Page 1 AUTOMATIC TRANSAXLE SYSTEM GENERAL INFORMATION SPECIAL SERVICE TOOLS Tool (Number and Illustration name) Measurement of the oil pressure (use 09452-21000 with 09452-21500, 09452-21600, 09452- Oil pressure gauge 32300) adapter 09452-21500 Measurement of the oil pressure (use Oil pressure gauge with 09452-21000, 09452-21600, 09452- 32300) 09452-21600 Measurement of the oil pressure (use...
Page 2 09453-32100 Removal of the clutch piston Piston spring compressor 09414-11000 Removal of the pin in the lock pawl rod Lock pin extractor 09455-38000 Removal of the overdrive return spring Spring compressor Removal of the forward clutch spring Removal of the direct clutch spring 09454-38000 Removal of second brake spring Second brake spring...
Page 3 09454-38300 Removal of reaction sleeve Reaction sleeve remover...
Page 4 SPECIFICATION SPECIFICATION TIGHTENING TORQUE Item N·m Kg·cm Ib·ft Transmission housing to case (10mm) Transmission housing to case (12mm) Extension housing to T/M case O/D case to T/M case Oil pump to T/M case Oil pump body to stator shaft Valve body Oil strainer Oil pan Speed sensor...
Page 5 COMPONENTS AUTOMATIC TRANSAXLE CONTROL SYSTEM SHIFT LEVER...
Page 6 REMOVAL 1. Remove the console upper cover plate. 2. Remove the center console assembly. 3. Remove the control cable, the shift lock cable and key lock cable. 4. Disconnect the inhibitor switch indicator connector. 5. Remove the control lever assembly. 6.
Page 7 When servicing the shift lock device, follow the service instructions and procedures described below in order to operateit normally. 1. Procedure to install the lock cam. a. Make sure to move shift lever to position "P" to set key lock cam and p-lock as figure. 2.
Page 8 (6) Adjust nut "A" and bolt "B" if necessary.
Page 9 TRANSAXLE RANGE SWITCH 1. Operating inspection (1) Check that the starter turns with the ignition switch at START position and the selector in the "P" and "N range only. (2) Check that the back-up (reverse) lights illuminate when shifted to the "R" range with the ignition switch in the ON position.
Page 11 AUTOMATIC TRANSAXLE SYSTEM COMPONENTS (1)
Page 12 COMPONENTS (2)
Page 14 Components...
Page 16 REMOVAL 1. Remove the battery (-) terminal. 2. Drain the automatic transmission fluid. 3. Remove the control cable. 4. Remove the under cover. 5. Remove the front propeller shaft. (4WD) 6. Remove the front muffler and the heater protector. 7. Remove the transfer case connector. (4WD)
Page 17 8. Remove the rear propeller shaft. 9. Remove the oil cooler pipe. 10. Remove the speed sensor connector. 11. Remove the back-up lamp switch connector. 12. Remove the starter motor. 13. Remove the transmission mounting bolt.
Page 18 14. Support the transmission on the sack. 15. Remove the transmission assembly. INSTALLATION 1. Installation is the reverse of the removal. DISASSEMBLY 1. Remove the torque converter. 2. Remove the oil filler gauge. 3. Remove the wire harness clamp. 4. Remove the control shaft lever.
Page 19 5. Remove the transaxle range switch. 6. Remove the union. 7. Remove the output speed sensor. 8. Remove the input speed sensor.
Page 20 9. Remove the transmission housing. 10. Remove the extension housing. 11. Using a dial indicator, measure the inside diameter of the extension housing bushing. Max. : 40.09mm (1.5783in.) If the inside diameter is greater than maximum, replace the extension housing.
Page 21 12. Remove the speedometer drive gear. 13. Remove the sensor rotor and key. 14. Remove the oil pan. 15. Remove the magnets and use them to collect steel particles. 16. Remove the oil strainer and gasket.
Page 22 17. Remove the stopper plate. 18. Remove the valve body mounting bolts. 19. Remove the check ball body, springs(4EA)and pins(2EA). 20. REMOVE ACCUMULATOR SPRINGS AND PISTONS (1) Applying compressed air to the ATF hole remove the Bo accumulator piston and spring.
Page 23 (2) Applying compressed air to the ATF hole remove the Co accumulator piston and spring. 21. Remove the oil pump. 22. Remove the overdrive planetary and the overdrive direct clutch. 23. Remove the overdrive ring gear.
Page 24 24. Remove the snap ring. 25. Remove the flanges, the plates and the discs. 26. Using the micrometer, measure the thickness of the disc. Minimum thickness: 1.84mm (0.0724in.) 27. Remove the snap ring.
Page 25 28. Applying compressed air to the ATF hole remove the second coast brake piston. 29. REMOVE OVERDRIVE SUPPORT (1) Remove the thrust bearing and race. (2) Remove the overdrive support mounting bolts. (3) After removing the snap ring, remove the overdrive support.
Page 26 30. Remove the direct clutch and the forward clutch. 31. SECOND COAST BRAKE BAND (1) Remove the E-ring and pin. (2) Remove the second coast brake band. 32. FRONT PLANETARY RING GEAR (1) Remove the race.
Page 27 (2) Remove the front planetary ring gear. 33. FRONT PLANETARY GEAR (1) Remove the race. (2) Remove the front planetary gear. 34. Remove the sun gear input drum and the oneway clutch.
Page 28 35. Using the thickness gauge, measure the clearance between the second brake snap ring and the flange. Standard value : 0.62~1.98 mm (0.024~0.078 in.) 36. FLANGE, PLATE, DISC (1) Remove the snap ring. (2) Remove the flange(1), discs(4) and plates(4).
Page 29 37. Using the micrometer, measure the thickness of disc. 38. PARKING LOCK ROD (1) Remove the parking lock pawl bracket. (2) Remove the parking lock rod from the manual valve lever. 39. Remove the parking lock pawl and shaft.
Page 30 40. Measure the clearance between the plate and the second brake drum. Standard value : 0.60~0.90 mm (0.024~0.035 in.) 41. Remove the second brake piston sleeve. 42. REAR PLANETARY, SECOND BRAKE DRUM (1) Remove the snap ring.
Page 31 (2) Remove the rear planetary gear, the second brake drum and the output shaft. 43. Using the screw driver, remove the gasket. REASSEMBLY 1. Install the rear planetary gear, the second brake drum and the output shaft. (1) Install the bearing and race. (2) Install the second brake drum, flange, disc and plate.
Page 32 (3) Align the rear planetary gear, second brake drum and output shaft. (4) Install the snap ring. 2. Measure the clearance between the plate and the second brake drum. Clearance : 0.6~0.9 mm (0.024~0.035 in.) 3. Install the second brake piston sleeve.
Page 33 4. Install the brake drum gasket. 5. Install the parking lock pawl and shaft. 6. INSTALL PARKING LOCK ROD (1) Connect the parking lock rod to the manual valve lever. (2) Install the parking lock pawl bracket.
Page 34 (3) Confirm that the planetary ring gear is correctly fixed. 7. Install the one-way clutch. 8. INSTALL FLANGE, DISC, PLATE (1) Install the plate with the rounded edge side of the plate facing the disc. (2) Alternately install discs and plates (Disc first) (3) Install the flange and snap ring.
Page 35 9. Using the thickness gauge, measure the clearance between snap ring and flange. Clearance : 0.62~1.98 mm (0.024~0.078 in.) 10. Install the sun gear input drum. 11. FRONT PLANETARY GEAR (1) Install the front planetary gear on the sun gear.
Page 36 (2) Install the snap ring. (3) Install the bearing race on the front planetary gear. 12. INSTALL SECOND COAST BRAKE BAND (1) Insert the second coast brake band to the case. (2) Install the pin through the brake band. (3) Install the E-ring to the pin.
Page 37 13. Install the bearing and race onto the forward clutch. 14. Install the race onto the front planetary gear. 15. Install the forward clutch onto the front planetary ring gear. INSTALL DIRECT CLUTCH, FORWARD CLUTCH (1) Install the bearing and race.
Page 38 (2) Install the direct clutch, the forward clutch and the front ring gear to the case. Using the vernier caliper, measure the distance between the sun gear. Standard value : 5.3~7.3 mm (0.21~0.29 in.) (4) Install the bearing and race onto the forward clutch.
Page 39 17. Reassemble the second coast brake piston. 18. After installing the piston cover, install the snap ring. 19. Measure the stroke applying the compressed air. Stroke : 2.0~3.0 mm (0.079~0.12 in.) 20. OVERDRIVE SUPPORT (1) Install the race onto the overdrive support.
Page 40 (2) Aim the bolt and oil holes of the overdrive support toward the valve hole side, and align then with the bolt hole of the transmission case and insert. (3) Install the snap ring. (4) Install the bolts(2EA). 21. Measure the end-play of the output shaft.
Page 41 Standard value : 0.27~0.86 mm (0.011~0.034 in.) 22. Install the flange with the rounded edge side of the flange facing the disc. 23. Install the snap ring. PISTON STROKE OF OVERDRIVE BRAKE (1) Place the dial indicator onto the overdrive brake piston. Measure the stroke applying and releasing the compressed air.
Page 42 25. REMOVE FLANGE, PLATE, DISC (1) Remove the snap ring. (2) Remove the flanges(2EA), plates(3EA) and discs(4EA). 26. OVERDRIVE RING GEAR (1) Install the bearing and the race onto the overdrive support. (2) Install the overdrive planetary ring gear.
Page 43 27. INSTALL OVERDRIVE PLANETARY GEAR (1) Install the bearing and the race onto the planetary ring gear. (2) Install the race onto the planetary gear. (3) Install the overdrive planetary gear and the direct clutch. (4) Install the bearing and the race onto the direct clutch.
Page 44 28. INSTALL FLANGE, DISC, PLATE (1) Install the flange with the rounded edge side of the flange facing the disc. (2) Alternately install discs and plates. (3) Install the flange and the snap ring. 29. INSTALL OIL PUMP (1) Install the race onto the oil pump.
Page 45 (2) Install the oil pump onto the transmission case. 30. Make sure the input shaft rotates smoothly. 31. Check for the sound of operation while injecting compressed air into the oil hole indicated in the figure. (1) Overdrive direct clutch (2) Direct clutch (3) Forward clutch (4) Overdrive brake...
Page 46 32. INSTALL ACCUMULATOR PISTON (1) Install the accumulator piston. C0 : Overdrive direct clutch C2 : Direct clutch B0 : Overdrive brake B2 : Second brake (2) Install the spring Spring Free length Outer diameter Color 70.50 19.70 (1)B2 Upper Yellow (2.776) (0.776)
Page 47 62.00 16.00 (6)B0 Upper Green (2.441) (0.630) 17.50 14.00 (7)B0 Upper Green (0.689) (0.551) 46.00 14.02 (8)C0 Inner Yellow (1.811) (0.552) 74.60 20.90 (9)C0 Outer Orange (2.937) (0.823) 33. Install the check ball body and the spring. 34. INSTALL VALVE BODY (1) Align the groove of the manual valve to the pin of the lever.
Page 48 (3) Install the valve body. 35. INSTALL SOLENOID CONNECTOR (1) Install the stopper plate. (2) Connect the solenoid connect. (3) Install the clamp bolt. 36. Install the oil strainer.
Page 49 37. Install the oil pan. 38. INSTALL ROTOR SENSOR (1) Install the key. (2) Install the snap ring. (3) Install the spacer and the sensor rotor. (4) Install the snap ring. 39. Install the extension housing. 40. Install the transmission housing.
Page 50 41. Install the input speed sensor. 42. Install the output speed sensor. 43. INSTALL TRANSAXLE RANGE SWITCH (1) Install the transaxle range switch onto the manual valve shaft and temporarily tighten the adjusting nut.
Page 51 (2) Install the washer and the nut. 44. Tighten the adjusting bolt. Disassembly 1. Remove the torque converter. 2. Remove the converter housing - transmission case installation bolts (8), then remove the converter housing.
Page 52 Be careful not to have your finger cut by the sharp edge in the converter housing engine section. Do not reuse bolts of the seal bolt section. 3. Remove the O-ring of the input shaft. Do not reuse O-ring. 4. Remove the oil pump-transmission case installation bolts (10).
Page 53 5. Use the oil pump puller to remove the oil pump assembly. Tighten screws of puller all the way. Make sure the Bearing race comes out simultaneously. Remove the outer O-ring. Do not reuse the O-ring. Puller installation position is as in figure below (Where the screws grinded) 6.
Page 54 7. Remove the front carrier assembly and the input clutch assembly as a unit. Make sure that thrust bearing come out together. 8. Remove the brake band. Keep the brake band to be in sphere shape after having been removed by using the fixture of the following figure made of metal seam.
Page 55 9. Remove the middle carrier assembly and the rear carrier assembly as a unit. 10. Remove the middle sun gear, the rear sun gear assembly, and the high & low reverse clutch hub as a unit. Be careful that the bearing race and bearing will come apart at the same time.
Page 56 11. Remove the high & low reverse clutch assembly. Make sure that the bearing race is attached to the section. 12. Remove the direct clutch assembly. Also remove the bearings (2) on the section that support the drum. 13. Remove oil pan bolts (22), then the oil pan. Remove the oil pan gasket.
Page 57 Do not reuse the removed bolts. (Non-reusable) Discard the gasket too. (Non-reusable) 14. Press the stable part of the connector from the terminal assembly with a hand (driver) to pull out the connector. 15. Remove the connector of the temperature sensor (Not necessary when not having to pull out the temperature sensor).
Page 58 16. Remove connector in front by hitting general tool 1 to fit intervals between the bracket and the connector. 17. Remove the control valve - T/M case installation bolts (12).
Page 59 18. Remove the control valve - T/M case installation bolts along with the clip with bolts attached to it at the same time. (Remove the clip that fixes the harness of the revolution sensor in advance.) 19. Remove the connector of the revolution sensor. Pull out the sensor connector upward using a hand or driver.
Page 60 20. Remove the clip that fixes the harness of the terminal assembly. Spread the harnesses of the terminal assembly and the revolution sensor in a row outward not to interfere with the one that is on hold during the control valve assembly installation. 21.
Page 61 Do not use the old seal bolts. 23. Tap the extension part lightly with a plastic hammer. (This does not easily come off since the sealant has been applied). 24. Remove the output shaft. Turn it right and left and pull it to the rear side. 25.
Page 62 Make sure the harness not to get damaged by the case corners. 26. Use two drivers to pull out the snap ring (that stops the plate) of the reverse brake part. Press and pull out the snap ring through the slit of the oil pan side of the case, then pull out it once again with the first driver.
Page 63 28. Use the driver to pull out the snap ring (that stops the spring retainer) of the reverse brake. 29. Remove the spring retainer and spring (plate screw). 30. Remove the piston. Pull out the pump seal, the D-ring, and then discard them.
Page 64 31. Remove the terminal from the connector. Use the general tool 1 said above. Place the tool between the bracket and the connector and lift up the connector projection part to pull out the connector. 32. Remove the terminal assembly. 33.
Page 65 Discard the spring pin. 34. Press the spring pin of the manual shaft with a nipper to pull out. Discard the spring pin. 35. Remove the manual shaft. 36. Remove the oil seal (2). Discard the oil seal.
Page 66 37. Pull out the detent spring. 38. Use the snap ring pliers to pull out the snap ring from the servo part. 39. Remove the servo retainer/stem piston/return spring.
Page 67 40. Pull out the actuator support part. 41. Remove the parking pole, shaft, and return spring. REASSEMBLY 1. Use drift to punch the oil seal (2).
Page 68 2. Assembly the manual shaft and the manual plate parking road. 3. Punch the spring pin that attaches the manual plate to the manual shaft. Use the punch or something similar to fit with the holes. Make sure that the spring pin can be pulled out. Leave 2 ±0.5 mm(0.0787~ 0.0197in.) of the tip.
Page 69 to the case. 5. Attach the manual shaft to the case. Punch the spring pin. Leave 5 ±1 mm(0.1969~ 0.0394in.). 6. Apply vaseline to the terminal assembly installation hole. 7. Insert the terminal assembly to the installation hole.
Page 70 8. Attach the terminal connector to the bracket. The position for each connector is as in figure below. 9. Attach the servo piston, servo retainer, and servo stem return spring to the case. 10. Attach the snap ring of the servo.
Page 71 11. Fix the detent spring. Tightening torque: 6.9 ~ 8.8 Nm (69 ~ 88kg·cm, 5.1 ~ 6.5lbf·ft) 12. Apply Vaseline to the outer O-ring of the reverse brake piston. 13. Assembly the reverse brake piston. Apply the drum support bearing to install.
Page 72 14. Assembly the return spring of the reverse brake piston and the spring retainer. Use the clutch compressor to install the snap ring that installs the spring retainer. Use the driver to make sure since the tension of the snap ring is somewhat weak. 15.
Page 73 Adjust the gap between reverse ~ brake Check L dimension using a thickness gauge and adjust it to become 0.7 ~ 1.1 mm(0.0276 ~ 0.0433in.) using the retainer plate. When L dimension is not within the aforesaid values, check the thickness of the retainer plate and select the proper part of the following table and replace it.
Page 74 18. Install the bearing that Vaseline has been applied to the rear case surface. 19. Scratch off the sealant. 20. Wipe the surface that is in contact with the extension with an oil whetstone lightly and remove the sealant completely. Tap the seal bolt slit lightly.
Page 75 22. Wipe the surface conjoined with the case with oil whetstone lightly and remove the sealant completely. Tap the seal bolt slit lightly. Apply the washer fluid to wipe with the whetstone so that the case not to become sticking after cleaning.
Page 76 24. Install the parking pole, return spring shaft. 25. Install the actuator support. 26. Assemble the output shat. Note that the shapes of the front and back are similar. (Front side is where the tip outer diameter is narrower (Torque converter side)) See the shape figure.
Page 77 27. Install the revolution sensor. Tightening torque: 4.6 ~ 6.9Nm(46 ~ 69kg·cm, 3.4 ~ 5.1lbf·ft) 28. Apply the sealant to the surface in contact with the extension case. Use Loctite 518 = part number: 313A98E000 made by Locktite Inc. in Japan. Remove the fluid gasket from the case contact surface, EXT contact surface and wipe the contact surface with washer not to have any harmful oil or dusts.
Page 78 31. Tighten the output shaft companion flange installation bolts at 50-54.9Nm (9) using the torque meter. The seal bolt part is tightened at 58 ~ 63Nm (1). 32. Apply vaseline to the seal ring of the drum support, and then assemble the direct clutch. 33.
Page 79 34. Mount the bearing with vaseline applied to the drum support surface. 35. Assemble the high & low reverse clutch. Use the one with the same part number when replacing the high & low reverse clutch.
Page 80 36. Align the spool lines of the high & low reveres clutch drive plate with a driver. 37. Assemble the rear sun gear and the high & low reverse clutch hub to the middle sun gear, and then fix it with the snap ring. Mount the bearing race and bearing.
Page 81 39. Check the flange-combined part of the rear sun gear is approximately 2 mm(0.0787in.) lower than the high & low reverse clutch drum surface. If there is no about 2mm(0.0787in.) of step height, it wont fit to the position. Remove it and try again. 40.
Page 82 42. Assemble the input clutch, front carrier, and rear internal gear. 43. Assemble the input clutch to the rear internal gear. Assemble the front carrier.
Page 84 45. Insert the snap ring to the slit in the front carrier.
Page 85 46. Tighten the snap ring with the snap ring pliers, and then combine the front carrier to the rear internal gear. Loosen the snap ring and fix the front carrier and the rear internal gear at the same time. 47. Assemble the input clutch pack. 48.
Page 86 49. Exchange the end anchor pin, and attach provisionally. Assemble the brake band provisionally. For band assembly, check "Brake band assembly* adjustment tips.". 50. Assemble the front sun gear. Apply ATF to the bush section of the front sun gear and the end bearing section of the one-way clutch.
Page 87 51. Adjust the leaning of the band using a wire as in the following figure so that the brake band is attached evenly with the front sun gear drum. 52. Adjust the brake band attaching status based on "Brake band assembly * adjustment tips." Brake band assembly-adjustment tips ●...
Page 88 55. Use the torque meter, tighten the bolts to the case with torque of 54.9 ~ 59.8 Nm(549 ~ 598kg·cm, 40.49 ~ 44.1lb·ft). Apply AFT to the bush section of the oil pump. Total end play adjustment tips a. Adjust with the bearing race so that clearance L1 becomes 0.25 ~ 0.55mm(0.0098 ~ 0.0217in.). Bearing race part number Dimension [mm(in.)] 45833-4C000...
Page 89 57. Mount the converter housing to the case. The notch comes to upward when having the oil pan upward. 58. Mount the housing converter tightening bolts. After provisional tightening, use the torque meter and tighten them all with torque of 50 ~ 54.9Nm(500 ~ 549kg·cm, 36.9 ~ 40.5lbf·ft).
Page 90 60. Wipe with the whetstone so that oil does not stick to the contact surface with the oil pan of the case. 61. Spread the terminal assembly and the harness of the revolution sensor to the outer side of the case. 62.
Page 91 63. Tighten the control valve assembly and case installation bolts provisionally and the use the torque meter to tighten. Tightening torque: 6.9 ~ 8.8 Nm(69 ~ 88 kg·cm, 5.1 ~ 6.5lb·ft) Make sure that the harness does not get stuck in the case. 64.
Page 92 a. Control valve - case installation bolts position and tightening tips. Tighten bolts 1, 2, 3 of the figure above to prevent dislocation provisionally. After that, tighten them in order of 1→2→3 and then tighten the other bolts. Code Size mm(in.) Bolt head Count 42 (0.1654)
Page 93 (1) Match the manual valve section part and the manual plate as shown in figure. (2) Be careful when inserting the harness since the slit between the case and the control valve is small in the figure.
Page 94 65. Connect the terminal assembly and the control valve assembly connector. 66. Connect the temperature sensor connector. 67. Connect the revolution sensor connector.
Page 95 68. Fix the revolution sensor harness to the control valve assembly with a clip. 69. Fix the terminal assembly harness to the control valve assembly with a clip. 70. Mount the oil pan gasket. Match the mounting orientation to the hole.
Page 96 71. Mount the oil pan. Mount so that the drain bolt comes to the position of the figure on the left. Make sure the harness does not get stuck. 72. Tighten the oil pan installation bolts provisionally, and then use the torque meter to tighten them with torque of 6.9 ~ 8.8 Nm (69 ~ 88kg·cm, 5.1 ~ 6.5lbf·ft).
Page 97 a. Bolt assembly tips are as follows: Assemble in the following order. Assemble diagonally at first. 73. Mount the torque converter. Check that the distance between the six point BOSS section and the converter housing section is A2.5 : 31.55 mm(1.242 in.), ∑3.5 : 27.1 mm(1.063 in.). Disassembly and assembly of oil pan drain bolts a.
Page 98 COMPONENTS AND COMPONENT LOCATION RING & LIPSEAL location and part number O-RING & SEALING & CUSHION SPRING location & product numbers...
Page 99 SNAP RING location and part numbers...
Page 100 1. VALVE BODY type...
Page 101 2. VALVE BODY valve type...
Page 103 3. VALVE BODY valve description 4. Fluid pressure measurement PORT location...
Page 105 SYSTEM DIAGRAM HYDRAULIC CONTROL SYSTEM...
Page 106 Based on the hydraulic created by the oil pump, TCM sends signals to solenoid and hydraulic control system governs the hydraulic pressure acting on the torque converter, planetary gear, clutches and brakes in accordance with the vehicle driving conditions. DESCRIPTION We have employed A5SR1, the 5th speed automatic transmission with full range electronic control and sports mode that provides smooth driving with lesser transmission shock as well as pleasant driving from manual transmission.
