bolts.
[Notice]
Align the 1/2 gear shift lug and interlock plate mating surface.
45. Partially engage the 5/R gear shift fork to the shift rail.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4B
63
46. Install the 5/R shift lug and 5/R shift fork on the shift rail.
[Notice]
Align the 5/R shift lug and the interlock plate surface.
47. Install the spring pin into the 1/2 shift lug. (intermediate
size: t= 6 x 25)
[Notice]
Place the spring pin with the pin slot facing to the shaft.
48. Install the spring pin into the 5/R shift lug. (intermediate
size: t= 6 x 25)
[Notice]
Place the spring pin with the pin slot facing to the shaft.
49. Install the spring pin into the 1/2 shift fork. (longer size:
t= 6 x 28)
[Notice]
Place the spring pin with the pin slot facing to the shaft.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
64
4B
50. Install the spring pin into the 5/R shift fork. (longer size:
t= 6 x 28)
[Notice]
Place the spring pin with the pin slot facing to the shaft.
51. Install the reverse lock plate and reverse lock spring on
the 1/2 shift rail.
52. Install the stopper plate on the 3/4 shift rail and insert the
spring pin. (intermediate size: t= 6 x 25)
[Notice]
Place the spring pin with the pin slot facing to the shaft.
CHANGED BY
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AFFECTED VIN
4B
65
CHANGED BY
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AFFECTED VIN
66
4B
42 ~ 57 Nm
58. Insert the offset lever into the 3/4 rail and install the spring
pin. (intermediate size: t= 6 x 25)
59. Apply the grease into the offset lever bushing.
60. Apply the grease to the interlock bolt and insert it into
the interlock plate hole and bolt hole.
[Notice]
Make sure that the gear is at neutral position. If not, the
interlock bolt cannot be inserted into the interlock plate
hole.
Sealant
LOCTITE 243
Tightening torque
40 ~ 50 Nm
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AFFECTED VIN
4B
67
Transmission Adaptor
1. Remove the reverse idler retainer ring.
17 ~ 26 Nm
70 ~ 100 Nm
Tightening torque
30 ~ 40 Nm
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AFFECTED VIN
68
4B
INSPECTION/MAINTENANCE
SHIM ADJUSTMENT
1. Unscrew the bolts and remove the front fork cover.
[Notice]
The shim adjustment is necessary when replacing the
housings, counter gear, input shaft and output shaft.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4B
69
CHANGED BY
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AFFECTED VIN
70
4B
0 ~ 0.05 mm
10. Put the probe end of the gauge on the main taper roller
bearing outer race and measure the end play.
* If the measured value is out of the specified range,
adjust it by using spacers
End play
0 ~ 0.05 mm
11. Apply the sealant to the front fork cover and tighten the
bolts. Measure the starting torque after installation.
Starting torque
20 ~ 25 Nm
Sealant
LOCTITE 5900
Tightening torque
17 ~ 26 Nm
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AFFECTED VIN
4B
71
Application
Removal/installation of transmission
Transmission fixture
W 99 31 001 1B
Bearing puller
W 99 31 002 1B
Pressure pipe
W 99 31 003 1B
Insert key
CHANGED BY
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AFFECTED VIN
72
4B
W 99 31 005 2B
Holder
W 99 31 006 1B
Dial gauge holder
W 99 31 007 1B
Drift
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AFFECTED VIN
Application
Assembly of gears and bearings on
the shafts
4C
GENERAL INFORMATION
1. OVERVIEW
Driving Elements
Operating Elements
This system directly releases the clutch by using hydraulic pressure while the conventional clutch system releases
the clutch by using release lever and release fork.
Driven Elements
A. Adaptor
D. Clutch assembly
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
4C
Operation description
Diaphram spring rotates the adjusting equipment as clutch disc is wearing and so, pressure plate is pushed to clutch
disc side at the amount of wearness.
* Disc wear (Free play) Diaphram spring (1) Adjusting equipment (2, 3) Pressure plate (4)
Clutch assembly
Adjusting equipment
Clutch replacement
1) Replacement of cluch disc Replace the clutch cover assembly together.
2) Reinstallation of clutch disc & cover Apply the zig set (SST) on the clutch cover set.
(Engine removal and reinstallation, Flywheel related job, Checking the clutch assy)
[Notice]
When reinstall the clutch assembly without the special zig, Disc can be slip and worn easily.
Diaphram
Adjusting
equipment
Cover
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
2. COMPONENTS
7. Hose
8. Pipe
13. Switch
3. Clutch cover
14. Bracket
4. Clutch disk
5. Adaptor
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
4C
Operation
Clutch pedal
CHANGED BY
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AFFECTED VIN
Pusha rod
Clutch master
cylinder
Concentric
(piston) slave
cylinder
Clutch cover
Clutch disk
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
Clutch Pedal
Clutch pedal
Pendant type clutch pedal (leverage effect is applied to reduce the effort to the feet).
Clutch pedal has freeplay to prevent the clutch disk heated and damaged.
If this freeplay is too wide, engine power disconnection is difficult and arise the gear damage with abnormal noise.
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4C
Clutch Assembly
Clutch assembly is composed of clutch cover (diaphram spring, pressure plate), clutch disk.
[Notice]
Because self adjust clutch includes compensation function
to make up for the wearness of clutch disk, this clutch
assembly applied to the vehicle can be oprated with constant
force in the clutch pedal.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
1. Transmission housing
4. Bolt
5. Washer
6. Bolt
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
10
4C
Specifications
Description
Specification
Operating type
Hydraulic
Clutch pedal
Suspended
Type
Maximum pedal stroke
Type
Dimension of facing
Facing size/quantity
263 cm2/2
Thickness of disc
28.4 mm
Stroke
17.46 mm
Inner diameter
Concentric slave cylinder
7.0 mm
Stroke
706.2 mm2
Sectional area
DOT 4
Clutch fluid
Tightening Torque
Description
Tightening Torque
50 ~ 60 Nm
21 ~ 27 Nm
17 ~ 26 Nm
20 ~ 25 Nm
10 ~ 16 Nm
15 ~ 18 Nm
30 ~ 40 Nm
16 ~ 22 Nm
8 ~ 18 Nm
Stopper bolt
16 ~ 22 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
11
3. AIR BLEEDING
[Notice]
Keep the fluid level over MAX in reservoir during bleeding
operation.
Do not let the fluid contact a painted surface.
Specified oil
DOT 4
Capacity
Procedure
[Notice]
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AFFECTED VIN
12
4C
MAINTENANCE
1. REMOVAL AND INSTALLATION
Clutch Assembly
Preceding Work: Remove the transmission assembly.
1. Insert the centering pin (special tool) into center spline. Loosen the clutch cover bolts 1/2 turns in cross sequence
until the spring tension is released.
Tightening torque
[Notice]
1) Do not remove the bolts at a time, or clutch cover may be damaged or deformed.
2) If the clutch disk is to be reused, insert a mounting plate between the dia phram spring and cover plate when uninstall.
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
21 ~ 27 Nxm
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
13
3. Unscrew the concentric slave cylinder mounting bolts (3EA) and remove the concentric slave cylinder
assembly in the clutch housing.
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
4C
15 ~ 18 Nm
[Notice]
Be careful not to contact the fluid into a painted surface.
8 ~ 18 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
15
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
4C
Clutch Pedal
1. Remove the snap pin from master cylinder push rod and
remove the clevis pin from pedal.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
17
Installation notice
1. Install in the reverse order of removal. Adjust pedal stroke
after installation.
[Notice]
Description
Tightening Torque
Fulcrum bolt/nut
16 ~ 22 Nm
8 ~ 18 Nm
Stopper bolt
16 ~ 22 Nm
158 mm
192 5 mm
[Notice]
To adjust the pedal stroke, loosen the lock nut (C) of the
stopper bolt (D) and turn the stopper bolt until the stroke is
correct. After adjustment, tighten the lock nut.
5 ~ 10 mm
[Notice]
To adjust the pedal free play, loosen the lock nut (F) of the
master cylinder and turn the push rod until the free play is
correct.
4. Check the fulcrum bolt and the bushing for wear, the
pedal for bending and the spring for damage.
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
4C
2. INSPECTION
Concentric Slave Cylinder
Check any heat damage, abnormal noise, poor rotation
and wear of the concentric slave cylinder bearing.
0.8 mm
Clutch Disc
Check the facing for rivet looseness, sticks, oil and grease.
Measure the rivet head depth. If out of limit, replace the
disc.
Wear limit
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
0.3 mm
CLUTCH ASSEMBLY
STAVIC - 2004.09
18
4C
2. INSPECTION
Concentric Slave Cylinder
Check any heat damage, abnormal noise, poor rotation
and wear of the concentric slave cylinder bearing.
0.8 mm
Clutch Disc
Check the facing for rivet looseness, sticks, oil and grease.
Measure the rivet head depth. If out of limit, replace the
disc.
Wear limit
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
0.3 mm
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
19
0.7 mm
Pressure Plate
1) Check the pressure spring for wear.
[Notice]
The excessively worn components should be replaced.
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
4C
Application
Centering the clutch disc
Centering pin
Engine lock
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
21
TROUBLE DIAGNOSIS
1. DIAGNOSTIC INFORMATION AND PROCEDURES
Check
Action
Replace
Repair or replace
Replace
Replace
Adjust
Repair or replace
Replace
Replace
Repair or replace
Oily facing
Repair or replace
Replace
Adjust
Repair or replace
Repair as necessary
Replace
Oily facing
Repair or replace
Replace
Replace
Replace
Replace
Repair or replace
Tighten or replace
Lubricate or replace
Lubricate or replace
Repair
Adjust
Replace
After disengagement
Replace
When disengaging
Replace
Repair
Replace
Clutch slips
Poor disengagement
Possible Cause
[Notice]
Clutch cover and disk should be replaced altogether.
CLUTCH ASSEMBLY
STAVIC - 2004.09
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EFFECTIVE DATE
AFFECTED VIN
MEMO
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4D
GENERAL INFORMATION
1. LAYOUT
Sub frame
T/M
Front propeller shaft
Exaust pipe
TOD
STAVIC - 2004.09
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AFFECTED VIN
4D
2. GENERAL DESCRIPTION
TOD system means the full time 4WD system and the
registered trade mark of Borg Warner. TOD is an abbreviation of Torque On Demand.
TOD receives the speed signals from speed sensors installed in front axle and rear axle, the TPS signals from
engine, and the operating signals from ABS control unit
via CAN. Based on these data, TOD control unit controls
the electro-magnetic clutch to distribute the 3:97 ~ 44:56
of driving force to front wheels and rear wheels.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
Transfer Case
Planetary gear set
Planetary Gear set consists of sun gear, ring gear and carrier. It is engaged with the gear in HIGH-LOW collar to
increase the driving force by reducing vehicle speed.
Sun gear is connected to input shaft and ring gear is fixed into the transfer case.
Splined rear output shaft is able to slide on the HIGH - LOW collar.
The inside and outside ends of HIGH - LOW collar have machined gear. The input shaft transmits the power to driving
wheels by engaging with sun gear and carrier gear.
If the 4WD switch is at 4WD HIGH, the TOD control unit operates the shift motor to engage HIGH - LOW collar
directly with input shaft for transmitting the driving force to front and rear propeller shafts.
When a driver selects 4WD LOW, the TOD control unit controls the electro-magnetic clutch and operates the shift
motor to engage HIGH - LOW collar with carrier. The power from transmission is increased up to 2.48:1 by reduction
ratio from planetary gear, and then is sent to front and rear propeller shafts.
TOD
STAVIC - 2004.09
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EFFECTIVE DATE
AFFECTED VIN
4D
NO
YES
Decreases clutch engagement
Increases clutch engagement
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EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
Signal Flow
Instrument Panel
4WD Switch
TOD Control
Output
Unit
Input
Rear Speed
Manetic Clutch
Motor
Front Output
TOD
STAVIC - 2004.09
Front Speed
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EFFECTIVE DATE
AFFECTED VIN
4D
Power Flow
4H Mode (4WD Drive - High Speed)
Rear Axle
(Rear Wheel)
Transmission
Front Axle
(Front Wheel)
Front Speed
Sensor
Rear Speed
Sensor
Throttle Open
Rate
(TPS Value)
Transmission
Input Shaft
Magnetic Clutch
Output Shaft
Multi-Plate Clutch
Chain
Front Propeller
Shaft
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Rear Propeller
Shaft
TOD
STAVIC - 2004.09
4D
Rear Axle
(Rear Wheel)
Transmission
Front Axle
(Front Wheel)
Front Speed
Sensor
Rear Speed
Sensor
Throttle Open
Rate
(TPS Value)
Transmission
Input Shaft
TOD Control Unit
Magnetic Clutch
MAX DUTY
Planetary Gear
(2.483)
Multi-Plate Clutch
Output Shaft
Chain
Front Propeller
Shaft
TOD
STAVIC - 2004.09
Rear Propeller
Shaft
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AFFECTED VIN
10
4D
Specifications
Description
TOD
Specification
Model
Overall length
343.0 mm
37.9 kg
Shifting mode
Gear ratio
Oil specification
4H and 4L
High
1:1
Low
2.48:1
Specification
Capacity
Change interval
TOD
control
unit
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1.4
Check at every 15,000 km,
replace at every 60,000 km
Approx. 76 kgm
Normal operating
range
9 ~ 16 V
CAN communication
6 ~ 16 V
IG switch OFF
2 mA
IG switch ON
1A
Maximum operating
current
Motor OFF
7A
Motor ON
20 A
TOD
STAVIC - 2004.09
4D
11
3. CIRCUIT DIAGRAM
TOD
STAVIC - 2004.09
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AFFECTED VIN
12
4D
4. OPERATION
System Layout
Combi meter
4WD switch
TOD control unit
Output
Input
Rear speed
Magnetic clutch
Motor
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AFFECTED VIN
Front speed
TOD
STAVIC - 2004.09
4D
13
Mode Position
4H
4L
Transferring
4H 4L
Operation Condition
4WD Drive
(High Speed)
4WD Drive
(Low Speed)
4WD Drive
High Speed
Low Speed
Manual Transmission
Transfer starts after the vehicle stops and the clutch is applied
Automatic Transmission
Transfer starts after the vehicle stops and the shift lever is shifted
[N] position.
[Notice]
To make the mode shift easier, stop the vehicle, depress the brake pedal, select the mode switch, and move the selector
lever with the sequence of [N-P-N].
Mode Switch
Selection Mode
The TOD system has 2 selectable mode, 4H and 4L.
4H is the normal operating mode when drive of which
gear ratio is 1:1 and 4L mode distributes power to front
and rear wheels 50:50 of which gear ratio is 2.48:1.
4L Mode
When selecting 4L mode, EMC is locked to apply maximum
torque into front and rear propeller shafts (when the wheel
speed is more than 87Hz). Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes
from 1:1 to 2.48:1 by planetary gear set.
TOD
STAVIC - 2004.09
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14
4D
COMPONENTS
1. TOD ASSEMBLY
Front case
Rear cover
T/M
Shift motor/Electronic
speed sensor
magnetic clutch
Input shaft
Rear cover
Companion flange
Shift motor
CHANGED BY
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AFFECTED VIN
TOD
STAVIC - 2004.09
4D
15
Item
TCCU
CAN
Cluster lamp
CAN
CAN
CAN
TOD
STAVIC - 2004.09
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AFFECTED VIN
16
4D
TCCU
Description
New TCCU
Connector type
Number of pins
30
Weight
0.22 kg
CAN-BUS
CAN communication
Lamp
CAN communication
CAN communication
CAN communication
Description
Pin No.
Description
Motor HI - LO
16
Motor LO - HI
17
Ground
EMC
18
Ground
Battery
19
Battery
Ignition
20
K-Line
Position ground
21
N/A
N/A
22
CAN H
N/A
23
CAN L
4H-4L switch
24
N/A
10
Position 2
25
ABS operation
11
26
N/A
12
N/A
27
Position 1
13
28
Position 3
14
Motor HI-LO
29
15
Motor LO-HI
30
Position 4
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
17
Battery voltage
19
15
T
Ignition switch ON/
OFF
14
EMC
Position encoder
ground
(Return position)
13
16
Front/rear speed
Sensor 5V power
supply
20
Self diagnosis
D
Position 1
27
Position 2
10
Position 3
28
Position 4
30
C
O
N
T
R
O
Front speed
sensor signal
11
Rear speed
sensor signal
29
U
N
CAN HIGH
22
I
T
CAN LOW
23
17
18
TOD
STAVIC - 2004.09
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AFFECTED VIN
18
4D
Section
Pin No.
Name
Description
Power
supply
17, 18
Ground
4, 19
B+
Input side
Ignition switch
27
Position 1
10
Position 2
Same as above
28
Position 3
Same as above
30
Position 4
Same as above
4H and 4L switch
11
29
25
ABS operation
Both sides
Output side
22
CAN HIGH
23
CAN LOW
20
K - LINE
16
1, 14
Motor HI-LO
2, 15
Motor LO-HI
EMC
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AFFECTED VIN
Speed return
13
Speed return
TOD
STAVIC - 2004.09
4D
19
SYSTEM OPERATION
TCCU Initialization
TCCU sends relevant data to meter cluster via CAN to diagnose and check the indicators when the ignition switch is
turned to ON. At this time, the 4WD indicators (4WD LOW, 4WD HIGH, 4WD CHECK) comes on for 0.6 seconds.
If the selector switch position and the shift motor position code does not match when the IG power is turned ON, the
shift is controlled to move in the direction of the selector switch position
Motor Position
Operation
4H
Left stop
4H
Left top
4H
Top
4H
Right top
- 4L lamp flickers
- Tries shifting to 4H if shifting conditions are satisfied.
- After shifting to 4H the flickering of 4L lamp stops.
4H
Zone 1
Same as above
4H
Neutral
Same as above
4H
Zone 2
Same as above
4H
Bottom
Same as above
4H
Right stop
Same as above
4L
Left stop
- 4L lamp flicker
- Tries shifting to 4L if shifting conditions are satisfied.
- After shifting to 4L the 4L lamp lights on.
TOD
STAVIC - 2004.09
4L
Left top
Same as above
4L
Top
Same as above
4L
Right top
Same as above
4L
Zone 1
Same as above
4L
Neutral
Same as above
4L
Zone 2
Same as above
4L
Bottom
4L
Right stop
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20
4D
If 4H/4L switch position is not matched with shift motor position code with the ignition switch ON, the shift requirements operate to the direction of 4H/4L switch. However, the shifting requirements should be met to shift.
Shifting requirements:
- The transmission is in neutral for 2 seconds after the shift is requested.
- Both propeller shaft speeds are below 43 Hz.
A command to shift will only be acted upon if the TOD is reading a valid code at the time the command to shift is made.
After a shift has started, the TOD will power the shift motor until the code for the requested position is read. If an invalid
code is read, the TOD will go into a default mode.
During a shift attempt, the shift motor will be energized for a maximum of 5 seconds.
In case of manual transmission, the clutch pedal should be depressed.