Page 107 A5SR1 Item Contents Improved - Integrated control over engine and A/T (CAN communication control) system transmission feel employed - Turbine sensor 1.2 employed - Real time feedback control at all phases applied Improved driving - Sports mode function employed - Snow mode function employed (2WD applied) - Gear ratio extension Improved fuel - Slip lock-up employed...
Page 108 OPERATION...
Page 109 OPERATING PRINCIPLES OF EACH RANGE 1. N range Since the forward and reverse brakes are released, driving force of input shaft is not transmitted to output shaft. 2. P range a. Since the forward and reverse brakes are released, as those in the N range, driving force of input shaft...
Page 110 is not transmitted to output shaft. b. Parking pawl that is linked with select lever parking gear meshes with and fastens output shaft mechanically. D, M2, M3, M4, M5 range 1st speed a. Fastens the front brake. b. The front brake and the forward one-way clutch regulate reverse rotation of the mid sun gear. c.
Page 111 The direct clutch is coupled and the rear carrier and the rear sun gear are connected. * POWER FLOW Input shaft→Front internal gear→Front carrier→Rear internal gear→Rear carrier→Rear carrier→Middle internal gear→Middle carrier→Output shaft D, M3, M4, M5 range 3rd speed a. Fastens the front brake. The 3rd one-way clutch regulates reverse rotation of the front sun gear.
Page 112 The input clutch is coupled and the front and middle internal gears are connected. c. Driving force is conveyed to the front internal gear, the middle internal gear, and the rear carrier and the three planetary gears rotate forward as a unit. * POWER FLOW Input shaft→Front internal gear→Front carrier→Rear internal gear→Rear carrier→Middle internal carrier→Middle carrier→Output shaft...
Page 113 . a. The front brake fastens the front sun gear. b. The high & low reverse clutch is coupled and the middle and rear sun gears are connected. The reverse brake fastens the rear carrier. * POWER FLOW Input shaft→Front internal→Front carrier→Rear internal→Rear sun gear→Middle sun gear→Middle carrier→Output shaft CONTROL SYSTEM DIAGRAM...
Page 114 MAIN COMMUNICATION SIGNAL Output to Input to ECM(CAN) Output to ECM(CAN) Input from external sys. external sys. Self-diagnosis A/T driving mode SW indicator Range signal Engine torque signal Output revolution signal Sports mode SW (P, R, N, D) Engine revolution signal Turbine sensor signal Up SW Range signal...
Page 115 Power 4 x 4 Low signal LINE PRESSURE CONTROL a. If the engine control unit sends the input torque signal equivalent to the engine driving force to the A/T control unit (TCM), the A/T control unit (TCM) controls line pressure solenoid. b.
Page 116 During shift change Set to line pressure that is necessary for shift change. Therefore, line pressure characteristic is set according to input torque and shift types. d. At low fluid temperature When the A/T fluid temperature drops below the prescribed temperature, in order to speed up the action of each friction element, the line pressure is set higher than the normal line pressure characteristic.
Page 117 Shift description Controls clutches with optimum timing and fluid pressure in response to engine speed, engine torque information, and etc. Lock-up control Lock-up control is to enhance delivery efficiency by preventing the torque converter from slipping, engaging the lock-up piston into the torque converter. It operates lock-up solenoid control in response to a signal from A/T control unit (TCM) and lock-up control valve behavior control, engages or releases the lock up piston of the torque converter.
Page 118 Lock-up released a. In the lock-up control valve, there is operating fluid pressure circuit connected into the lock-up piston and lock-up solenoid operates valve shift in response to a signal from the A/T control unit. Therefore, the lock-up piston is not coupled. Lock-up applied a.
Page 119 a. The operation of the low coast brake solenoid switches the low coast brake switch valve and controls the coupling and releasing of the low coast brake. The low coast brake reducing valve controls the low coast brake coupling force. CONTROL VALVE Control valve functions Valve name...
Page 120 Regulates line pressure to the optimum pressure to be applied to the low Low coast brake reducing valve coast brake when the low coast brake is coupled. N-R accumulator Produces the stabilizing pressure for when N-R is selected. Direct clutch piston switching Operates in 4th gear and switches the direct clutch coupling capacity.
Page 121 differential. Principle: Install additional ROM onto valve body of automatic transmission and input fluid pressure differential of solenoid &valve body so that TCM reads the input data to perform fluid pressure compensation. 4. Maintenance (1) When replacing with a new TCM in the vehicle a.
Page 122 TCM WIRING DIAGRAM (1) TCM WIRING DIAGRAM (2)
Page 123 CIRCUIT DIAGRAM...
Page 125 TROUBLESHOOTING PROCEDURE DRIVE PLATE DEFLECTION 1. Inspect drive plate deflection if within standard value. Standard value : within 0.2 mm (0.0079in.) <NG> Replace drive plate. When "abnormal wear" or "stick" on T/C sleeve or Oil pump is found, replace T/C and A/T. When installing T/C to drive plate, make sure to use specified bolts.
Page 126 2. Apply compressed air of 28psi(2kg/cm²) from cooler pipe inlet side, inspect whether there is not cooler pipe choke by confirming air flow smooth. <NG> Remove foreign particles and clean inside of pipe line. Bending and choke of cooler pipe a.
Page 127 (3) Park vehicle on a level surface. (4) Inspect that ATF level is in "HOT" range after pulling out level gauge and wipe it out. Inspect by low level if ATF level is different from front side and back side. <NG>...
Page 128 INPUT SPEED SENSOR (C0) OUTPUT SPEED SENSOR (SP)
Page 129 <NG> Replace input, output speed sensor. a. Make sure to inspect resistance again at 20 °C(68°F) when resistance differ from standards except 20 °C(68°F). b. It might become infinity ohm when inspect resistance at higher temperature. ROAD TEST Confirm whether below condition before road test. a.
Page 130 <NG> Replace valve body assy. (No replacement line pressure control solenoid itself) a. Make sure to inspect resistance again at 20°C(68°F) when resistance differ from standards except 20°C(68°F). b. It might become infinity ohm when inspect resistance at higher temperature. OIL TEMPERATURE SENSOR (OT) 1.
Page 131 1. Inspect resistance of each shift solenoid between terminal and the body earth. S1, S2, SL <NG> Replace each shift solenoid. a. Make sure to inspect resistance again at 20°C(68°F) when resistance differ from standards except 20°C(68°F). b. It might become infinity ohm when inspect resistance at higher temperature. 2.
Page 132 (2) Normal open type: SL No connect battery Leak air Connect battery No leak air <NG> Replace each shift solenoid. SHIFT CABLE OR INHIBITOR SWITCH MISADJUTMENT FAILURE 1. Inspect operation of shift cable. (1) Inspect that shift lever can be shifted smoothly and accurately when shifting shift lever from "N" to other range.
Page 133 neutral basic line. (3) Inspect continuity of inhibitor switch. <NG> Adjust SST pointer align neutral basic line again after removing inhibitor switch. OIL SEAL 1. Simulation test Wipe out and clean oil leaked part sufficiently, perform simulation test after spraying die-check liquid. (Time duration is for 10 - 120 min due to oil leak condition) Misunderstanding oil leak failure.
Page 134 2. Oil leak from outside oil seal. (Oil pump, EXT housing, Manual shaft) (1) Inspect oil seal has been installed correctly. (2) Inspect contact surface condition for T/M case and T/M housing "no scratch" and "no dent". <NG 1> Replace oil seal, install it correctly. <NG 2>...
Page 135 2. Shift the selector lever to "D" range. 3. Read the oil pressure at engine idle speed. 4. Depress the brake pedal firmly with the left and gradually depress the accelerator pedal with the right foot. 5. Read the oil pressure as soon as the engine speed becomes constant, then release the accelerator pedal.
Page 136 Defective low & reverse brake Fluid leakage in the "R" range line pressure hydraulic circuit Excessive line pressure at idle Direct clutch slipping Defective low reverse brake STALL TEST The object of this test is to check the overall performance of the transmission and engine by measuring the stall speeds in the D and R ranges.
Page 137 Direct clutch slipping Low & reverse clutch slipping In "R" range only Line pressure too low OD clutch slipping OD one-way clutch not operating properly All shift control elements within transmission Within standard functioning normally Engine out of tune Below standard Slipping of one way clutch within torque converter TIME LAG TEST If selector lever is shifted while the engine is idling, there will be a certain time lapse or time lag before...
Page 138 SOLENOID VALVE 1. Disconnect the solenoid valve connector. 2. Measure the resistance between each terminal and ground. Resistance : 11 ~ 15Ω 3. If not corrected, replace the solenoid valve. (1) Solenoid valve NO.1 (2) Solenoid valve NO.2 (3) Lock-up solenoid valve (4) Line pressure sol.
Page 139 B2 VSP SIG DRIVING PULSE V(Hi) - V(Low) <- OUTPUT 12PULSE/TM SPEED REV. (VEHICLE SPEED SENSOR) B15 O/D OFF SW OFF SW OFF V(IG.1) OFF SW ON V(GND)-0.3-2V B24 INHIBITOR Vbatt SW(P) R/N/D/2/L BELOW 0.8V B6 INHIBITOR Vbatt SW(R) P/N/D/2/L BELOW 0.8V A17 BATT IGN OFF...
Page 140 B4 SNOW LAMP LAMP OFF Vbatt (2WD VEHICLE) LAMP ON 1.5V MAX B13 O/D OFF LAMP LAMP OFF Vbatt LAMP ON 1.5V MAX B16 INHIBITOR Vbatt SW(N) P/R/D/2/L BELOW 0.8V B17 INHIBITOR Vbatt SW(D) P/R/N/2/L BELOW 0.8V A1 POWER(IGN 1) IGN OFF IGN ON 9V - 16V...
Page 141 1.5V A24 CAN(HIGH) CONTINUITY (500kbit/s) A16 CAN(LOW) CONTINUITY (500kbit/s) HOW TO PROCEED WITH TROUBLESHOOTING...
Page 142 How to erase memory trouble code? Memory contents are deleted with scan tool. In addition, TCM erases every memory when "DGC" terminal does not short circuit for more than 5 speeds and then it short circuit "body earth" for more than 5 speeds. Make sure to implement the above operation because all the DTC remains in TCM, once they are memorized, even if a battery is removed.
Page 143 P0722 Output speed sensor circuit no signal P0726 Engine speed input sensor range/performance P0727 Engine speed input sensor no signal P0740 Torque converter clutch circuit malfunction(SL) P0743 Torque converter clutch circuit electrical(SL) P0748 Pressure solenoid electrical P0750 Shift solenoid A malfunction(S1) P0753 Shift solenoid A electrical(S1) P0755...
Page 145 TROUBLESHOOTING FOR DIAGNOSIS TROUBLE CODE(DTC) (1) DTC CHART Detection Cancel DTC Detection item Lamp FAILE SAFE condition condition P0750 Failure stick P0753 Open Shift solenoid a. Emergency 1 No.1 circuit +B short After IG b. No L-up (S1) OFF→ON c. No torque reduction cont. Ground short d.
Page 146 P0707 Open a. Open: All range "D" Inhibitor switch TCM judge P0708 b. GND short: TCM judge following circuit normal GND short priority D>2>L>R>N>P c. No L-up P0710 Temperature After TCM Open fluid sensor judge circuit (OT) a. No L-up normal, b.
Page 147 (2) Advice 1. Symptom simulation test Perform symptom simulation test on the basis of user's condition refer to below factor. Factor for "occurring-road condition, speed, accelerate, reduce speed, straight, curve, time, weather and etc". 2. Inspect connection condition of between connectors Inspect failure between connectors by visual check and contact pressure check.
Page 148 The TCM has an electrical fail-safe mode. This mode makes it possible to operate safe driving even though a input/outputsignal circuit of electronic controls has been compromised. Under the fail-safe mode, the select lever is fixed in 2nd,4th or 5th gear (depending on malfunction position) either being "D" or "M"...
Page 149 Vehicle speed sensor 1 (The output shaft rotation sensor) a. Signals are input from two systems from vehicle speed sensor1(revolution sensor) installed on the...
Page 150 transmission and from combination meter. Accelerator sensor signal if an error occurs in the accelerator sensor signal, detect accelerator opening angle in response to accelerator angle opening signal (input according to CAN communication) that is transmitted from ECM, control line pressure as below to enable driving. Inhibitor switch a.
Page 151 A/T 1st gear engine braking a. If there is an A/T 1st gear engine brake judgment malfunction, turn OFF the low coast brake solenoid so that the engine brake does not operate. Line pressure solenoid a. Turn solenoid OFF and make line pressure maximum so that driving is enabled. Lock-up solenoid a.
Page 152 Turbine sensor 1, 2 a. The control is the same as if there were no turbine revolution sensors, 5th gear is prohibited. Troubleshooting procedures To perform failure diagnosis faster and more accurately, it is crucial to exactly understand what is the problem.
Page 153 Questionnaire sheet example...
Page 154 CUSTOMER INPUT QUESTIONNAIRE POINTS a. What - a vehicle type, engine type b. When - date, occurring frequency c. Where - road conditions d. What conditions - driving status, environment e. How - symptoms Customer name Vehicle type VIN. A/T model Engine Mileage Malfunction data...
Page 155 □ Low coast brake input clutch and the front brake □ Forward brake □ Forward one-way clutch □ Line pressure check - suspected part: □ Perform all load test and enter checks in required inspection items. □ Engine check before starting □...
Page 156 □ Does not start in D1 『Does not start in 1st gear』 □ Does not D1 → D2 shift up or does not D4→D2 quick down 『Does not 1 → 2 shift up does not 4→2 quick down in D range』 □...
Page 157 □ Inhibitor switch □ Fluid temperature sensor 1, 2 □ Turbine sensor 1, 2 □ A/T Inter lock □ A/T 1st gear engine brake □ Starter relay □ Throttle sensor □ Engine revolution signal □ CAN communication □ A/T C/U power □...
Page 167 Primary check A/T fluid check Check fluid leakage, fluid level, fluid leakage, and fluid amount. Check the amount under the HOT condition (fluid at 70~80°C(158~176°F) with following methods . 1. Do urban driving for approx. 10 minutes after the engine is warmed up (When ambient temperature is 20°C(68°F), fluid temperature reaches 70~80°C(158~176°F) after approximately 10 minutes of driving.) 2.
Page 168 a. When it is required to check the fluid level at low fluid temperature (20~30°C(68~86°F)) including fluid exchange, adjust to 「COLD」 level of the level gauge and then be sure to verify the fluid level under the above HOT condition. b.
Page 169 3. Securely engage the parking brake so that the tires do not turn. 4. Start the engine. Depress the foot brake. Move the select lever to "D" range. 5. Gradually depress the accelerator pedal while depressing the foot brake.
Page 170 6. Quickly read the stall speed. And quickly remove the feet from accelerator pedal. Do not depress the accelerator pedal for more than 5 seconds during test. 7. Move the select lever to "N" range. Cool down the ATF. Run the engine at idle for at least 1 minute. * During A2.5 Idle : N range-750rpm(A/CON OFF) Others-800rpm(A/CON ON)
Page 171 ● Front brake ● High&low reverse clutch ● 1st one-way clutch ● Engine&torque converter one-way clutch H ● Line pressure is low ● Check one-way clutch in the torque converter for stucking or check with another item tests O: Stall speed is within the specified level. H: Stall speed is higher than the specified level.
Page 172 approximately 10 minutes of urban driving. 3. Remove fluid pressure detection plug after warming up A/T, install fluid pressure gauge (special tool: ST2505 S001). When using the fluid pressure gauge, use O-ring that is installed to the fluid pressure detection plug.
Page 173 Do not reuse O-ring. Line pressure standard values Line pressure (kpa(kg/cm²)) Engine speed R range D range Idle 490(5.0) 490(5.0) Stall 1180(12.0) Trouble selection Result Possible cause The probable causes are faulty pressure delivery system, low output of oil pump, etc. For example: a.
Page 174 speed rise higher than during For example: idle a. Faulty accelerator sensor b. TCM malfunction c. Line pressure solenoid malfunction (sticking and/or short during d. Sticking of pressure regulator valve and plug e. Sticking of the pilot valve and clogging of pilot filter The probable causes are faulty pressure delivery system or sensors, and poor pressure regulation.
Page 175 Check at idle...
Page 176 Drive test part 1...
Page 179 Drive test part 2...
Page 180 Drive test part 3...
Page 181 Shift pattern...
Page 182 Trouble symptom chart...
Page 183 If an error occurs in A5SR1 transmission, replace with transmission assembly. Symptom Condition Diagnosis Item 1. Key switch&starter The engine does not start in N, P 2. Control cable adjustment ranges. On vehicle only 3. Inhibitor SW 1. Control cable adjustment The engine starts in other ranges except N or P ranges.
Page 184 6. ATF pressure SW 1&Front brake solenoid 7. Engine speed signal 8. Line pressure solenoid valve 1. Fluid level&state Driving disabled in D range. 2. Line pressure test Clutch slips. On vehicle only 3. Line pressure solenoid valve Extremely poor acceleration. 4.
Page 185 1. Inhibitor SW adjustment 2. Control cable adjustment 3→4 shift failure. On vehicle only 3. Vehicle speed sensor 1, 2 4. Fluid pressure SW3& Input clutch solenoid 1. Engine idle speed 2. Accelerator sensor adjustment 3. Throttle sensor adjustment 4. Line pressure test Large shock..
Page 186 solenoid 1. Inhibitor SW 2. Control cable adjustment 1→2 shift failure. On vehicle only 3. Vehicle speed sensor 1, 2 4. Fluid pressure SW5&Direct clutch solenoid 1. Inhibitor SW adjustment 2. Control cable adjustment 2→3 shift failure. On vehicle only 3.
Page 187 2. Line pressure test 3. Fluid pressure SW6&High&low reverse clutch solenoid 1. Accelerator sensor adjustment 2. Line pressure test Shift shock is high in 3→4. On vehicle only 3. Fluid pressure SW3&Input clutch solenoid 1. Accelerator sensor adjustment 2. Line pressure test Shift shock is high in 4→5.
Page 188 1. Fluid level&state No shock during 1→2 shift or clutch 2. Vehicle speed sensor 1, 2 On vehicle only slips. 3. Fluid pressure SW5&Direct clutch solenoid 1. Fluid level&state No shock during 2→3 shift or clutch 2. Vehicle speed sensor 1, 2 On vehicle only slips.
Page 189 solenoid 1. Fluid level&state Does not change from 4, 3, 2→1. On vehicle only 2. Vehicle speed sensor 1, 2 1. Fluid level&state The engine idles when changing 2. Vehicle speed sensor 1, 2 from 5→4 by depressing the On vehicle only accelerator pedal.
Page 190 2. Control cable adjustment 3. Line pressure test 4. Inhibitor SW Strange noise in D, R range. On vehicle only 1. Fluid level&state 1. Inhibitor SW 2. Fluid level&state The engine brake does not operate On vehicle only in 5→4. 3.
Page 191 clutch solenoid 1. Fluid level&state 2. Engine revolution The engine stalls during N→D, R On vehicle only select. 3. Lock-up solenoid valve 4. Turbine sensor TCM Input/Output Signal Reference values TCM terminal array Reference values table Reference values according to hi-scan Item name Reference value Measurement status...
Page 192 ATF1 Fluid temperature sensor 1 (Oil fan temperature) BATT Battery power C1-SOL I/C (Input Clutch) solenoid actuation output signal C2-SOL H&LR/C (High&low reverse clutch) solenoid output signal VIGN-OUT Control valve power B3-ON/OFF SOL LC/B (Low coast brake) solenoid actuation output signal GND-P Ground (power) GND-A...
Page 193 TURBIN1 Turbine sensor 1 input signal (operate in 4th gear) INHSW-3 Inhibitor switch 3 input signal INHSW-4 Inhibitor switch 4 input signal DATABIT 1 Control valve communication line REV-LAMP RLY Reverse lamp relay output VIGN VIGN power TURBIN 2 Turbine sensor 2 input signal (operate in 1, 2, 3, 5th gears) GND-C Ground (power) INH SW3-MON...
Page 194 ABS signal Input ABS signal L4 SW signal Input L4 (4X4 LOW) switch signal R range LAMP R range LAMP output signal P/N range signal P/N range status output signal (SIGMA 3.5 engine only) N range signal P/N range status output signal (4WD only) ACC SW signal Auto cruise control SW input signal SNOW SW...
Page 195 Fluid temperature approx. 80°C(176°F) Approx. 0.9V Key SW ON or Power supply Power voltage When solenoid valve operating (1, 2, or Over 2V 3rd gears) Input clutch solenoid valve When solenoid valve not operating (4, 5 Approx. 0V gears) When driving When solenoid valve operating (1st gear: Over 2V over 6km/h or 2nd gear)
Page 196 When the solenoid valve operating (1st Over 2V and 5th gear) Direct clutch solenoid valve When the solenoid valve not operating Approx. 0V (2nd, 3rd, 4th gear) SEL2 Ground-C High&low reverse clutch solenoid valve Approx. 0V PSC2 (Fluid pressure When driving High&low reverse clutch solenoid valve SW6) Power voltage...
Page 197 function of the diagnosis device when 1.1k(Hz) driving in 1st gear at 20km/h with IDLE SW OFF. Make sure to connect normal diagnosis data link cable to the vehicle side diagnosis connector. Select to D range. Over 5V Inhibitor SW 3 Select to R range.
Page 198 P-range Select to P range. Power voltage P-range lamp Others Select to other ranges. Approx. 0V Shift gear display N-range Power voltage N-range lamp Others Approx. 0V SW ON Depress the brake pedal. Power voltage Stop lamp SW SW OFF Release the brake pedal.
Page 199 Key SW ON Approx. 0V 4WD L4 SW signal Key SW OFF Power voltage R-range Select to P range. Power voltage R-range lamp Others Select to other ranges. Approx. 0V P/N range signal N-range Select to N range. Power voltage N-range signal Others Select to other ranges.
Page 200 a. When an error code has occurred, check inhibitor, Sports mode, Brake, Idle, and Pull SW system. Refer to "Inhibitor, Sports mode, Brake, Idle, and Pull SW system." HOW TO ERASE THE SELF DIAGNOSIS a. To easily identify the cause of low-reproducing trouble, TCM remembers trouble data frequently for user.
Page 201 P0893 Multiple gears engaged Inter lock confirm P0731 Gear 1 incorrect ratio 1st gear engine brake confirm Transmission fluid temperature sensor "A" circuit P0841 Fluid pressure SW1 range/performance P0845 Transmission fluid temperature sensor "B" circuit Fluid pressure SW2 P0870 Transmission fluid temperature sensor "C" circuit Fluid pressure SW3 P0875 Transmission fluid temperature sensor "D"...
Page 202 Confirm normal when the set Fluid temperature When an error occurs, inhibit sports P0711 level of oil sensor is over 124 sensor mode and 5th gear. count. Transmission When an error occurs, fix to D range, P0705 range(Inhibitor) indicator confirm off, starter relay signal Reset at key off sensor off, and reverse lamp signal off.
Page 203 (Fr/B) ON error: fix to 5th, PL Max, L/U OFF error: Only LC/B always OFF, the Fluid pressure SW2 P0845 rest follows normal control Reset at key off (LC/B) ON error: fix to 2nd gear Fluid pressure SW3 P0870 ON/OFF error: fix to 4th Reset at key off (I/C) Fluid pressure SW5...
Page 204 VALVE BODY fluid pressure circuit diagram (D Range) * Refer to body valves for L(number) valve name. 1st gear...
Page 205 2nd gear...
Page 206 3rd gear...
Page 207 4th gear...
Page 208 5th gear (lock-up)
Page 209 5th gear...
Page 210 P&N range...
Page 211 R range...
Page 213 CLUTCH AND BRAKES DIRECT CLUTCH COMPONENTS...
Page 214 DISASSEMBLY 1. Remove the direct clutch drum from the forward clutch. 2. Remove the thrust washer from the direct clutch.
Page 215 FORWARD CLUTCH COMPONENTS...
Page 216 DISASSEMBLY 1. Remove the direct clutch and the forward clutch. 2. Remove the bearing and the race. 3. Remove the snap ring, the flange, the disc and the plate. 4. Remove the cushion plate. 5. Remove the pistion return spring and the snap ring.
Page 217 6. Remove the forward clutch piston. 7. Remove the O-ring from the forward clutch. 8. Remove the oil seal ring. 9. Remove the bearing and the race.
Page 218 INSPECTION 1. Using a micrometer, measure the thickness of the disc. Minimum : 1.84 mm (0.072 in.) 2. Measure the free length of the return spring. 3. Check that check ball is free by shaking the piston.
Page 219 4. Measure the inner diameter of the forward clutch drum bushing. Maximum I.D : 24.08 mm (0.948 in.) REASSEMBLY 1. Reassemble the bearing and the race. 2. Install the oil seal onto the forward clutch. 3. Install the O-ring on the forward clutch drum and the piston. 4.
Page 220 5. Install the piston return spring and the snap ring. 6. Install the piston return spring and the snap ring. 7. Install the cushion plate. 8. Install the disc, the flange and the plate.
Page 221 9. Install the snap ring. 10. Install the race and the bearing. 11. Install the direct clutch onto the forward clutch assembly.
Page 222 LOW AND REVERSE BRAKE COMPONENTS...
Page 223 DISASSEMBLY 1. Remove the bearing and the race. 2. Remove the snap ring and the piston return spring. 3. Apply the compressed air to the transmission case to remove the NO.2 first reverse brake piston. 4. Remove the second brake from the output shaft. 5.
Page 224 INSPECTION 1. Using a micrometer, measure the thickness of the discs. If the thickness is less than the minimun, replace the disc. Minimun thickness : 1.51 mm (0.059 in) REASSEMBLY 1. Make sure the first and reverse brake piston moves smoothly when applying and releasing the compressed air into the transmission case.
Page 225 ONE WAY CLUTCH COMPONENTS...
Page 226 DISASSEMBLY 1. Hold the planetary sun gear and turn the brake hub. The brake hub should turn freely clockwise and should lock counterclockwise. 2. Separate the one-way clutch from the brake hub. 3. Remove the thrust washer. 4. Remove the oil seal ring. 5.
Page 227 6. Remove the sun gear input drum. 7. Remove the snap ring of the planetary sun gear. INSPECTION 1. Using a dial indicator, measure the inner diameter of the planetary sun gear. Maximum diameter : 27.08 mm (1.066 in)
Page 228 REASSEMBLY 1. Install the one-way clutch and the brake hub. 2. Hold the planetary sun gear and turn the hub. The brake hub should turn freely clockwise and should lock counterclockwise.
Page 229 OVERDRIVE BRAKE COMPONENTS...
Page 230 DISASSEMBLY 1. Remove the bearing and the race. 2. Remove the clutch drum washer. 3. Hold the OD brake piston so it is not slanted and apply compressed air into the passage to remove the OD brake piston. 4. Remove the OD brake piston. 5.
Page 231 REASSEMBLY 1. Install the oil seal ring. 2. Install the overdrive brake piston. 3. Install the return spring. 4. Install the clutch drum washer onto the OD support.
Page 232 5. Install the race.
Page 233 REVERSE AND OVERDRIVE CLUTCH DISASSEMBLY 1. Hold the O/D direct clutch drum and turn the input shaft. The input shaft should turn freely clockwise and should lock counterclockwise. 2. Remove the overdrive direct clutch from the overdrive planetary gear. CHECK PISTON STROKE OF OVERDRIVE DIRECT CLUTCH (Co) (1) Place the oil pump onto the torque converter, and then place the O/D direct clutch assembly onto the oil pump.
Page 234 4. Remove the snap ring and the piston return spring. 5. Remove the overdrive direct clutch piston. 6. Remove the bearing and the race from the planetary ring gear. 7. Remove the snap ring.
Page 235 8. Remove the ring gear flange. 9. Remove the race from the overdrive planetary gear. 10. Remove the snap ring. 11. Remove the retaining plate.
Page 236 12. Remove the overdrive one-way clutch with the outer race. 13. Remove the thrust washer. 14. Remove the one-way clutch. INSPECTION 1. Using a micrometer, measure the thickness of the disc. Standard value : 1.84 mm (0.072 in)
Page 237 2. CHECK PISTON RETURN SPRING Using calipers, measure the free length of the return spring. Standard length : 15.8 mm (0.622 in) 3. CHECK OVERDRIVE DIRECT CLUTCH PISTON a. Check that check ball is free by shaking the piston. b. Check that the valve does not leak by applying low pressure compressed air. 4.
Page 238 5. CHECK OVERDRIVE PLANETARY GEAR BUSHING Using a dial indicator, measure the inside diameter of the planetary gear bushing. Maximum inside diameter : 11.27 mm (0.444 in) If the inside diameter is greater than the maximum, replace the planetary gear. REASSEMBLY 1.
Page 239 3. Install overdrive one-way clutch with outer race to overdrive planetary gear. 4. Install retaining plate. 5. Install snap ring. 6. Coat the race with petroleum jelly and install it to the planetary gear.
Page 240 Race diameter Inside diameter : 27.1mm (1.067in.) Outside diameter : 41.8mm (1.646in.) 7. Install ring gear flange to overdrive planetary ring gear. 8. Install snap ring. 9. Install race and bearing.
Page 241 10. Install the race on the planetary gear. 11. Install the piston return spring. 12. Install the plate and the disc. 13. Install the flange.
Page 242 14. Install the snap ring. CHECK PISTON STROKE OF THE DIRECT CLUTCH PISTON (1) Place the oil pump onto the torque converter, and then place the O/D direct clutch assembly onto the oil pump. Using a dial indicator, measure the overdrive direct clutch piston stroke applying and releasing the compressed air.
Page 243 16. Install the bearing and the race. 17. Install the direct clutch assembly onto the O/D planetary gear. 18. Hold the O/D direct clutch drum and turn the input shaft. The input shaft should turn freely clockwise and should lock counterclockwise.
Page 244 COMPONENTS...
Page 245 SECOND BRAKE COMPONENTS...
Page 246 DISASSEMBLY 1. Remove the second brake assembly from the output shaft. 2. Remove the thrust washer. 3. Remove the snap ring, the spring and the piston return spring. 4. Remove the second brake piston. INSPECTION...
Page 247 1. Check the free length of the return spring. Standard length : 19.64 mm (0.773 in.) REASSEMBLY 1. Being careful not to damage the O-ring, press in the second brake piston into the second brake drum. 2. Install the return spring, the spring retainer and the snap ring. 3.
Page 248 4. Install the thrust washer. 5. Install the second brake assembly to the output shaft.
Page 249 GEAR SYSTEM FRONT PLANETARY GEAR COMPONENTS...
Page 250 DISASSEMBLY 1. Remove the bearing and the race from the front planetary ring gear. 2. Remove the race from the front planetary gear. 3. Turn over the planetary gear and remove the bearing and the race. INSPECTION 1. Measure the inner diameter of the front planetary ring gear bushing. Maximum I.D : 24.08 mm (0.948 in.)
Page 251 REASSEMBLY 1. Install the race onto the planetary gear. 2. Turn over the planetary gear and install the race. 3. Install the race and the bearing onto the front planetary ring gear. 4. Turn over the planetary ring gear and install the race.
Page 253 OUTPUT SHAFT COMPONENTS...
Page 254 DISASSEMBLY 1. Remove the second brake assembly from the output shaft. 2. Remove the output shaft from the rear planetary gear. 3. Remove the oil seal from the output shaft. 4. Remove first and reverse brake discs, plates and flange. 5.
Page 255 6. Hold the planetary gear and turn the one-way clutch inner race. The one-way clutch inner race should turn freely counterclockwise and should lockclockwise. 7. Remove the one-way clutch inner race from the rear planetary gear. 8. Remove the snap ring with a screwdriver. 9.
Page 256 10. Remove NO.2 and NO.1 thrust washers. 11. Remove races and bearing from rear planetary ring gear. 12. Remove the snap ring. 13. Remove the ring gear flange.
Page 257 REASSEMBLY 1. Install the race and the bearing. 2. Install the NO.2 one-way clutch.
Page 258 OIL PUMP COMPONENTS...
Page 259 DISASSEMBLY 1. Remove the oil seal ring. 2. Remove the stator shaft. 3. Remove the driven and the drive gear. INSPECTION 1. Measure the inner diameter of the oil pump bushing. Standard value : 38.19 mm (1.504 in)
Page 260 2. Measure the inner diameter of the stator shaft bushing. Front : 21.58 mm (0.850 in) Rear : 27.08 mm (1.066 in) 3. Using a filler gauge, measure the clearance of the driven gear. Standard value : 0.07~0.15 mm (0.003~0.006 in) REASSEMBLY 1.
Page 261 2. Install the stator shaft to the oil pump. 3. Install the oil seal ring. 4. Make sure the drive gear rotates smoothly when installed to the torque converter.
Page 262 BODY ELECTRICAL SYSTEM AUDIO INSPECTION 1. Connect an ohmmeter to the 1 and 3 terminal of remote control connector. 2. Check the resistance between 1 and 3 terminal when each switch is operated. Function Resistance 55.3 kΩ ± 5% Power 22.3 kΩ...
Page 263 COMPONENTS...
Page 266 SERVICE INSTRUCTIONS TAPE HEAD AND CAPSTAN CLEANING 1. To obtain oprimum performance, clean the head, and capstan as often as necessary, depending on frequency of use and tape cleanness. 2. To clean the tape head and capstan, use a cotton swab dipped in ordinary rubbing an alcohol.
Page 267 5. Remove the screws holding the audio unit then remove the audio assembly. 6. Installation is the reverse of removal.
Page 268 SPEAKERS REMOVAL AND ISTALLATION REMOVAL AND INSTALLATION FRONT SPEAKER 1. Remove the front door trim panel and remove the front speaker. 2. Installation is the reverse of removal. REAR SPEAKER 1. Remove the rear door trim panel and remove the rear speaker. 2.
Page 269 Specification impedance : 4 Ω...
Page 270 DAYTIME RUNING LAMP CIRCUIT DIAGRAM...
Page 271 INSPECTION OPERATION CHECK REMOVAL AND INSTALLATION 1. Remove the driver side lower crash pad panel and disconnect the wire connector to DRL module.
Page 272 ETACS ETACS MODULE CIRCUIT DIAGRAM ETACS PIN NO. AND DESCRIPTION...
Page 273 CONNECTOR "A" CONNECTOR "B" CONNECTOR "B" Remote key setting TNS switch Rear fog lamp relay terminal Driver door actuator Seat belt warning lamp switch A3 Keyless switch B3 Seat belt switch C3 Tail gate open relay Driver door switch Main door switch (LOCK) Tail gate switch Front door key switch...
Page 274 heating switch Tail gate key switch Head lamp switch Super lock relay (LOCK) Tail gate glass switch Main door switch Door lock relay (UNLOCK) (UNLOCK) 120 km/h over speed Front door key switch (Middle east) (UNLOCK) B16 Door warning lamp B17 - B18 - B19 Hazard relay...
Page 275 REMOVAL AND INSTALLATION 1. Disconnect the negative (-) battery terminal. 2. Remove the audio unit (Refer to BD group). 3. Remove the 2 nuts holding the ETACS module and disconnect the connectors. 4. Installation is the reverse of removal. INSPECTION ETACS FUCTION 1.
Page 276 Time specification. T1 : 0.6 ± 0.1 sec. T2 : 2.5 - 3.8 sec. T3 : 0.2 - 0.6 sec. T4 : 0.7 ± 1.0 sec. This function should be operated preferentially even though the variable intermittent wiper is operating. 3.
Page 277 T1 : 6 ± 1.5 sec. T2 : 0.5 ± 0.1 sec. (2) Seat belt warning (Europe) Time specification T1 : 5 ± 0.1 sec. T2 : 6 ± 0.5 sec. T3 : 10 ± 0.5 sec. T4 : 15 ± 0.1 sec. T5 : 60 ±...
Page 278 Time specification T1 : 5 - 6 sec. T2 : 30 ± 3 sec. T3 : 20 ± 2 min. 7. Ignition key reminder 8. Battery saver. 9. Power window timer...
Page 279 Time specification T1 : 30 ± 3 sec. 10. Crash door unlock Time specification T1 : 200msec. T2 : 0.5 ± 0.1 sec. T3 : 60 ± 2 msec. 11. Rear fog lamp control 12. Over speed warning (Middle east area)
Page 280 Time specification T1 : 0.5 ± 0.1 sec. 13. Door ajar Alarm occurs while the door or rear hatch opened when the vehicle speed is 5km/h over. 14. Rear hatch glass open Time specification T1 : 3 ± 0.5 sec. T2 : 0.5 ±...
Page 281 Time specification T1 : 3 ± 0.5 sec. T2 : 0.5 ± 0.1 sec. 17. Remote keyless Entry system. (1) Door lock Time specification T1 : 1.0 sec. (2) Door unlock.
Page 282 Time specification T1 : 1.0 sec. (3) Rear hatch glass open Time specification T1 : 0.5 sec. (4) Panic Time specification...
Page 283 T1 : 27 ± 2 sec. T2 : 0.5 ± 0.1 sec. T3 : 0.5 ± 0.1 sec. T4 : 2.7 ± 0.5 sec 18. Code saving method Receiver (ETACS module) can save maximum two codes from the transmitter. (1) Apply the battery voltage to the terminal "6" of DLC (Data Link Connector). (2) Turn the ignition switch to "ON"...
Page 284 (6) Check the operation of the keyless entry system.
Page 285 SPECIFICATIONS Items Specifications Rated voltage DC 12V Operating voltage DC 9 - 16V Operating temperature -30°C - 80°C 100MΩ or more Insulation resistance Rated load Tail lamp relay DC 12V, 200mA (Relay load) Rear defogger relay DC 12V, 200mA (Relay load) Hazard relay DC 12V, 200mA (Relay load) Power window relay...
Page 286 FUSES AND RELAY FUSES INSPECTION 1. Be sure there is no play in the fuse holders, and that the fuses are held securely. 2. Are the fuse capacities for each circuit correct? 3. Are there any blown fuses? If a fuse is to be replaced, be sure to use a new fuse of the same capacity.
Page 287 and is less frequent than #1 above. In this case, you may simply replace with a new fuse of the same capacity. A blade type fuse is identified by the numbered value in amperes. If the fuse is blown, be sure to replace a fuse with the same ampere rating.
Page 288 SPECIFICATION...
Page 289 RELAY BOX COMPONENTS...
Page 290 RELAY COMPONENTS...
Page 291 INSPECTION 1. Check for a burnt fuse with an ohmmeter. 2. If a fuse burns out, there is a short or some other problem in the circuit. Carefully determine the cause and correct it before replacing the fuse. The fuse will burn out within 15 seconds if a higher than specified current flows through the circuit.
Page 292 GENERAL INFORMATION SPECIFICATIONS MULTIFUNCTION SWITCH Items Specifications Rated Voltage DC 12V Operating temperature range -30°C - +80°C (-22 - +176°F) Rated load Dimmer & passing switch High : 1A (Relay load) Low : 1A (Relay load) Passing : 1A (Relay load) Lighting switch Lighting : 1A (Relay load) Turn signal switch &...
Page 293 O/D OFF Amber Air bag Engine check Amber Auto cruise Green Oil pressure Parking brake Battery charge Snow Amber Glow Amber Amber Green Seat belt 4WD Low Green Washer Low Amber Immobilizer Amber Low fuel Amber P, N, D, 2, L Green SERVICE SPECIFICATIONS INDICATORS AND GAUGES...
Page 295 LIGHTING SYSTEM Items Bulb wattage(W) Head lamp 55W / 55W (High / Low) Front turn signal lamp Front position lamp Front fog lamp Rear combination lamps Tail/stop lamp 5W / 21W Back up lamp Turn signal lamp Rear fog lamp Side repeater lamp License plate lamp Sun visor illumi.lamp...
Page 296 Position & side marker lamp AUDIO Items Specification Rated output Max. 41W x 4 Speaker impedance 4ΩX4 Band AM/FM Tuning type PLL Synthesized type Dark current Max. 2mA Items General Europe AM : 531~1602KHZ/9KHZ AM : 522~1620KHZ/9KHZ Frequency range / Channel FM : 87.5~108MHZ/100KHZ FM : 87.5~108MHZ/50KHZ...
Page 297 TROUBLESHOOTING INSTRUMENTS AND WARNING SYSTEM Symptom Possible cause Remedy Tachometer does not operate Fuse blown Check for short and replace fuse Tachometer faulty Check tachometer Wiring faulty Repair if necessary Fuel gauge does not operate Fuse blown Check for short and replace fuse Fuel gauge faulty Check gauge Fuel sender faulty...
Page 298 Head lamps do not light Bulb burned out Replace bulb Fuse blown - Low beam Check for short and replace fuse Fuse blown - high beam Check for short and replace fuse Head lamp relay faulty Check relay Lighting switch faulty Check switch Wiring or ground faulty Repair if necessary...
Page 299 CHART 1...
Page 301 CHART 2 CHART 3...
Page 303 CHART 4...
Page 304 CHART 5...
Page 307 CHART 6...
Page 308 CHART 7 CHART 8...
Page 309 CHART 9 CHART 10...
Page 310 WINDSHIELD WIPER Symptom Possible cause Remedy Wipers do not operate or return to Wiper fuse blown Check for short and replace fuse off position. Wiper motor faulty Check motor Wiper switch faulty Check switch Wiring or ground faulty Repair if necessary Wipers do not operate in INT ETACS Module faulty Check ETACS Module...
Page 311 Wiper motor faulty Check motor Wiring or ground fautly Repair if necessary POWER WINDOW Symptom Possible cause Remedy No windows operate from the Fuse blown Check for short and replace fuse main switch on the driver's door Poor ground Clean and retighten the ground terminal mounting bolt Defective power window main Check the switch...
Page 312 HEAD LAMP LEVELLING DEVICE HEAD LAMP LEVELLING SWITCH CIRCUIT DIAGRAM...
Page 313 INSPECTION 1. Disconnect the switch from harness side, lower panel. 2. Measure the voltage between terminals 1 and 4 (V). Position No. Rotation Ratio (±5%) Voltage (V) 0° 99.52% 11.94 ± 0.5V 20° 82.67% 9.92 ± 0.5V 40° 68.58% 8.23 ± 0.5V 60°...
Page 314 HORN REMOVAL AND INSTALLATION 1. Remove the bolts holding the horn and remove the horn assembly. 2. Installation is the reverse of removal. INSPECTION 1. Test the horn by connecting battery voltage to the 1 terminal and ground the 2 terminal.
Page 315 IMMOBILIZER SYSTEM DIAGNOSTIC TROUBLE CODES Smartra immobilizer (2.5D E/G) Diagnostic trouble codes and associated procedures 1. Locate the data link connector (DLC) in the engine compartment and install the Hi-Scan Pro Tool. 2. Turn the ignition switch to ON and record any Diagnostic Trouble Codes displayed by Hi-Scan Pro Tool.
Page 316 Smartra immobilizer (2.5D E/G) Replacing of ems and smartra In case of defective EMS it has to be replaced by "virgin" or "neutral" EMS. All keys have to be taught to the new EMS. keys which are not taught to EMS are invalid for the new EMS. For key teaching procedure refer to "key teaching procedure".
Page 317 3 of the harness connector. Go to step 3. a. Check if the terminal 4 of the harness connector Go to step 4 Repair or replace is grounded. a. Turn the ignition switch to OFF and connect the immobilizer harness connector to the SMARTRA.
Page 318 Only if the EMS is in status "learnt" and the user password status is "learnt" and the user password is the correct one,the EMS is unlocked for approximately 30 seconds. The engine can be started during this time. After elapsing of timer noengine start is possible. After new input of user password the time starts again.
Page 319 The status is stored in EEPROM. In case of not plausible data from this circuit the EMS cannot check the status and EMS sends 00. b. Learnt At least one Key has been taught successfully. c. Virgin This is the status at the end of EMS production line before delivery to final customer. d.
Page 320 The attempt of repeated teaching of a key which has been taught already during the same teaching cycle is recognised by EMS. The EMS rejects this key and a message is sent to the tester. The EMS rejects invalid keys which are presented for teaching. A message is sent to the tester. The key can be invalid due to faults of transponder or other reasons which result into not successful programming of data.
Page 321 Once the password has been changed from 2345, the ICM is ready to record the ID code. Keys registration and correction Initial registration method Registration correction for master keys In cases when the master key is lost or where a new set of master keys need to be produced, it can be achieved using two methods.
Page 322 Using password When the customers lost the ID key, new master keys can be registered by using Hi-scan pro only. ID key can not be corrected and reproduced.
Page 323 a. Once the password is mis-registered, it is impossible to register new password during 10 seconds regardless of ignition ON/OFF. b. When the new master keys have been registered, the codes for existing master keys are all cleared. c. The password should consist of 4 numbers among ten (0~9) numbers. Limp home (override) procedure by ignition key This procedure allows the unlocking of the EMS by entering the user password via the IG SW, in case the transponder codecannot be read or is unknown after ignition-ON, a valid transponder code must have...
Page 324 Neutralized Virgin Only if the EMS is in status "learnt" and the user password status is "learnt" and the user password is the correct one,the EMS is unlocked for approximately 10 seconds. The engine can be started during this time. After elapsing of timer noengine start is possible. After new input of user password the time starts again.
Page 325 Smartra immobilizer (2.5D E/G) Schematic diagram Description Description Antenna Ground EMS-ECU Antenna IG 1...
Page 326 Shinchang Immobilizer (2.4G, 3.5G E/G) System block diagram...
Page 327 Pin connection...
Page 328 Shinchang Immobilizer (2.4G, 3.5 G E/G0...
Page 329 Smartra immobilizer (2.5D E/G) Description and operation This describes the function of EMS(Engine Management System) for vehicle immobilizing in conjunction with the SMARTRA device(SMART Transponder Antenna). The EMS carries out the immobilizer function and the key management. The immobilizer function is the unlocking of EMS only after detection of a valid ignition key and the locking of EMS only after detection of invalid ignition key and the locking of EMS after switching off the engine.
Page 330 Shinchang immobilizer (2.4G, 3.5G) COMPONENT DESCRIPTION Must be used first to register unique ID code in the ICM. KEYS ID KEY This ID code is then recorded into the master keys. Once the ID code is recorded into the MASTER KEY, this key is for MASTER KEY general use.
Page 331 DATA LINK CONNECTOR By connecting the Hi-scan pro, the control module diagnostic code can be read. DIAGNOSTIC TESTER Has the function of ICM, ECM, and keys diagnosis and change.
Page 332 Smartra immobilizer (2.5D E/G) Specification Type Encrypt type Manufacture Bosch Limp home function switch Ignition Key SW "IMMO" indicator "IMMO" indicator illuminates for approximately 30 seconds and goes out.
Page 333 INDICATORS AND GAUGES INSTRUMENT CLUSTER CIRCUIT DIAGRAM SPECIFICATION...
Page 334 Specification Item Bulb wattage (w) Color High beam Blue Sediment Rear fog Amber Rear defroster Amber Back door open Door ajar O/D OFF Amber Air bag Engine check Amber Auto cruise Green Oil pressure Parking brake Battery charge Snow (2WD) Amber Glow Amber...