CHANGED BY
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AFFECTED VIN
TOD
STAVIC - 2004.09
4D
21
Shift Requirements
When a range change is initiated a diagnostic test will be completed on the motor, speed sensors, and position
encoder. If the diagnostic test fails, the shift will not be attempted. If all components are operating properly, the TOD will
attempt a range change after the following shift requirements are met:
1. The transmission is in neutral for 2 seconds after the shift is requested.
In case of manual transmission, the clutch pedal should be depressed.
2. Both propeller shaft speeds are below 43 Hz.
If the transmission is taken out of neutral before 2 seconds has elapsed, or either propeller shaft speed increases above
the limit, the shift will be suspended and the 4L indicator will continue to flicker until the requirements are met again or
the 4H/4L switch is returned to the original position. However, if the initial switch position is 4L, 4L indicator remains
on. If the shift requirements are met, the shift motor attempt to shift again.
Range Change
When the shift requirements are met, the motor rotates to the appropriate direction (as determined by the selector
switch) until one of the following occurs:
1. The motor reaches its destination.
2. The motor is on for 5 seconds without reaching its destination. The shift has failed and the TOD will respond as
default mode.
3. A fault occurs with either the motor or position encoder. Refer to the diagnosis requirement.
When the motor is energized, the Ignition, 4H/4L switch, propeller shaft speeds, and transmission neutral inputs are
ignored.
Shift operation is only allowed when some conditions are satisfied. These shift conditions should be satisfied for 2
seconds before starting motor. The motor has three seconds of delay at its initial operation to do trouble diagnosis.
Once the motor starts, the shift conditions are no longer checked.
Shift conditions are as follows:
-
TOD
STAVIC - 2004.09
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AFFECTED VIN
22
4D
Shift Conditions
Shift is allowed only when certain conditions for the vehicle are satisfied. This means that the shift conditions must
satisfy the operating conditions for 2 seconds before motor starts and 2 seconds of delay at initial stage is to diagnose
the system.
The shift requirements are as follows:
- There should be no fault with battery voltage and shift motor for all shifts.
- Shift between 4H and 4L is operated only under the vehicle speed of below 43 Hz.
- There should be no fault with speed sensors.
- Transmission must be in neutral position (In case of manual transmission, the clutch pedal should be depressed).
Motor Controls
The shift steps have the sequence of 4H 4L and 4L 4H 2H. TCCU operates the shift motor until it reads
required position code. If it detects the faulty code, the system is operated with the compensation mode.
Once the shift operation is started, it is completed regardless of ignition power. If there are not operating signals from
position sensor, the shifting failure due to timeout occurs. This failure appears when the shifting time between 2H
and 4H and between 4H and 4L is delayed over 5 seconds compared to normal shift. Once the shifting time exceeds
the specified time, TCCU cannot properly supply the voltage to shift motor and is operated in compensation mode.
Even though the system recognize a fault before motor starts, it is considered as fault.
Motor stops operation when it reaches at target range.
Compensation Mode
The motor stops when the encoder related troubles are detected during shift operation. It moves toward LOW-HIGH
direction for 5 seconds so that the motor is not left in unidentified position.
0.3 seconds
Shift completed
0.3 seconds
(4H 4L)
0.3 seconds
Shift completed
0.3 seconds
(4L 4H)
TOD
STAVIC - 2004.09
4D
23
Etc
The TOD system is responsible for distributing torque between the front and rear axles. The TOD monitors the propeller
shaft speeds, operating range (High/Low), and ABS activity and then applies a calculated amount of torque to the front
axle by Pulse Width Modulating the current applied to the EMC.
Touch-off torque
The minimum EMC Duty Cycle is based on the vehicle speed and throttle position.
The TOD receives the TPS signal from the following sources:
On vehicles equipped with CAN, the TOD receives the TPS signal from the CAN bus.
TOD
STAVIC - 2004.09
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AFFECTED VIN
24
4D
Shifting Sequence
Flow chart
Start
Shift
requirements
No
Yes
Satisfied shift
conditions for 2
seconds
Check shift
conditions
Yes
Analyzing position
encoder
No
Is the position
code valid?
No
Yes
Move further to
requested direction
Yes
No
Is the position
code valid and
sequential?
No
Moto stops
General
encoder DTC
Yes
No
Reached at
target location?
Motor ON to L-H
during maximum limit
Completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
25
Shift Requirements
If 4H/4L switch position is not matched with shift motor position code with the ignition switch ON, the shift requirements
operate to the direction of 4H/4L conversion switch.
The next shift requirements are identified only when those are different from current operation.
Shift Conditions
Shift is allowed only when certain conditions for the vehicle are satisfied. This means that the shift conditions must
satisfy the operating conditions for 2 seconds before motor starts and 2 seconds of delay at initial stage is to diagnose
the system.
The shift requirements are as follows:
- There should be no fault with battery voltage and shift motor for all shifts.
- Shift between 4H and 4L is operated only under the vehicle speed of below 43 Hz.
- There should be no fault with speed sensors.
- Transmission must be in neutral position (In case of manual transmission, the clutch pedal should be depressed).
Motor Position
Left Stop
Left top
Top
Right top
Zone 1
Neutral
Zone 2
Bottom
Right stop
Off State
TOD
STAVIC - 2004.09
Remark
Input voltage
1 : above 4.5V (HIGH)
0 : below 0.5V (LOW)
CHANGED BY
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AFFECTED VIN
26
4D
Pin
Function
Clutch coil
6, 7
1, 2, 5
Sensor signal
Sensor ground
1(G)
2(G)
3(B)
5(Sb)
6(Gr/R)
7(Gr/R)
4(Br)
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AFFECTED VIN
TOD
STAVIC - 2004.09
4D
27
Pin
Function
Position A
Position B
Position C
Position D
Position ground
1(Br/W)
2(P/W)
3(W)
5(Y/W)
6(Y)
7(P)
4(V)
TOD
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
28
4D
Installation Notice
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10 1.0 Nm
TOD
STAVIC - 2004.09
4D
29
2. SHIFT MOTOR
1. Disconnect the negative battery cable.
2. Disconnect the shift motor/electronic magnetic clutch connector (black, 7-pin) and front and rear speed sensor
connector (white, 4-pin) at the rear top section of the transfer case.
3. Disconnect the front and rear speed sensor connector (white, 7-pin) from bracket.
TOD
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30
4D
6. Pull the shift motor assembly out while keeping the level.
CHANGED BY
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AFFECTED VIN
TOD
STAVIC - 2004.09
4D
31
3. SPEED SENSOR
1.
2.
3.
4.
5.
TOD
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
32
4D
6. Remove the rear speed sensor bolts on the rear case flange.
Tightening torque
3 ~ 6 Nm
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AFFECTED VIN
TOD
STAVIC - 2004.09
4D
33
10. Hold the L pin in speed sensor connector with long nose pliers and push it rearward to disconnect from the
connector.
3 ~ 6 Nm
TOD
STAVIC - 2004.09
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EFFECTIVE DATE
AFFECTED VIN
34
4D
4. TOD ASSEMBLY
1. Disconnect the negative battery cable.
2. Lift up the vehicle and fix it safely.
3. Place the empty container to collect the draining oil.
4. Remove the drain plug and drain the oil. Reinstall the
drain plug.
[Notice]
Oil drain should be along with whole transfer case
disassembly and assembly.
81 ~ 89 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
35
21 ~ 35 Nm
62 ~ 93 Nm
62 ~ 93 Nm
20 ~ 25 Nm
[Notice]
Apply long-life grease to the inner spline of transfer case
input shaft.
TOD
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
36
4D
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
37
TOD ASSEMBLY
1. CROSSE SECTIONAL DIAGRAM
Chain
Clutch pack
EMC
Ball lamp
Input shaft
Oil pump
TOD
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
38
4D
Exploded View
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
39
1. Snap ring
35. Breather
2. Snap ring
3. Snap ring
4. Bearing
39. Magnet
5. Hub
7. Thrust plate
8. Sun gear
43. Chain
9. Snap ring
46. Bearing
47. Bearing
48. Cover
49. Clip
50. Bolt
16. Hop
17. Filter
52. Washer
53. Nut
20. Ball
21. Cam
56. Spacer
22. Spring
23. Armature
58. Nut
59. J clip
61. Clip
62. Connector
TOD
STAVIC - 2004.09
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AFFECTED VIN
40
4D
2. DISASSEMBLY PROCEDURE
1. Disconnect transfer case from vehicle
2. Using a 30 mm thin-wall socket, first remove the rear
output nut, output shaft yoke washer, oil seal then the
case flange.
3. Disconnect shift motor/clutch coil connector and speed
sensor connector from upper bracket of transfer case.
[Notice]
When disconnect connector, pull forwards grasping
connector housing.
03E-019
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
41
14. Remove the speedometer drive gear and upper tone wheel.
15. If the rear output shaft bearing requires replacing, remove
the internal snap ring that retains the bearing in the bore.
16. From the outside of the case, drive out the bearing using
the driver.
17. Remove the three nuts and washers retaining the clutch
coil assembly to the rear case.
18. Pull the assembly, along with the O-ring and wire, from
the case.
TOD
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
42
4D
21. Remove the balls and apply cam and wave washer from
the output shaft.
22. Remove snap ring from output shaft.
23. Remove clutch pack assembly from output shaft.
26. Remove the magnet from the slot in the front of the case
bottom.
27. Remove the output shaft and oil pump as an assembly.
28. If required, to remove the pump from the output shaft,
rotate the pump to align.
29. Pull out the shift rail.
30. Remove the helical cam from the front case.
31. If required, remove the helical cam, torsion spring and
sleeve from the shaft.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
43
37. Remove the internal snap ring from the planetary carrier.
38. Separate the front planet from the input shaft.
39. Remove the external snap ring from the input shaft.
40. Place the input shaft in a vise and remove the bearing.
41. Remove the thrust washer, thrust plate and the sun gear
off the input shaft.
42. Inspect the bushing and needle bearing in the end of the
input shaft for wear or damage.
[Notice]
Under normal use, the needle bearing and bushing should
not require replacement. If replacement is required, the
bushing and needle bearing must be replaced as a set.
TOD
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
44
4D
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
45
3. ASSEMBLY PROCEDURE
1. Before assembly, lubricate all parts with Automatic
Transmission Fluid or equivalent.
2. If removed, drive the bearing into the front output case
bore.
[Notice]
Drive the bearing in straight, making sure it is not cocked in
the bore.
TOD
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
46
4D
7. The recessed face of the sun gear and the snap ring
groove on the bearing outer race should be toward the
rear of the transfer case.
8. The stepped face of the thrust washer should face toward
the bearing.
9. Slide the sun gear, thrust plate and thrust washer into
position on the input shaft.
10. Press the bearing over the input shaft.
11. Install the external snap ring to the input shaft.
12. Install the front planet to the sun gear and input shaft.
13. Install the internal snap ring to the planetary carrier.
14. Place the tangled snap ring in the case. Expand snap
ring with snap ring pliers and install planetary carrier
assembly. Check installation by holding the case and
carefully tapping the face of the input shaft against a
wooden block to make sure the snap ring is installed.
15. Remove all traces of gasket sealant from the front case
and mounting adapter mating surfaces. Install a bead of
gasket sealant on the surface of the front case.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
47
18. Inspect the outside surfaces and bore of the oil pump.
19. Install the output shaft and oil pump in the input shaft.
Make sure that the internal splines of the ouput shaft
engage the internal splines of the high-low shift collar.
Make sure that the oil pump retainer arm and oil filter leg
are in the groove and slot of the front case.
20. Install the magnet in the slot in the front case just above
the oil filter leg.
21. Install the front output shaft in the front case.
22. Install the thrust washer on the rear output shaft.
TOD
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
48
4D
24. Install tone wheel onto the front output shaft. Make sure
the spline on the tone wheel engages the spline on the
front output shaft.
25. Install clutch pack assembly onto the rear output shaft.
Make sure the spline of the clutch pack engages to the
spline of the sprocket.
26. Install snap ring onto the rear output shaft. Start the snap
ring over the spline and use the wave spring to seat the
snap ring in the snap ring groove.
If the snap ring will not install, the thrust washer inside
the clutch pack may not be seated properly.
27. Install wave spring, insulator washer and armature. (Three
offset slots must align with housing to be installed)
[Notice]
Three slots on the thrust washer must be aligned with the
three tabs on the clutch pack housing.
32. If removed, drive the front output shaft ball bearing into
the rear cover bore with Front Shaft Needle Bearing
Replacer and Driver Handle.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
49
33. If removed, install the rear output bearing in the rear case
bore. Drive the bearing into the rear case bore with Output
Shaft Bearing Replacer and Driver Handle. Make sure
that the bearing is not cocked in the bore.
34. Install the internal snap ring that retains the bearing to
the rear case.
35. Install the clutch coil from inside the rear case until the
wire and studs extend through the cover.
[Notice]
Do not kink or trap the wire while seating the clutch coil to
the case.
8 - 11 Nm
(71 - 97 lb-in)
39. Rotate the second spring tang clockwise past the drive
tang.
43a
TOD
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
50
4D
40. Push the torsion spring and sleeve in as far as it will go.
41. Install the helical cam and slide the drive tang between
the torsion spring tangs as far as it will go.
42. Install the pin on the tang end of the helical cam into the
hole in the front case. Position the torsion spring tangs
so that they are pointing toward the top side of the
transfer case and just touching the high-low shift fork.
[Notice]
Do not bend the helical cam during installation to the front
case because of possible damage to the pin at the tang end of
the motor shaft.
43. Install the shift rail through the high-low shift fork and
make sure that the reverse gear shift rail is seated in the
front case bore.
44. Install upper and lower speed sensors into the cover.
Feed the coil wire through the upper speed sensor wire
shield.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
51
46. Coat the mating surface of the front case with a bead of
Black Non-Acid Cure Silicone Rubber or equivalent.
47. The following procedure must be followed prior to installing
the rear case onto the front case half:
Align the output shaft with the rear case output shaft
bore.
Align the helical cam with the rear case motor bore.
If difficulty is encountered with seating the rear case,
tap the rear output shaft with a sharp blow using a
rubber mallet in a direction away from the triangular
shaft while pushing down on the rear case.
48. Install the bolts retaining the case halves and tighten.
Installation Notice
Tightening torque
25 - 37 Nm
(8 - 27 lb-in)
50. Using pliers equipped with soft jaws, rotate the triangular
shaft so it is aligned with the triangular slot in the transfer
case shift motor.
[Notice]
If triangular shaft will not rotate, rotate the rear output shaft.
TOD
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
52
4D
51. Tighten manually the two nuts that attach the slotted
support bracket to the end of the motor house.
52. Apply Black Non-Acid Cure Silicone Rubber or equivalent
to motor housing base and install on transfer case.
53. Install the transfer case shift motor and three bolts along
with speed sensor wire harness bracket and tighten.
Installation Notice
Tightening torque
8 - 11 Nm
(71 - 97 lb-in)
54. Holding the slotted support bracket tight against the motor
housing end, secure the bracket to the transfer case,
tightening the bolt with lock washer.
Installation Notice
Tightening torque
8 - 11 Nm
(71 - 97 lb-in)
55. Retighten the two nuts that attach the slotted support
bracket to the end of the motor.
Installation Notice
Tightening torque
3 - 6 Nm
(27 - 53 lb-in)
56. Install the clutch coil wire terminal(brown) and other shift
motor wires to the 7-pin connector(black).
57. Install the connector retainer at the connector end.
58. Connect the front and rear speed sensors wiring to the
7-pin connector(white).
59. Install the rear case flange on the output shaft.
60. Install the rubber seal, output shaft yoke washer and nut.
Tighten the nut.
Installation Notice
Tightening torque
137 - 196 Nm
19 - 30 Nm
(14 - 22 lb-in)
19 - 30 Nm
(14 - 22 lb-in)
TOD
STAVIC - 2004.09
4D
53
TOD
STAVIC - 2004.09
Application
Removal/installation of carrier
assembly in transfer case
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
54
4D
TROUBLE DIAGNOSIS
TCCU periodically monitors the input and output while the system is in operation. When a fault is detected, the trouble
code is stored into TCCU memory.
If the ignition switch is turned to OFF, TCCU stops monitoring for input and output, however, when the ignition switch
is turned to OFF before shifting completes, TCCU continues monitoring for input and output required for the shifting.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
55
EMC Test
The EMC tests whether the circuit is short or open to ground. When the system detects a fault for 0.8 seconds, 4WD
CHECK warning lamp comes on and TOD stops its operation. When the EMC is restored continuously for 0.8 seconds,
the TOD control unit functions normally. At this time, 4WD CHECK warning lamp comes on but the trouble code still
remains in the memory.
TOD
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
56
4D
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
57
Coding required
1. Replacement of TOD control unit.
2. Adjustment by input error.
Coding method
1. Check and record engine type, axle ratio and tire size.
2. Turn the ignition switch to OFF position.
3. Connect the scanner with diagnosis connector.
4. Turn the ignition switch to ON position.
5. Select TOD from CONTROL UNIT SELECTION screen
and press ENTER.
6. Read the current memorized specification in TOD control
unit.
7. Compare memorized specification with the checked
record. If not matched, perform a coding.
8. Read again memorized coding specification in TOD
control unit for confirmation of coding.
9. Turn the ignition switch to OFF position.
10. After 5 seconds, turn the ignition switch to ON position.
11. Check coding specification whether it matches with
vehicle or not. If not, perform a coding again.
TOD
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
58
4D
Description
Action
P1806
P1816
P1814
P1815
P1817
P1821
P1822
P1830
P1831
P1832
P1833
P1834
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
Code
P1835
P1836
59
Description
Action
- Reference voltage: below 4 V
- Check the relevant harnesses.
- Check the relevant connectors for contact.
- Replace sensors if necessary.
- Reference voltage: over 8 V
- Check the relevant harnesses.
- Check the relevant connectors for contact.
- Replace sensors if necessary.
P1841
P1842
P1843
P1844
TOD
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MEMO
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4E
GENERAL INFORMATION
1. SYSTEM OVERVIEW
4WD
Power steering pipe
Sub frame
assembly
Brake assembly
Brake assembly
Front axle
assembly
C.G.P
(Center Gravity Point)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4E
* 4WD
* 2WD
2WD
Power steering pipe
Sub frame
assembly
Brake assembly
Brake assembly
Stabilizer bar
FRONT SUSP & AXLE
STAVIC - 2004.09
4E
2. SPECIFICATION
Suspension type
Double wishbone
Spring type
Gas type
Stabilizer type
Torsion bar : 30
Wheel alignment
30
Caster : 4.5 30
Camber : 0
Toe-in : 0 ~ 4 (mm)
214 (mm)
Axle size
3.7
3.9
4.1
4.3
4.6
4.9
5.4
5.9
Pinion
11
11
11
Gear
41
43
37
47
41
44
43
41
Axle ratio
Number of tooth
Weight
34 (kg)
Length
250.43 (mm)
Oil capacity
1.4 ( )
Specified oil
SAE 90
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4E
(Unit : mm)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4E
Mounting Point
Mounting Point
Mounting Point
Location
Grease capacity
In boot
140 ~ 160g
Out boot
200 ~ 220g
Wheel side
Out boot
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
In boot
4E
4. FRONT SUSPENSION
Coil spring
Upper arm
Knuckle
Stabilizer bar
Lower arm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4E
1) Knuckle (4WD)
2) Upper arm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4E
9
5) Shock absorber and coil spring
Shock absorber and coil spring is a device for damping
sudden and rapid motion, as the recoil of a springmounted object from shock.