Page 335 Immobilizer Amber Low fuel Amber P, N, D, 2, L Green Turn signal (LH, RH) Green...
Page 336 REMOVAL AND INSTALLATION 1. Disconnect the negative (-) battery terminal. 2. Remove the cluster housing after removing 2 screws. 3. Remove the 4 screws holding the cluster and remove the instrument cluster. 4. Installation is the reverse of removal. INSPECTION OF COMPONENTS SPEEDOMETER 1.
Page 337 Do not operat clutch suddenly or increase/ decrease speed rapidly while testing. Tire wear and tire over or under inflation will increase the indication error. Velocity (Km/h) 180 200 Tolerance (%) +0 +0 -12.6 -7.3 -5.9 -5.2 Velocity (MPH) Tolerance (%) -13.6 -8.8 -5.7...
Page 338 When removing or installing the tachometer, be careful not to drop it or subject it to severe shock. Revolution (RPM) 1,000 2,000 3,000 4,000 5,000 6,000 7,000 Remark Tolerance (%) ±6 ±5 ±4.5 ±4.2 Diesel +7.5 Tolerance (%) Gasoline -1.5 FUEL GAUGE 1.
Page 339 2. Check the temperature gauge by changing the resistance between the terminals. 3. Apply battery voltage to the terminal 9, ground the terminal 1a, and connect the resistance to the terminal 2c and then check that the pointer is moved as shown in below table. Temperature Resistance (Ω) Angle( °...
Page 340 LIGHTNING SYSTEM REPLACEMENT OF LAMPS HEAD LAMP/TURN SIGNAL LAMP 1. Disconnect the negative battery terminal. 2. Remove the turn signal lamp mounting bolts(3EA) and remove the lamp assembly. 3. Disconnect the wire connector. 4. Installation is the reverse of removal. FRONT FOG LAMP 1.
Page 341 3. Disconnect the connector and remove the lamp assembly. 4. Installation is the reverse of removal. CENTER HIGH MOUNTED STOP LAMP 1. Disconnect the negative battery terminal. 2. Remove tailgate upper trim. 3. Remove the two mounting bolts. 4. Disconnect the connector and then remove the lamp assembly.
Page 342 5. Installation is the reverse of removal. LICENSE PLATE LAMP 1. Disconnect the negative battery terminal. 2. Detach the lamp assembly and disconnect the lamp connector. 3. Installation is the reverse of removal. OVERHEAD CONSOLE LAMP 1. Disconnect the negative battery terminal. 2.
Page 343 3. Installation is the reverse of removal. ROOM LAMP 1. Disconnect the negative battery terminal. 2. Using a flat-bladed screwdriver, detach the room lamp lens. 3. Detach the lamp assembly from the headliner after removing the 2 bolts. 4. Disconnect the connector from the roof harness. 5.
Page 344 Turn the low beam on without the driver aboard. The cut-off line should be projected in the allowable range (shaded region).
Page 345 Turn the high beam on without the driver aboard. The cut-off line should be projected in the allowable range (shaded region).
Page 346 Turn the front fog lamp on without the driver aboard. The cut-off line should be projected in the allowable range (shaded region).
Page 347 MULTIFUNCTION SWITCH COMPONENTS...
Page 348 REMOVAL AND INSTALLATION a. Never attempt to disassemble or repair the air bag module or clock spring. If faulty, replace it. b. Do not drop the air bag module or clock spring or allow contact with water, grease or oil. Replace if a dent, crack, deformation or rust is detected. c.
Page 349 Tightening torque 40 - 50Nm (4.0-5.0kg·cm, 28-36lb·ft) 3. Remove the shroud side cover and then remove the steering column upper shroud and steering column lower shroud. 4. After removing the screws in the illustration, remove the clock spring. 5. Remove the 3 screws holding the multi function switch and disconnect the connectors.
Page 350 6. Installation is the reverse of removal. INSPECTION LIGHTING SWITCH [Connector "1"] LIGHTING SWITCH (With Auto light) [Connector "1"] DIMMER AND PASSING SWITCH [Connector "1"]...
Page 351 TURN SIGNAL AND LANE CHANGE SWITCH [Connector "1"] WIPER AND INTERMITTENT SPEED SWITCH [Connector "2"] WASHER SWITCH [Connector "2"] MIST SWITCH [Connector "2"]...
Page 352 FRONT FOG SWITCH [Connector "1"] REAR WIPER & WASHER SWITCH [Connector "2"]...
Page 353 POWER DOOR LOCK COMPONENTS...
Page 354 INSPECTION 1. Disconnect the actuator connector from the wiring harness. 2. Apply battery voltage (12V) to each terminal as shown in the table and verify that the actuator operates correctly.
Page 355 POWER DOOR MIRRORS CONTROL UNIT CIRCUIT DIAGRAM...
Page 356 INSPECTION 1. Check that the folding mirror operate according to the following timing chart. 2. If operation is not normal, inspect the wire connector on the mirror folding control unit. It is installed in the driver's door trim.
Page 357 POWER DOOR MIRROR ACTUATOR INSPECTION INSPECTION 1. Disconnect the power door mirror connector from the harness. 2. Apply battery voltage to each terminal as shown in the table and verify that the mirror operates properly. MIRROR FOLDING INSPECTION...
Page 359 POWER DOOR MIRROR SWITCH INSPECTION INSPECTION 1. Remove the power door mirror switch from the door trim panel. 2. Check for continuity between the terminals in each switch position according to the table. If continuity is not as specified, replace the power door mirror switch.
Page 360 COMPONENTS...
Page 361 POWER WINDOW POWER WINDOW MOTOR COMPONENTS...
Page 362 INSPECTION Connect the motor terminals directly to battery voltage(12V) and check that the motor operates smoothly. Next, reverse the polarity and check that the motor operates smoothly in the reverse direction. If the operation is abnormal, replace the motor.
Page 363 POWER WINDOW SWITCH CIRCUIT DIAGRAM...
Page 364 INSPECTION 1. Remove the switch from the door trim panel. 2. Check for continuity between the terminals. If continuity is not as specified in the table, replace the power window switch. Power window sub switch...
Page 366 INSPECTION 1. With the washer motor connected to the reservoir tank, fill the reservoir tank with water. 2. Apply the battery voltage to the terminal a and ground the terminal b or c to see that the washer motor runs and water sprays from the front or rear nozzles.
Page 367 REMOVAL 1. Remove the windshield wiper arm and blade after removing the 2 nuts. Care must be taken not to scratch the engine hood. Tightening torque : 19-28Nm (190-280kg·cm, 14-20.6lb·ft) 2. Remove the weather strip and the cowl top cover then remove the 5 bolts holding the linkage. Tightening torque : 4-6Nm (40-60kg·cm, 2.9-4.4lb·ft) 3.
Page 368 Set the washer nozzle on the specified spray position. INSPECTION...
Page 369 SPEED OPERATION CHECK 1. Remove the connector from the wiper motor. 2. Attach the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 3. 3. Check that the motor operates at low speed. 4.
Page 370 COMPONENTS...
Page 371 REAR WINDOW DEFOGGER INSPECTION Wrap tin foil around the end of the voltmeter test lead to prevent damaging the heater line. Apply finger pressure on the tin foil, moving the tin foil along the grid line to check for open circuits. 1.
Page 372 4. To check for open circuits, slowly move the test lead in the direction that the open circuit seems to exist. Try to find a point where a voltage is generated or changes to 0V. The point where the voltage has changed is the open- circuit point.
Page 373 After repairing, clean the glass with a soft dry cloth or wipe along the grid line with a slightly moistened cloth.
Page 374 BODY INTERIOR AND EXTERIOR BODY DIMENSION INDICATION PROJECTED DIMENSIONS STRAIGHT-LINE DIMENSIONS (ACTUAL MEASURED DIMENSIONS) UNDER BODY PROJECTED DIMENSIONS Measurement point Description Hole size Body mounting bracket No.1 ø 36 mm Body mounting bracket No.2 LH : ø 32 mm, RH : ø 34 mm Body mounting bracket No.3 ø...
Page 375 Body mounting bracket No.5 LH : ø 34x38 mm, RH : ø 32x36 mm...
Page 377 UNDER BODY STRAIGHT-LINE DIMENSIONS Measurement point Description Hole size Body mounting bracket No.1 ø 36 mm Body mounting bracket No.2 LH : ø 32 mm, RH : ø 34 mm Body mounting bracket No.3 ø 30 mm Body mounting bracket No.4 ø...
Page 380 BUMPERS rear bumper COMPONENTS...
Page 381 REMOVAL AND INSTALLATION 1. Remove rear combination light. (1) Remove rear combination light screws (2). (2) Remove bulb and socket. 2. Remove rear bumper face. (1) Remove bumper fasteners(9) and screws(2) from top of bumper face.
Page 382 (2) Remove rear mud guard screws (3). (3) Remove bumper face fasteners(8) from left and right side of bumper face.
Page 383 (4) Remove bumper face screws(2) from left and right side of bumper face.
Page 384 (5) Remove bumper face nuts (4) from inside of vehicle. (6) Remove bumper face. 3. Remove rear step member assembly. (1) Remove rear step member nuts(10). 4. Install in reverse order of removal.
Page 385 front bumper COMPONENTS...
Page 386 REMOVAL AND INSTALLATION 1. Remove headlight/combination light. (1) Remove headlight/combination light bolts (3). (2) Remove headlight/combination light bulb and socket. 2. Remove bumper guard. (1) Remove bumper guard nuts (2) and bolts (4). (2) Remove bumper guard. 3. Remove bumper seal board. (1) Remove bumper seal board fasteners (10).
Page 387 4. Remove bumper upper cover. (1) Remove headlight washer nozzle cover. (2) Remove bumper upper cover fasteners (8). 5. Remove bumper face. (1) Remove bumper face fasteners (10) and nuts (2) from top of bumper face. (2) Remove bumper face fasteners (6) from bottom of bumper face.
Page 388 (3) Remove bumper face screws (2) from side of bumper face. (4) Remove bumper mounting bolt (2) from front of bumper face. (5) Disconnect electrical connector and then remove bumper face. 6. Install in reverse order of removal.
Page 389 EXTERIOR body side molding COMPONENTS...
Page 390 REMOVAL AND INSTALLATION 1. Remove flange nut (12). 2. Remove roof rack assembly. 3. Install in reverse order of removal.
Page 391 front door COMPONENTS...
Page 393 REMOVAL AND INSTALLATION 1. Disconnect negative battery cable. 2. Remove door inner handle cover. (1) Remove door inner handle cover screw (1). (2) Remove inner handle cover. 3. Remove outside rearview mirror garnish. (1) Remove garnish from door frame. (2) Disconnect electrical connector. 4.
Page 394 (1) Remove assist grip cover. (2) Remove screws (2). 5. Remove door trim. (1) Remove door pull handle screw (1). (2) Remove door trim fasteners (4). (3) Disconnect electrical connector. 6. Door inner handle and pull handle bracket.
Page 395 (1) Remove door lock rod. (2) Remove inner handle bracket screws (3). (3) Remove pull handle bracket screws (2). 7. Remove outside rearview mirror folding control unit. (1) Remove screw (1). (2) Disconnect electrical connector. 8. Remove door speaker. (1) Remove door speaker screws (3). (2) Disconnect electrical connector.
Page 396 Remove window glass. (1) Reconnect power window switch connector. (2) Connect negative battery cable. (3) Turn ignition switch "ON" and position window glass bolt access hole. (4) Turn ignition switch "OFF". (5) Remove glass run channel. Remove widow glass grip bolts (2). Tightening torque : 8-12 N·m (0.8-1.2 kg·m, 6-9 lb·ft)
Page 397 (7) Disconnect negative battery cable. Remove window glass guide. Remove window glass guide (front) bolt (1) and nut (1). Tightening torque : 8-12 N·m (0.8-1.2 kg·m, 6-9 lb·ft)
Page 398 Remove window glass guide (rear) bolt(1). Tightening torque : 8-12 N·m (0.8-1.2 kg·m, 6-9 lb·ft) Remove power window regulator assembly. Remove power window regulator nuts (6). Tightening torque : 4-6 N·m (0.4-0.6 kg·m, 3-4 lb·ft)
Page 399 (2) Disconnect electrical connector. Remove door outer handle and key set. (1) Remove remote control rod. Remove door outer handle nuts (2) and bolt (1). Tightening torque : 7-11 N·m (0.7-1.1 kg·m, 5-8 lb·ft)
Page 400 (3) Disconnect electrical connector. Remove door latch assembly. Remove door latch screws (3). Tightening torque : Door latch 4-6 N·m (0.4-0.6 kg·m, 3-5 lb·ft) Tightening torque : Door striker 18-26 N·m (1.8-2.6 kg·m, 13-19 lb·ft)
Page 401 (2) Disconnect electrical connector. Remove outside rearview mirror. Remove bolts (3) and clip. Tightening torque : 5-7 N·m (0.5-0.7 kg·m, 4-5 lb·ft)
Page 402 (2) Disconnect electrical connector. Remove door outside belt weatherstrip. Remove door outside belt weatherstrip nut (1). Tightening torque : 2.5-3.6 N·m (0.25-0.36 kg·m, 2-3 lb·ft) (2) Remove door outside belt weatherstrip from door frame. 17. Remove door wiring harness.
Page 403 18. Remove door checker bolt(1) from body frame. Tightening torque : Body side 22-27 N·m (2.2-2.7 kg·m, 16-20 lb·ft) Tightening torque : Door side 9-13 N·m (0.9-1.3 kg·m, 7-9 lb·ft) 19. Remove door lower hinge bolts(2) and door upper hinge bolts(2) from body frame. Tightening torque : Body side 35-42 N·m (3.5-4.2 kg·.m, 25-30 lb·ft) Tightening torque : Door side...
Page 406 DOOR LOCK STRIKER 1. Check that door can be closed easily. If there is a problem, loosen the striker install bolts and adjust the door by moving the striker verticallyand horizontally. 2. Adjust the rear offset of the door to the body by moving the door lock striker horizontally.
Page 407 hood ADJUSTMENT HOOD 1. Adjust the hood laterally and vertically by loosening the hood to hinge mounting bolts and repositioning the hood. Tightening torque : 22-27 N·m (2.2-2.7 kg·m, 16-20 lb·ft) 2. Turn the hood rubber cushion either clockwise or counter clockwise to adjust the height of the hood.
Page 409 COMPONENTS...
Page 410 mirror COMPONENTS...
Page 411 REMOVAL AND INSTALLATION 1. Disconnect negative battery cable. 2. Remove outside rearview mirror garnish. (1) Remove garnish from door frame. (2) Disconnect electrical connector. Remove outside rearview mirror. Remove bolts(3) and clip(1). Tightening torque : bolt 5-7 N·m (0.5-0.7 kg·m, 4-5 lb·ft)
Page 412 (2) Disconnect electrical connector. 4. Remove mirror. Wear gloves to remove and install the mirror holder (1) Insert flat bladed screwdriver between the outside rearview mirror holder and the mirror assembly. 5. Remove outside rearview mirror actuator. When prying with a flat bladed screwdriver, wrap it with a shop towel to prevent damage. (1) Remove the outside rearview mirror actuator from the outside rearview mirror housing.
Page 413 6. Install in reverse order of removal.
Page 414 rear door COMPONENTS...
Page 416 REMOVAL AND INSTALLATION 1. Disconnect negative battery cable. 2. Remove door inner handle cover. (1) Remove door inner handle screw (1). (2) Remove door inner handle cover. 3. Remove assist grip cover. (1) Remove assist grip cover. (2) Remove screws (2). 4.
Page 417 (1) Remove door pull handle screw (1). (2) Remove door trim fasteners (4). (3) Disconnect electrical connector. 5. Remove door inner handle and door pull handle bracket. (1) Remove door lock rod. (2) Remove door inner handle screws(2). (3) Remove door pull handle bracket screws (2). 6.
Page 418 (2) Disconnect electrical connector. 7. Remove door screen. Peel door screen off carefully so that it can be reused. 8. Remove window glass run channel.
Page 419 Remove window glass guide. Remove window glass guide (front) bolts (2) and screw (1). Tightening torque : 8-12 N·m (0.8-1.2 kg·m, 6-9 lb·ft)
Page 420 10. Remove fixed glass. Remove window glass. (1) Reconnect power window switch connector.
Page 421 (2) Connect negative battery cable. (3) Turn ignition switch "ON" and position window glass grip bolt access hole. (4) Turn ignition switch "OFF". Remove window glass grip bolts (2). Tightening torque : 8-12 N·m (0.8-1.2 kg·m, 6-9 lb·ft) (6) Disconnect negative battery cable. Remove window regulator assembly.
Page 422 (2) Disconnect electrical connector. Remove door outer handle. Remove door outer handle nuts(2). Tightening torque : 7-11 N·m (0.7-1.1 kg·m, 5-8 lb·ft)
Page 423 Remove door latch assembly. Remove door latch screws (3). Tightening torque : Door latch 4-6 N·m (0.4-0.6 kg·m, 3-5 lb·ft) Tightening torque : Door latch striker 19-26 N·m (1.8-2.6 kg·m, 13-20 lb·ft)
Page 424 (2) Disconnect electrical connector. Remove door outside belt weatherstrip. Remove door outside belt weatherstrip nut (1). Tightening torque : 2.5-3.6 N·m (0.25-0.36 kg·m, 2-3 lb·ft)
Page 425 (2) Remove door outside belt weatherstrip from doorframe. 16. Remove door wiring harness. 17. Remove door lock checker install bolt(1) from body frame. Tightening torque : Body side 22-27 N·m (2.2-2.7 kg·m, 16-20 lb·ft) Tightening torque : Door side 9-13 N·m (0.9-1.3 kg·m, 7-9 lb·ft) 18.
Page 426 To adjust the door-to-body offset, loosen the door hinge install bolts and make the adjustment.
Page 428 DOOR LOCK STRIKER 1. Check that the door can be closed easily. If there is a problem, loosen the striker install bolts and adjust the door by moving the strikerve rtically and horizontally. 2. Adjust the rear offset of the door to the body by moving the door lock striker horizontally.
Page 429 tail gate COMPONENTS...
Page 430 REMOVAL AND INSTALLATION 1. Disconnect negative battery cable. 2. Remove tailgate upper trim. (1) Disconnect rear window defroster connector. (2) Remove upper trim fastener. 3. Remove high-mounted brake light. (1) Disconnect electrical connector. (2) Remove high-mounted brake light screws (2). 4.
Page 431 (2) Remove inner assist handle screws (2). 5. Remove tailgate screen. Remove license plate light assembly. Remove license light nuts (2) and bolts (2). Tightening torque : 7-11 N·m (0.7-1.1 kg·m, 5-8 lb·ft) (2) Disconnect electrical connector. Remove rear wiper arm and wiper blade. (1) Remove head cap.
Page 432 8. Remove rear wiper control unit. (1) Disconnect electrical connector. (2) Remove wiper control unit bolts (2). Remove rear wiper motor. (1) Remove wiper motor cover. (2) Remove wiper motor nut. Remove wiper motor bolts (3). Tightening torque : nut 3-6 N·m (0.3-0.6 kg·m, 2-4 lb·ft) Tightening torque : bolts 7-10 N·m (0.7-1.0 kg·m, 5-7 lb·ft)
Page 433 10. Remove tailgate lifter. (1) After pulling out lifter clip with (-) screwdriver, extract lifter. Remove tailgate glass. Remove tailgate glass hinge bolt (1). Tightening torque : bolts 7-10 N·m (0.7-1.0 kg·m, 5-7 lb·ft)
Page 434 Remove tailgate latch controller. (1) Disconnect electrical connector. (2) Remove tailgate latch controller rod. Remove tailgate latch controller bolts(3). Tightening torque : bolts 7-11 N·m (0.7-1.1 kg·m, 5-8 lb·ft) Remove tailgate glass latch assembly. Remove tailgate glass latch bolts(2). Tightening torque : bolts 7-11 N·m (0.7-1.1 kg·m, 5-8 lb·ft)
Page 435 Remove tailgate key cylinder. (1) Remove remote control rod. Remove tailgate key cylinder nuts(2). Tightening torque : 12 N·m (1.2 kg·m, 9 lb·ft) (3) Disconnect electrical connector. Remove tailgate outside handle. (1) Remove remote control rod. Remove tailgate outside handle nuts(2). Tightening torque : nuts 7-10 N·m (0.7-1.0 kg·m, 5-7 lb·ft)
Page 436 Remove tailgate latch assembly. (1) Remove remote control rod. Remove tailgate latch bolts (2). Tightening torque : tailgate latch 7-11 N·m (0.7-1.1 kg·m, 5-8 lb·ft) Tightening torque : tailgate lock striker 9-14 N·m (0.9-1.4 kg·m, 7-10 lb·ft) (3) Disconnect electrical connector. 17.
Page 437 Remove tailgate hinge. Remove tailgate hinge bolts (2). Tightening torque : bolts 7-10 N·m (0.7-1.0 kg·m, 5-7 lb·ft)
Page 438 20. Install in reverse order of removal. ADJUSTMENT TAILGATE HINGE 1. Check that the tailgate can be closed easily and that there is no play. If there is a problem, open the tailgate and tighten the tailgate hingeinstall bolts. To adjust the tailgate-to-body offset, loosen the tailgate hinge install bolts and make the adjustment.
Page 440 TAILGATE LOCK STRIKER 1. Check that the tailgate can be closed easily. If there is a problem, loosen the striker install bolts and adjust the tailgate by moving the strikervertically and horizontally. 2. Adjust the rear offset of the tailgate to the body by moving the tailgate lock striker horizontally.
Page 441 GENERAL INFORMATION SPECIFICATIONS Hood Rear hinged, front opening type (gas lifter Type type) Front door Construction Front hinged, full door construction Regulator system X-arm type Locking system Pin-fork system Rear door Construction Slide type Locking system Pin-fork system Tailgate Type Inner hinged, gas lifter type Glass thickness.
Page 442 TIGHTENING TORQUE Item Description N·m kg·m lb·ft Front fender Mounting bolts 7 ~ 9 0.7 ~ 0.9 5 ~ 7 Hood Hinge 22 ~ 27 2.2 ~ 2.7 16 ~ 20 Latch assembly 7 ~ 11 0.7 ~ 1.1 5 ~ 8 Rear hatch Hinge 7 ~ 10...
Page 443 Checker (Door side) 9 ~ 13 0.9 ~ 1.3 7 ~ 9 Hinge (Body side) 35 ~ 42 3.5 ~ 4.2 25 ~ 30 Hinge (Door side) 18 ~ 30 1.8 ~ 3.0 13 ~ 22 Glass grip bolt 8 ~ 12 0.8 ~ 1.2 6 ~ 9 Regulator assembly...
Page 444 TROUBLESHOOTING Hood Problem Possible cause Action Hood does not open or Striker and latch not properly Adjust close completely aligned Incorrectly installed hood Adjust Incorrect hood bumper height Adjust Tailgate Problem Possible cause Action Water leak from tailgate Cracked or defective opening Replace edge weatherstrip...
Page 445 handle Damaged or defective sash Correct or replace Damaged or defective regulator Correct or replace arm or regulator Water leak through door Cracked or defective opening Replace edge weatherstrip Water leak from door Drain hole clogged Remove foreign objects center Inadequate waterproof film contact Correct or replace or damage...
Page 446 sunroof in body work replace Sunroof makes a noise Check drive cable and Foreign particles lodged in guide when moved guide rails for foreign rail particles Loose guide rails and lid Retighten Motor runs but sunroof Check drive cable and Foreign particles lodged in guide does not move or moves guide rails for foreign...
Page 447 Broken slide rail Accident Replace slide rail Broken cross bar Accident Replace cross bar Broken slide Accident Replace slide Missing base cover Vibration or accident Replace base cover Windshield Problem Possible cause Action Water leak through Defective weatherstrip seal Fill sealant windshield Cracked or defective weatherstrip Replace Defective body flange...
Page 448 Major crack Accident, malicious mischief Replace Deformation Accident, malicious mischief Replace Pitting Sand storm Replace Bumpers Problem Possible cause Action Bumper face damaged Accident Replace Energy absorbing foam Accident or exposure Replace damaged or deteriorated Reinforcement damaged Accident Replace Brackets or stays Accident Repair or replace damaged...
Page 449 Belt does not extend Replace retractor Faulty mechanism completely assembly Replace retractor Belt does not retract Wear or accident assembly Replace retractor Belt does not extend Faulty mechanism assembly Tighten to specified Buckle assembly is loose Vibration or accident torque Retractor assembly is Tighten to specified Vibration or accident...
Page 450 INTERIOR COMPONENTS crash pad...
Page 451 REMOVAL AND INSTALLATION 1. Disconnect negative battery cable. 2. Remove A pillar trim. 3. Remove cowl side trim. (1) Remove front door scuff trim. (2) Remove cowl side trim screw and fastener.
Page 452 4. Remove shroud cover. (1) Remove screws(3). 5. Remove lower instrument panel. (1) Remove side cover. (2) Remove hood release cable. (3) Remove lower instrument panel screws(4). (4) Disconnect electrical connector. 6. To remove the instrument panel, first remove the following parts. (1) Steering wheel (2) Shroud cover (3) Lower instrument panel...
Page 453 (4) Steering shaft 7. Remove instrument cluster hood. (1) Remove instrument cluster hood screws (2). 8. Remove instrument cluster assembly (1) Remove instrument cluster screws (4). (2) Disconnect electrical connector. 9. Remove upper tray. (1) Remove screw (4). 10. Remove instrument center side panel.
Page 454 11. Remove audio panel. (1) Remove audio panel screws (4). (2) Disconnect electrical connector. 12. Remove audio. (1) Remove audio screws (4).
Page 455 (2) Disconnect electrical connector and antenna cable. 13. Remove heater controller. (1) Remove heater controller screws (4). (2) Disconnect electrical connector. 14. Remove center panel. (1) Remove center panel screws (6).
Page 456 (2) Disconnect electrical connector. 15. Remove center lower panel (LH). (1) Remove center lower panel screws (4). 16. Remove glove box. 17. Remove instrument lower panel (RH). (1) Remove side cover (RH).
Page 457 (2) Remove instrument lower panel screws (10). (3) Disconnect electrical connector. Remove main instrument panel assembly. (1) Disconnect electrical connector. Remove crossbar side mounting bolts (4). Tightening torque : 17-26 N·m (1.7-2.6 kg·m, 12-19 lb·ft)
Page 458 Remove crossbar lower mounting bolts (4). Tightening torque : 17-26 N·m (1.7-2.6 kg·m, 12-19 lb·ft)
Page 459 (4) Remove cross bar bracket bolts (2). (5) Remove main instrument panel assembly. 19. Install in reverse order of removal.
Page 460 interior trim COMPONENTS...
Page 461 REMOVAL AND INSTALLATION FRONT PILLAR TRIM 1. Remove front pillar trim. (1) Remove screw(1) and cover. (2) Remove front pillar trim. COWL SIDE TRIM 1. Remove cowl side trim. (1) Remove front door scuff trim. (2) Remove cowl side trim fastener and screw.
Page 462 CENTER PILLAR TRIM Remove center pillar lower trim. (1) Remove front door scuff trim. (2) Remove rear door scuff trim. Remove seat belt lower anchor bolt (1). Tightening torque : 40-55 N·m (4.0-5.5 kg·m, 29-40 lb·ft)
Page 463 (4) Remove center pillar lower trim screws (2). Remove center pillar upper trim. Remove seat belt upper anchor bolt (1). Tightening torque : 40-55 N·m (4.0-5.5 kg·m, 29-40 lb·ft)
Page 464 (2) Remove B pillar upper trim screws (2) and cover. REAR SIDE TRIM 1. Remove rear door scuff trim. 2. Remove transverse trim. 3. Remove D pillar trim.
Page 465 4. Remove hanger net. 5. Remove rear side trim. (1) Remove rear side trim screws (5). (2) Remove rear package side garnish screws (2). (3) Remove rear package side garnish. (4) Disconnect electrical connector. C PILLAR TRIM 1. Remove seat belt lower anchor bolt (1). 2.
Page 466 (1) Remove seat belt anchor bolt (1) (2) Remove C pillar trim screws (3) and cover. (3) Remove seat belt cover.
Page 467 roof trim COMPONENTS...
Page 468 REMOVAL 1. Unscrew two mounting screws from sunvisors. 2. Remove sunvisors and sunvisors retainers. 3. Remove assist handle covers, unscrew mounting screws. 4. Remove three assist handles. 5. Gently remove lens assembly on interior and map light.
Page 469 6. Remove light bulb. 7. Remove two mounting screws. 8. Disconnect power connector and remove interior and map light. 9. Remove front, center, C and D-pillar trims. 10. Remove seven fasteners. 11. Remove headling 12. Install in reverse order of removal.
Page 470 tailgate glass COMPONENTS...
Page 471 REMOVAL AND INSTALLATION 1. Remove Tailgate upper trim. (1) Disconnect rear window defroster connector. (2) Remove upper trim fastener. 2. Remove high-mounted brake light. (1) Disconnect electrical connector. (2) Remove high-mounted brake light screw (2). 3. Remove tailgate trim. (1) Remove tailgate fasteners (6) and screws (1).
Page 472 (2) Remove inner assist handle screws (2). 4. Remove tailgate screen. 5. Remove tailgate glass lifter. (1) After pulling out lifter clip with (-) screwdriver, extract lifter. Remove tailgate glass. Remove tailgate glass hinge bolt (1). Tightening torque : 7-9 N·m (0.7-0.9 kg·m, 5-7 lb·ft)
Page 473 Remove tailgate glass latch assembly. Remove tailgate glass latch bolt (2). Tightening torque : 7-11 N·m (0.7-1.1 kg·m, 5-8 lb·ft) 8. Install in reverse order of removal.
Page 474 windshield glass COMPONENTS...
Page 475 REMOVAL 1. To remove the windshield, first remove the following parts : (1) Front pillar trims (2) Inside rear view mirror (3) Wiper arms (4) Cowl top cover (5) Windshield glass molding 2. Use the knife to cut through the sealant. 3.
Page 476 4. Take out the windshield glass with the Glass Holder. INSTALLATION 1. Using a cutter knife scrape the old sealant smoothly to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire windshieldflange. Be careful not to remove more adhesive than necessary, and also not to damage the paintwork on the body surface with the knife.
Page 477 2. Clean the body bonding surface with a sponge dampened in alcohol or wax and grease remover. 3. Center a new windshield glass in the opening. Mark the location by marking lines across the glass and body with a grease pencil at the fourpoints as shown. 4.
Page 478 5. Apply a light coat of glass primer to the outside of the dam. a. Never touch the surface applied primer with your hand.If you do, the adhesive may not bond to the glass properly, causing a leak after the windshield glass is installed.
Page 479 7. Apply a sealant around the edge of the glass. Apply the adhesive within 5 minutes after applying the primer to the glass. 8. Apply a light coat of body primer to the original sealant remaining around the window opening flange. The glass should be installed within 5 minutesafter you apply the primer.
Page 480 9. Using suction cups or the special tool, lower the glass over the opening, align it with the marks made in step 3 and set it down on the sealant. 10. Scrape or wipe excess adhesive off with a putty knife or gauze. Fill all cavities around the windshield glass.
Page 481 13. Install the removed parts. a. Keep the windshield dry for the first hour after installation. b. Let the car stand for at least four hours after windshield installation. If the car has to be used within the first 8 hours, it must be driven slowly. c.
Page 482 SEAT BELT front seat belt COMPONENTS...
Page 483 REMOVAL AND INSTALLATION 1. Remove seat belt lower anchor bolt. Tightening torque : 40-55 N·m (4.0-5.5 kg·m, 29-40 lb·ft) 2. Remove seat belt upper anchor bolt. Tightening torque : 40-55 N·m (4.0-5.5 kg·m, 29-40 lb·ft) 3. Remove B pillar lower trim (1) Remove front door scuff trim.
Page 484 (2) Remove rear door scuff trim. (3) Remove B pillar lower trim screws (2). Remove retractor. (1) Turn ignition switch "OFF". (2) Disconnect negative battery cable. (3) Wait for about 1 minute.
Page 485 (4) Disconnect gas generator connector. Remove retractor screw. Tightening torque : 18-27 N·m (1.8-2.7 kg·m, 13-20 lb·ft) (6) Remove wire harness clip. a. A pretensioner functions one time only. Be sure to replace the pretensioner seat belt after it is deployed. b.
Page 486 rear seat belt COMPONENTS...
Page 487 REMOVAL AND INSTALLATION 1. Remove seat belt lower anchor bolt. Tightening torque : 40-55 N·m (4.0-5.5 kg·m, 29-40 lb·ft) 2. Remove rear side trim. (1) Remove rear door scuff trim. (2) Remove rear transverse trim. (3) Remove hanger net. (4) Remove rear side trim screws (5).
Page 488 3. Remove C pillar trim. 4. Remove seat belt upper anchor bolt. Tightening torque : 40-55 N·m (4.0-5.5 kg·m, 29-40 lb·ft) Remove retractor. Remove retractor anchor bolt. Tightening torque : 40-55 N·m (4.0-5.5 kg·m, 29-40 lb·ft)
Page 489 Remove retractor screw. Tightening torque : 18-27 N·m (1.8-2.7 kg·m, 13-20 lb·ft) 6. Install in reverse order of removal.
Page 490 seat heater INSPECTION...
Page 491 COMPONENTS...
Page 492 seat and power seat front seat COMPONENTS...
Page 493 REMOVAL AND INSTALLATION 1. Remove seat mounting bolt (3) and nut (1). Tightening torque : 39 N·m (3.9 kg·m, 28 lb·ft) 2. Disconnect electrical connector. 3. Install in reverse order of removal.
Page 494 rear seat COMPONENTS...
Page 495 REMOVAL AND INSTALLATION 1. Remove seat mounting bolt(8). Tightening torque : 39 N·m (3.9 kg·m, 28 lb·ft) 2. Install in reverse order of removal.
Page 496 SUN ROOF COMPONENTS...
Page 497 REMOVAL AND INSTALLATION 1. To remove the sunroof, first remove the following parts : (1) Overhead console lamp (2) Sunvisor and assist grip handle (3) Pillar trims 2. Remove sunroof glass. (1) Remove screw (6). 3. Disconnect drain hose. 4. Remove sunroof assembly. (1) Remove bolt and nut.
Page 498 When removing the sunroof assembly, carefully pull out the sunroof assembly to avoid damage to the other parts. CHECK OPERATING CONDITION AFTER INSTALLATION 1. Make sure the battery is fully charged. 2. Make sure that the sunroof sliding unit is free of abrasive materials. 3.
Page 499 5. After adjustment, be sure to lock the nut with the pawl washer. DISASSEMBLY 1. Remove motor. When removing the motor, the guide assembly should always be in the fully closed position.
Page 500 2. Remove drip rail. 3. Remove stopper. 4. Remove drip shoe and guide.
Page 501 5. Remove slider.
Page 502 6. Remove culisse and slider. 7. Remove sunshade.
Page 503 8. Remove deflector. REASSEMBLY 1. Install in reverse order of removal. 2. Align the position of slider when installing the motor.: Be sure to align the center 'A' and 'B'.
Page 504 Be sure to initiate the motor when removing and installing it. 3. Method of motor initialization. (1) Confirm the installation of glass. : The state of finishing gap control. (2) Press the "UP" switch. (The state of pressing switch). : After pressing "UP" switch for 3-5 seconds, the slider must be moved 5mm forward.
Page 505 (3) Switch OFF after the slider has been moved 5mm and switch "UP" again.(Switch is being pressed) : If all conditions are normal, Sunroof will open and close once. (4) It makes initializing done to convert switch "UP" into "OFF" when the sunroof is closed.
Page 506 (3) Install motor after adjusting the position of slide as shown in the figure. (4) Initialize motor according to the way of initialization. ADJUSTMENT Front side : 0 (+0, -1.0) mm Rear side : 0 (+1, +0) mm 1. Loosen the front screw and rear screw. Adjust the height between the glass panel...
Page 507 and roof panel. 2. Loosen the nuts holding the glass panel and adjust the gap between the glass panel and roof panel.
Page 508 Check the continuity between the terminals while operating the switch.
Page 509 CIRCUIT DIAGRAM...
Page 510 Inspection 1. Apply the battery voltage to terminal 3, 10 and ground the terminal 5. 2. Apply the battery voltage to terminals as below table, and check that the sunroof unit operates as below table. Resetting the Sunroof When your battery happens to be disconnected or discharged, or you use the emergency handle to operate the sunroof, you have to reset your sunroof system as follows : 1.
Page 511 BRAKE SYSTEM ABS control module COMPONENTS...
Page 512 REMOVAL 1. Disconnect the HECU (Hydraulic and electronic Control Unit) and motor connector. 2. Disconnect the brake lines from the HECU. 3. Remove the HECU mounting nut, HECU bracket bolt and the HECU. a. Never attempt to disassemble the HECU. b.
Page 513 DESCRIPTION The EBD system (Electronic Brake force Distribution) as a sub-system of the ABS system is to control the effective adhesion utilization by the rear wheels. It further utilizes the efficiency of highly developed ABS equipment by controlling the slip of the rear wheels in the partial braking range.
Page 514 front wheel speed sensor REMOVAL 1. Remove the front wheel speed sensor mounting bolt. 2. Remove the front wheel speed sensor after disconnecting the wheel speed sensor connector. INSPECTION 1. Connect an ohmmeter between the wheel speed sensor terminals and measure the resistance. Service standard Front : 1600Ω...
Page 515 Set the voltmeter to measure AC voltage. Service standard : AC voltage detected. ABS OPERATION CHECK WHEEL SPEED SENSOR OUTPUT VOLTAGE CHECK 1. Lift the vehicle up and release the parking brake. 2. Disconnect the HECU harness connector and measure from the harness side connector. Be sure to remove the connector double lock and insert the probe into the harness side.
Page 516 rear wheel speed sensor REMOVAL...
Page 517 INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES DTC No. C0110 Electrical Probable cause (Motor relay, motor) a. Malfunction of wiring harness or When the motor power line is normal but no signal is input to connector. the motor monitor line, it is abnormal. b.
Page 518 INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES DTC No. C0121 Valve relay Probable cause (Including fuse failure) a. Malfunction of wiring harness or When the ignition switch is turned ON, the HECU switches the connector valve relay off and on during the initial check. In that way, the b.
Page 519 INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES DTC No. C0161 Brake lamp switch Probable cause a. Check relevant connector. a. Malfunction of wiring harness or connector. b. Check malfunction of wiring harness. b. Malfunction of brake lamp switch. c. Check malfunction of brake lamp switch. when applying brake pedal : BV c.
Page 520 INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES DTC No. C0245 Probable cause (Wheel speed sensor frequency error.) a. Malfunction of wheel speed sensor A wheel speed sensor outputs no signal b. Improper installation of wheel speed sensor c. Malfunction of rotor (excitor) d.
Page 521 INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES DTC No. C0550 ECU Hardware Probable cause (EEPROM and ECU failure) The HECU always monitors the solenoid valve drive circuit. It a. Malfunction of wiring harness determines that there is an open or short-circuit in the solenoid b.
Page 522 INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES DTC No. C0800 Voltage out of range Probable cause (Low and over voltage) a. Malfunction of wiring harness or The voltage of the HECU power supply drops lower than or connector rises higher than the specified value. If the voltage returns to b.
Page 523 INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES DTC No. C0930 G-sensor signal Probable cause (Only 4WD) a. Malfunction of G-sensor. This code is output at the following times: b. Malfunction of wiring harness or The output from G-sensor is between 0.5V and 5.0V. connector An open or short circuit is present in the G-sensor system.
Page 524 INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES DTC No. C0035, C0040, C0045, C0050 Probable cause Wheel speed sensor open or short to GND circuit a. Malfunction of wheel speed sensor. The HECU determines that an open or short circuit has b. Malfunction of wiring harness or occured in more than one wire of the wheel speed sensors connector.
Page 525 INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES DTC No. C0060, C0065, C0070, C0075, C0080, C0085, Probable cause C0090, C0095 HECU hardware error a. Malfunction of wiring harness or Replace HECU connector. b. Malfunction of hydraulic unit. c. Malfunction of HECU.
Page 526 ABS WIRING DIAGRAM...
Page 528 INSPECTION AT HECU TERMINALS TERMINAL VOLTAGE CHART Terminal No. Description Condition Output a. Battery power source 1 Always System voltage b. Solenoid valve power source Ground Diagnosis interface (K-Line) Data to the Hi-Scan Wheel speed sensor (Left rear) Resistance R=1.6kΩ ± 50% Wheel speed sensor (Left front) Wheel speed sensor (Right front) Min.
Page 529 ABS warning lamp Energized ABS Max. current: below 200mA Brake (EBD) Warning lamp relay Max. voltage Stop lamp switch input Input voltage threshold 5.00V -10.5V G-Sensor input Longitudinal Torque on demand G-Sensor signal ground G-Sensor Output voltage INPUT-OUTPUT SPECIFICATION Mark Terminal Name Specification Note...
Page 530 WLAS ABS Warning Lamp Max. curent : I < 200mA output terminal Max. voltage : 3.6V Low level output voltage : Brake warning V < 2.0V(at 200mA) lamp(EBD) output Leakage current : I < 1mA terminal Diagnosis interface Input voltage threshold : terminal Output votlage threshold : VB : Ignition voltage...
Page 532 STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING NOTES WITH REGARD TO DIAGNOSIS Phenomenon Explanation System check sound When starting the engine, a thudding sound can sometimes be heard coming from inside the engine compartment. This is because the system operation check is being performed. 1.
Page 533 ABS CHECK SHEET HI-SCAN (PRO) CHECK 1. Turn the ignition "OFF". 2. Connect the Hi-scan to the data link connector located underneath low crash pad panel. 3. Turn the ignition "ON". 4. Use the Hi-scan to check the self-diagnosis codes.
Page 534 5. After completion of the repair or correction of the problems, turn the ignition switch "ON" ; then erase the stored faults codes using the clear key. 6. Disconnect the Hi-scan. INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES DTC on Hi-Scan Description C0800 Device power #1 (Low current #1) circuit malfunction...
Page 535 C0930 Longitudinal acceleration sensor C0161 ABS brake switch circuit malfunction C0550 ECU malfunction C0121 Fuse failure C0110 Electrical (Pump-Motor) circuit malfunction C0245 Wheel speed sensor frequency error ACTUATOR DRIVING Description Condition Recognition Time Motor KEY ON Motor pump relay operation (Click 20 seconds ENG.
Page 536 RL wheel speed Rear left wheel speed sensor SNSR RR wheel speed Rear right wheel speed sensor SNSR ABS SRI status Warning lamp ON/OFF Brake SW Brake switch Motor pump relay Motor relay Valve relay Valve relay Motor pump status Motor FL valve (In) Front left valve (In)
Page 537 Large brake pedal vibration (Caution 2.) During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is not an abnormality. INSPECTION PROCEDURE 1 Communication with Hi-Scan is not possible.
Page 538 INSPECTION PROCEDURE 3 When the ignition key is turned "ON" (engine stopped), ABS Probable cause warning lamp does not illuminate a. Blown fuse When current flows through the HECU, the ABS relay turns b. Burnt out ABS warning lamp bulb from on to off as the initial check.
Page 539 an open circuit in the lamp power supply circuit, a blown bulb, or an open circuit in both the circuits between the ABS warning lamp and the HECU and in the circuit between the ABS warning lamp and the ABS relay. INSPECTION PROCEDURE 4 Even after the engine is started, the ABS warning lamp Probable cause...
Page 540 INSPECTION PROCEDURE 5 Brake operation is abnormal Probable cause a. Improper installation of wheel speed This varies depending on driving conditions and road surface sensor conditions, so problem diagnosis is difficult. However, if a b. Incorrect sensor harness contact normal diagnosis code is displayed, carry out the following c.
Page 541 BLEEDING OF BRAKE SYSTEM This procedure should be used to insure adequate bleeding and filling of ABS unit, brake lines, master cylinder. 1. Remove the reservoir cap and fill the brake reservoir with brake fluid. Do not allow brake fluid remain on a painted surface. Wash it off immediately.
Page 542 3. Connect Hi-Scan to Data Link Connector located underneath the dash panel. 4. Select and operate according to the instruction on the Hi-Scan screen. You have to obey maximum operating time (60sec) of ABS motor with Hi-Scan to prevent motor pump burnt. (1) Select KIA vehicle diagnosis.
Page 543 (2) Select Anti-Lock brake system. (3) Select air bleeding mode. (4) Press 'YES' to operate motor pump and solenoid valve. (5) 'ON' and 'OFF' controls are automatically perfomed to prevent the motor pump from being burnt. (If not, you may damage the motor)
Page 544 5. Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without bubbles. Then close the bleeder screw. 6. Repeat the step 5. until there are no more bubbles in the fluid for each wheel in the sequence shown in the illustration.
Page 545 SYSTEM COMPONENT The Anti-Lock Brake System (ABS) controls the hydraulic brake pressure of all four wheels during sudden braking and braking on hazardous road surfaces, preventing the wheels from locking up. ABS provides the following benefits : a. Enables steering around obstacles with a greater degree of certainty, even during emergency braking. b.
Page 546 (5) During its lighting, ABS control is interrupted and only ordinary brake operates in same way as ABS noninstalled vehicle. (6) It is lighted when ECU connector is removed. 2. EBD (electronic brake-force distribution) warning lamp (1) It is lighted at time of ON of ignition Key. (2) It is extinguished at start of operation.
Page 547 Pump failure does not operate Operate Low valtage of does not operate Operate battery Failure of Plural does not operate does not operate sensor HYDRAULIC MODULE INSPECTION Turn the ignition switch off before connecting or disconnecting the Hi-Scan. 1. Jack the vehicle up and support the vehicle with rigid racks at the specified jack-up points or replace the wheels which are checked on the rollers of the braking force tester.
Page 549 ABS OPERATING MODES Normal brake (ABS is not operated) ABS operating (Maintaining pressure mode)
Page 550 ABS operation (Decreasing pressure mode)
Page 551 ABS operation (Increasing pressure mode)
Page 553 brake booster REMOVAL 1. Remove master cylinder and gasket. 2. Disconnect vacuum hose from the booster. 3. Remove the shift knock cable (A/T) and then remove joint pin and snap pin. 4. Remove the lock nut and then remove brake booster. INSTALLATION 1.
Page 554 3. Connect the booster push rod and brake pedal with a joint pin and install a snap pin to the joint pin and then install the shift knock cable (A/T). When installing the snap pin, A new one must be used. Adjust push rod length (1) Insert the gasket onto the master cylinder.
Page 555 Check whether the clearance between the edge of the adjust bolt and the push rod of the booster is 1.2 - 1.7 mm (0.047 - 0.067 in.) If it is not 1.2 - 1.7 mm (0.047 - 0.067 in.), loosen the lock nut of the push rod, and turn the push rod to make the adjustment.
Page 556 5. If the parking brake warning lamp turns on, it is in good condition. For detail checking of the vacuum switch operation, carry out the following tests: 1. Remove the vacuum hose. 2. When IG ON, check whether parking brake warning lamp turns on. 3.
Page 557 brake line COMPONENTS...