Stabilizer bar
Mounting bracket
Mounting bracket
Stabilizer link
Stabilizer link
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
4E
Specification
4WD
2WD
8.8 5 %
8.8 5 %
16.7
16.6
D1
75.0
75.0
D2
105.0
105.0
Pitch (mm)
85.0
85.0
Number of winding
9.36
9.36
7.86
7.86
Height (mm)
256.0
256.0
Weight (kg)
1047 5 %
905 5 %
65.8
68.2
Rightward
Leftward
Strength (kg/mm)
Winding direction
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4E
11
540 (mm)
452 (mm)
Working distance
88 (mm)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
4E
1. Coil spring
2. Shock absorber
7. Dust cover
13. Knuckle
9. Stopper-bumper
8. Cam bolt
11. Lower arm
4. bush
4WD
2WD
23. Hub assembly
13. Knuckle
18. Brake dust shield
22. Brake disk
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
21. Washer
21. Washer
4E
13
Air bleeder
Carrier cover
Ring gear
Axle mounting bracket
Ball bearing
Shim
Pinion gear
Oil seal
Ball bearing
Pinion drive seal
Shim
Ball bearing
Flage
Lock nut
Inner shaft
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
4E
16.5 cm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Rear
4E
15
4. Remove the engine lnsulating brackets from the front sub frame as the
engine hung by an additional lift (crane)
5. Install the engine mounting bracket
Before removal of sub frame, install the special tool (Engine mounting
brackets) on the body frame
RH
LH
Engine insulating
brackets on the sub frame
RH
LH
Engine mounting
brackets on the body
Part number : A9912 008 2B
RH
LH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
4E
2. Remove the front calier (C) and wheel speed sensor (D)
(Fix the caliper and speed sensor on the body. Disconnect the brake
hose clip)
Wheel
Power steering
pipes (Front)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4E
17
5. Leave mark with a marking painter on the sub frame mounting bolts (19mm - 4EA).
(Tightening torque: 95 ~ 142 Nm)
6. Locate two sypplement lifts under sub frame (Front/Rear) and unscrew the sub frame mounting bolts (19mm 6EA). And then, drop the lifts slowly.
[Notice]
Apply rubber blocks under sub frame to prevent the frame and other components from damage.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
4E
Rubber block at the front side
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4E
19
7. Installation is in the reverse order of removal (Keep the exact mount holes and tightening torque)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
4E
Guide bar
Guide pin
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4E
21
2. Do the same preceding work to remove the sub frame (page 624 ~ 626).
3. Remove the sub frame mounting bolts (19mm - 6EA)
Tightening torque
95 ~ 142 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
4E
Upper arm
Knuckle
Brake caliper
Stablilizer
Power steering assembly
Brake disk
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
250 ~ 350 Nm
4E
23
140 ~ 160 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
4E
10 1.0 Nm
95 ~ 142 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4E
25
Axle assembly
Bolt
Bolt
Bush
Bush
Washer
Bush
Washer
Nut
Bush
Nut
Washer
Nut
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
4E
1. Unscrew the axle housing mounting bolt on the sub frame and disassemble the axle.
A. Axle mounting bolt/nut
(Tightening torque: 95 ~ 142 Nm)
Color coke
coated
Lower bush
4E
27
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
4E
1. Remove wheel speed sensor and cable. (10 mm - 1EA, Tightening torque : 6 ~ 8 Nm)
Cable
2. Unscrew knuckle upper mounting bolt/nut (19 mm - 1EA) and upper arm mounting bracket bolts (14 mm - 4EA) to
remove upper arm assembly.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4E
29
Rear
Cam bolt
Washer / Bolt
Cam bolt
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30
4E
1. Unscrew the shock absorber lower mounting bolt/nut (1) and stabilizer link low nut (2).
Tightening torque
120 ~ 140 Nm
180 ~ 190 Nm
4E
31
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
32
4E
Under FFH
LH
Tightening torque
30 ~ 45 Nm
3. Unscrew the shock absorber lower bolt and pull upward as putting down the assembly.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4E
33
Mounting bracket
Mounting bracket
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
34
4E
Mounting bracket
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
110 ~ 120 Nm
Mounting bracket
Upper bolt : 60 ~ 80 Nm
Lower bolt : 110 ~ 130 Nm
4E
35
Knuckle Assembly
Preceding Work: 1. Removal of tires.
2. Removal of brake caliper and wheel speed sensor (Fix the sensor to the body).
Knuckle assembly
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
36
4E
1. Unscrew the lock nut (1) and brake disk mounting bolts
(2: 5 mm - 2EA) and then, remove the disk from knuckle
assembly.
Tightening torque
8 ~ 12 Nm
8 ~ 12 Nm
Tightening torque
35 ~ 45 Nm
4E
37
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
38
4E
TROUBLE DIAGNOSIS
Symptom
Vehicle rolling
Abnormal noises
Poor riding
Cause
Broken stabilizer bar
Replace
Replace
Loosening mountings
Re-tighten
Replace
Replace
Damaged tire
Replace
Hard steering
Replace
Worn bushing
Replace
Replace
Worn bushing
Replace
Replace
CHANGED BY
AFFECTED VIN
Damaged tire
EFFECTIVE DATE
Replace
Replace
Vehicle bottoming
Pressure adjust
Steering instability
Action
Repair
Replace
Adjust
Repair or replace
Repair
Re-tighten or replace
Replace
4F
Axle shaft
Wheel carrier
Tension link
Track rod
Thrust link
Stabilizer
Axle mounting
Front View
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
Rear View
Axle mounting
Axle shaft
Spring link
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
2. SPECIFICATION
Suspension type
Multi-link
Spring type
Coil spring
K=120 kgf/mn
Gas
Torsion bar
14
Toe-in
0.04 0.08
Camber
-1.0 0.5
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
230
37
3.9
4.1
4.3
4.6
4.9
5.4
5.9
Pinion
11
11
11
Gear
41
43
37
47
41
44
43
41
Weight (kg)
40
Length (mn)
250.43
Oil capacity ( )
1.7
Specified oil
4F
30 ~ 40 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
3. Remove the rear propeller shaft.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
7. Unscrew the stabilizer mounting bolt (A) and remove it from the vehicle.
A
8. Remove rear frome mounting bolt (B) at the rear axle carrier module.
B
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
9. Remove the rear axle carrier module from the vehicle.
Front
Rear
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
Camber link
Tension link
Track rod
Thrust link
Stabilizer bar
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
4F
Spring link
Wheel carrier
Stabilizer link
Coil spring
Shock absorber
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
11
2. COMPONENTS
1) Rear Shock Absorber
Keep the suitable distance when compressed and
expanded.
Minimum length is 10 mm longer than the minimum length
under compression.
Specification
Max. length
Min. length
Working distance
487 mm
326.6 mm
160.4 mm
Marking Point
X : Part No.
Y : Lot Number
Ex : 3
12
12 ......... Day
3 ........... Month
2003 ...... Year
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
4F
3. Unscrew the lower mounting nut on the spring link (17 mm).
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
50 ~ 60 Nm
4F
13
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
4F
2) Coil Spring
Steel for high tensional spring is adapted.
Maintain more than 20 mm of freeplay when compressed.
Spring seat applied.
Specification
4WD
C.V.W
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Part Number
45110-21000
12.0 5%
15.9
69.1
Pitch (mm)
85.0
Number of winding
9.55
8.35
Height (mm)
250
Weight (kg)
880.0
Strength (kg/mm/mm)
62.1
Winding direction
Right
323.3
REAR SUSP & AXLE
STAVIC - 2004.09
4F
15
[Notice]
Pay attention to use special tool and coil spring.
Sudden release of coil spring could cause a serious accident.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
4F
Tension Link
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
17
1. Unscrew the thrust link mounting bolts (19 mm-2EA) and remore the link.
2. When install, apply two washers to the thrust link mounting bolt/nut (A. Wheel carrier)
Tightening torque (A, B)
70 8 Nm
A. Wheel carrier
B. Body
[Reference]
1. Keep the right position when reinstall (faced outward).
2. Apply the longer bolt to the thrust link wheel carrier side.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
4F
Tension Link
Body: 70 8
Wheel carrier: 70 8
A. Wheel carrier
B. Body
[Reference]
1. Keep the right position when reinstall.
2. Apply the longer bolt to the tension link wheel carrier side.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
19
4) Track Rod
70 8
2. Unscrew the track rod mounting bolt (B. Wheel carrier-17 mm)
Tightening torque
A. Body
30 5
B. Wheel carrier
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
4F
5) Camber Link
70 8
2. Unscrew the camber link mounting bolt (A. Wheel carrier-19 mm)
Tightening torque
70 8
A. Wheel carrier
B. Body
[Notice]
1. When install, apply two washer to the camber link mounting
bolt/nut (A. Wheel carrier).
2. Keep the right position when reinstall.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
21
Stabilizer bar
Stabilizer link
1. Unscrew the stabilizer link upper mounting bolt (17 mm) and lower mounting bolt (13 mm).
A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
4F
Stabilizer Bar
Preceding work: Removal of stabilizer link
- Remove stabilizer bar mounting bracket to seperate the stabilizer bar from the vehicle.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
23
7) Spring Link
1. Compress the spring with special tool for easier removal and installation.
2. Unscrew the wheel carrier mounting bolt (A), stabilizer link mounting nut (B) and shock absorber mounting nut (C).
Wheel carrier: 20 Nm
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
4F
Spring Link
Wheel carrier
Shock absorber
Stabilizer link
Body
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
25
3. Unscrew the brake disk mounting unt (2 EA) and remove the disk.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
4F
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
27
A. Front view
B. Rear view
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28
4F
Drive shaft
Axle housing
Specification
Axle size
214
3.3
3.9
4.1
4.3
4.6
4.9
5.4
5.9
Pinion
13
11
11
Gear
43
43
37
47
41
44
43
41
Gear ratio
Number of tooth
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AFFECTED VIN
4F
29
CHANGED BY
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AFFECTED VIN
30
4F
CHANGED BY
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AFFECTED VIN
4F
31
Initial: 70 ~ 80 Nm
Secondary: 90 5
[Notice]
Replace the bolts by every removal
2. Unscrew lock nut (30 mm) from wheel disk side and
remove the axle shaft.
Tightening torque
200 ~ 240 Nm
[Notice]
Replace the lock nut to new one by every disassembly.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
32
4F
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
33
Tightening torque
90 110 Nm
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AFFECTED VIN
34
4F
20 4 Nm
Inner flange
Radial sealing
Shim
O-ring
Snap ring
Back lash adjust shim
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
35
120 Nm
[Notice]
Replace the lock nut to new one by every disassembly.
Lock nut
Inner flange
Radial sealing
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EFFECTIVE DATE
AFFECTED VIN
MEMO
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4G
GENERAL INFORMATION
1. OVERVIEW
The power steering system consists of pump, oil reservoir, rack and pinion gear. The power steering pump is a vane type
and delivers hydraulic pressure to operate the power steering system. The pressure relief valve in pump controls the
discharging pressure.
The rotary valve in rack and pinion gear directs the oil from the power steering pump to one side of rack piston.
The integrated rack piston converts the hydraulic pressure to linear movement.
The operating force of rack moves the wheels through tie rod, tie rod end and steering knuckle.
Even though the hydraulic pressure cannot be generated, a driver can steer the vehicle without power assist but it needs
very high steering force.
In this case, the operating force of steering wheel is conveyed to pinion, and the movement of pinion moves the rack
through pinion gear combined to rack gear.
2. SPECIFICATION
Item
Steering wheel
Specification
Number of spoke
4 spokes
Outer diameter
390 mm
Rotation
Gear box
3.6 rotations
Type
Gear ratio
Steering
angle
Inner
37 42
Outer
32 56
Tilting angle
2
5.882 m
Oil
Type
Displacement
11.3 cc/rev
Max. pressure
90 bar
Specified oil
Capacity
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4G
GENERAL INFORMATION
1. OVERVIEW
The power steering system consists of pump, oil reservoir, rack and pinion gear. The power steering pump is a vane type
and delivers hydraulic pressure to operate the power steering system. The pressure relief valve in pump controls the
discharging pressure.
The rotary valve in rack and pinion gear directs the oil from the power steering pump to one side of rack piston.
The integrated rack piston converts the hydraulic pressure to linear movement.
The operating force of rack moves the wheels through tie rod, tie rod end and steering knuckle.
Even though the hydraulic pressure cannot be generated, a driver can steer the vehicle without power assist but it needs
very high steering force.
In this case, the operating force of steering wheel is conveyed to pinion, and the movement of pinion moves the rack
through pinion gear combined to rack gear.
2. SPECIFICATION
Item
Steering wheel
Specification
Number of spoke
4 spokes
Outer diameter
390 mm
Rotation
Gear box
3.6 rotations
Type
Gear ratio
Steering
angle
Inner
37 42
Outer
32 56
Tilting angle
2
5.882 m
Oil
Type
Displacement
11.3 cc/rev
Max. pressure
90 bar
Specified oil
Capacity
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4G
3. COMPONENTS
Steering wheel
Power steering
pump assembly
Column shaft
Power steering
oil pipe & hose
Lower shaft
Steering gear
box assembly
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
Tie rod
Tie rod
Boot
Bush mounting
Boot
Oil Reservoir
The oil reservoir sends the oil to the power steering pump
and receives the oil from the power steering gear.
The oil level in the reservoir depends on the steering wheel
positions. therefore, measure the oil level when the steering wheel is positioned at straight ahead direction (neutral).
POWER STEERING
STAVIC - 2004.09
Steering pump
Reservoir tank
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EFFECTIVE DATE
AFFECTED VIN
4G
GENERAL INSPECTION
1. STEERING WHEEL
Power Steering Wheel Free Play
Check
1. Start the engine and place the wheels at straight ahead
direction.
2. Turn the steering wheel until the tires starts to move and
measure the distance on the circumference of the
steering wheel.
Specified value
30 mm
[Notice]
If the free play is out of the specified value, check the
clearance in steering column shaft connection and steering
linkage. Replace or repair if necessary.
Below 3.0 kg
[Notice]
The difference between both sides should be within 0.6 kg.
Inner
37 42
Outer
32 56
[Notice]
If the free play is out of the specified value, check and adjust
the toe-in.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4G
[Notice]
Before checking the pressure, check the oil level and belt
tension. Prepare the empty container to collect the spilled
oil during the service.
89 ~ 97 kg/cm2
9. Measure the oil pressure with the gauge valve fully closed.
Pump pressure at no load
3 ~ 5 kg/cm2
HOT
HOT
ADD
ADD
Engine off
Engine on
POWER STEERING
STAVIC - 2004.09
4G
4. OIL CHANGE
1. Lift up the vehicle carefully.
2. Disconnect the oil supply hose from the power steering
pump.
3. Drain the oil from the power steering oil reservoir.
4. Connect the oil supply hose to the power steering pump.
5. Disconnect the oil return line from the power steering oil
reservoir.
6. Periodically crank the starting motor and turn the steering
wheel to its both ends to drain the oil in the reservoir
through the return line.
7. Connect the return line to the steering oil reservoir.
8. Fill the oil into the steering oil reservoir to the specified
level.
[Notice]
Always keep the oil level over the ADD line.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
4G
6. AIR BLEEDING
After the power steering repairing, do the air bleeding job.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
11
Bolt
Steering wheel
Washer
Wheel damper
Cover
Bolt
Power steering high pressure hose
Column shaft
Lower shaft
Bolt
Cot pin
Nut
Bolt
Nut
Tie rod
Tie rod end
Bolt
POWER STEERING
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
12
4G
Tightening Torque
Kgfxxm
Nxx m
2.0 ~ 2.5
20 ~ 25
4.0 ~ 6.1
40 ~ 60
0.7 ~ 1.1
7.0 ~ 11
1.8 ~ 2.5
18 ~ 25
7.0 ~ 9.0
70 ~ 90
1.8 ~ 2.5
18 ~ 25
3.5 ~ 4.5
35 ~ 45
6.5 ~ 8.0
65 ~ 80
1.2 ~ 1.8
12 ~ 18
1.2 ~ 1.8
12 ~ 18
2.0 ~ 2.3
20 ~ 23
4.0 ~ 5.0
40 ~ 50
1.2 ~ 1.8
12 ~ 18
Item
Power steering column
shaft
mounting bolt
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EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
13
3. Unscrew the steering wheel lock nut and remove the wheel with special tool.
[Notice]
Leave marks on the column shaft and steering wheel for
correct installation.
4. Remove the instrument lower panel and disconnect all related connectors.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
4G
4. Airbag connector
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
15
7. Unscrew the contact coil mounting screw and remove it from multi function switch.
8. Disconnect both left and right connectors of multi function switch and unscrew the multi function switch mounting
bolt to disassemble from steering column.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
4G
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
17
12. Unscrew the lower shaft housing floor mounting bolt(A) and lower shaft mounting bolt on the steering gear box.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
4G
16.5 cm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Rear
POWER STEERING
STAVIC - 2004.09
4G
19
4. Remove the engine lnsulating brackets from the front sub frame as the
engine hung by an additional lift (crane)
5. Install the engine mounting bracket
Before removal of sub frame, install the special tool (Engine mounting
brackets) on the body frame
RH
LH
Engine insulating
brackets on the sub frame
RH
LH
Engine mounting
brackets on the body
Part number : A9912 008 2B
RH
POWER STEERING
STAVIC - 2004.09
LH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
4G
2. Remove the front calier (C) and wheel speed sensor (D)
(Fix the caliper and speed sensor on the body. Disconnect the
brake hose clip)
Wheel
Power steering
pipes (Front)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
21
5. Leave mark with a marking painter on the sub frame mounting bolts.
(Tightening torque: 95 ~ 142 Nm)
6. Locate two sypplement lifts under sub frame (Front/Rear) and unscrew the sub frame mounting bolts (19mm 6EA).
And then, drop the lifts slowly.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
4G
7. Unscrew the clamp mounting bolt of stabilizer bar and fix to the upper side of axle flange.
8. Remove the coat pin and nut(1), and unscrew the gear box clamp bolt(2) and bush mounting nut(3).
1. Coat pin and nut
Tightening torque
25 ~ 30 Nm
Tightening torque
100 ~ 130 Nm
A. Stabilizer
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Upper bolt : 70 ~ 90 Nm
Lower bolt : 70 ~ 90 Nm
POWER STEERING
STAVIC - 2004.09
4G
23
9. Disassemble the steering gear box as shown below with arrow mark.
Sloted nut
: 25 ~ 30 N .m
POWER STEERING
STAVIC - 2004.09
Sloted nut
: 25 ~ 30 N.m
Gear box mounting bolt
(Bushing)
: 70 ~ 90 N.m
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
4G
2. Remove the feed lines (2) from the cylinder tube in gear
box.
3. Remove the feed lines (1) from the valve housing in gear
box.
4. Unscrew the lock nut (1) and remove the plug (2) and
spring (3).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
25
9. Remove the pinion shaft seal (7), needle bearing (8) and
retaining ring (9).
[Notice]
Do not disassemble the power steering gear housing and
rack gear. Replace it as an assembly if needed.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
4G
Reassembly
1. Install the steering pinion gear.
1) Install the retaining ring.
2) Install the needle bearing.
3) Install the pinion shaft seal by tapping it with a long
and flat end drift.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
27
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
4G
Inspection
Rack Gear Shaft
1. Check the rack gear for deformation and damage.
Place the V-blocks (1) on the flatten plate.
Put the rack gear (2 and 4) on the V-blocks.
Measure the straightness of rack gear with a dial
gauge.
Check the rack gear for abnormal wear and damage.
3. Check the tie rod end and the rack and pinion bellows for
damage.
Check the tie rod end boot (1) for crack and abnormal
wear.
Check the rack and pinion boot (2) for crack and
abnormal wear.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
29
5. Check the tie rod end and the tie rod ball joint for damage.
Check the tie rod end ball joint for operation.
Check the tie rod ball joint for operation. Check the
tie rod for deflection due to its weight.
6. Replace all the defective components with new ones.
7. Check the tie rod end and the rotating area (1) of tie rod
ball joint for damage.
8. Check the tie rod end and the rack and pinion boot for
crack and abnormal wear.
9. Check the metal components for wear.
Check the pinion gear for abnormal wear and damage.
Check the rack gear for abnormal wear and damage.
Check the steering gear housing for wear and damage.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30
4G
2. Remove the pump clip and disassemble the pump from reservoir tank.
Mounting clip
Reservior tank
Mounting clip
Pump assembly
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
31
2. Gear box
Sub frame
[Notice]
If two oil pipes ( High, Low pressure ) are installed as
changed, abnormal vibration is detected through steering
handle and this damage to the power steering system.
(Smaller hole diameter for high pressure pipe)
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
32
4G
- Layout of high and low pressure pipe
Front
Rear
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EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
33
TROUBLE DIAGNOSIS
Symptom
Hard steering
Cause
Lack of lubrication
Abnormal wear or binding of steering ball joint
Damaged or faulty steering gear
Improper preload of steering pinion
Faulty steering shaft joint
Steering fluid leaks
Lack of fluid or air-in system
Faulty steering oil pump
Action
Rubricate & Replace
Replace
Replace gear assembly
Adjust
Replace
Repair or replace
Replenish or bleed
Replace
Adjust or replace
side
Repair or replace
Repair or replace
Repair or replace
Repair
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Replace
(Shimmy)
Replace
Replace
Repair or replace
Repair or replace
Retighten
STAVIC - 2004.09
Retighten
Air-in system
POWER STEERING
Retighten
Bleed
Replace
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
34
4G
Symptom
Cause
Action
Retighten
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AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
35
POWER STEERING
STAVIC - 2004.09
Application
Removal of the upper and lower
end assemblies of front
suspension
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4H
1. GENERAL INFORMATION
Tire And wheel Balancing
There are two types of the tire and wheel balancing: static
and dynamic.
Static balance is the equaldistribution of weight around
the wheel. assemblies that are statically unbalanced cause
a bouncing action called wheel tramp. This condition may
eventually cause uneven tire wear.
Dynamic balance is the equal distributio of weight on eeach
side of the centerline so that when the assembly spins
there is no tendency for it to move frim side to side . Assemblies that are dynamically unbalanced may cause
wheel shimmy.
2. Breaker
A cord belt between tread and carcass prevents
damages of inner code due to outer shock and
vibration.
3. Carcass
This major part made by pilling code papers of strong
synthetic fiber forms a structure of tire. Since it
maintains tire pressure and endures applied load and
shock to tire, it should have a high anti-fatigue
characteristic.
4. Side Wall
It is provided to improve the comfortable driving by
protecting carcass and cushion movement.
5. Bead
A steel wire winding the ending part of carcass code,
coated with rubber film and wrapped with nylon cord
papers. It fixes tire to a rim.
Inspect the tire for any damage. Balance the tire according to the equipment manufacturers recommendations.
Outside
Diameter
Width
Height
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EFFECTIVE DATE
AFFECTED VIN
4H
225
65
16
104 T
Max Speed :
190 km/h
Excessive Air-Pressure
Life
(%)
Load Index :
900 kg
Insufficient Air-Pressure
Load Index
Symbol
Limit Speed
(km/h)
Symbol
Limit Speed
(km/h)
80
94
670
130
95
690
140
96
710
150
97
730
160
98
750
170
99
775
180
100
800
190
101
825
200
102
850
210
103
875
240
104
900
Above 240
105
925
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Life
Index
4H
2. SPECIFICATION
Description
Wheel
Tire
Specification
Size
Aluminum type
Aluminum wheel
Type
Radial tire
Toe-in
Camber
6.5J x 16
13 ~ 16 kgf.m
Radial Tire
P225/65R16
35 psi
Front
0 ~ 4 mm
Rear
Front
0 30' (0 0.5)
Rear
Caster
4.5 30'
Hydroplaning
High speed
driving
Low speed
driving
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AFFECTED VIN
4H
4. WHEEL ALIGNMENT
The first responsibility of engineering is to design safe
steering and suspension systems. Each component must
be strong enough to with stand and absorb extreme punishment. Both the steering system and the front and the rear
suspension must function geometrically with the body
mass.
Camber
Tire centerline
Perpendicularline
Perpendicularline
Tire centerline
Toe-in
Camver (+)
Camver 0
Camver (-)
Camber is the tilting of the top of the tire from the vertical
when viewed from the front of the vehicle. When the tires
tilt outward, the camber is positive. When the tires tilt
inward, the camber is negative. The camber angle is measured in degrees from the vertical. Camber influnces both
directional control and tire wear.
Front side
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4H
Caster
Front side
Center line
Steering
axle
Center line
Steering
axle
Caster (+)
Caster 0
Caster (-)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4H
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4H
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
4H
Spare Tire
1. Prepare the spare tire handle and wheel nut wrench.
2. Install the handle through the hole at the rear side of the
vehicle.
3. Connect the wheel nut wrench at the end of the handle.
4. Turn the wheel nut wrench counterclockwise until the wire is loosened.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4H
11
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
4H
4. Separate the tires bead from the rim flange using the
approved lubricant.
[Notice]
Do not use silicone, synthetic detergent and gasoline, etc.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4H
13
6. Insert the removal lever between the tires bead and the
rim and separate the rim from the tire.
[Notice]
Do not use the tool that may cause any damage such as pipe,
damaged bar.
7. Pull out the opposite bead upward using the lever and
then separate the bead from the rim.
Maintenance
1. Check any damage the rim and replace as needed.
[Notice]
Do not repair the rim as welding or soldering.
Replace the new valve as replaces new tire.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
4H
Installation
1. Clean the rust, damaged rubber and dust, etc on the
rims surface with the brush.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4H
15
Specification of the
tire pressure
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
4H
7. INSPECTION
Visual Inspection
Condition
Rapid wear at
Cause
Under inflation or lack of rotation
Action
Adjust inflation pressure
shoulders
Tread damage
Uneven wear
Incorrect camber
Adjust camber
Incorrect toe-in
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4H
17
Condition
Cause
Action
Feathered edge
Incorrect toe-in
Adjust toe-in
Bold spot
Unbalanced wheel
Unbalanced wheel
Adjust
Check play
Check pre-load
Check
Check
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
4H
General Inspection
Tread
Inspect the tread condition on the tire surface and various
damages resulting from the foreign material, crack, stone or
nail etc. If there is any damage in the tire, repair or replace it.
Tire Wear
Measure the depth of the tire tread. If the depth of the tread
is below the specified value, replace the tire.
Limit of the Tread Wear
1.6 mm
You can see the mark in the groove, this is the indicator
of the tread wear limit.
The limit of the tread wear for all season tires are 1.6 mm
as same as the general tires and the platform mark
indicates as .
35 psi
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Insufficient
Excessive
4H
19
Wheel Runout
Measure wheel runout with an accurate dial indicator. Measurement may be taken with the wheels either on or off the
vehicle, using an accurate mounting surface such as a wheel
balancer. Measurements may be taken with or without the
tire mounted on the wheel.
1. Measure the dial runout and lateral runout on both the
inboard and outboard rim flanges.
Specification
2.66 mm
2.03 mm
[Notice]
If any measurement exceeds the above specifications, replace
the applicable tires or wheels.
Wheel Balance
Balance is the easiest procedure to perform and should be
done first if the vibration occurs at high speeds or if the tires or
the wheels are replaced.
When proceeding the wheel balancing procedure refer to the
following;
1. Do not the wheel weight over two at the inboard and the
outboard flanges.
2. The total weight ofthe wheel weight should not exceed
the 150 g (3.5 ounces)
3. Balancing the assemblies with the factory aluminum
wheels requires the use of the special nylon-coated, clipon wheel weights.
Weight point
Balance weight
Balance weight
10 g
20 g
30 g
40 g
50 g
60 g
0.4 oz
0.7 oz
1.10 oz
1.40 oz
1.80 oz
2.10 oz
Balance weight
Weight point
CHANGED BY
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AFFECTED VIN
20
4H
Rotation of Tires
Front and rear tires perform different jobs and can wear differently depending on the tires of road driven, driving condition,
etc.
The front tires will wear faster than the rear ones. To avoid
uneven wear of tires and to prolong tire life, inspect and rotate
the tires every 5,000 km (3,100 miles). After rotating the tires,
adjust the tire inflation pressures and be sure to check wheel
nuts tightness.
[Notice]
Do not mix different types of tires on the same vehicle such as
radial, bias and bias-belted tires except in emergencies,
because vehicle handling may be seriously affected and may
result in loss of control.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4H
21
8. TROUBLE DIAGNOSIS
Condition
Irregular tire wear
Cause
Improper tire inflation pressure
Adjust
Adjust
Poor toe-in
Adjust
Adjust
Adjust
Adjust
Adjust
STAVIC - 2004.09
Adjust or replacement
Check and adjust
Adjust
Adjust
Action
Proper weight
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MEMO
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4I
1. GENERAL INFORMATION
The propeller shaft transfers the power through the transmission and transfer case to the front/rear axle differential carrier
(final reduction gear). It is manufactured by a thin rounded
steel pipe to have the strong resisting force against the torsion
and bending.
Both ends of propeller shaft are connected to the spider and
the center of propeller shaft is connected to the spline to accommodate the changes of the height and length. The rubber
bushing that covers the intermediate bearing keeps the balance of rear propeller shaft and absorbs its vibration.
Specification
Description
Specification
Structure
Joint type
Number of spiders
Front
TOD T/C
Rear
17.893
below 0.4 mm
Below 14.5 g.cm @ 4500 rpm (Front shaft + Full time T/C)
Unbalance
Below 18.0 g.cm @ 4500 rpm (Rear shaft + Full time T/C)
Front shaft dimension
923.5 x 76.2(2t)
+ 750.4 (compressed) x 63.5 (2t)
PROPELLER SHAFT
STAVIC - 2004.09
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4I
Bolt
Bolt
CV joint
Universial joint
CV joint
Universial joint
Bolt/washer/nut
Center bearing assembly
Universial joint
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Bolt
PROPELLER SHAFT
STAVIC - 2004.09
4I
PROPELLER SHAFT
STAVIC - 2004.09
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AFFECTED VIN
4I
Center bearing
Axle side
T/C side
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PROPELLER SHAFT
STAVIC - 2004.09
4I
Installation
1. Installation in the reverse order of removal.
2. Keep the tigtening torque.
3. Keep the guide mark when install.
4. Check and replace parts if defective.
Tightening torque : 81 ~ 89 Nm
3. Rear axle
Tightening torque : 80 ~ 90 Nm
1. Rear - T/C
4. Front axle
2. Center bearing
5. Front - T/C
PROPELLER SHAFT
STAVIC - 2004.09
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4I
4. INSPECTION
Disassembly
1. Place an alignment mark and remove the propeller shaft.
2. Place an alignment on the spiders before removing.
3. Remove the snap ring with snap ring pliers.
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PROPELLER SHAFT
STAVIC - 2004.09
4I
Inspection
1. Visual Check
Check the components for wear and crack and replace if
needed.
2. Outer diameter of spider journal
Specified value
17.893 mm
Limit
17.910 mm
0.03 ~ 0.098 mm
Limit
0.25 mm
0.4 mm
3 ~ 8 kg.cm
PROPELLER SHAFT
STAVIC - 2004.09
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10
4I
Assembly
Clean the components and replace if damaged.
Flange yoke
Snap ring
Grease
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PROPELLER SHAFT
STAVIC - 2004.09
4I
11
5. TROUBLE DIAGNOSIS
Symptom
Vibration
Noise
Cause
Poor installation of sliding joint
Adjust
replace
Adjust
Tighten
Replace
STAVIC - 2004.09
Tighten
Replace
Lack of grease
PROPELLER SHAFT
Action
Add
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12
4I
Application
Centering the clutch disc
Removal of bearing
Pulling arms
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PROPELLER SHAFT
STAVIC - 2004.09
4J
BRAKE SYSTEM
1. GENERAL INFORMATION
Brake System
Brake Pedal
Even though a driver cuts off the power, while driving, the
vehicle continues to move due to the law of inertia.
Therefore, a braking device is needed to stop the vehicle.
The brake system normally uses the frictional discs that
converts the kinetic energy to the thermal energy by frictional operation.
The brake system consists of the brake disc (front wheel),
brake disc or drum (rear wheel), parking brake (mechanical
type), master cylinder, booster, pedal and supply lines
(pipes and hoses).
Hydraulic Brake
Brake pedal uses the leverage effect to apply bigger force
to the brake master cylinder.
Master Cylinder
BRAKE - GENERAL
STAVIC - 2004.09
Rear
Front
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4J
Brake Booster
The brake booster is a power assist device for brake
system. It relieves the pedal depressing force by using
the pressure difference between the vacuum pressure generated by vacuum pump in intake manifold and the atmospheric pressure.
Vacuum pump
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When releasing the brake pedal, the valve plunger (3) returns back to the original position by return spring (4) and
the air valve (6) closes. At this time, the vacuum valve (9)
opens and the pressure difference between chamber (A)
and (B) in power cylinder is eliminated. Accordingly, the
power piston (5) returns back to original position by the
reaction of master cylinder (10) and the diaphragm return
spring (8).
BRAKE - GENERAL
STAVIC - 2004.09
4J
2. SPECIFICATION
Item
Ventilated disk
Solid disk
Booster type
BRAKE - GENERAL
STAVIC - 2004.09
Tendem type
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4J
3. COMPONENTS
Return spring
Vacuum pump
Pedal bracket
Vacuum
hose
Booster
Booster
Gasket
Brake pedal
O-ring
Reservoir tank
Pad
Pressure sensor
Cable - RR
speed sensor
Pad
M/T
A/T
Cable - FRT
speed sensor
Knuckle
Brake dust shield
Hub flange
Knuckle
Hub flange
Brake disk
Brake disk
Steering
knuckle assy
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BRAKE - GENERAL
STAVIC - 2004.09
4J
Release lever
Parking brake assy
HECU
Cable
Brkt - HECU
Damper
Pad
Tension spring
Equalizer
Brake shoe
Adjuster
Return spring - Upper
Return spring - Lower
Knuckle
Operating lever
Brake dust shield
Hub flange
Brake disk
BRAKE - GENERAL
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4J
Vacuum Pump
Booster
Vacuum hose
Gasket
O-ring
Brake fluid
reservoir
tank
Pressure
sensor
Master
cylinder
Master cylinder
[Notice]
Do not disassemble the brake oil pressure sensors These can not be reinstalled of disassembled.
After reinstall the reserver tank perform a air bleeding of brake system
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BRAKE - GENERAL
STAVIC - 2004.09
4J
5. INSPECTION
Air Bleeding (With ABS)
6. Repeat the step 4 through 5 until clear brake fluid
comes out of air bleed screw.
7. Perform the same procedures at each wheel.
[Notice]
Repeat the step 4 through 5 until clear brake fluid comes
out of air bleed screw.
After bleeding the air, make sure that the brake system is
properly operated.
[Notice]
Replace the brake oil at every 2 years.
[Notice]
Bleed air in the following order:
Right rear brake Left rear brake Right front brake
Left front brake
Check the fluid level repeatedly during air bleeding, and
add fluid if needed.
BRAKE - GENERAL
STAVIC - 2004.09
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10
4J
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BRAKE - GENERAL
STAVIC - 2004.09
4J
11
BRAKE - GENERAL
STAVIC - 2004.09
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12
4J
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BRAKE - GENERAL
STAVIC - 2004.09
4J
13
BRAKE - GENERAL
STAVIC - 2004.09
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14
4J
Brake Booster
Preceding work : Drain the brake fluid
1. Disassembly the master cylinder assembly and remove
clevis pin on the booster push rod.
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BRAKE - GENERAL
STAVIC - 2004.09
4J
15
21 ~ 35 Nm
BRAKE - GENERAL
STAVIC - 2004.09
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16
4J
Brake Pedal
1. Remove two stop lamp switch bracket bolts.
Tightening torque
18 ~ 22 Nm
18 ~ 22 Nm
Return spring
Washer
Brake pedal
Bolt
Bracket
16 ~ 32 Nm
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BRAKE - GENERAL
STAVIC - 2004.09
4J
17
Pedal height
Specified value (A)
Operating
rod
Stop lamp
switch
[Notice]
If the value is out of the specified range, adjust the pedal
height by using lock nut of stop lamp switch.
Operating rod
lock nut
Stop lamp
switch lock nut
Maximum stroke
Specified value (C)
138 mm
[Notice]
If the value is out of the specified range, adjust the maximum
stroke by using stop lamp and lock nut.
BRAKE - GENERAL
STAVIC - 2004.09
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18
4J
3 ~ 8 mm
If the free play is below the specified value, check if the clearance between the outer case of the stop lamp and the brake
pedal is within the specified range.
If the clearance is out of the specified range, the clearance
between the clevis pin and the brake pedal arm is too large.
Check the components and repair if needed.
Normal
1. Let the engine run for 1 ~ 2 minutes and stop it. If the
brake pedal stroke is shortened as pumping the brake
pedal, the system is normal. If not, the system is
defective.
Faulty
Engine stop
Engine running
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BRAKE - GENERAL
STAVIC - 2004.09
4J
19
7. TROUBLE DIAGNOSIS
Symptom
Noise or vehicle vibration when applied
Cause
Incorrectly mounted back plate or caliper
Loosened bolt of back plate or caliper
Crack or uneven wear of brake drum or disc
Retighten
Replace
Clean
Replace
Repair
Repair
Loosened suspension
Poor braking
Repair
Lack of lubrication
Pulls to one side when
braking
Action
Lubrication
Retighten
Adjust
Repair
Replace
Replace
Repair
Repair
Replenish or replace
Bleeding
Repair
Repair
Replace
Repair
Repair
Repair
Repair
Fluid leaking
Repair
Adjust
Repair
Adjust
Brake dragging
Repair
Replace
Lubrication
Replace
Adjust
Replace
Replace
Replace
STAVIC - 2004.09
Replace
BRAKE - GENERAL
Bleeding
Repair
Adjust lever travel or
check the cable
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20
4J
FRONT BRAKE
1. GENERAL INFORMATION
Caliper
Adjustment of Clearance
*
*
*
*
However, the piston seal shape is deformed since the piston seal is fixed at the cylinder groove as shown in below
figure.