Page 558 REMOVAL Holding the nut at the brake hose side, loosen the flare nut of the brake tube. INSTALLATION 1. Install the brake hoses without twisting them. When installing, be sure the brake hose does not contact edges, welding or moving parts. 2.
Page 559 brake pedal COMPONENTS...
Page 560 REMOVAL 1. Remove the stop lamp switch connector. 2. Remove the joint pin and snap pin. 3. Remove the nut and then remove the brake pedal. INSTALLATION 1. Installation is the reverse of removal. Nut tightening torque : 20-35 N·m (2.0-3.5 kg-m, 14-25 lb-ft) Coat the inner surface of the bushings with the specified grease.
Page 561 4. Check all parts for crack and wear.
Page 562 INSPECTION AND REPLACEMENT OF FRONT DISC BRAKE PAD 1. Check the brake pad thickness through the caliper body inspection hole. Pad lining thickness Standard value : 10.5 mm (0.413 in.) Service limit : 2.0 mm (0.0787 in.) a. If the pad lining thickness is out of specification, left and right pads must be replaced as a complete set.
Page 563 INSTALLATION 1. Install the pad clips. 2. Install the pads on each pad clip. a. All four pads must be replaced as a complete set. b. When replacing the brake pads, check for deformation. When replacing the guide spring, use a new one or thoroughly clean the used one.
Page 564 4. Lower and insert the brake cylinder carefully so as not to damage the boot. 5. Tighten the two guide rod bolts to the specified torque. Tightening torque Guide rod bolt : 22 - 32 Nm (220 - 320 kg·cm, 16 - 24 lb·ft) DISASSEMBLY Front disc brakes should be disassembled separately into the left and right as a set.
Page 565 Remove the piston seal. (1) Remove the piston seal with your finger. Do not use a screwdriver or another tool because it may damage the cylinder. Clean the piston surface and inner cylinder using alcohol or the specified brake fluid. Brake fluid : DOT 3 or DOT 4 INSPECTION 1.
Page 566 4. Check that grease is applied, and the pad and backing metal are not damaged. 5. Check the pad wear. Measure the pad thickness and replace it if it is less than the specified value. Pad thickness Specification : 10.5 mm (0.413 in.) Service limit : 2.5 mm (0.098 in.) INSPECTION FRONT BRAKE THICKNESS CHECK...
Page 567 2. Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc. Brake disc runout Limit : 0.03mm (0.0012 in.) or less Fix the disc to the hub by tightening the nut. FRONT BRAKE DISC RUN OUT CORRECTION 1.
Page 568 (2) If the runout does not exceed the limit specification, install the brake disc after turning it 180° from the chalk mark, and then check the runout of the brake disc again. 2. If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc. REASSEMBLY 1.
Page 570 master cylinder REMOVAL 1. Remove master cylinder and gasket. 2. Disconnect vacuum hose from the booster. 3. Remove the shift knock cable (A/T) and then remove joint pin and snap pin. 4. Remove the lock nut and then remove brake booster. INSTALLATION 1.
Page 571 3. Connect the booster push rod and brake pedal with a joint pin and install a snap pin to the joint pin and then install the shift knock cable (A/T). When installing the snap pin, A new one must be used. Adjust push rod length (1) Insert the gasket onto the master cylinder.
Page 572 Check whether the clearance between the edge of the adjust bolt and the push rod of the booster is 1.2 - 1.7 mm (0.047 - 0.067 in.) If it is not 1.2 - 1.7 mm (0.047 - 0.067 in.), loosen the lock nut of the push rod, and turn the push rod to make the adjustment.
Page 573 5. If the parking brake warning lamp turns on, it is in good condition. For detail checking of the vacuum switch operation, carry out the following tests: 1. Remove the vacuum hose. 2. When IG ON, check whether parking brake warning lamp turns on. 3.
Page 574 proportioning valve inspection INSPECTION 1. to the inlet valve and outlet valve of rear wheel. 2. Bleed the air from the brake system. 3. Depress the brake pedal until the master cylinder pressure equal to A; then record rear brake pressure 4.
Page 575 rear disc brake removal REMOVAL 1. Remove the wheel. 2. Remove the guide bolt, lift up the caliper assembly, and remove the pad assembly. DISASSEMBLY SERVICE POINT 1. Remove the piston boot/piston. Wrap the caliper body with a rag. Blow compressed air into the brake hose, and remove the piston and the piston boot.
Page 576 REMOVAL (CALIPER) 1. Remove the rear wheel. 2. Remove the caliper assembly. 3. Remove the brake hose from the caliper. INSTALLATION 1. Before replacing the brake pads, drain brake fluid from the master cylinder reservoir until it remains half full. 2.
Page 577 INSTALLATION (CALIPER) 1. Install the caliper mounting bolts. Tightening torque : 65-75 N·m (6.5-7.5 kg-m, 47-54 lb-ft) 2. Refer to "Brake pad installation" for detail. 3. Install the brake hose connector Tightening torque : 17-20 N·m (1.7-2.0 kg-m, 12-14 lb-ft) 4.
Page 578 3. Remove the piston by applying compressed air through the brake hose fitting. Do not place your fingers in front of the piston when using compressed air. 4. Remove the piston seal carefully so as not to damage the cylinder wall. 5.
Page 579 INSPECTION 1. Check the cylinder for wear, damage and rust. 2. Check the piston surface for wear, damage and rust. 3. Check the caliper body and sleeve for wear. 4. Check that grease is adhesive, and the pad and backing metal are damaged. 5.
Page 580 REASSEMBLY (CALIPER) 1. When disassembling the caliper assembly, use a new piston seal and boot. 2. Apply the recommended fluid to the bearing part of the piston seal and piston. Insert the piston seal into grooves inside the caliper, being careful not to twist the seal. Item Recommended fluid Quantity...
Page 581 GENERAL INFORMATION SERVICE ADJUSTMENT PROCEDURES INSPECTION AND ADJUSTMENT 1. Measure the brake pedal height. If the brake pedal height is not within the standard value, adjust as follows. Standard value : 200 mm (7.87 in.) (1) Disconnect the stop lamp switch connector, loosen the lock nut, and move the stop lamp switch to a position where it does not contact the brake pedal arm.
Page 582 2. With the engine stopped, depress the brake pedal two or three times. After eliminating the vacuum in the power brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met (the free play) is within the standard value. Standard value : 4 - 7 mm (0.157 - 0.275 in.) If free play does not reach the standard value, check that clearance between the outer case of stop light switch and brake pedal is within the standard value.
Page 583 If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains unchanged, the booster is defective. 2. With the engine stopped, step on the brake pedal several times. Then step on the brake pedal and start the engine.
Page 584 The check valve is pressed into the vacuum hose, and there is an arrow on the hose surface to indicate the installation direction. BLEEDING THE BRAKE SYSTEM 1. Remove the reservoir cap and fill the brake reservoir with brake fluid. a.
Page 585 6. Repeat steps 4 and 5 until there are no more bubbles in the fluid. 7. Tighten the bleeder screw. Tighten torque: 7 - 9 N·m (70-90 kg·cm, 5-6.6 lb·ft) 8. Repeat the above procedure for each wheel in the sequence shown in the illustration.
Page 586 SPECIAL SERVICE TOOLS Tool (Number and Illustration Name) Pushing back of the front disc and rear 09581 - 11000 disc brake piston Piston expander 0K993 430 032 Adjustment gauge...
Page 587 SPECIFICATIONS Part Item Standard value Remark HECU (Hydraulic Operating voltage 8V - 16V ABS, EBD Integrated control and Electronic Operating temp -40° - 110°C unit Control Unit) Motor 12V, 35A NO : Normal Open Motor power 230W NC : Normal Close Pump capacity 5.5cc/sec HS : Hydraulic Shuttle...
Page 588 Cylinder type Double piston Cylinder I.D. 46 mm (1.81 in.) (x2) Rear disk brake Type Floating with ventilated disc Disc O.D. 315 mm (12.4 in.) Disc thickness 20 mm (0.787 in.) Pad thickness 10 mm (0.39 in.) Cylinder type Single piston Cylinder I.D.
Page 589 Six brake tubes on the Hydraulic Unit 13-22 130-220 9-16 LUBRICANTS Items Recommended lubricant Quantity Brake fluid DOT 3 or equivalent As required Brake pedal bushing and brake Chassis grease SAE J310, NLGI As required pedal bolt No.0 Joint pin Wheel bearing grease SAE J310, As required NLGI No.2...
Page 590 TROUBLESHOOTING Trouble symptom Possible cause Remedy Noise or vibration when brakes are Caliper improperly mounted Correct applied Loose caliper mounting bolts Retighten Unevenly worn or cracked brake drum or Replace brake disc Clean Foreign material in brake drum Replace Seized pad or lining contact surface Correct Excessive clearance between pad Correct...
Page 591 parking brake system COMPONENT...
Page 592 REMOVAL (LEVER) 1. Remove the console 2. Loosen the lever adjusting nut 3. Detach the cable from the lever 4. Remove the lever mounting bolts and nuts 5. Disconnect the parking brake switch connector REMOVAL (CABLE) 1. Remove the console 2.
Page 593 5. Remove the parking brake cable mounting nuts. 6. Remove the parking brake shoes. ASSEMBLY (BRAKE SHOE) 1. Install the parking brake cable to the operating lever and then install the operating lever as shown in the figure. 2. Tighten the parking brake cable mounting nuts. Tightening torque 47-54 N·m (4.7-5.4 kg·m, 34-39 lb·ft) 3.
Page 594 4. Install the upper return spring and brake shoes 5. Turn the adjuster in clockwise direction and install. Direction of adjuster turn Clockwise : narrowing the shoe gap. Counterclockwise : widen the shoe gap. 6. Install the lower return spring. 7.
Page 595 Standard value : 190mm (7.48 in.) Service limit : 191mm (7.52 in.) If the brake drum inner diameter is greater than the service limit, replace the brake drum. 2. Measure the brake lining thickness. Standard value : 4mm (0.157 in.) Service limit : 1.5mm (0.059 in.) If the brake lining thickness is less than the service limit, replace the brake lining.
Page 596 ADJUSTMENT PROCEDURE Parking brake stroke adjustment 1. Pull the brake lever with force of 100N (10kg, 22lbs) and count the number of notches. Parking brake stroke Standard value : 4 ~ 6 clicks 2. If the parking brake stroke is out of the standard value, adjust it as follows : (1) Loosen the adjusting nut to release the parking brake cable.
Page 597 2. Repeat step 1 more than 2 times. 3. Parking should be possible on a hill of 30% with gross vehicle weight. a. BED-IN : Procedure of operating the vehicle with parking brakes active for the purpose of setting the position of the brake pads. b.
Page 598 CLUTCH SYSTEM GENERAL INFORMATION SPECIAL SERVICE TOOLS Tool (Number and Illustration name) Installation of the clutch disc 09411-43000 Clutch disc guide...
Page 599 SPECIFICATIONS Clutch operating method Hydraulic type Clutch disc Type Single, dry with diaphragm. Facing diameter (Outside x Inside) mm (in.) 254 x 165 (10 x 6.5) : A2.5 240 x 155 (9.4 x 6.1) : S2.4D, ∑3.5 Clutch cover assembly Type Diaphragm spring strap 7000 min.
Page 600 LUBRICANTS Items Specified lubricants Quantity Contact surface of release bearing and CASMOLY L 9508 As required fulcrum of clutch release fork Inner surface of clutch release bearing CASMOLY L 9508 As required Inner surface of clutch release cylinder Brake fluid DOT3 As required and outer circumference of piston and Inner surface of clutch disc spline...
Page 601 TROUBLESHOOTING Trouble symptom Probable cause Remedy Clutch slipping Insufficient pedal free play Adjust a. Car will not respond to Clogged hydraulic system Correct or replace parts engine speed during acceleration Excessive wear of clutch disc facing Replace b. Insufficient car speed Hydraulic system fluid leaks, air trapped or c.
Page 602 lever shaft Insufficient lubrication of the front bearing Repair retainer Hard to shift or will not shift Excessive clutch pedal free play Adjust the pedal free play Faulty clutch release cylinder Repair the release cylinder Clutch disc out of place, runout is excessive or Inspect the clutch disc lining broken Dirty spline on input shaft or the clutch disc...
Page 603 aclutch cover and dinode COMPONENTS...
Page 604 REMOVAL 1. Insert the special tool (09411-43000) in the clutch disc to prevent the disc from shifting. 2. Loosen the bolts which attach the clutch cover to the flywheel in a star pattern. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover. Do not clean the clutch disc or the release bearing with cleaning solvent.
Page 605 4. Remove guide washer (stockage plate) when install SAT cover and disc assembly on the flywheel (only for ∑3.5 engine). INSPECTION CLUTCH COVER&DISC ASSEMBLY 1. Clean the dust from the clutch housing using a vacuum or cloth, Do not use compressed air. Check for oil leakage from the engine rear bearing oil seal and transaxle front oil seal.
Page 606 5. Check the hub spline and torsion spring of the clutch disc for excessive wear. 6. Clean the friction surface of the pressure plate with cleaning solvent. 7. Measure the flatness of the pressure plate with a square. If it exceeds 0.5 mm, replace it. Check the pressure plate surface of wear, cracks, and color change.
Page 607 clutch master cylinder COMPONENTS COMPONENTS...
Page 609 REMOVAL INSTALLATION 1. Connect the clutch pipe (clutch hose side). 2. Temporarily tighten the flare nut by hand, then tighten it to the specified torque, being careful that the clutch hose does not become twisted. 3. Install the clutch line and clips. 4.
Page 610 Hold piston assembly to prevent it from flying apart. 3. Release returning tabs of piston stopper with a suitable tool. INSPECTION INSPECTION 1. Check the inside of the cylinder body for rust, pitting or scoring. 2. Check the piston cup for wear or distortion. 3.
Page 611 6. If the master cylinder-to-piston clearance exceeds the limit, replace the master cylinder and/or piston assembly. Limit : 0.15 mm (0.006 in.) REASSEMBLY 1. Apply brake fluid to the inner surface of the master cylinder body and to the entire periphery of the piston assembly.
Page 612 clutch pedal COMPONENTS...
Page 613 REMOVAL INSTALLATION 1. Apply the specified grease to the clutch pedal and bushings. Chassis grease : SAE J310a, NLGI No.1 2. Install the clutch pedal mounting bolt. 3. Apply the specified grease to the clevis pin and washer. Wheel bearing grease : SAE J310, NLGI No.2 4.
Page 614 clutch release bearing components COMPONENTS...
Page 615 clutch release cylinder COMPONENTS...
Page 617 COMPONENTS...
Page 618 REMOVAL 1. Remove the clutch hose, spring, push rod, and boot. 2. Remove any dirt from the piston bore opening of the release cylinder. 3. Remove the piston from the release cylinder using compressed air. a. Use rags to prevent the piston from popping out and causing injury. b.
Page 619 2. Check the clutch release cylinder boots for damage. 3. Check the release cylinder bore for rust and damage. 4. Measure the release cylinder bore at three locations (bottom, middle, and top) with a cylinder gauge and replace the release cylinder assembly if the bore-to-piston clearance exceeds the limit. Limit : Clearance to pistion : 0.15 mm (0.006 in.)
Page 620 SERVICE ADJUSTMENT PROCEDURE CLUTCH PEDAL INSPECTION AND ADJUSTMENT 1. Measure the clutch pedal height (From the face of the pedal pad to the floorboard) and the clutch pedal free-play (measured at the face of the pedal pad). Standard value: (A) 7.3 -13.9 mm (0.29 - 0.55 in) (A') 163.8 mm (6.45 in) 2.
Page 621 Standard value : 6-13 mm (0.2-0.5 in.) 4. If the clutch pedal free play and the distance between the clutch pedal and the floor board when the clutch is disengaged do not meet the standard values, the cause may be either air in the hydraulic system or a faulty master cylinder clutch.
Page 623 DRIVESHAFT AND AXLE differential carrier assembly front differential carrier Components Front differential components...
Page 625 Removal 1. Drain oil. 2. Remove the drive shaft and the output shaft. When removing the drive shaft, be careful not to damage the differential carrier oil seal by interference of spline part. 3. Remove the front propeller shaft. Make match mark on the flange yoke and differential companion flange to avoid any mistake when installing them again.
Page 626 Tightening torque : 18-23 N·m (1.8-2.3 kg·m, 13-16 lb·ft) 5. Remove the differential mounting bracket. 6. Remove the front member. 7. Remove the differential mounting bolt. 8. Remove the differential carrier. Installation 1. Installation is the reverse of removal. 2. Align the matchmark on the flange yoke and the companion flange. Tighten the propeller shaft and the front differential carrier.
Page 627 INSPECTION BEFORE DISASSEMBLY Mount the differential carrier on the special tool(09517-43401). FINAL DRIVE GEAR BACKLASH 1. Fix the drive gear so it cannot move and measure the final drive gearbacklash with a dial indicator. Measure at four points or more on the circumference of the drive gear. Standard value : 0.09-0.11mm (0.0035-0.0043 in.) DRIVE GEAR RUNOUT Check the back-face lash as follows:...
Page 628 2. If the runout is beyond the limit, check that there are no foreign substances between the drive gear and differential case and, that the bolts fixing the drive gear are not loose. 3. If nothing is wrong in check (2), adjust the drive gear depth and remeasure. If these adjustments are impossible, replace the case or install a new drive gear/drive pinion as a set.
Page 629 1. Apply the same amount of machine blue slightly to both surfaces of the drive gear teeth. 2. Insert a brass rod between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to the drive gear so that some torque (approximately 25-30 kg-cm) is applied to the drive pinion.
Page 630 pinion height Increase the thickness of the pinion height adjusting shim, and position the drive pinion The drive pinion is positioned too far from the closer to the center of the drive gear. center of the drive gear. Also, for backlash adjustment, reposition the drive gear further from the drive pinion.
Page 631 2. Turn the ignition switch on and shift the transfer lever 2H →4H. 3. Check that the motor starts to revolve in 1 second and stops when Air pressure gauge value displayed with in the specified value. Specified pressure : 37-57 kPa (5.4-8.2 lb/in², 0.38-0.58 kgf/cm²) 4.
Page 632 INSPECTION 1. Check the companion flange for wear or damage. 2. Check the bearings for wear or discoloration. 3. Check the gear carrier for cracks. 4. Check the drive pinion and drive gear for wear or cracks. 5. Check the side gears, pinion gears and pinion shaft for wear or damage. 6.
Page 633 Check also air leak. Read voltmeter indication value so as to check if it is within specified range. Voltage : about 0 V (when motor runs) 10-14 V (when motor stopped) Check the actuator. (1) Attach air pressure gauge to actuator as in figure. Loosen adjustment screw before attaching air hose to air pressure gauge.
Page 634 DISASSEMBLY 1. REMOVAL OF THE DIFFERENTIAL CASE ASSEMBLY Remove the differential case assembly slowly and carefully. Be careful so that the side bearing outer race is not dropped. Keep the right and left side bearings separate so that they are not mixed during reassembly. 2.
Page 635 3. REMOVAL OF DRIVE GEAR a. Make the matchmarks to the differential case and the drive gear. b. Loosen the drive gear attaching bolts in diagonal sequence to remove the drive gear. 4. REMOVAL OF LOCK PIN (FOR CONVENTIONAL DIFFERENTIAL) 5.
Page 636 a. Make the matchmarks to the drive pinion and companion flange. Matchmarks should not be made to the contact surfaces of the companion flange and the propeller shaft. b. Drive out the drive pinion together with the drive pinion spacer and drive pinion front shims. 7.
Page 637 REASSEMBLY 1. PRESS-FITTING OIL SEAL 2. DRIVE PINION OUTER BEARING OUTER RACE INSTALLATION When press-fitting the outer race, do not incline it. 3. DRIVE PINION INNER BEARING OUTER RACE INSTALLATION When press-fitting the outer race, do not incline it.
Page 638 ADJUSTMENT OF PINION HEIGHT Adjustment the drive pinion height by the following procedure. (1) For assembly of pinion, use drive pinion model(0K993 270 A01), pinion height adjustment gauge body(0K993 270 A09) and gauge block(ht. 28 mm(1.102 in)). (2) Assemble spacer and inner bearing inner race to pinion model and fix it with O-ring. Use spacer disassembled.
Page 639 a. Tighten to the extent the companion flange can be screwed by hand. (6) Put pinion height adjusting gauge body at right angle and adjust it to 0. (7) Put pinion height adjusting gauge body and gauge block to the upper side of pinion model. (8) Dial gauge needle should be placed at the lowest part of side bearing.
Page 640 If the value of the above step 10 is not within specification, use new spacer adding the values to current spacer. Standard clearance : -0.025~0.025 mm (-0.001~0.001 in) MARK THICKNESS MARK THICKNESS 3.08(0.1212) 3.29(0.1259) 3.11(0.1224) 3.32(0.1307) 3.14(0.1236) 3.35(0.1318) 3.17(0.1248) 3.38(0.1330) 3.20(0.1259) 3.41(0.1342) 3.23(0.1271)
Page 641 (5) Install drive pinion assembly. Install companion flange and tighten lock nut. Tightening torque : 127-284 N·m (13-29 kg·m, 94-210 lb·ft) Do not install oil seal. (7) Turn companion flange by hand so that bearing be put at the right place. Measure preload of drive pinion.
Page 642 Insert a wedge in the side gear and measure the differential gear backlash with a dial indicator on the pinion gear. Measure both pinion gears separately. Standard value : 0-0.1 mm (0-0.0039 in.) Limit : 0.2 mm (0.008 in.) (4) If the differential gear backlash exceeds the limit, adjust the backlash by selecting thicker side gear thrust spacers.
Page 643 INSTALLATION OF THE DRIVE GEAR (1) Clean the drive gear attaching bolts. (2) Remove the adhesive on the threaded holes of the drive gear use a tap (M10 x 1.25), and then clean the threaded holes with compressed air. Apply the specified adhesive to the threaded holes of the drive gear. Specified adhesive : LOCTITE #262 or equivalent (4) Install the drive gear in the differential case with the matchmarks properly aligned.
Page 644 10. Attach actuator at differential case RH side as figure Take heed of actuator direction. ADJUSTMENT OF FINAL DRIVE GEAR BACKLASH Adjust the final drive gear backlash according to the following procedures : (1) Install side bearing spacers which are thinner than those removed, to the side bearing outer races, and then mount the differential case assembly into the gear carrier.
Page 645 (3) Select two pairs of spacers, which correspond to the value calculated according to the expression in the illustration. Install one pair each to the drive pinion side and the drive gear side. (4) Install the side bearing spacers and differential case assembly, as shown in the illustration, to the gear carrier.
Page 646 With the drive pinion locked in place, measure the final drive gear backlash with a dial indicator on the drive gear. Measure at four points or more on the circumference of the drive gear. Standard value : 0.09-0.11 mm (0.0035-0.0043 in.) (8) Change the side bearing spacers as illustrated and then adjust the final drive gear backlash between the drive gear and the drive pinion.
Page 647 (9) Check the drive gear and drive pinion for tooth contact. If poor contact is evident, adjust again. Measure the drive gear runout at the shoulder on the reverse side of the drive gear. Limit : 0.05 mm (0.002 in.) (11) If the drive gear runout exceeds the limit, reinstall by changing the position of the drive gear and differential case, and remeasure.
Page 648 limited slip differential COMPONENTS...
Page 649 DISASSEMBLY 1. Remove the threaded lock screw and the cross shaft. 2. Without preload on the side gears they can be turned by hand. Rotate the side gears until the pinions are in the window area. Remove the pinions and pinion thrust washers. 3.