Piston
Pad
Disc
* General description
1. Piston
3. Pad
2. Piston seal
a. Clearance
Specifications
Item
Specification
Type
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42.9 x 2 mm
Pad thickness
10.5 mm
Disc thickness
26 mm
BRAKE - GENERAL
STAVIC - 2004.09
4J
21
2. COMPONENTS
For strong and safe brake force, ventilated disk and double piston type is adapted to front brakes.
Brake disk
Caliper
Brake hose
Disk
Caliper carrier
Pad spring
Brake pad
Bolt - Caliper
Piston
Brake
BRAKE - GENERAL
STAVIC - 2004.09
Caliper assembly
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22
4J
20 ~ 30 Nm
2. Unscrew two caliper mounting bolts and disassemble the caliper assembly.
Tightening torque
85 ~ 105 Nm
BRAKE - GENERAL
STAVIC - 2004.09
4J
23
22 ~ 34 Nm
BRAKE - GENERAL
STAVIC - 2004.09
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24
4J
Inspection
Clean the dissembled components and visually check the
followings:
Wear, rust and damage on the cylinder and piston
Damage, crack and wear on cylinder body and guide pin
Uneven wear and oil contamination on boot
Damage and tear on boot
Scratch and bending on disc plate
Pad Thickness
1. Remove the tire.
2. Measure the pad thickness and replace it if it is below
the wear limit.
New pad thickness
Wear limit
10.5 mm
2 mm
Wear limit
28 mm
25.4 mm
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BRAKE - GENERAL
STAVIC - 2004.09
4J
25
Application
Removal of ABS front brake
tooth wheel
Piston Puller
BRAKE - GENERAL
STAVIC - 2004.09
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32
4J
PARKING BRAKE
1. COMPONENTS
Pedal assembly
Equalizer assembly
Operating lever
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BRAKE - GENERAL
STAVIC - 2004.09
4J
33
Release lever
Release cable
Brake damper
Pedal assembly
Pedal
Equalizer assembly
Equalizer bolt
Tension spring
BRAKE - GENERAL
STAVIC - 2004.09
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AFFECTED VIN
34
4J
2. Remove the clamping ring from pedal assembly and disconnect the brake cable (1).
3. Disconnect the parking brake switch (2).
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BRAKE - GENERAL
STAVIC - 2004.09
4J
35
4. Remove pedal assembly mounting bolts (12 mm) & nuts (12 mm).
Tightening torque
10 ~ 14 Nm
Nut
Bolt
BRAKE - GENERAL
STAVIC - 2004.09
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36
4J
Equalizer Assembly
Adjustment
1. Park the vehicle on the car lift and set blocks under front
tires.
2. Place the shift lever to N (A/T) or Neutral (M/T).
3. Release the parking brake.
4. Lift the rear wheels with supplementary lift.
5. Check the brake force as rotating the wheels - specified
hand brake notch : 5
6. If the brake force is not made enough, adjust the parking
brake adjust nut in the brake drum.
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BRAKE - GENERAL
STAVIC - 2004.09
4J
37
Adjusting bolt
Operating lever
BRAKE - GENERAL
STAVIC - 2004.09
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38
4J
3. Remove lower return spring and disassemble sperating lever from brake cable.
Adjustment
1. Have the brake shoe contact the inner face of brake disk by winding the brake adjust bolt using a tool (screw
driver), and then, unscrew the bolt by 4 ~ 5 notch. (Clearance between brake disk and brake shoe : 0.2 mm)
2. Check if the wheel become locked when brake force is applied.
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BRAKE - GENERAL
STAVIC - 2004.09
4K
ABS SYSTEM
1. GENERAL INFORMATION
The aim of the ABS is to mmaintain steerability and driving stability and to take the burden off the driver. If the stopping
distance is shorter on some road surfaces (carriageway conditions), this is a gift of physics and not a development aim.
ABS is a device which senses that one or more of the wheels are locking up during braking. It monitors the rotational
speeds of the wheels and reduces hydraulic pressure to any wheel it senses locking up. It is controlled by both
mechanical and electronic components. When you apply the brakes, the ABS will regulate the flow of brake fluid being
delivered to the brake calipers. By the use of electronic computers, the brakes rapidly alternate (at a rate of 30 times per
second) from full pressure to full release.
DRIVING PHYSICS
To give you a better understanding of the tasks and functions of ABS, we will first look at the physics principles.
ABS/ESP SYSTEM
STAVIC - 2004.09
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4K
Slip
The brake slip is the difference between the vehicle speed and the wheel circumference speed. If the wheel locks, the
slip is greatest, that is 100 %. If the wheel is running freely and unbraked, the slip is the lowest, equal to 0 %. Slip can
be calculated from the vehicle speed Vveh and the wheel speed Vw. The equation for this is:
S=
Vveh - Vw
Vveh
X 100 %
100 - 70
100
X 100 %
The slip is 30 %.
Kamm circle
Before we go into the Kamm circle, you should know that a
tire offers a maximum of 100 % transmissibility. It is all the
same for the tire whether we require 100 % in the direction of
braking or in the direction of the acting lateral force, e.g. when
driving round curves. If we drive into a curve too fast and the
tire requires 100 % transmissibility as cornering force, the tire
cannot transmit any additional brake force. In spite of the ABS
the car is carried out of the curve. The relationship between
brake force B and cornering force S is shown very clearly in
the Kamm circle. If we put a vehicle wheel in this circle, the
relationship becomes even clearer. In this relationship: as long
as the acting forces and the resulting force remain within the
circle, the vehicle is stable to drive. If a force exceeds the
circle, the vehicle leaves the road.
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Dry concrete
Friction coefficient
Wet concrete
Snow
Ice
Slip
Cornering
side force
KAMM circle
Braking force
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
ABS-Control range
Stable
Unstable
- Cornering force
Brake force
Cornering force
Slip
Reference speed
Vehicle speed
Wheel speed
- Wheel speed
- Reference speed
- Deceleration
- Slip
Reference speed
The reference speed is the mean, I.e. average speed of all wheel speeds determined by simple approximation.
Simplified ABS control
If, during braking, one wheel speed deviates from the reference speed, the ABS control unit attempts to correct that
wheel speed by modulating the brake pressure until it again matches the reference speed. When all four wheels tend to
lock, all four wheels speeds suddenly deviate from the previously determined reference speed. In that case, the control
cycle is initiated again in order to again correct the wheel speed by modulating the brake pressure.
Selector low control
This control is used for regulating the brake pressure for rear axle during ABS operation. This control uses lower
adhesion coefficient to prevent the rear wheels from locking.
ABS/ESP SYSTEM
STAVIC - 2004.09
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AFFECTED VIN
4K
System Description
Service precautions
Observe the following general precautions during any
ABS/TCS service. Failure to adhere to these precautions may result in ABS/TCS system damage.
1. Disconnect the EBCM harness connector before
performing the electric welding procedures.
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ABS/ESP SYSTEM
STAVIC - 2004.09
4K
ON-VEHICLE SERVICE
Service Precautions
[Notice]
Brake Fluid may irritate eyes and skin. In case of contact,
take the following actions:
Eye contact - rinse thoroughly with water.
Skin contact - wash with soap and water.
Ingestion - consult a physician immediately.
[Notice]
To help avoid personal injury due to poor braking. DO
NOT Tap into the vehicles brake system to operate a
trailer brake system.
[Notice]
When fasteners are removed, always reinstall them at the
same location from which they were removed. If a fastener
needs to be replaced, use the correct part number fastener
for is not available, a fastener of equal size and strength
(or stronger) may be used. Fasteners that are not reused,
and those requiring thread-locking compound will be
called out. The correct torque values must be used when
installing fasteners that require them. If the above
procedures are not followed, parts or system damage
could result.
[Notice]
Use only DOT-3 equivalent hydraulic brake fluid. The use
of DOT-5 (silicone) brake fluid is not recommended.
Reduced brake performance or durability may result.
Bleeding system
Replacement modulators are shipped already filled and
bled. In normal procedures requiring removal of the
modulator, such as to replace the HECU, air will not enter
the modulator, and normal bleeding will be all that is
needed.
If air enters the hydraulic modulator, or if an unfilled modulator is installed, use the brake bleeding program in the
scan tool to bleed the modulator. Manual bleeding of the
hydraulic modulator is not possible.
[Notice]
Avoid spilling brake fluid on any the vehicles painted
surfaces, wiring, cables or electrical connectors. Brake
fluid will damage paint and electrical connections. If
any fluid is spilled on the vehicle, flush the area with
water to lessen the damage.
ABS/ESP SYSTEM
STAVIC - 2004.09
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AFFECTED VIN
4K
ABS HECU
ABS & EBD warning lamp
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AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
CAN LO
CAN HI
Battery +
(pump supply power)
IG1
Brake switch
H
E
C
U
ABS/ESP SYSTEM
STAVIC - 2004.09
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AFFECTED VIN
10
4K
4. ELECTRICAL CIRCUIT
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ABS/ESP SYSTEM
STAVIC - 2004.09
4K
11
Master cylinder
Primary
circuit
Secondary
circuit
Damping
chamber
Pump
Low pressure
accumulator
Inlet
valve
(FR)
Inlet
valve
(FL)
Outlet valve
(FR)
Inlet valve
(all rear
wheel)
Outlet valve
(FL)
Wheel (FR)
Low pressure
accumulator
Wheel (FL)
Outlet valve
(all rear wheel)
Wheel (RR)
Wheel (RL)
The vehicle equipped only with the ABS controls the wheels braking force using three 3-channel 4-sensor method. The
front wheels that are the primary circuit of the brake system is composed of two wheel speed sensors and two channel
valves system with two inlet valves and two outlet valves. The rear wheels that are the secondary circuit of the brake
system is composed of two wheel speed sensors, one inlet valve and one outlet valve. This system is similar to the one
from the previous model.
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
12
4K
Low pressure
chamber
Pump
Inlet valve
Outlet valve
The hydraulic pressure in the master cylinder increases through the vacuum booster and it is delivered to the wheel via
the normal open inlet valve. At this moment, the normally-closed outlet valve is closed. The speed of the wheel that
hydraulic pressure is delivered reduces gradually .
Low pressure
chamber
Inlet valve
Pump
Outlet valve
Constant pressure
As hydraulic pressure on each wheel increases, the wheel tends to lock. In order to prevent the wheel from locking, the
hydraulic valve modulator operates the inlet valve control solenoid to close the inlet valve and stop the hydraulic pressure
increases. At this moment, the outlet valve is closed. This procedure helps the wheel to maintain a stable hydraulic
pressure.
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EFFECTIVE DATE
AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
13
Low pressure
chamber
Pump
Inlet valve
Outlet valve
Pressure decreases
Even when the hydraulic pressure on each circuit is stable, the wheel can be locked as the wheel speed decreases.
This is when the ABS ECU detects the wheel speed and the vehicle speed and gives the optimized braking without
locking the wheels. In order to prevent from hydraulic pressure increases, the inlet valve is closed and the outlet valve is
opened. Also, the oil is sent to the low pressure changer and the wheel speed increases again. The ABS ECU operates
the pump to circulate the oil in the low pressure chamber to the master cylinder. This may make the driver to feel the
brake pedal vibration and some noises.
Low pressure
chamber
Pump
Inlet valve
Outlet valve
Pressure increases
As the wheel speed increases, the inlet valve opens and the wheels pressure increases due to the master cylinder
pressure. The oil in the low pressure chamber circulates to the wheel by the pump and the wheel speed decreases as
the hydraulic pressure at wheel increases. This operation continues repetitively until there are no signs that the ECU is
locking the wheels. When the ABS hydraulic pressure control takes place, there may be some vibration and noises at
the brake pedal.
ABS/ESP SYSTEM
STAVIC - 2004.09
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AFFECTED VIN
14
4K
6. COMPONENTS DESCRIPTION
HECU (Hydraulic & Electronic
Control Unit)
HECU consists of motor pump (1), solenoid valve (2) and ECU
(3).
ECU connector has 47 pins and the number of valves in valve
body is 6 when equipped with only ABS and 12 when equipped
with ESP system.
Motor Pump
The motor is operated when ABS is activated. The cam-shaped
output shaft of the motor enables the brake system to receive
and supply the brake fluid during the motor operation.
Valve Body
The cam bushing is installed between plungers and it draws
and discharges the brake fluid.
CHANGED BY
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AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
15
(Pumping)
When the cam pushes the left plunger during motor operation,
the system pressure is generated in the left cylinder. At this
time, the right plunger is expanded by spring force and the
expanded volume of the right cylinder draws the brake fluid.
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
4K
<Wheatstone bridge>
Active type wheel speed sensor generate square wave insteal of sine wave
Specifications
Item
Specifications
Supplying voltage
DC 12V
Air gap
Output current (vehicle speed: at 2.75 km/h)
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Reference
7.5 ~ 20 V
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
17
ABS/ESP SYSTEM
STAVIC - 2004.09
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18
4K
15 ~ 19 Nm
15 ~ 19 Nm
Secondary
Primary
[Notice]
Be careful not to damage the HECU pipe and nut thread when reinstall.
[Notice]
When you install a new HECU to the vehicle, Coding is excuted automatically.
CHANGED BY
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AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
19
19 ~ 25 mm
Airgap
0.369 ~ 1.213 mm
19 ~ 25 Nm
Airgap
0.3677 ~ 1.229 mm
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
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20
4K
System Fuse
The ABS/TCS system fuse and SB2 is located at the fuse
box in engine compartment.
Indicators
The ABS and TCS indicators are in instrument cluster.
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ABS/ESP SYSTEM
STAVIC - 2004.09
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21
Installation
1. Install the ABS front tooth wheel using the ABS tooth
wheel installer (2).
ABS/ESP SYSTEM
STAVIC - 2004.09
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22
4K
Application
661 589 16 33 00
ABS tooth wheel puller
661 589 17 33 00
ABS tooth wheel installer
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STAVIC - 2004.09
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23
ESP SYSTEM
1. GENERAL INFORMATION
Principle of ESP
ESP (Electronic Stability Program) recognizes critical driving conditions, such as panic reactions in dangerous situations,
and stabilizes the vehicle by wheel-individual braking and engine control intervention with no need for actuating the
brake. This system is developed to help the driver avoid the danger of losing the control of the vehicle stability due to
under-steering or over-steering during cornering.
The yaw rate sensor, lateral sensor and longitudinal sensor in the sensor cluster and the steering wheel angle sensor
under the steering column detect the spin present at any wheels during over-steering, under-steering or cornering. The
ESP ECU controls against over-steering or under-steering during cornering by controlling the vehicle stability using the
input values from the sensors and applying the brakes independently to the corresponding wheels.
The system also controls during cornering by detecting the moment right before the spin and automatically limiting the
engine output (coupled with the ASR system).
Under steering
Over steering
Desired
course
With ESP
Without
ESP
Desired
course
With ESP
Braked
wheel
Braking force
Without
ESP
Compensating yaw
moment
Braked
wheel
Compensating yaw
moment
Braking force
Understeering
Understeering is when the steering wheel is steered to a
certain angle during driving and the front tires slip toward
the reverse direction of the desired direction. Generally,
vehicles are designed to have under steering. The vehicle
can return back to inside of cornering line when the steering wheel is steered toward the inside even when the vehicle front is slipped outward. As the centrifugal force
increases, the tires can easily lose the traction and the
vehicle tends to slip outward when the curve angle gets
bigger and the speed increases.
ABS/ESP SYSTEM
STAVIC - 2004.09
Oversteering
Oversteering is when the steering wheel is steered to a
certain angle during driving and the rear tires slip outward
losing traction. When compared with under steering
vehicles, the controlling of the vehicle is difficult during
cornering and the vehicle can spin due to rear wheel moment when the rear tires lose traction and the vehicle speed
increases.
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24
4K
ESP Control
The ESP system includes the ABS/EBD and ASR systems allowing the system to be able to operate depending to the
vehicle driving conditions. For example, when the brakes are applied during cornering at the speed of 100 km/h, the ABS
system will operate at the same time the ASR or ABD systems operate to reduce the power from the slipping wheel. And
when yaw rate sensor detects the rate exceeding 4/seconds, the ESP system is activated to apply the brake force
to the corresponding wheel to compensate the yaw moment with the vehicle stability control function. When various
systems operate simultaneously under a certain situation, there may be vehicle control problems due to internal malfunction of a system or simultaneous operations. In order to compensate to this problem, the ESP system sets the
priority among systems. The system operates in the order of TCS (ASR or ABD), ESP and ABS. The order may be
changed depending on the vehicle driving situations and driving conditions. As the single-track vehicle model used for
the calculations is only valid for a vehicle moving forward, ESP intervention never takes place during backup.
Turning
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Turning
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
25
Understeering Control
Oversteering Control
ESP auto brake
Engine
control
No braking by driver
ESP auto brake
: Service brake
ESP
+
Conventional
brake
(ABS not operating)
2 : ABS operation
ESP
+
ABS brake
1 : The slip occurs
under ESP
operation
2 : ABS operation
2 : ASR operation
ESP
Engine
control
+
ASR
1 : The slip occurs
under ESP
operation
ABS/ESP SYSTEM
STAVIC - 2004.09
2 : ASR operation
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26
4K
Experienced drivers
Inexperienced drivers
Time (s)
(1) Purpose
HBA (Hydraulic Brake Assist) system helps in an emergency braking situation when the driver applies the brake fast,
but not with sufficient pressure, which leads to dangerously long braking distance. ECU recognizes the attempt at full
braking and transmits the signal calling for full brake pressure from the hydraulic booster. An inexperienced, elderly or
physically weak driver may suffer from the accident by not fully pressing the brake pedal when hard braking is required
under emergency. The HBA System increases the braking force under urgent situations to enhance the inputted braking
force from the driver.
Based on the fact that some drivers depress the brake pedal too soft even under when hard braking is necessary, the
HECU system is a safety supplementary system that builds high braking force during initial braking according to
pressure value of the brake pressure sensor and the pressure changes of the pressure sensor intervals.
When the system is designed to apply high braking force when brake pedal is depressed softly by an elderly or
physically weak driver, the vehicle will make abrupt stopping under normal braking situation due to high braking pressure
at each wheels.
(2) Operation
The brake pressure value and the changed value of the pressure sensor are the conditions in which the HBA System
operates. There are 2 pressure sensors under the master cylinder. When the ESP ECU system determines that emergency braking is present, the pump operates, the brake fluid in the master cylinder is sent to the pump and the braking
pressure is delivered to the wheels via the inlet valves.
If the drive depress the brake pedal slowly, the pressure change is not high. In this case, only the conventional brake
system with booster is activated.
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27
2. Pressure sensor
4. Sensor cluster:
(Yaw rate + lateral sensor +
longitudinal sensor)
ABS/ESP SYSTEM
STAVIC - 2004.09
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28
4K
ABS
ESP
HECU
Location
Under battery
Each 4 wheels
Wheel speed sensor
Active Type
Active Type
Steering wheel
angle sensor
N/A
Sensor cluster
N/A
Longitudinal sensor
Integrated in HECU
Pressure sensor
N/A
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Longitudinal sensor
Analog Output
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STAVIC - 2004.09
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29
CAN LO
CAN HI
IG1
Brake switch
STICS (Vehicle speed)
ESP switch
Signal
Ground
Signal
Ground
Signal
E
S
P
Ground
Pressure sensor 1
Ground
Power
source
Pressure sensor 2
Signal
Ground
H
E
C
U
ESP buzzer
While ESP is in operation buzzer work by
every 0.1sec
Diagnostic connector
IG1
ST1
SWAS
ST2
STN
Ground (Pump)
Ground
Power
source
Ground (Valve)
CAN-H
Sensor cluster
CAN-L
Ground
ABS/ESP SYSTEM
STAVIC - 2004.09
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30
4K
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ABS/ESP SYSTEM
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31
Brake Pressure Sensor, ESP Sensor, Sensor Cluster, ESP OFF Switch
ABS/ESP SYSTEM
STAVIC - 2004.09
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4K
Pressure
sensor
Damper
(primary circuit)
Damper
(secondary circuit)
Separation
valve (NO)
Separation valve
(NO)
Damping chamber
Shuttle
valve
Shuttle valve
Pump
Low pressure
accumulator
FR
inlet valve
(NO)
FL inlet
valve
(NO)
RR
inlet valve
(NO)
RL
inlet valve
(NO)
FR
outlet
valve(NC)
FL
outlet
valve(NC)
RR
outlet
valve(NC)
RL
outlet
valve(NC)
Wheel (FR)
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Wheel (FL)
Wheel (RR)
Wheel (RL)
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STAVIC - 2004.09
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33
System Overview
When equipped with ABS, the braking force at each wheel will be controlled with 3-channel 4-sensor method. And when
equipped with ESP, 4 wheels will be controlled independently with 4-channel method. (When controlling ABS system
only, it will be operated with 3-channel method.) When compared to the vehicle equipped with ABS/EBD only, the
internal hydraulic circuit has a normally-open separation valve and a shuttle valve in primary circuit and in secondary
circuit. When the vehicle brakes are not applied during engine running or when applying the non-ABS operating brakes,
the normally-open separation valve and the inlet valve are open, whereas the normally-closed shuttle valve and the outlet
valve are closed. When the ESP system is operating, the normally-open separation valve will be closed by the solenoid
valve operation and the hydraulic circuit will be established by the shuttle valve. Then, the inlet and outlet valves will be
closed or open depending on the braking pressure increase, decrease or unchanged conditions.
The warning lamp comes on and warning beep sounds when the ESP is operating
When the ESP operates during vehicle movement, the ESP warning lamp on the instrument panel flickers and
beep comes on every 0.1 seconds. The ESP operation shows that the vehicle stability is extremely unstable
and it is used to warn the driver. The ESP system is just a supplementary system for the vehicle motion and it
cannot control the vehicle when it exceeds the physical limits. Do not solely rely on the system but be advised
to drive the vehicle safely.
Noise and vibration that driver senses when the ESP is operating
The ESP system may transfer noise and vibration to the driver due to the pressure changes caused by the
motor and valve operations in a very short period of time. Extreme cornering will trigger the ESP operation and
this will make the driver feel noise and vibration due to sudden brake application. Also, the ESP system controls
the engine output. So, the driver may notice the engine output decrease even when the accelerator pedal is
being applied.
ABS/ESP SYSTEM
STAVIC - 2004.09
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34
4K
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Outlet valve
Inlet valve
In this position, the separation valve and the inlet valve are open (normal open), the electrically operated shuttle valve and
the outlet valve are closed. When the brake is applied under these conditions, the brake fluid will be sent to each wheel
via the separation valve and inlet valve.
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STAVIC - 2004.09
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35
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Inlet valve
Outlet valve
The pressure decreases just before the wheel speed drops and the wheels. The inlet valve closes and the outlet valve
opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied.
Then the pump operates to allow fast oil drainage.
ABS/ESP SYSTEM
STAVIC - 2004.09
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AFFECTED VIN
36
4K
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Inlet valve
Outlet valve
The Inlet valve and outlet valve will be closed to maintain the pressure in the hydraulic circuit applied at the wheels. By
closing the valves, the hydraulic pressure at the wheels will not be lost or supplied any more. During ESP operation, the
separation valve closes and only the shuttle valve at the pump opens.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
37
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Outlet valve
Inlet valve
The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed. Then, the pump is
operated.
When ESP operates while the ABS is operating, the pressure will be increased continuously until just before the
corresponding wheel gets locked.
ABS/ESP SYSTEM
STAVIC - 2004.09
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AFFECTED VIN
38
4K
Low pressure
chamber
Shuttle valve
Outlet valve
Separation valve
Inlet valve
Pump
Rear wheel
Outlet valve
Inlet valve
Front wheel
The above figure shows one front and one rear wheel and the same hydraulic circuit forms as in the ESP operation.
When HECU recognizes that it is an emergency and it is required for hard braking, depending on the pressure value of
the brake pressure sensor and pressure changes caused by the pressure sensor timing, it operates the pump immediately to apply the brake pressure at the wheels.
Then, the pressure in the pump increases until just before the corresponding wheel gets locked. The motor still keeps
rotating and the outlet valve and the separation valve are will stay closed. When the wheel starts to lock, the HBA
function cancels and switches to ABS operation.
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39
6. COMPONENTS DESCRIPTION
HECU (Hydraulic and Electronic Control Unit)
HECU Installed in a Vehicle
Primary
FR: Front right
ABS/ESP SYSTEM
STAVIC - 2004.09
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40
4K
# ABS control
If during braking, one wheel speed deviates from the reference
speed, the ABS control unit attempts to correct that wheel by
modulating the brake pressure until it again matches the reference speed. When all four wheels tend to lock, all four wheels
speeds suddenly deviate from the previously determined reference speed. In that case, the control cycle is initiated again
in order to again correct the wheel speed by modulating the
brake pressure.
Brake pressure
Reference speed
Vehicle speed
Wheel speed
Mote pump
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AFFECTED VIN
Valve body
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
41
Connector
Pin no.
1
2
3
Name
Battery (B+)
Self diagnosis (K-Line)
Steering wheel angle sensor (STN)
Current Tange
Max. 30 A
Max.100 mA
Max. 10 mA
Voltage Range
0 ~ 18 V
0 ~ 18 V
0 ~18 V
ABS ECU
O
O
-
4
5
6
7
IGN1
Steering wheel angle sensor ground
Sensor cluster power
Steering wheel angle sensor power
Max. 200 mA
Max. 100 mA
Max. 250 mA
Max. 10 mA
0 ~ 18 V
0V
0 ~ 18 V
0 ~ 18 V
O
-
Max. 100 mA
0 ~ 18 V
0 ~ 18 V
0V
O
O
8
9
10
11
CAN (High)
12
13
14
15
16
CAN (Low)
Ground
Max. 100 mA
Max. 20 A
17
18
19
Max. 20 mA
Max. 20 mA
5V
0V
20
21
22
23
Pressure
Pressure
Pressure
Pressure
Max.
Max.
Max.
Max.
5
0
5
5
24
25
26
27
28
Max. 10 mA
Max. 10 mA
0 ~ 18 V
1.3 ~ 4.1 V
29
30
31
32
Max. 10 mA
Max. 10 mA
Max. 250 mA
Max. 20 A
0 ~ 18 V
1.3 ~ 4.1 V
0V
0 ~ 18 V
33
34
35
36
37
mA
mA
0V
0 ~ 18 V
-
O
O
-
mA
mA
Max. 10 mA
0 ~ 18 V
0V
0 ~ 18 V
O
O
-
Max. 10 mA
3 ~ 45 mA
3 ~ 45 mA
Max. 20 mA
0 ~ 18 V
0V
0 ~ 18 V
0 ~ 18 V
O
O
O
O
3 ~ 45 mA
3 ~ 45 mA
Max. 30 A
0 ~ 18 V
0V
0V
O
O
O
38
39
40
41
42
43
44
45
46
47
ABS/ESP SYSTEM
STAVIC - 2004.09
10
20
20
10
3 ~ 45
3 ~ 45
3 ~ 45
3 ~ 45
mA
mA
mA
mA
V
V
V
V
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AFFECTED VIN
42
4K
Permanent
magnet
Sensor filament
Specifications
Description
Specifications
Supplying voltage
DC 12 V
Air gap
Output current
(vehicle speed at 2.75 Km/h)
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Reference
7.5 ~ 20 V
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STAVIC - 2004.09
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43
1. Clock spring
2. Multi-function switch
Specifications
Descriptions
Specifications
Working voltage
9 ~ 16 V
10 mA
1500/S
Working temperature
-30 ~ 75C
Supplying voltage
9 ~ 16 V(battery voltage)
When short
0V
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
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44
4K
Steering column
Phototransistor
Slotted plate
The steering wheel angle sensor is integrated with the phototransistor and the LED and there is a slotted plate between
them. When the inner slotted plate rotates with the steering column shaft when the steering wheel is turned, the voltage
occurs through the holes. The detected voltage will be transmitted to the ESP unit as a pulse from the 3 terminals.
Then, the two voltage pulses are used to get the average value for detecting the steering wheel position and its angle
speed. And the other pulse is used for checking the alignment of the steering wheel.
Steering
Wheel
Angle
Sensor
(SWAS)
ESP
unit
With ESP
Working voltage
9 ~16 V
Number of pulse
per revolution
45 Pulses /1rev
Duty
Approx. 50 %
High - V
3.0 ~ 4.1 V
Low - V
1.3 ~ 2.0 V
STN
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AFFECTED VIN
4K
45
Sensor Cluster
The lateral sensor, logitudinal sensor and the yaw rate sensor are important components of the Electronic Stability
Program. The cluster links these sensors to an on-board computer unit and to a CAN interface, incased in a sturdy
housing, that is mounted on the chassis. Its modular concept allows the integration of further sensor functions.
Location
Sensor cluster
Power supply
Power supply
circuit
Yaw rate sensor
Micro controller
(self diagnosis)
ECU
A/D converter
Lateral sensor
CAN
CAN module
ABS/ESP SYSTEM
STAVIC - 2004.09
Longitudinal sensor
CHANGED BY
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AFFECTED VIN
46
4K
Power
Ground
Power
Sensor cluster
ESP unit
Specification
(sensor cluster: yaw rate sensor + lateral acceleration sensor + Longitudinal acceleration sensor)
Descriptions
Specifications
Supplying voltage
Approx. 8 ~ 16 V
Output range
0.2 ~ 4.8 V
-75/s ~ +75/s
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EFFECTIVE DATE
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ABS/ESP SYSTEM
STAVIC - 2004.09
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47
Installation position
Tuning forks vertical
Required accuracy of position: max. 3 tolerance to
maintain full comfort
Failure to maintain the specified installation position will
result in asymmetrical control
Lateral/Longitudinal Acceleration
Sensor
These sensors sense the lateral/longitudinal acceleration of
the vehicle and located in sensor cluster. For 4WD vehicle,
the longitudinal sensor is located in sensor cluster and the
functions are same only except the direction. The lateral acceleration sensor detects the movement of lateral direction
and the longitudinal acceleration sensor detects the movement of longitudinal direction (driving direction).
Between two electrically charged stationary plates having the
same polarity, an electrically charged silicon element having
the opposite polarity is attached to the end of a cantilever
arm. Between these three plates, two electric fields are generated by the capacitors C1 and C2. The capacitances of C1
and C2 change in response to lateral acceleration. This change
can be used to calculate the direction and amount of lateral/
longitudinal acceleration acting on the vehicle. For 0 g lateral
acceleration, the sensor produces an output signal with a voltage of 2.5 V.
The signal of the lateral acceleration sensor alone cannot trigger an ESP intervention.
The ESP sensor cluster can be considered as one module.
The measured value by lateral/longitudinal and yaw rate sensors is transmitted to ESP unit via two CAN lines.
When a sensor is faulty, the sensor cluster produces an output signal of 0 V (fail safe function).
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
48
4K
Pressure Sensor
Location
1. Master cylinder
5. Connector
Power
- pressure: 20 bar
Signal output
Ground
Power
Signal output
<Secondary pressure sensor>
<ESP unit>
Specifications
Descriptions
Specifications
Supplying voltage
4.75 ~ 5.25 V
Output range
0.25 ~ 4.75 V
2.5 V
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49
Description
a. The pressure sensor senses the drivers braking
intentions (braking while an ESP intervention is in
progress) and detects the precharging pressure.
Brake not
applied
Brake
applied
ABS/ESP SYSTEM
STAVIC - 2004.09
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50
4K
If two signals from pressure sensor deviates from the specified value, HECU determines the sensor is faulty. The sensor
output is analog signal that is proportional to voltage and the HECU recognized the pressure value as signal value
against supplying voltage.
Maximum measurable pressure: 170 bar
Linear changes of about 0.5 volts when the brake is not operating and 4.75 volts when the brake is operating.
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EFFECTIVE DATE
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51
Automatic coding
When replacing the HECU with new one, it is coded automatically. Therefore, additional coding operation is not needed.
When the existing ECU installed to another vehicle or a new HECU recognizes that the coded data is not matched with
the vehicle, the warning lamp lights up and ABS/ESP is not activated.
The HECU is coded when it is initially installed to the vehicle, and once coded data cannot be changed.
* If DTC C1170 (5170) is generated during automatic coding, clear it with a scan tool to resume automatic coding
process.
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STAVIC - 2004.09
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4K
ON
ESP operation
(including ASR)
OFF
Min. 4 times
ON
ESP warning lamp
OFF
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53
RELEASE
PUSH
RELEASE
PUSH
HI
Disabled range
ESP operation
LO
ESP function
(including ASR)
ON
OFF
ON
ESP warning lamp
OFF
[Notice]
When turning the ignition switch off while the ESP system is activated, the ESP system will be resumed when ignition
switch is turned on again.
When the vehicle is controlled by ESP system during driving, the ESP OFF switch does not operate.
The ESP OFF switch operates when it is pushed for over 150 ms. When it is pushed for less than 150 ms, the ESP OFF mode
and the ESP warning lamp will not be changed.
When the ESP OFF switch is pushed within 350 ms of being turned off, the ESP warning lamp and ESP system will not be
turned on.
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
54
4K
Push
HI
ESP operation
Release
LO
60 sec
3.5 sec
ON
ESP function
(including ASR)
OFF
Cancellation of ESP OFF mode
Turning the ESP warning lamp off
ON
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
OFF
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
55
Controls
EBD
ABS
ASR
ABD
Vehicle
yaw
control
OFF
BLINKS
WHEN ESP
OPERATION
INTERMITTENT BEEP
SOUNDS WHEN ESP
OPERATION
OFF
ON
OFF
OFF
ON
ON
OFF
EBD
ABS
ESP
ESP
W/L
W/L
W/L
BUZZER
ON
ON
ON
OFF
OFF
ESP fault
OFF
ABS fault
Initial start
(for 1.8 sec)
Normal mode
ON
ON
ON
OFF
st
OFF
ON
ON
OFF
nd
ON
ON
ON
OFF
ON
ON
ON
OFF
OFF
OFF
ON
OFF
**O
ESP-OFF mode
OFF
OFF
ON
OFF
*O
ON
ON
ON
OFF
System fault
Low batt. voltage 1
Low batt. voltage 2
*) When the driver presses the brake pedal during the ESP OFF mode, the yaw control is performed to compensate
the vehicle stability (posture) during ESP operation.
* *) The ASR controls only engine control
ABS/ESP SYSTEM
STAVIC - 2004.09
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56
4K
2. Unscrew preheating relay mounting bracket bolts (12M 2EA) and battery tray mounting bolts (12M - 4EA).
CHANGED BY
EFFECTIVE DATE
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57
20 ~ 24 Nm
15 ~ 19 Nm
Primary
FR: Front right
[Notice]
Be careful not to damage the HECU pipe and nut thread
when reinstall.
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
58
4K
3. Unscrew the steering wheel mounting nut and remove the wheel.
4. Remove the I/P panel lower cover.
[Notice]
Leave marks on the column shaft(A) and on the wheel(B).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
59
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
60
4K
Sensor Cluster
1. Remove center panel and aircon controller.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
61
Defective Components
Descriptions
ABS
ESP
Cause
C1011
(5011)
C1012
(5012)
C1021
(5021)
C1022
(5022)
C1031
(5031)
Action
- Check the wheel speed sensor connector
- Check the EBCM connector
- Check the harness connection
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
62
Trouble
Code
4K
Defective Components
Descriptions
ABS
ESP
Cause
- Defective rear RH wheel speed sensor
- No signals from wheel speed sensor and tooth wheel
C1032
(5032)
C1041
(5041)
C1042
(5042)
C1051
(5051)
Pressure sensor
Action
- Check the pressure sensor connector
- Check the output voltage (stop): 0.5 V
- Check the output voltage (brake applied): 0.25 ~ 4.75 V
Cause
- Internally defective steering wheel angle sensor
- Abnormal signals from steering wheel angle sensor
- Short circuit between supplying voltage output and ground
C1061
(5061)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
Trouble
Code
C1073
(5073)
63
Defective Components
Descriptions
ABS
ESP
Cause
- Operating voltage exceeds specified range
(Hi: 18.0 1.0 V / Lo: 6.5 0.5 V)
X
- Others
Cause
- Internally defective HECU
- Abnormal A/D converter voltage: 5.0 3 %
- Abnormal supplying voltage (4.580 ~ 4.960 V) to sensor
cluster
Short circuit between supplying voltage output of
sensor cluster and ground
- Poor ground of sensor cluster (0.0 ~ 0.5 V)
C1074
(5074)
Sensor cluster-internal
C1102
(5102)
C1111
(5111)
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
64
Trouble
Code
C1201
(5201)
C1202
(5202)
4K
Defective Components
Descriptions
Cause
- Mechanical defective in brake switch
- Defective brake switch harness
ABS
ESP
Action
- Check the harness and connector
Cause
- Mechanical defective in ESP OFF switch
- Defective ESP OFF switch harness (short to ground)
Action
- Check the harness and connector for ESP OFF switch
Cause
- Abnormal supplying voltage to valve solenoid
- Internally defective HECU
C1301
(5301)
Action
- Check the battery voltage
- Check the HECU connector
- Replace the HECU
Cause
- Too low (below 6.0 V) or no supplying voltage to pump
motor
- Over 0.93 V from pump motor voltage
C1311
(5302)
Motor pump
C1401
(5401)
HECU hardware
C1501
(5501)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
No calibration or SC
checksum error
Cause
- Abnormal signals from sensors
- Poor calibration for sensors
Action
- Check and initialize the sensors
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
Trouble
Code
C1170
(5170)
65
Defective Components
Descriptions
ABS
ESP
(O)
(O)
Cause
- Coding error
- Defective CAN communication line
Variant coding error
C1601
(5601)
C1603
(5603)
(communication error
between engine ECU
and CAN)
C1604
(5604)
C1612
(5612)
Cause
- Defective signal transmit of Engine ECU
Action
- Check the engine ECU varient coding
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
66
4K
Contnet
Unit
ESP
ABS
1 km/h
1 km/h
1 km/h
1 km/h
Battery Voltage
0.1 V
0.01 g
- : Straight ahead
7
0.01 g
(Fixed Value: 0)
O
+ : Left Turn
8
0.5 deg/s
(Fixed Value: 0)
O
+ : Left Turn
9
5 deg
1 bar
X
(Fixed Value: 0)
+ : Left Turn
10
X
(Fixed Value: 0)
X
(Fixed Value: 0)
11
1 bar
X
(Fixed Value: 0)
12
EBD Control
Operation / Non-operation
13
BTCS Control
Operation / Non-operation
14
Operation / Non-operation
15
ESP Control
Operation / Non-operation
16
ON / OFF
17
ABS Control
Operation / Non-operation
18
ON / OFF
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
67
Name
Operation
Front LH Inlet
Operation / Non-operation
Operation / Non-operation
Front RH Inlet
Operation / Non-operation
Operation / Non-operation
Operation / Non-operation
Operation / Non-operation
Operation / Non-operation
Operation / Non-operation
Operation / Non-operation
10
Operation / Non-operation
11
Operation / Non-operation
12
Operation / Non-operation
13
14
15
Motor Pump
ABS/ESP SYSTEM
STAVIC - 2004.09
Operation / Non-operation
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
68
4K
INTIALIZE SENSOR
1] LONGITUDINAL ACCEL SENSOR(4WD only)
2] LATERAL ACCEL SENSOR
3] PRESSURE SENSOR
4] ABOVE 1, 2, 3 ALL SENSOR
INTIALIZE SENSOR
CONDITION :
-
PROCEDURE :
MUST BE FOLLOW THE ABOVE CONDITION.