Page 650 the 0.76mm (0.30in.) Shim to obtain theproper backlash. 9. Remove the side gear subassembly and repeat the tooth backlash procedure for the other gear pack on the opposite side of the case. 10. Remove the cross shaft, pinions and thrust washers and reinstall the first side gear subassembly and shim in the flange end of the case.
Page 651 rear differential carrier COMPONENTS REAR DIFFERENTIAL COMPONENTS...
Page 653 REMOVAL 1. Drain the differential gear oil. 2. Remove the rear disk brake. 3. Remove the parking brake and cable. 4. Remove the stabilizer bar. 5. Pull out the rear axle shaft. Be careful not to damage the oil seal when pulling axle shaft. 6.
Page 654 INSTALLATION 1. DIFFERENTIAL CARRIER ASSEMBLY Apply specified sealant to axle housing flange surface, and install the differential carrier assembly. Specified sealant : Three bond 1215 or equivalent Tightening torque : 23-27 Nm (2.3-2.7 kg·m,16-19 lb·ft) 2. PROPELLER SHART Align the match marks on the flange yoke and companion flange, and install the propeller shaft. Tightening torque : 50-60 Nm (500-600 kg·cm, 37-44 lb·ft) AXLE SHAFT ASSEMBLY...
Page 655 2. REMOVAL OF THE DIFFERENTIAL CASE ASSEMBLY a. Remove the differential case assembly slowly and carefully. b. Be careful so that the side bearing outer race is not dropped. c. Keep the right and left side bearing outer races separate so that they are not mixed during reassembly.
Page 656 a. Make the match marks to the differential case and the drive gear. b. Loosen the drive gear attaching bolts in diagonal sequence to remove the drive gear. 5. REMOVAL THE LOCK NUT 6. REMOVAL OF DIRVE PINION a. Make the match marks on the drive pinion and companion flange. Match marks should not be made on the contact surfaces of the companion flange and the propeller shaft.
Page 657 8. REMOVAL OF OIL SEAR / DRIVE PINION FRONT BEARING INNER RACE / DRIVE PINION FRONT BEARING OUTER RACE 9. REMOVAL OF DRIVE PINION REAR BEARING OUTER RACE INSPECTION BEFORE DISASSEMBLY FINAL DRIVE GEAR BACKLASH Check the final drive gear backlash by the following procedure.
Page 658 Place the drive pinion and move the drive gear to check backlash is within the standard range. Measure at 4 points on the gear periphery. Standard value 0.13-0.18 mm (0.0051-0.0071 in.) (2) Adjust with the side bearing nuts if backlash values are not within standard range. After adjusting, check the state of the final drive gear's tooth contact.
Page 659 Take the measurements at two places on the pinion gear. Standard value : 0-0.1 mm (0-0.0039 in.) (2) If the backlash exceeds the limit, adjust using side bearing spacers. If adjustment is impossible, replace the side gear and pinion gears as a set. 4.
Page 660 a. Narrow tooth side b. Drive-side tooth surface (the side receiving power during acceleration) c. Wide tooth side d. Coast-side tooth surface (the side receiving power during coast-down) Problem Solution Tooth contact pattern resulting from excessive pinion height The drive pinion is positioned too far from the center Also, for backlash adjustment, reposition the drive of the drive gear.
Page 661 The drive pinion is positioned too close to the center Decrease the thickness of the pinion height of the drive gear. adjusting shim, and position the drive pinion further from the center of the drive gear. Also, for backlash adjustment, reposition the drive gear closer to the drive pinion.
Page 662 ADJUSTMENT OF PINION HEIGHT Adjustment the drive pinion height by the following procedure. (1) For assembly of pinion, use drive pinion model (0K993 270 A01), pinion height adjustment gauge body (0K993 270 A09) and gauge block (ht. 28 mm (1.102 in)). (2) Assemble spacer and inner bearing inner race to pinion model and fix it with O-ring.
Page 663 a. Tighten to the extent the companion flange can be screwed by hand. (6) Put pinion height adjusting gauge body at right angle and adjust it to 0. (7) Put pinion height adjusting gauge body and gauge block to the upper side of pinion model. (8) Dial gauge needle should be placed at the lowest part of side bearing.
Page 664 If the value of the above step 10 is not within specification, use new spacer adding the values to current spacer. Standard clearance : -0.025~0.025 mm (-0.001~0.001 in) MARK THICKNESS MARK THICKNESS 3.08(0.1212) 3.29(0.1259) 3.11(0.1224) 3.32(0.1307) 3.14(0.1236) 3.35(0.1318) 3.17(0.1248) 3.38(0.1330) 3.20(0.1259) 3.41(0.1342) 3.23(0.1271)
Page 665 (5) Install drive pinion assembly. Install companion flange and tighten lock nut. Tightening torque : 127-284 N·m (13-29 kg·m, 94-210 lb·ft) a. Do not install oil seal. (7) Turn companion flange by hand so that bearing be put at the right place. Measure preload of drive pinion.
Page 666 3. Insert a wedge in the side gear and measure the differential gear backlash with a dial indicator on the pinion gear. Measure both pinion gears separately. Standard value : 0-0.1 mm (0-0.0039 in.) Limit : 0.2 mm (0.008 in.) 4.
Page 667 Apply the specified adhesive to the threaded holes of the drive gear. Specified adhesive : LOCTITE #262 or equivalent d. Install the drive gear in the differential case with the matchmarks properly aligned. Tighten the bolts to the specified torque (11-15 kg·m) in a diagonal sequence. 7.
Page 668 ADJUSTMENT OF FINAL DRIVE GEAR BACKLASH Adjust final drive gear backlash as follows : (1) Using the special tool (09521-43001), temporarily tighten the side bearing nut until it is in the state just before preloading of the side bearing. Measure the final drive gear backlash. Standard value : 0.13-0.18mm (0.0051-0.0071 in.) Measure at lease 4 points on the drive gear periphery.
Page 669 First turn the side bearing nut for loosening, and then turn (by the same amount) the side bearing nut for tightening. (4) Using the special tool (09521-43001) to apply the preload, turn down both right and left side bearing nut on half the distance between centers of two neighboring holes. (5) Choose and install the lock plates two kinds.
Page 671 driveshaft assembly REMOVAL (OUTPUT SHAFT) 1. Remove diff mounting bracket. 2. Remove output shaft from differential housing. INSTALLATION 1. Install output shaft to differential case. Tightening torque : 80-120 N·m (8-12 kg·m, 58-86 lb·ft) a. Be carefully that oil seal does not damage by clip during install. 2.
Page 672 110-150 N·m (11-15 kg·m, 80-108 lb·ft) 3. Tighten diff mounting bracket bolt. DISASSEMBLY 1. Remove axle clip using plier. 2. Remove output shaft housing. 3. Using a hydraulic press, remove bearing housing from the output shaft.
Page 673 4. Remove dust seal and then using a hydraulic press, remove bearing. INSPECTION a. Output shaft for damage. b. Bearing for roughness or noise. c. Dust seal for damage. d. Bearing housing for cracks. REASSEMBLY (OUTPUT SHAFT) 1. Install dust seal into bearing housing. a.
Page 674 Tightening torque : 71-95 N·m (7.1-9.5 kg·m, 51-68 lb·ft) 5. Using a plier, install new clip onto output shaft.
Page 675 front driveshaft COMPONENTS (T.S.J.-B.J.) REPAIR KIT Kit name Illustration Components...
Page 676 a. T.S.J boot band T.S.J boot kit b. T.S.J boot c. Snap ring d. Spider assembly e. Snap ring f. T.S.J assembly g. Clip h. Grease B.J boot kit a. B.J assembly b. B.J inner race and ball c. Snap ring d.
Page 677 INSPECTION 1. Check the drive shaft spline for wear. 2. Check for water, foreign matter, or rust in the boot. 3. Check the spider ring for revolution and wear. 4. Check the T.S.J case inside for wear and rust. REMOVAL (HALFSHAFTS) 1.
Page 678 4. Mark drive shaft for identical installation position. 5. Using tool, pry the drive shaft from the differential housing. a. Do not pull on the drive shaft ; doing so will damage the boots. Be sure to use the pry bar. 6.
Page 679 Install the knuckle assembly and tighten. Tie-rod ball joint Tightening torque : 70-80 N·m (7.0-8.0 kg·m, 51-57 lb·ft) Upper arm link lock bolt Tightening torque : 44-55 N·m (4.4-5.5 kg·m, 32-39 lb·ft) 3. Tighten the lock nut and then caulk the flange of lock nut on the end of drive shaft. Tightening torque : 245-275 N·m (24.5-27.5 kg·m, 177-198 lb·ft) 4.
Page 680 2. Remove the clip using a screwdriver. 3. Remove the drive shaft from the T.S.J outer race. 4. Remove the snap ring and disassemble the inner race and ball from the shaft. 5. Remove the B.J boot band and pull out the T.S.J boot and the B.J boot. If the boot is reused, wrap a tape around the drive shaft splines to protect the boot.
Page 681 REASSEMBLY 1. Wrap a tape around the drive shaft spline (T.S.J side) to avoid boot damage. 2. Apply specified grease to the drive shaft and install the boots. Items Quantity (gr.) T.S.J 3. Add specified grease as much as was wiped away at the time of inspection. 4.
Page 683 front axle assembly REMOVAL 1. Remove the vehicle speed sensor. 2. Remove two bolts and remove brake caliper from brake rotor. Temporarily tie caliper to vehicle frame with wire. 3. Remove two screws and remove brake rotor. 4. Using a lock nut wrench (or equivalent), remove lock nut and plain washer (2WD). 5.
Page 684 7. Remove lower arm cotter pin using a ball joint remover, and remove lower arm from steering knuckle. 8. Remove steering knuckle from vehicle. INSTALLATION 1. Put steering knuckle on the drive shaft end with upper and lower ball joints in mounting holes. 2.
Page 685 4. Insert upper arm link lock bolt with spring washer and tighten nut. Tightening torque : 44-55 N·m (4.4-5.5 kg·m, 32-39 lb·ft) 5. Install the chamfer of plain washer toward the bearing (2WD) 6. Screw lock nut up against wheel hub assembly and using a lock nut wrench, tighten nut to tightening torque to set bearing preload.
Page 686 7. Caulk the flange of lock nut on the end of drive shaft. 8. Put brake rotor on wheel bearing hub bolts and install the two retaining screws. 9. Mount dial indicator with plunger zeroed against brake rotor at 4.7 in (12 cm) from rotor center. 10.
Page 687 2. Press the wheel hub from the knuckle (4WD). Press the knuckle and then remove wheel hub (2WD). INSPECTION 1. Inspect bearing for wear or damage. 2. Inspect steering knuckle for wear or damage. REASSEMBLY 1. Install the dust cover to the knuckle. Tightening torque : 16-23 N·m (1.6-2.3 kg·m, 12-16 lb·ft) 2.
Page 688 INSPECTION 1. Remove two bolts and remove brake caliper from brake rotor. Temporarily tie caliper to vehicle frame with wire. 2. Mount dial indicator with plunger zeroed against brake rotor at 4.7 inch (12 cm) from rotor center. 3. Turn rotor and read dial indicator for run out dimension. Run out not to exceed 0.0012 in (0.03 mm)
Page 689 GENERAL INFORMATION SPECFICATIONS...
Page 690 LUBRICANTS Items Specified lubricants Quantity B.J. - T.S.J. Drive shaft type B.J. Boot grease Repair kit grease 170 gr. (6.0 oz) T.S.J. Boot grease Repair kit grease 140 gr. (4.9 oz) Differential Front Hypoid gear oil Fill the reservoir to the plug Rear SAE90, API GL-5 hole...
Page 691 SPECIAL TOOL Tool (Number and Name) Illustration Press-fitting of the inner shaft Bushing remover and installer housing dust seal 09216-21100 Bearing outer race installer Installation of the front hub 09432-33700 bearing (Use with 09500-21000) Installation of the front hub 09500-21000 bearing (Use with 09432-33700) Draft...
Page 692 Oil seal installer Press-fitting of the differential 09517-21000 drive pinion oil seal (Use with 09500-21000) Remove plate Removal of the differential drive 09527-4A000 pinion inner bearing Bearing puller a. Removal of the front lower 09517-43001 arm ball joint b. Removal of the differential side bearing Preload socket Measurement of the drive pinion...
Page 693 Ball joint remover Disconnection of the tie rod ball 0K670 321 019 joint Oil seal installer Installation of the differential 09532-32100B drive pinion rear bearing outer race (Use with 09500-11000) Working base Supporting for the differential 09517-43401 carrier End yoke holder Removal and installation of the 09517-21700 differential self-locking nut...
Page 694 Drive pinion model 0K993 270 A10 Adjusting nut wrench For adjusting screw disassembly 0K993 270 014 LSD test adapter For testing of LSD performance 09530-FM000...
Page 695 TROUBLESHOOTING Symptom Probable cause Remedy Propeller shaft Noise at start Worn journal bearing Replace Worn sleeve yoke spline or flange yoke Replace Loose propeller shaft installation Retighten Noise and vibration Unbalanced propeller shaft Replace at high speed Improper snap ring selection Adjust the clearance Worn journal bearing Replace...
Page 696 (Replace the parts if necessary) Insufficient oil Replenish Differential Gear noise while Poor gear engagement Correct or replace driving Improper gear adjustment Improper drive pinion preload adjustment Damaged gear Replace Foreign material Eliminate the foreign material and check (Replace the parts if necessary) Insufficient oil Replenish...
Page 697 propeller shaft assembly COMPONENTS...
Page 698 INSPECTION 1. Check the sleeve yoke, center yoke and flange yoke for wear, damage or cracks. 2. Check the propeller shaft yokes for wear, damage or cracks. 3. Check the propeller shaft for bends, twisting or damage. 4. Check the universal joints for smooth operation in all directions. 5.
Page 699 3. Remove four bolts holding universal flange to transfer case (4WD). Remove bolts holding center bearing bracket (2WD). 4. Remove four bolts holding universal flange to differential. 5. Remove propeller shaft. a. When removing the propeller shaft, be careful not to damage the dust cover or spline. INSTALLATION Connect propeller shaft flange to companion flange on front differential (4WD).
Page 700 Connect front propeller shaft flange to companion flange on transfer (4WD). a. Align index marks on the flange and connect the flanges with four bolts and nuts. Tighten the bolts. Tightening torque : 50-60 N·m (5.0-6.0 kg·m, 36-43 lb·ft) Connect rear propeller shaft flange to companion flange on transfer. (4WD) a.
Page 701 Tightening torque : 37-54 N·m (3.7-5.4 kg·m, 27-39 lb·ft) a. Be careful not to damage the dust cover of propeller shaft when installing the propeller shaft (2WD) Connect propeller shaft flange to companion flange on rear differential. a. Align index marks on the flange and connect the flange with four bolts and nuts. Tighten the bolts and nuts.
Page 702 5. Check the center bearing for smooth movement (2WD). 6. Check the center bearing mounting rubber for damage or deterioration (4WD). 7. Measure the propeller shaft run out with a dial indicator. 0.3 mm Front (0.012 in.) or less Limit 0.3 mm Rear (0.012 in.) or less...
Page 703 rear axle assembly REMOVAL 1. Remove the disk brake and parking brake assembly (Refer to "BR Group"). 2. Remove the parking brake cable and speed sensor cable. 3. Remove the rear axle shaft mounting bolt. 4. Remove the rear axle shaft. 5.
Page 704 4. After installing the axle shaft, tighten the nut. Tightening torque : 43-60 N·m (4.4-6.2 kg·m, 32-44 lb·ft) 5. Adjust the parking brake lever stroke.
Page 705 SERVICE INSPECTION PROCEDURE AXLE SHAFT END PLAY CHECK 1. Measure the axle shaft end play using a dial indicator. Standard value : 0-0.05mm (0-0.002 in.) 2. If the axle shaft end play exceeds the standard value, replace the bearing with a new one. GEAR OIL LEVEL CHECK 1.
Page 706 CHARGING SYSTEM alternator DISASSEMBLY AND REASSEMBLY...
Page 708 GENERATOR (DIESEL) The conventional internal voltage detection type alternator controls the charging voltage regardless of the battery condition and according to the external load change so that it sometimes causes battery under or overcharging or causes flickering of meters and lamps due to ripples of generated voltage resulting from load fluctuation.
Page 710 REMOVAL AND INSTALLATION (DIESEL) INSTALLATION ALTERNATIOR ASSEMBLY For belt tension, refer to Group EM Engine-Service adjustment procedures. a. Install the oil hose to the alternator in advance. When the alternator is installed, connect the oil hose to the nipple on the oil pan side. Clamp the hose clip at the straight portion of the nipple.
Page 711 STATOR ASSEMBLY, REGULATOR AND BRUSH HOLDER a. When soldering or unsoldering, use care not to expose the diode to soldering iron heat for extended time. Complete soldering or unsoldering in as short a time as possible. b. Do not overstress the diode leads. 1.
Page 712 ROTOR 1. Check the rotor coil continuity. Make sure that there is continuity between slip rings. Measure the rotor resistance. If it is excessively small, it indicates a shorted rotor, If without continuity or shorted, replace the rotor assembly. Standard value : 3 - 5 ohms 2.
Page 713 2. Check the coil grounding. Make sure that there is no continuity between the coil and core. Replace the stator assembly if there is continuity. RECTIFIER 1. Inspection of (+) Heat Sink Assembly Using a circuit tester, check continuity between the (+) heat sink and the stator coil lead connection terminals.
Page 714 3. Inspection of Diode Trio With a circuit tester connected to both ends of each diode, check continuity of the three diodes. If there is continuity or no continuity in both directions, the diode is damaged. Then, replace the rectifier assembly.
Page 715 REASSEMBLY ROTOR ASSEMBLY 1. Before installing the rotor on the rear bracket, thread a steel wire through the small hole provided in the rear bracket to lift up the brush. After rotor installation, remove the steel wire. 2. When installing the rotor on the alternator rear bracket, wind vinyl tape round the splined shaft to prevent damage to the oil seal ROTOR AND VANES 1.
Page 716 4. When tightening the housing, lightly push it in the direction of arrow so as to minimize the clearance at "A" and tighten the bolts uniformly. After the assembly, be sure to conduct the performance test to check to see that the ultimate vacuum is as specified below.
Page 717 REMOVAL AND INSTALLATION (DIESEL) INSTALLATION ALTERNATIOR ASSEMBLY For belt tension, refer to Group EM Engine-Service adjustment procedures. a. Install the oil hose to the alternator in advance. When the alternator is installed, connect the oil hose to the nipple on the oil pan side. Clamp the hose clip at the straight portion of the nipple.
Page 718 STATOR ASSEMBLY, REGULATOR AND BRUSH HOLDER a. When soldering or unsoldering, use care not to expose the diode to soldering iron heat for extended time. Complete soldering or unsoldering in as short a time as possible. b. Do not overstress the diode leads. 1.
Page 719 ROTOR 1. Check the rotor coil continuity. Make sure that there is continuity between slip rings. Measure the rotor resistance. If it is excessively small, it indicates a shorted rotor, If without continuity or shorted, replace the rotor assembly. Standard value : 3 - 5 ohms 2.
Page 720 2. Check the coil grounding. Make sure that there is no continuity between the coil and core. Replace the stator assembly if there is continuity. RECTIFIER 1. Inspection of (+) Heat Sink Assembly Using a circuit tester, check continuity between the (+) heat sink and the stator coil lead connection terminals.
Page 721 3. Inspection of Diode Trio With a circuit tester connected to both ends of each diode, check continuity of the three diodes. If there is continuity or no continuity in both directions, the diode is damaged. Then, replace the rectifier assembly.
Page 722 REASSEMBLY ROTOR ASSEMBLY 1. Before installing the rotor on the rear bracket, thread a steel wire through the small hole provided in the rear bracket to lift up the brush. After rotor installation, remove the steel wire. 2. When installing the rotor on the alternator rear bracket, wind vinyl tape round the splined shaft to prevent damage to the oil seal ROTOR AND VANES 1.
Page 723 4. When tightening the housing, lightly push it in the direction of arrow so as to minimize the clearance at "A" and tighten the bolts uniformly. After the assembly, be sure to conduct the performance test to check to see that the ultimate vacuum is as specified below.
Page 724 BATTERY VISUAL INSPECTION (1) 1. CHECKING FLOW 2. CHECKING SHEET Responsibility Item Trouble Cause Remedy User Manufacturer 1. Visual inspection * Battery terminal * Carelessness damage * Over tightening Replace the battery cable Cover Breakage * Carelessness Replace * Electrolyte leakage * Carelessness Replace...
Page 725 over 10mm * Vaporization Replace caused by excessive temperature * Electrolyte loss Replace * Shortage of caused by over- electrolyte charge 3. Voltage 1. Battery voltage 1. Over charge Replace inspection >13.2V * Check the electric system 2. 12.5V < Battery 2.
Page 726 3. If the battery is left alone for 2 hours after re-charging and its output is over 12.5V, and the voltage after a load test is over the standard value, the battery can be used. BATTERY VISUAL INSPECTION (2) 1. Make sure the ignition switch and all accessories are in the OFF position. 2.
Page 728 GENERAL INFORMATION The charging system included a battery, an generator with a built-in regulator, and the charging indicator light and wire. The generator has eleven built-in diodes (four positive, four negative and three exciter diodes), each rectifying AC current to DC current. Therefore, DC current appears at generator "B" terminal.
Page 729 INSPECTION GENERATOR OUTPUT LINE VOLTAGE DROP TEST 1. Be sure to check the following before testing: a. Generator installation and wiring connections b. Generator drive belt tension c. Fusible link d. Abnormal noise from the generator while the engine is running. 2.
Page 730 10. If the value displayed on the voltmeter is still above the limit, a malfunction in the generator output wire may exist. Check the wiring between the generator "B" terminal and the battery (+) terminal (including fusible link). If a terminal is not sufficiently tight or if the harness has become discolored due to overheating, repair, the test again.
Page 731 TEST 1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the open circuit in the wire between the generator "B" terminal and battery (-) terminal, a blown fusible link or poor grounding is suspected.
Page 732 2. Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch. 3. Disconnect the battery ground cable. 4. Remove the ammeter and voltmeter and the engine tachometer. 5. Connect the generator output wire to the generator "B" terminal. 6.
Page 733 2. Start the engine. Keep all lights and accessories off. 3. Run the engine at a speed of about 2,500 rpm and read the voltmeter when the generator output current drops to 10A or less. Result 1. If the voltmeter reading agrees with the value listed in the Regulating Voltage Table below, the voltage regulator is functioning correctly.
Page 734 CRUISE CONTROL SYSTEM COMPONENTS LOCATION...
Page 735 DESCRIPTION CRUISE CONTROL Cruise control system is engaged by "CRUISE" main switch located on center instrument panel, left of steering wheel. System has the capability to cruise, coast, resume speed, and accelerate, and raise "tap- up" or lower "tap-down" set speed. It also has a safety interrupt, engaged upon depressing brake or shifting select lever.
Page 736 TROUBLE SYMPTOM CHARTS TROUBLE SYMPTOM 1 TROUBLE SYMPTOM 2 Trouble symptom Probable cause Remedy The set vehicle speed varies Malfunction of the vehicle speed Repair the vehicle speed sensor greatly upward or downward sensor circuit system, or replace the part "Surging"...
Page 737 acceleration and deceleration) drive gear occurs after setting Malfunction of the ECM Replace the ECM TROUBLE SYMPTOM 3 Trouble symptom Probable cause Remedy The CC system is not canceled Damaged or disconnected wiring Repair the harness or replace the when the brake (clutch) pedal is of the brake (clutch) pedal switch brake (clutch) pedal switch depressed...