IF YOU START "INITIALZE SENSOR",
ADART TO AUTOMATIC.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
69
9. AIR BLEEDING
The vehicle equipped only with ABS can use the conventional air bleeding procedure, however, the vehicle equipped with
ESP should use the oil supply device with compressor to bleed the air.
Rear
Front
Oil supply
Oil return
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
70
4K
Notice
Always bleed the air after replacing the brake fluid or master cylinder, caliper, brake hose and pipe.
Never reuse the used brake fluid.
Do not pump the brake pedal too fast. It may cause some troubles for air bleeding operation.
Be careful not to splash the brake fluid on painted area or body.
Check the connection areas for leaks after air bleeding.
CHANGED BY
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AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
5A
OVERVIEW
Passengers airbag
Passengers
Drivers
Front seat
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AFFECTED VIN
Drivers airbag
BODY INTERIOR
STAVIC - 2004.09
5A
Pretensioner
Retractor
5A
AIRBAG
1. COMPONENTS
Drivers Airbag Module
Airbag module
Steering wheel
Contact coil
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
Cushion
Retainer
Housing
Inflator
Bracket
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
5A
2. FUNCTION DESCRIPTION
Bag (Cushion)
Airbag Module
The passenger airbag module is installed in the instrument panel at passenger side.
[Notice]
Module Cover/Housing
It is a type of a container that includes the cushion
and the inflator.
The module housing functions to deliver the reaction
force between the body structure and the airbag (The
airbag reaction is absorbed generally to the steering
wheel or instrument panel).
The module cover must be considered in a viewpoint
of protection between exterior, internal units and
cushion. Also the module cover should be designed
not to cause any personal injury for deployment.
Inflator
The inflator is a type of the direct gas generated device.
The inflator with initial low pressure provides negative
restraint effect regarding passengers moving and time.
On the contrary, the inflator with initial high pressure
allows other components of the airbag to make a
excessive impact resulting in any personal injury.
Thus, the inflator output must be optimized according
to the characteristic of the vehicle and passenger
moving.
The discharge gas has no toxicity or inflammability
and also it is the important parameter to control the
high temperature for gas firing.
CHANGED BY
EFFECTIVE DATE
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BODY INTERIOR
STAVIC - 2004.09
5A
Malfunction detection and recording any faults that
are detected.
Monitor the supplemental restrain system electrical
components and set a diagnostic trouble code when
malfunction is detected.
Contact Coil
The contact coil is installed between the steering wheel
and the steering column and contains a coil that enables
to contact electrically between the airbag wiring harness,
the driver airbag module and the horn switch.
[Notice]
Turning the steering wheel more than three and onequarter turns may damage the clock spring. The contact
coil should never be disassembled and must be replaced
if the airbag have been deployed.
Accelometer Sensor
The accelerometer sensor electronically represents the
acceleration or deceleration of the vehicle during a frontal
impact.
In this electronic representation, the electrical signal is
proportional to the acceleration or deceleration of the
vehicle.
Safety Sensor
The safety sensor is safety device made up of a dualcontact, electro-mechanical switch that:
1. Acts independently of the electronic components.
2. Connects the acceleration sensor in series in order
to make up for the weak points in the current
electronic sensor.
[Notice]
Turn the label of the clock spring clockwise to lock and
turn the label of the clock spring counterclockwise
approximately 2.9 0.2 turns to the neutral positions
with the front wheels ahead.
Align the pointed marks 43 .
Micro Controller
This device receives the impact signal from the sensor for
vehicle impact and identifies whether the current condition is necessary for airbag deployment or not. And then
the controller sends the specified currents to the airbag
ignition circuit as needed.
This device always monitors the airbag system in conduction with the diagnostic circuit. When it is detected
any problem, it illuminates the airbag warning indicator to
inform driver of the fault and stores the fault information.
BODY INTERIOR
STAVIC - 2004.09
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AFFECTED VIN
5A
Belt Pretensioner
The belt pretensioner enables to retract the driver and the
passenger seat belt webbing to reduce any personal impact when accounted a frontal collision.
Fault Contents
System OK
System fault
Internal SDM fault
No turn on
CHANGED BY
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BODY INTERIOR
STAVIC - 2004.09
5A
3. INFLATION OF AIRBAG
BODY INTERIOR
STAVIC - 2004.09
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5A
10
Drivers
airbag
Passengers
airbag
Airbag unit
Drivers seat
Passengers seat
SDM Specification
Item
Specification
Voltage range
9 ~ 16V
Temperature range
-30 ~ 85C
-50 ~ 50G
Impact record
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BODY INTERIOR
STAVIC - 2004.09
5A
11
5. WIRING DIAGRAM
BODY INTERIOR
STAVIC - 2004.09
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5A
12
6. TROUBLE DIAGNOSIS
Possible Cause
Ignition ON
Check warning
lamp on I/P
Action
Yes
System OK
No
Yes
No
Select the fault code display menu and clear code menu.
Replace fuse.
Is there any open in fuse?
Yes
No
Yes
Repair wiring.
No
Yes
No
Check any open between ALDL connector No.4, No.5 terminal and ground.
Yes
Repair wiring
No
Ignition ON
Measure voltage at the cigar lighter socket.
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Yes
No
Yes
Repair wiring
No
Yes
No
BODY INTERIOR
STAVIC - 2004.09
5A
13
Fault Contents
High battery voltage
Check
Check the alternator voltage
Check the battery
Check the airbag unit terminal
1102
1346
1347
1348
1349
1352
1353
1354
1355
1361
1362
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
5A
14
Code
Fault Contents
1363
Check
Check the connection of the driver pretensioner connector.
Check the wiring condition of the driver pretensioner.
Check the bending of the airbag terminal.
1364
1367
1368
1369
1370
1620
1650
1651
1652
1657
1670
2500
Warning is faulty
[Notice]
Use only the scan tool to check the airbag module and the sensing and diagnostic module (SDM). Never measure the
resistance of an airbag module with an ohmmeter. An ohmmeters battery can deploy the airbag and cause injury.
Before testing, disconnect the negative battery cable. Wait 1 minute for the SDM capacitor to discharge. The capacitor
supplies reserve power to deploy the airbags, even if the battery is disconnected. Unintentional deployment of the
airbags can cause injury.
Do not attempt to repair the supplemental inflatable restraints (SIR) wiring harness. An SIR repair can create a highresistance connection which can keep the airbags from deploying when needed, resulting in injury.
CHANGED BY
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AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
15
BODY INTERIOR
STAVIC - 2004.09
Wheel wrench
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5A
16
2. Disconnect airbag module and horn connector, and then remove the module from steering wheel.
CHANGED BY
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STAVIC - 2004.09
5A
17
Contact Coil
1. Remove horn, airbag module, steering wheel(1), and lower
panel(2) from steering column.
3. Unscrew the contact coil mounting bolts and remove it from the steering column.
BODY INTERIOR
STAVIC - 2004.09
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5A
18
4. Install in the reverse order of removal.
Tightening torque
10 1.0 Nm
[Notice]
Allgn the contact coil to the right direction. (Refer to the arroow mark in the following picture)
If thealignment of contact coil, is not precise. It could result in a accident due to bad steering condition.
Also, it can damage a contact coil and therefore, can be a reason of airbag failure.
CHANGED BY
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AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
19
Passengers Airbag
1. Disconnect the battery negative cable.
2. Remove the I/P panel.
BODY INTERIOR
STAVIC - 2004.09
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AFFECTED VIN
5A
20
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
21
SEAT BELT
1. COMPONENTS
11 Passengers
Front Seat Belt (3 point)
Height adjuster
Buckle
Pretensioner
Lower anchor
Upper anchor
Retractor
Buckle
Lower anchor
Upper anchor
Retractor
Buckle
Lower anchor
Retractor
Buckle
Lower anchor
BODY INTERIOR
STAVIC - 2004.09
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EFFECTIVE DATE
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5A
22
9 Passengers
Front Seat Belt (3 point)
Height adjuster
Buckle
Pretensioner
Lower anchor
Upper anchor
Retractor
Buckle
Lower anchor
Upper anchor
Retractor
Buckle
Lower anchor
Retractor
Buckle
Lower anchor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
23
7 Passengers
Front Seat Belt (3 point)
Height adjuster
Buckle
Pretensioner
Lower anchor
Upper anchor
Retractor
Buckle
Lower anchor
Retractor
Buckle
Lower anchor
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
5A
24
Scarf trim
Front
Rear
2. Unscrew seat belt upper / lower anchor bolts (17 mm - 2 EA) and remove the seat belt.
Pretensioner
CHANGED BY
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AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
25
Rear 2nd
seat belt
[Notice]
To remove rear 3rd row seat belt, remove the seat from vehicle first.
BODY INTERIOR
STAVIC - 2004.09
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AFFECTED VIN
5A
26
2. Unscrew the retractor mounting bolts to remove seat belt assembly.
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EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
27
[Reference]
2-point type seat belt are installed at the center seat of rear 1st / 2nd / 3rd row seat.
Rear 1st seat have two types of seat belt. Normally it adapts 3 point type, however, it adapts 2 point type seat belt when
swivle.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
5A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
29
BODY INTERIOR
STAVIC - 2004.09
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5A
30
Buckle
1. Fixed type buckle
Preceding Work: Removal of the seat assembly
1. Remove seat cover.
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BODY INTERIOR
STAVIC - 2004.09
5A
31
2. Remove screws on the seat and pull away the seat cloth.
BODY INTERIOR
STAVIC - 2004.09
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AFFECTED VIN
5A
32
SEAT
1. COMPONENTS
Reclining control
Sliding control
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
33
Head rest
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
34
2. SEAT LAYOUT
Layout - 11 Passengers
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
35
Layout - 9 Passengers
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
5A
36
Layout - 7 Passengers
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
37
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
38
Rear 1st seat (when swiveled)
Rear 1st swiveled and rear 2nd seat back folding while driving
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
39
Rear 1st seat swiveled and rear 2nd seat back folding (while parking)
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
5A
40
5 passengers with loading
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
41
Entry Way
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
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5A
42
Seat
Sliding distance
Seat
Sliding distance
Front
228 mm
Rear 3rd
Fixed
Rear 1st
280 mm
Rail overlength
1,610 mm
Rear 2nd
400 mm
CHANGED BY
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AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
43
Front
Seat
Rear 1st
seat
Rear 2nd
seat
Rear 3rd
seat
BODY INTERIOR
STAVIC - 2004.09
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AFFECTED VIN
5A
44
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
45
Removable Seat
1. Fold down the seatback of the third row seat while puling
up the seatback reclining lever ( ).
2. Remove the seat rail covers (
3. Slide the third row seat to its rear end (arrow direction)
while pulling up the seat sliding lever ( ).
4. Carefully remove the third row seat from the rail by using
the hand grips ( ,
) on the seat as shown in the
figure.
5. Install the seat in the reverse order of removal.
[Caution]
Be careful not to drop the seat when removing it. It may
cause a personal injury.
Make sure that the seat is securely engaged on the rail
during installation.
BODY INTERIOR
STAVIC - 2004.09
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AFFECTED VIN
5A
46
4. OPERATION OF SEAT
Front Seat (Drivers Seat)
1) Components
Seat warmer
connector
Seat position
(up/down motor)
Seat position
(front up/down
rail)
Seat position
(up/down rail)
Sliding rail
Seat position
(rear up/down
motor)
Sliding motor
Reclining motor
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AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
47
2) Operation of seat
Sliding
: Seat moves from front to rear controllde
by sliding control switch
BODY INTERIOR
STAVIC - 2004.09
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5A
48
Reclining
: Seat back reclining controlled by
seat reclining control switch
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BODY INTERIOR
STAVIC - 2004.09
5A
49
Disconnect the seat wiring connector and check if the power is supplied (Refer to the wiring diagram)
1) If the power supply has no problem, remove the seat.
2) Check the motor and wiring if damaged.
3) Connect the battery to the seat connector.
4) Control the seat switch and check the opration.
[Notice]
Electrical parts are not supplied by a part separately.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
50
5A
When jumping
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BODY INTERIOR
STAVIC - 2004.09
5A
51
Rear Seat
1) Rear 1st seat (swivel seat)
Seat back folding cable
Jumping
mechanism
Sliding cable
Sliding lever
Swivel lever
BODY INTERIOR
STAVIC - 2004.09
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5A
52
2) Operation of rear seat (Rear 1st and 2nd seat)
Seat sliding
Front
Rear
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BODY INTERIOR
STAVIC - 2004.09
5A
53
Rear 1st
Rear 2nd
Rear
1st/2nd seat
BODY INTERIOR
STAVIC - 2004.09
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54
5A
- As the seat is folded, disconnect hook and spread out the board
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BODY INTERIOR
STAVIC - 2004.09
5A
55
5. SEAT RAIL
Distance (cm)
A. Inner rail
50
B. Inner rail
74
- Outter rail
C. Outter rail
BODY INTERIOR
STAVIC - 2004.09
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AFFECTED VIN
98
56
5A
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BODY INTERIOR
STAVIC - 2004.09
5A
57
ACCESSORIES
1. STORAGES
Overhead console
Console box
Glove box
Passengers cabinet
BODY INTERIOR
STAVIC - 2004.09
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5A
58
1) Console Box
- Foot lamp and a speaker are installed.
CD Changer (6 EA)
Components
1. Armrest
2. Console main rid & tray
3. Console rear facia
4. Console main rid cover
5. Rear foot lamp
6. Console main & tray
7. Console main bracket
8. CD Changer cover
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
59
When Installed
BODY INTERIOR
STAVIC - 2004.09
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5A
60
10 mm - 2 EA
Nut
10 mm - 2 EA
- Unscrew the bracket bolts (10 mm - 4 EA) and remove the changer assembly.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
61
2) Glove Box
BODY INTERIOR
STAVIC - 2004.09
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5A
62
3) Overhead Console
Removal and Installation
1. Unscrew two mounting screws in the sun glass
cabinet and remove the overhead console by using a
tool.
3. Unscrew three screws behind the console assembly to remove multi meter.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
63
4) Passengers Cabinet
Above glove box
2. Unscrew the passengers cabinet mounting screws (LH / RH / center) at the back of lower panel.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
5A
64
2. CONVINIENT DEVICES
Front cup holder
Ticket holder
Back table
Power outlet
Tea table
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
65
Cup holder
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
66
5A
2. Disconnect power outlet and cigar lighter lighter connector and remove the assembly.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
67
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
68
3) Sunvisor
Drivers
Passengers
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
69
4) Tea Table
[Notice]
Dont put a load heavier than 3.5kg on the tea table.
Dont use the table while driving to prevent body injury.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
70
BODY INTERIOR
STAVIC - 2004.09
5A
71
3. ETC
1) ECM Room Mirror
Removal and Installation
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
72
5A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
73
3) Hand Grip
Passengers Overhead
B Piller
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
74
OVM Tool
- Under rear 3rd seat floor cover.
Components
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
75
P pillar
A pillar
Door molding
Center speaker
Center speaker
Door molding
Center console
assembly
Lower panel - passenger
BODY INTERIOR
STAVIC - 2004.09
and AV head
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
76
5A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
77
1) Driver
1. Sun roof
7. GPS
16. Earth
17. Earth
9. Rear monitor
18. Earth
9. Rear monitor
3. LH floor connector
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
78
3) Center
5. T/M control connector
7. Earth
8. Earth
4) ETC
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
79
(10 mm - 2 EA:Bolt)
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
80
3. Remove the following parts from the instrument panel.
1. Tweeter speaker
4. GPS
5. Optical cable
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
81
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MEMO
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
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.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
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.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................
5B
Roof rack
Front door
BODY EXTERIOR
STAVIC - 2004.09
Rear door
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5B
Tailgate
Sunroof assembly
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
DOOR SYSTEM
1. LAYOUT - FRONT DOOR
A. Inside door handle
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5B
Check linkage
Door hinge
Door connector
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
Inside handle
Twitter speaker
Door hinge
BODY EXTERIOR
STAVIC - 2004.09
Door striker
Contact switch
5B
3. OPERATION - WINDOW
Window regulator
Guide rail
Window motor
Operating Process
Power window motor (1) which is controlled by the window switch draws up and down the window regulator (2) and
operating cable. The window glass move up and down with the window regulator.
Window motor
Operating cable
Window up/down
Window regulator
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
Door latch
Lock / Unlock
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Operating Process
10
5B
Operating Process
Lock / Unlock (Inside door handle)
Operating cable
Inside handle
Operating cable
Outside handle
Key cylinder
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5B
11
Rear Door
Lock / Unlock
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
5B
Operating Process
Lock / Unlock (Inside door handle)
Lock button
Operating cable
Inside handle
Operation of handle
Operating cable
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
13
1. Door connector
3. Door hinge
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
5B
[Notice]
Disconnect door handle cover with slim tool(driver) from
down side first otherwise, the grip holder can be damaged.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
15
5. After getting some space (1), disassemble door trim from the door panel as pushing up (2).
6. Remove door courtesy lamp connector & outside mirror connector at the inside of door trim.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
5B
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
17
[Notice]
Be careful not to damage the body coating by window glass.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
5B
- Disassemble power window motor mounting bolts (10 mm ~ 3 EA) from the requlator.
1. Disconnect key cylinder rod (1), outside handle rod (2) and rear view mirror folding unit connector.
2. Disconnect latch and crank assembly with mounting nuts (Hex - 3 EA).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
19
20 ~ 28 Nm
20 ~ 28 Nm
[Notice]
The door lock striker is an important attaching part that can affect the performance of vital components and systems and
can cause major repair expenses. If replacement becomes necessary, the door lock striker must be replaced by one with the
same part number or with an equivalent part. Do not use a replacement part of lesser quality or of a substitute design. The
specified torque values must be used during reassembly in order to ensure the proper retention of the part.
The door lock striker consists of a striker with two screws that are threaded into a tapped, floating cage plate located in
the appropriate body pillar. This floating cage plate allows the striker to be easily adjusted in or out and up or down. The
door is secured in the closed position when the door lock fork snaps over and engages the striker.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
5B
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
21
Passengers side
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
5B
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
23
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
5B
BODY EXTERIOR
STAVIC - 2004.09
5B
25
1. Door connector
3. Door hinge
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
5B
1. Remove upper guide channel with two bolts, as weather strip is pulled.
2. Remove two screws in carrier plate and disassemble the window glass.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
27
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
5B
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
29
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30
5B
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
31
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
32
5B
Tailgate handle
Actuator
Key cylinder
Connecting rod - actuator handle
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
33
2. LAYOUT - TAILGATE
Washer nozzle
BODY EXTERIOR
STAVIC - 2004.09
Rear spoiler
Key cylinder
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
34
Door latch
5B
Shock absorber
Door hinge
Door striker
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
35
36
5B
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
37
Rear Spoiler
1. Remove upper trim - tailgate.
2. Disconnect rear view camera & HMSL (High Mounted Stop Lamp) connector (B).
3. Unscrew spoiler mounting nut (4EA).
1.
2. "B"
3. "A"
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
38
5B
Connector
Rear spoiler
Bulb
HMSL
HMSL cover
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
39
Tailgate Trim
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
40
5B
2. Disconnect motor connector and disassemble wiper motor assembly with two bolts.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
41
Latch
Latchand
andAcuator
Acuator- -Tailgate
Tailgate
Latch - Tailgate
1. Disconnect latch wiring connector (1) and connecting rod
(2) at the inside of the door.
2. Unscrew latch mounting nut (6 mm - 3 EA).
Actuator - Tailgate
1. Disconnect connecting rod at the inside of the tailgate.
2. Unscrew mounting nut (6 mm -2 EA).
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
42
5B
Cowl assembly
Hinge
Cap
Screw
Screw cap
Peace
Hood
Hood seal
- rear
Hinge
Bumper
Hood insulator
Nut
Braket
Cable
Bolt
Hood latch
Key
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
43
Adjustment
1. Release the hinge bolts.
2. Have the hood mounted properly.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
44
5B
2. Unscrew hood latch mounting bolts (6 mm - 4EA) and disconnect spring hood cable to disassemble hood latch.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
45
4. Disassemble left / right cowl grill (Left side first, disassemble washer hose before take the cowl out)
Left
BODY EXTERIOR
STAVIC - 2004.09
Right
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
46
5B
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
47
Upper cover
Bolt
Bracket - side
Nut
Bolt
Bracket - side
Front guide
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
48
5B
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
49
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
50
5B
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
51
Mounting screw
Mounting Grommet screw
Shock absorber - Energy
Bolt
PAS (Parking Aid Sensor)
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
52
5B
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
53
2. Disconnect parking aid sensor (3ea) inside of bumper assembly and unscrew mounting bolts to disassemble the
bumper assembly.
3. Disassemble bumper facia and shock absorber - Energy from bumper assembly.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
54
5B
KEY CYLINDER
1. COMPONENTS
Door handle - Front
Key cylinder
Key cylinder
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
55
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
56
5B
Tailgate Key
Preceding Work: Removal of failgate trim, seal
1. Disconnect connecting rod from key cylinder.
Connector
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
57
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
58
5B
SUN ROOF
1. LAYOUT - SUN ROOF
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
59
Wind deflector
Side cover - outter
Side cover - inner
Drain channel
support bar RH
Drain channel
support bar pin
Sunshade assembly
Drain channel
support
Panel
curve on
Riret roll
Return spring
Ventilation roof
Front lever
spring
Drain lever
Slider LH
Front
lever LH
Drain lever LH
Main lever LH
Retraction
bar
Pin
Breed nail
Prain channel
Frame assembly
Drive tube
Sunroof motor
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
60
5B
4. Control unit
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2. Control switch
BODY EXTERIOR
STAVIC - 2004.09
5B
61
3. OPERATION
Tilting
Sliding
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
62
5B
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
63
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
64
5B
ACESSORIES
1. ROOF RACK
Center mounting
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
65
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
66
5B
* Rear
* Front
[Notice]
Be sure to lift the vehicle only on the deginated jack point otherwise, the vehicle could be body damaged.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5C
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
5C
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
5C
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
2. SIDE GARNISH
A. Wide Garnish
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
5C
B. Narrow Garnish
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
BODY DIMENSION
1. EXTERIOR
(unit: mm)
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
10
2. BODY STRUCTURE
5C
(unit: mm)
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
11
3. SIDE STRUCTURE
(unit: mm)
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
12
5C
4. WIND SHIELD
.6
1500
1563.2
15
63
.2
1321
.2
(unit: mm)
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
13
5. TAILGATE
(unit: mm)
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
14
5C
6. UNDER BODY I
732
850
300
930
1200
2203
1099.28
444
(unit: mm)
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
15
7. UNDER BODY II
(unit: mm)
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
16
8. FLOOR MEMBER
5C
(unit: mm)
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
17
(unit: mm)
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
18
5C
(unit: mm)
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
19
Rear
Front
[Note]
Front/center/rear each washer is
incompatible. The other parts are
same.
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
20
5C
Rear Frame
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
21
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
22
5C
No
Item
1
2
3
Gap
Allowance
Center accord
41
4.6
44
6.7
-2
45
H/LAMP
(+1.0)
(0, -0.5)
46
47
11
4.5
(+1,0)
(-1,0)
A pillar ~ Fander
43
HOOD to
10
Allowance
42
Gap
(+1.0)
Item
40
Hood-outter
~ Bumper-upper
No
6.8
(1)
48
-1.5 1.0
Quad ~ Fender
49
50
12
51
13
52
Quad ~ A pillar
14
15
16
Front bumper
17
~ Head lamp
6.8 1.0
-1.5 1.0
18
19
20
21
22
23
Fender
24
~ Hood-outter
25
4.5 0.5
-0.5
(0, -0.5)
26
27
28
29
Fender
30
~ Front bumper
2.4 1.0
-2.0
(+1.5, -1.0)
31
32
33
34
35
36
37
38
39
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
23
2. REAR
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
24
5C
No
No
Item
Gap
40
Panel ~ Lamp
5.5 0.5
41
Rear lamp
~ Taillamp
0.5
Item
Gap
Roof rail
10
~ Spoiler-Rear
(+1.0)
Allowance
-2 1.0
42
43
44
45
46
8
9
10
Quarter glass-side
~ Quarter glass-rear
1.9 1.0
48
~ Tailgate panel
1.0
Tailgate panel
~ Bumper
1.0
Garnish ~ Bumper
2.0
2.5
2.2
-2.0
51
15
16
17
~ Tailgate glass
Quarter glass-side
~ Tailgate panel
5 1.0
-1
20
21
Tailgate panel
~ Tailgate glass
52
+1.5, -0.7
53
5 1.0
54
55
+0, -1
56
18
19
0.8
49
12
14
0.5
Extensior cover
50
Quarter glass-rear
~ Panel
0.0
47
11
13
Tailgate gaenish
Allowance
2.3 1
Panel ~ Bumper
0.5
57
Cover ~ Bumper
58
Cover ~ Bumper
59
Panel
3.2
60
~ Fuel door
0.5
+0, -1
22
61
23
62
Quarter glass-front
-2.2
24
63
+1, -0
+1, -0.5
25
64
26
Quarter glass-side
27
~ Rear combi
65
2.0
66
28
67
29
68
30
69
31
32
33
Combi lamp-rear
~ extension cover
2.2 1.0
Quarter glass-front
Compressed
~ Side panel
0
1.0
34
35
Combi lamp-tailgate
36
~ Tailgate
1.8
37
38
Gap
1.0
39
Panel ~ Lamp
2.0
-0.5
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
(LHD)
2. COMPONENTS LOCATION
(LHD)
Connecting Wiring
Harness
Engine - Main
ABS (ESP)
Engine - Main
-ABS(ESP)
Engine - Main
PTC
Engine - Main
Engine - Starter ST
RR Pre-Heating Unit
Engine - Alternator
Alternator
Engine - Alternator
Alternator
Main - Roof
Main - Roof
W/H Air-Bag
W/H Air-Bag
W/H Main
FATC
Manual
Connector Position
Remark
GSL
GSL
GSL
(LHD)
Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
Connector Position
Remark
W/H Main
W/H Air-Bag
Dual A/C
Floor (RH)
Glass ANT
RR View Camera
-AV
Floor (LH) - TM
A/T
Floor (LH) - TM
M/T
Parking Aid
EPB/EAS
PTC
Pre-tensioner
Seat Warmer
(LHD)
Connecting Wiring
Harness
Connector Position
Remark
W/H Main
W/H Main
GND
W/H Main
ILL
W/H Main
CAN
W/H Main
GND
W/H Main
Beside TCU
EPB/EAS
S202
S203 (GND)
(LHD)
S205 (CAN)
S206 (GND)
(LHD)
(LHD)
Connecting Wiring
Harness
Connector Position
G101
W/H Engine
G102
W/H Engine
G103
W/H Engine
G104
W/H Engine
G105
W/H Engine
G201
W/H Main
G202
W/H Main
G203
W/H Air-bag
G204
W/H Main
G205
W/H Main
G206
W/H Main
G207
G301
G302
G303
G304
G305
G401
G402
G901
W/H EPB/EAS
Remark
EPB/EAS
(LHD)
(LHD)
2) SB6 ~ SB11
(LHD)
3) Ef1 ~ Ef4
(LHD)
4) Ef5
(LHD)
5) Ef6 ~ Ef10
(LHD)
6) Ef11 ~ Ef18
(LHD)
7) Ef19 ~ Ef21
(LHD)
8) Ef22 ~ Ef26
(LHD)
(LHD)
2) F6 ~ F12
30
(LHD)
3) F13 ~ F16
(LHD)
4) F17 ~ F24
(LHD)
5 ) F25 ~ F31
(LHD)
6) F32 ~ F36
(LHD)
SECTION 5
ELECTRICAL WIRING
DIAGRAMS
TABLE OF CONTENTS
1. STARTING & CHARGING ........................................................................................... 5-4
2. PREHEATING UNIT CIRCUIT (XDI) .......................................................................... 5-6
3. ECU (ENGINE CONTROL UNIT - D27DT EU IV) ................................................... 5-8
1) ENG MAIN RELAY, PEDAL MODULE, HFM SENSOR, VALVE, ENG MOUNT .. 5-8
2) FUEL FILTER WARNING LAMP, IMMOBILIZER, SENSOR (FUEL PRESSURE,
CAM SHAFT, BOOSTER PRESSURE, CRANK SHAFT, COOLANT/FUEL TEMP.)
A/CRUISE SW CIRCUIT ....................................................................................... 5-10
3) INJECTOR, CAN LINE, STOP LAMP SW, SENSOR (A/CON, E-GAS), CLUTCH
SW ......................................................................................................................... 5-12
4. ECU (GSL G32) ......................................................................................................... 5-14
1) IGN COIL, CPS, AIR FLOW SENSOR, THROTTLE SENSOR, TPS ............... 5-14
2) O2 SENSOR, PEDAL MODULE, CRUISE CONTROL SW,
STOP LAMP SW .................................................................................................. 5-16
3) INJECTOR, KNOCK SENSOR, IMMOBILIZER, CANISTER PURGE VALVE .... 5-18
5. DIAGNOSIS CIRCUIT ................................................................................................ 5-20
6. TCU (5-SPEED) .......................................................................................................... 5-22
1) START MOTOR, TGS LEVER, CAN LINE .......................................................... 5-22
2) SOLENOID, OIL TEMP. SENSOR, SPEED SENSOR (N2, N3) ....................... 5-24
7. TOD ............................................................................................................................. 5-26
8. CLUSTER .................................................................................................................... 5-28
1) GAUGE(SPEED, RPM, FUEL, TEMP, WARNING LAMP(4WD, FUEL FILTER,
ABS/ESP) .............................................................................................................. 5-28
2) WARNING (EAS, EPB, TGS LEVER, AUTO PARKG) ...................................... 5-30
3) WARNING (BAT CHANGE, OIL, BRAKE ENG CHCK, AIR BAG, IMMOM SEATBELT) TURN SIGNAL, DEFOGGER, DOOR OPEN .......................................... 5-32
9. CIGAR LIGHTER, POWER OUTLET ....................................................................... 5-34
10. HEAD LAMP, DRL(DAY TIME RUNNING LIGHT) UNIT ....................................... 5-36
(LHD)
Connecting Wiring
Harness
Engine - Starter ST
RR Pre-Heating Unit
Engine - Alternator
Alternator
Engine - Alternator
Alternator
W/H Main
W/H Main
G201
G302
Connector Position
Remark
GSL
GSL
(LHD)
(LHD)
Connecting Wiring
Harness
W/H Main
CAN
W/H Main
GND
W/H Main
G102
W/H Engine
G104
W/H Engine
Connector Position
Remark
(LHD)
(LHD)
Connecting Wiring
Harness
Engine - Main
W/H Main
W/H Main
W/H Main
G201
W/H Main
Connector Position
Remark
GND
(LHD)
(LHD)
Connecting Wiring
Harness
W/H Main
W/H Main
G102
W/H Main
G204
W/H Main
RR TGS Lever
Connector Position
Remark
GND
(LHD)
3) INJECTOR, CAN LINE, STOP LAMP SW, SENSOR (A/CON, E-GAS), CLUTCH SW
(LHD)
Connecting Wiring
Harness
Connector Position
RR A/V Unit
G205
W/H Main
Remark
ECU GND
(LHD)
ECU (E32)
(LHD)
Connecting Wiring
Harness
Connector Position
Engine - Main
G201
W/H Main
G205
W/H Main
Remark
ABS (ESP)
GSL
ECU GND
(LHD)
(LHD)
Connecting Wiring
Harness
W/H Main
W/H Main
G201
W/H Main
G205
W/H Main
Connector Position
Remark
ECU GND
(LHD)
(LHD)
Connecting Wiring
Harness
Connector Position
Remark
GSL
GSL
W/H Main
W/H Main
G201
W/H Main
G203
W/H Air-bag
G301
GND
(LHD)
5. DIAGNOSIS CIRCUIT
(LHD)
Connecting Wiring
Harness
Engine - Main
RR A/V Unit
W/H Main
GND
W/H Main
CAN
G201
W/H Main
Connector Position
Remark
GSL
(LHD)
6. TCU (5-SPEED)
1) START MOTOR, TGS LEVER, CAN LINE
(LHD)
Connecting Wiring
Harness
Engine - Starter ST
RR Pre-Heating Unit
W/H Main
ILL
W/H Main
CAN
G204
W/H Main
RR TGS Lever
G302
G401
Connector Position
Remark
(LHD)
(LHD)
Connecting Wiring
Harness
Connector Position
Floor (LH) - TM
G302
Remark
A/T
(LHD)
7. TOD
(LHD)
Connecting Wiring
Harness
Connector Position
Remark
W/H Main
GND
W/H Main
ILL
W/H Main
CAN
G202
W/H Main
G204
W/H Main
G301
(LHD)
8. CLUSTER
1) GAUGE(SPEED, RPM, FUEL, TEMP, WARNING LAMP(4WD, FUEL FILTER, ABS/ESP)
(LHD)
Connecting Wiring
Harness
Connector Position
Remark
W/H Main
ILL
W/H Main
CAN
W/H Main
GND
W/H Main
G204
W/H Main
RR TGS Lever
(LHD)
(LHD)
Connecting Wiring
Harness
Main - Roof
C902(12Pin, Black)
Floor (LH) - TM
A/T
C902(4Pin, Black))
Floor (LH) - TM
M/T
W/H Main
G206
W/H Main
Connector Position
Remark
(LHD)
3) WARNING (BAT CHANGE, OIL, BRAKE ENG CHCK, AIR BAG, IMMOM SEAT-BELT)
TURN SIGNAL, DEFOGGER, DOOR OPEN
(LHD)
Connecting Wiring
Harness
Connector Position
Engine - Alternator
Alternator
Engine - Alternator
Alternator
RR A/V Unit
W/H Main
W/H Main
G204
W/H Main
RR TGS Lever
Remark
GSL
GSL
GSL
GND
(LHD)
(LHD)
Connecting Wiring
Harness
Connector Position
W/H Main
G202
W/H Main
G204
W/H Main
RR TGS Lever
G303
G305
Remark
(LHD)
(LHD)
Connecting Wiring
Harness
W/H Main
G102
W/H Engine
G103
W/H Engine
G201
W/H Main
G204
W/H Main
RR TGS Lever
Connector Position
Remark
GND
(LHD)
(LHD)
Connecting Wiring
Harness
Connector Position
Remark
RR View Camera
M/T
(LHD)
(LHD)
Connecting Wiring
Harness
Engine - Main
PTC
PTC
RR A/V Unit
W/H Main
RR A/V Unit
Connector Position
Remark
(LHD)
(LHD)
Connecting Wiring
Harness
Connector Position
Engine Room Fuse Box
Engine Room Fuse Box
Engine Room Fuse Box
Engine Room Fuse Box
Engine Room Fuse Box
Engine Room Fuse Box
Under the Coolant Reserve Tank
Under the Coolant Reserve Tank
ICM Box (IP Relay Box)
Behide A/V Unit
Behide Glove Box
Inside Passenger Side Cowl PNL
Inside Passenger Side Cowl PNL
Inside Passenger Side Cowl PNL
Inside the Right A/V Head Unit
Behind the Washer Tank
Behind the Air Cliner Housing
Remark
DSL
GSL
FATC
Manual
(LHD)
(LHD)
Connecting Wiring
Harness
Engine - Main
RR A/V Unit
RR Glove Box
W/H Main
G102
W/H Engine
G104
W/H Engine
G204
W/H Main
W/H Main
Connector Position
Remark
FATC
Power Seat (Seat Warmer)
ILL
(LHD)
(LHD)
Connecting Wiring
Harness
Connector Position
Main - Roof
RR Parking Brake
RR A/V Unit
G201
W/H Main
G202
W/H Main
G204
W/H Main
RR TGS Lever
Remark
Dual A/C
(LHD)
(LHD)
Connecting Wiring
Harness
XDi
GSL
W/H Main
G102
W/H Air-bag
G103
W/H Main
RR TGS Lever
Connector Position
Remark
Manual
ILL
W/H Air Bag
(LHD)
(LHD)
Connecting Wiring
Harness
Main - Roof
G201
W/H Main
G202
W/H Main
G204
W/H Main
W/H Main
Connector Position
Remark
FATC
Dual A/C
(LHD)