Page 738 speed CC : Cruise Control ECM : Engine Control Module TROUBLE SYMPTOM 8 Trouble symptom Probable cause Remedy The cruise control lamp does not Damaged or disconnected bulb of Repair the harness or replace the illuminate (But CC system is cruise control lamp part normal)
Page 739 SPECIFICATIONS STARTER MOTOR D4CB Type Reduction drive (with planetary gear) Voltage Output 2.2KW No-load characteristics Terminal voltage Amperage 130A or below Speed 4,500 RPM Number of pinion teeth GENERATOR D4CB Type Battery voltage sensing Rated output 12V / 110A Voltage regulator type Built in I.C regulator Regulator setting voltage 14.4 ±...
Page 740 Battery terminal 40-60 2.9-4.3...
Page 741 TROUBLESHOOTING CHARGING SYSTEM Trouble symptom Probable cause Remedy Charging warning indicator does not light Fuse blown Check fuses with ignition switch "ON" and engine off Light burned out Replace light Wiring connection loose Tighten loose connections Electronic voltage regulator Replace voltage regulator faulty Charging warning indicator does not go Adjust tension or replace drive...
Page 742 Battery cables loose, corroded or Repair or replace cables worn out Transaxle range switch faulty Adjust or replace switch (Vehicle with automatic transaxle only) Fusible link blown Replace fusible link Starter motor faulty Repair starter motor Ignition switch faulty Replace ignition switch Ignition lock switch faulty Replace ignition lock switch Engine cranks slowly...
Page 743 necessary Yellow glow lamp will not turn- Open lamp Replace lamp Wiring connection loose or bad wiring Repair or replace wiring Shorted wiring Repair or replace wiring ECM failed Replace ECM, if necessary...
Page 744 preheating system REMOVAL AND INSTALLATION COMPONENTS INSPECTION GLOW PLUG 1. Check the continuity between the terminal and body as illustrated. Replace if discontinuity or with large resistance. Standard value : 1.0-1.8Ω Remove oil from plug before measuring as glow plug resistance is very small.
Page 745 2. Check for rust on glow plug plate. 3. Check glow plug for damage.
Page 746 starting system DISASSEMBLY AND REASSEMBLY...
Page 747 GENERAL INFORMATION The starting system includes the battery, starter motor, solenoid switch, ignition switch, inhibitor switch (A/T only), connection wires and the battery cables. When the ignition key is turned to the start position, current flows and energizes the starter motor's solenoid coil.
Page 748 repair procedures INSPECTION PINION GAP ADJUSTMENT 1. Disconnect the field coil wire from the terminal M of the magnetic switch. 2. Connect a battery between the terminal S and starting motor body. (Connect the positive terminal of battery to the terminal S.) This test must be performed quickly within 10 seconds to prevent the switch coil from burning.
Page 749 The test must be finished within 10 seconds. HOLD-IN TEST OF MAGNETIC SWITCH With a battery connected between the terminal S and body of magnetic, manually pull the pinion up to the pinion stopper. The hold-in coil is in good condition if the pinion remains out when releasing it. This test must be completed with 10 seconds.
Page 750 1. Set up a circuit as shown which connects a starter motor, battery, ammeter, voltmeter, and variable resistance. 2. The starting motor should be in good condition if it turns smoothly and steadily when the switch is turned ON with a maximum variable resistance value. Adjust the variable resistor so that the voltmeter reads 11.5V.
Page 751 ENGINE MECHANICAL SYSTEM cooling system radiator COMPONENT...
Page 752 REMOVAL 1. Drain the engine coolant. 2. Remove the battery negative terminal. 3. Loosen the drive belt tension by turn auto-tensioner with spanner, and then remove the drive belt. 4. Remove the radiator upper hose and lower hose. 5. Remove the radiator cowl upper cover.
Page 753 6. Remove the cooling fan. 7. Remove the radiator cowl lower cover. 8. Remove the air-con condenser fixing bolt and the ATF oil cooler bracket fixing bolt from the radiator assembly. 9. Remove the ATF oil hoses. 10. Remove the radiator assembly from engine room, after remove the radiator assembly bracket fixing nut.
Page 754 radiator cap COMPONENTS...
Page 755 INSPECTION 1. Check the radiator cap for damage, cracks or weakening. 2. Connect the tester to the radiator cap. 3. Increase the pressure until the indicator stops moving. 4. Replace the radiator cap if the reading does not hold steady for about 10 seconds.
Page 756 thermostat COMPONENTS...
Page 757 REMOVAL 1. Drain the coolant so its level is below the thermostat. 2. Remove the inlet fitting and gasket. 3. Remove the thermostat. INSPECTION 1. Heat the thermostat as shown in the illustration. 2. Check that the valve operates properly. 3.
Page 758 water pump COMPONENTS...
Page 759 DISASSEMBLY 1. Drain the engine coolant. 2. Remove the radiator cowl upper cover. 3. Loosen the drive belt tension by turn auto-tensioner with spanner, and then remove the drive belt. 4. Remove the cooling fan. 5. Remove the water pump from cylinder block. INSPECTION 1.
Page 760 Tightening torque : A bolts (8x45) 2EA : 19.6-26.5 N·m (2.0-2.7 kg·m, 14.5-19.5 lb·ft) B bolts (8x45) 2EA : 19.6-26.5 N·m (2.0-2.7 kg·m, 14.5-19.5 lb·ft) 2. Install the cooling fan. 3. Install the drive belt. 4. Install the radiator cowl upper cover. 5.
Page 761 cylinder block balance shaft COMPONENTS...
Page 762 REPLACEMENT LH BALANCE SHAFT DRIVE GEAR BEARING (BUSH) 1. Use the special tool (09231-4A000) to install or remove the LH balance shaft drive gear bearing. 2. To remove the bearing, install the special tool (09231-4A000). 3. When installing the bearing, apply enough fluid to the bearing surface and cover. 4.
Page 763 3. Remove the RH balance shaft sprocket with bolt. 4. Remove the LH balance shaft sprocket with nut. Remove the LH balance shaft driven gear bolt. 5. Remove the timing chain lower under cover. 6. Remove the balance shaft. INSPECTION 1.
Page 764 (0.0024 - 0.0045) 4. Check the drive gear shaft of LH balance shaft for oil clearance. If wear is excessive, replace the drive gear or timing chain lower under cover. Item Specification (mm(in)) Drive gear shaft 23.968 - 23.980 Outer diameter (0.9436 - 0.9441) Drive gear shaft bearing(bush) 24.004 - 24.025...
Page 765 5. Install the timing chain lower under cover. Tightening torque Bolt Size Quantity N-m (kg-m, lb-ft) 6 x 14 4 EA 9.8-11.8 (1.0-1.2, 7.2-8.7) 8 x 22 1 EA 19.6-26.5 (2.0-2.7, 14.5-19.5) 8 x 30 3 EA 19.6-26.5 (2.0-2.7, 14.5-19.5) 8 x 40 1 EA 19.6-26.5 (2.0-2.7, 14.5-19.5)
Page 766 7. Install the LH balance shaft driven gear bolt(8 x 16). Tightening torque : 33.3-39.2 N-m (3.4-4.0 kg-m, 24.6-28.9 lb-ft) 8. Install the balance shaft sprocket Tightening torque:...
Page 767 LH balance shaft sprocket nut: 49.0-58.8 N-m (5.0-6.0 kg-m, 36.2-43.4 lb-ft) RH balance shaft sprocket bolt (8 x 16): 33.3-39.2 N-m (3.4-4.0 kg-m, 24.6-28.9 lb-ft) 9. Install plug on the cylinder block after remove screw driver. Tightening torque (plug) : 14.7-21.6 N-m (1.5-2.2 kg-m, 10.8-15.9 lb-ft) 10.
Page 768 crankshaft COMPONENTS...
Page 769 REPLACEMENT MAIN JOURNAL BEARING 1. Check the cylinder block main bearing bore size code. Record the cylinder block main bearing bore size code letters on cylinder block as shown. Reading order is from left to right with front main bearing bore size code shown first. CYLINDER BLOCK MAIN BEARING BORE DIAMETER Code Cylinder block main bearing bore diameter (mm (in))
Page 770 66.994 - 67.000 (2.6376 - 2.6378) 66.988 - 66.994 (2.6373 - 2.6376) 66.982 - 66.988 (2.6371 - 2.6373) 3. Choose proper main journal bearing in below table. MAIN JOURNAL BEARING SELECTION TABLE Cylinder block main bearing bore size code Main journal bearing Green Yellow None...
Page 771 DISASSEMBLY 1. Remove the timing chains, timing chain cover, cylinder head assembly, oil pan, bed plate and oil pump. For details, refer to the respective chapters. 2. Remove the rear oil seal case. 3. Remove the connecting rod cap. Mark the connecting rod bearing caps to be able to reassemble in the original position and direction.
Page 772 4. If oil clearance exceeds specification, replace the main bearing. Refer to "main bearing replacement". REASSEMBLY 1. Install the main bearing on the cylinder block and main bearing cap. 2. Install the main bearing cap after place crankshaft and thrust bearing on the cylinder block. Tightening torque : 127.5-137.3 N-m (13-14 kg-m, 94.0-101.3 lb-ft) 3.
Page 773 cylinder block COMPONENTS...
Page 774 DISASSEMBLY Remove the cylinder head, timing chain, timing chain cover, flywheel, pistons and crankshaft. For further details, refer to the appropriate section. INSPECTION a. Before inspection and repair, clean parts to remove dirt, oil, carbon, deposits, and scale. b. Before cleaning the cylinder block, be sure to check for evidences of water leaks and damage. c.
Page 775 REASSEMBLY 1. Crankshaft 2. Flywheel 3. Piston 4. Cylinder head 5. Timing chain 6. Timing chain cover...
Page 776 engine mount COMPONENTS...
Page 777 pistons and connecting rod COMPONENTS COMPONENTS...
Page 779 CONNECTING ROD BEARING 1. Check the connecting rod big-end bore size code. Record the connecting rod big-end bore size code letters on connecting rod cap as shown. CONNECTING ROD BIG-END DIAMETER Code Connecting rod big-end diameter mm (in) 60.000 - 60.006 (2.3622 - 2.3624) 60.006 - 60.012 (2.3624 - 2.3627) 60.012 - 60.018 (2.3627 - 2.3629) 2.
Page 780 56.982 - 56.988 (2.2434 - 2.2436) 3. Choose proper connecting rod bearing in below table. CONNECTING ROD BEARING SELECTION TABLE Connecting rod big-end bore size code Connecting rod bearing Green Yellow None Crankshaft pin journal size Yellow None Blue code None Blue Connecting rod bearing oil clearance :...
Page 781 2. Check the piston size code on the piston top face. Code Piston outer diameter (mm (in)) 90.910-90.920 (3.5791-3.5795) 90.920-90.930 (3.5795-3.5799) 90.930-90.940 (3.5799-3.5803) 3. Select the piston related to cylinder bore size code. Oil clearance : 0.080-0.100 mm (0.0031-0.0039 in) DISASSEMBLY 1.
Page 782 7. Remove the piston pin with snap ring. 8. Remove the piston from connection rod. 9. Remove the piston ring from piston. DISASSEMBLY 1. Remove the timing chain "C". Refer to "Timing chain". 2. Remove the camshaft. Refer to "Camshaft". 3.
Page 783 Tightening torque : Tighten 58.8 N-m (6.0 kg-m, 43.4 lb-ft), and fulley loosen bolt. Retighten 34.3 N-m (3.5 kg-m, 25.3 lb-ft) + 60 ~ 64° Remove the connecting rod cap, and measure oil clearance at each journal. Oil clearance : 0.024 - 0.042 mm (0.0009 - 0.0017 in) 4.
Page 784 4. Place a piston ring in the cylinder bore and set it square by pushing it down with piston. 5. Measure the end gap using a thickness gauge. Eng gap : No.1 ring : 0.25-0.40 mm (0.0098-0.0157 in) No.2 ring : 0.50-0.70 mm (0.0197-0.0276 in) Oil ring : 0.20-0.40 mm (0.0079-0.0157 in) REASSEMBLY PISTON PIN...
Page 785 1. Insert the piston and connecting rod assembly from above the top of cylinder. Ensure that the front mark on the piston crown and that (front mark) on the connecting rod face toward the front of engine (to the crankshaft pulley side). 2.
Page 786 REASSEMBLY PISTON PIN 1. Check the front mark of the piston and connecting rod. 2. Line up the front marks and insert the piston pin. The piston pin must be smoothly pressed by hand into position. 3. Install the snap ring. PISTON AND CONNECTING ROD ASSEMBLY 1.
Page 787 4. Install the connecting rod and cap to crankshaft pin journal. Tightening torque : Tighten 58.8 N-m (6.0 kg-m, 43.4 lb-ft), and fully loosen bolt. Retighten 34.3 N-m (3.5 kg-m, 25.3 lb-ft) + 60~64° 5. Install the oil pan and bed plate. Refer to "Oil pan". 6.
Page 788 cylinder head assembly COMPONENTS...
Page 789 REMOVAL 1. Disconnect the negative battery cable. 2. Remove the high pressure pipe and the injector. Refer to "FL" (Fuel system) section. a. Never perform any work on injection system with engine running or within 30 seconds after stopping the engine. b.
Page 790 engine and transaxle repair procedures 1. Remove the engine hood. 2. Remove the engine cover. 3. Drain the engine coolant. 4. Drain the transmission oil. 5. Remove the battery and battery tray. 6. Remove the inter cooler hose and pipe on the intake manifold side.
Page 791 7. Disconnect the air cleaner hose. 8. Disconnect the engine coolant reservoir tank hose and the heater hose. 9. Remove the inter cooler hose on the turbo charger side. 10. Loosen the drive belt tension by turning auto-tensioner with spanner, and then remove the drive belt.
Page 792 11. Disconnect the radiator upper hose and lower hose. 12. Remove the radiator cowl upper cover. 13. Remove the cooling fan. 14. Remove the radiator cowl lower cover. 15. Remove the fixing bolt of air-con condenser and ATF oil cooler bracket from the radiator assembly. 16.
Page 793 17. Remove the radiator assembly from engine room, after remove the radiator assembly bracket fixing nut. 18. Drain the power steering oil. 19. Disconnect the power steering pump hose and pipe. 20. Disconnect the earth terminal and the glow plug connector. 21.
Page 794 30. Remove the front propeller shaft. 31. Remove the front exhaust pipe and muffler.
Page 795 32. Remove the shift cable from the transmission. 33. Disconnect the connectors (8EA) from the transmission.
Page 796 34. Remove the transmission oil pipes. 35. Remove the drive plate-to-torque converter fixing bolts (6EA), after remove the bell housing cover. Rotate crank shaft pulley to gain access to all bolts. 36. Remove the starter. 37. Remove the transmission housing fixing bolts. 38.
Page 797 INSTALLATION (A/T EQUIPPED VEHICLE) 1. Install the engine assembly to engine room, by using a engine crane. 2. Install the engine mounting. Tightening torque 68.6-88.3 N·m ( 7.0- 9.0 kg·m, 50.6-65.1 lb·ft) 3. Install the transmission to the vehicle by using a jack. 4.
Page 798 5. Install the transmission housing fixing bolts. 6. Install the starter. Tightening torque 26.5-33.3 N·m (2.7-3.4 kg·m, 19.5-24.6 lb·ft) 7. Install the drive plate-to-torque converter fixing bolts (6EA). Rotate crank shaft pulley to gain access to all bolts. 8. Install the bell housing cover. Tightening torque 9.8-11.8 N·m(1.0-1.2 kg·m, 7.2-8.7 lb·ft) 9.
Page 799 16. Install the earth terminal to the cylinder block. 17. Reconnect the vacuum hoses to the EGR valve and intake manifold. 18. Reconnect the fuel hose to the high pressure pump. 19. Reconnect the injector, TDC sensor, water temperature sensor and starter connector. 20.
Page 800 GENERAL INFORMATION CHECKING ENGINE OIL 1. Position a vehicle on a level surface. 2. Turn off the engine. If a vehicle that has not been used for a prolonged period, run the engine for several minutes. Turn off the engine and wait for 5 minutes at least, and then check the oil level. 3.
Page 801 Restricted by driving condition and environment. Not recommended for sustained high speed vehicle operation. For best performance and maximum protection of all types of operation, select only those lubricants which: a. Satisfy the requirements of the API classification. b. Have the proper SAE grade number for expected ambient temperature renge. Lubricants which do not have both SAE grade number and an API service classification on the container should not be used.
Page 802 1. Run the engine until it reaches normal operating temperature. 2. Turn off the engine. 3. Remove the oil filler cap and the drain plug. Drain the engine oil. 4. Tighten the drain plug to the specified torque. Tightening torque Oil pan drain plug: 35 - 45 N·m (350 - 450 kg·cm, 25 - 33 Ib·ft) Whenever tightening the oil drain plug, use a new drain plug gasket.
Page 803 4. Start and run the engine and check for engine oil leaks. 5. After stopping the engine, check the oil level and add oil as necessary. CHECKING COOLANT LEAK 1. Loosen the radiator cap. 2. Confirm that the coolant level is up to the filler neck. 3.
Page 804 3. Check that the pressure level is maintained at or above the limit. 4. Replace the radiator cap if the reading does not remain at or above the limit. Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an incorrect reading.
Page 805 1.103 1.098 1.092 1.084 1.076 -50 (-58) -45 (-49) a. If the concentration of the coolant is below 30%, its anti-corrosion properties will be adversely affected. b. If the concentration is above 60%, both the anti-freeze and engine cooling property will decrease, affecting the engine adversely.
Page 806 9. If a cylinder's compression or pressure differential is outside the specification, add a small amount of oil through the injector hole, and repeat steps 6 to 8. (1) If the addition of oil causes the compression to rise, it is likely that there may be wear between the piston ring and cylinder wall.
Page 807 Water pump pulley b. Install the belt in LH side of the auto-tensioner pulley. Auto-tensioner pulley → Power steering pump pulley → Alternator pulley c. Loosen the belt tension by turning the auto-tensioner clockwise (about 39°), and then install the belt on the idler between the alternator pulley and the water pump pulley.
Page 808 SPECIAL TOOLS Tool Illustration (Number and Name) Installation of bolts & nuts needing an Torque angle adapter angular method (09221-4A000) Valve spring compressor Removal and installation of intake and (09222-22100) exhaust valves Compression gauge & Checking engine compression pressure adapter (09351-27000) (09351-4A100) Valve stem seal installer...
Page 809 High pressure pump Removal of high pressure pump sprocket remover sprockert (09331-4A000) Crank shaft rear oil seal Installation of crank shaft rear oil seals installer (09231-4A100) Timing chain lower front Installation of timing chain lower front cover oil seal installer cover oil seal (09214-4A000) Balance shaft drive gear...
Page 810 SPECIFICATIONS (D4CB) DESCRIPTION SPECIFICATION (D4CB) LIMIT General Type In-line, DOHC Number of cylinders Bore 91 mm (3.58 in) Stroke 96 mm (3.78 in) Total displacement 2497 cc (121.5 cu.in) Compression ratio 17.7 : 1 Firing order 1-3-4-2 Valve timing Intake valve Opens (BTDC) 8°...
Page 811 Valve length Intake 110.55 mm (4.352 in) Exhaust 110.55 mm (4.352 in) Stem outer diameter Intake 6.965 - 6.980 mm (0.2742 - 0.2748 in) Exhaust 6.935 - 6.950 mm (0.2730 - 0.2736 in) Face angle 45° Thickness of valve head (margin) Intake 1.8 - 2.0 mm (0.071 - 0.079 in) Exhaust...
Page 812 (51.5 ± 2.4 kg /28.8 mm, 1114.4 ± 53 lb/1.134 in) Cylinder block Cylinder bore 91.000 - 91.030 mm (3.5827 - 3.5839 in) Flatness of gasket surface 0.05 mm (0.0020 in) Piston Piston outer diameter 90.910 - 90.940 mm (3.5791 - 3.5803 in) Piston to cylinder clearance 0.080 - 0.100 mm (0.0031 - 0.0039 in) Ring groove width...
Page 813 Crankshaft Main journal outer diameter 66.982 - 67.000 mm (2.6371 - 2.6378 in) Pin journal outer diameter 56.982 - 57.000 mm (2.2434 - 2.2441 in) Main bearing oil clearance 0.024 - 0.042 mm (0.0009 - 0.0016 in) 0.1mm(0.0039in) End play 0.05 - 0.25 mm (0.0020 - 0.0098 in) Flywheel Runout...
Page 814 Opening temperature 82°C (180°F) Closing temperature 77°C (171°F) Pull opening temperature 95°C (203°F) Radiator cap Main valve opening pressure 107.9±14.7 Kpa Main valve closing pressure Vaccum valve opening pressure Water temperature sensor Type Thermister type Resistance 20°C (68°F) 2.45 ± 0.14 kΩ 80°C (176°F) 0.3222 kΩ...
Page 815 Oil pump bolt (8 x 22) 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5 Oil pump bolt (10 x 35) 42.2 - 53.9 4.3 - 5.5 31.1 - 39.8 Oil pump bolt (10 x 60) 42.2 - 53.9 4.3 - 5.5 31.1 - 39.8 Oil screen bolt 19.6 - 26.5...
Page 816 Turbo charger water inlet pipe bolt 34.3 - 49.0 3.5 - 5.0 25.3 - 36.2 Turbo charger heat protector bolt 14.7 - 21.6 1.5 - 2.2 10.8 - 15.9 Intake manifold bolt (8 x 112) 14.7 - 19.6 1.5 - 2.0 10.8 - 14.5 Intake manifold bolt (8 x 32) 14.7 - 19.6...
Page 817 Timing chain upper front cover bolt (8 x 40) 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5 Timing chain upper under cover nut 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7 Timing chain guide "C" (1) bolt 9.8 - 11.8 1.0 - 1.2 7.2 - 8.7 Timing chain guide "C"...
Page 818 Starter fixing bolt 26.5 - 33.3 2.7 - 3.4 14.5 - 24.6 Engine support bracket bolt 47.1 - 51.0 4.8 - 5.2 34.7 - 37.6...
Page 819 TROUBLESHOOTING Symptom Probable cause Remedy Low compression Damaged cylinder head gasket Replace gasket Worn or damaged piston rings Replace rings Worn piston or cylinder Repair or replace piston and/or cylinder block Worn or damaged valve seat Repair or replace valve and/or seat ring Oil pressure drop Low engine oil level...
Page 820 Corroded or cracked hoses Replace (radiator hose, heater hose, etc) Faulty radiator cap valve or setting Replace of spring Faulty thermostat Replace Faulty engine coolant pump Replace Clogged radiator Foreign material in coolant Replace Abnormally high coolant Faulty thermostat Replace temperature Faulty radiator cap Replace...
Page 821 intake and exhaust system COMPONENT air cleaner...
Page 822 exhaust manifold COMPONENTS...
Page 823 intake manifold COMPONENTS...
Page 824 INSTALLATION 1. Install the intake manifold with new gasket. Tightening torque Bolt Size Quantity N-m (kg-m, lb-ft) 8 x 112 4 EA 14.7-19.6 (1.5-2.0, 10.8-14.5) 8 x 32 4 EA 14.7-19.6 (1.5-2.0, 10.8-14.5) 2 EA 14.7-19.6 (1.5-2.0, 10.8-14.5) * Bolts size = Diameter x Length 2.
Page 825 muffer COMPONENT...
Page 826 turbocharger COMPONENTS...
Page 827 LUBRICATION SYSTEM oil cooler COMPONENTS...
Page 828 REMOVAL 1. Drain engine coolant and engine oil. 2. Remove the engine oil filter. 3. Remove the oil cooler assembly from the cylinder block. 4. Remove the oil cooler from the oil cooler cover. 5. Remove the oil cooler by-pass valve and the relief valve from the oil cooler cover. INSTALLATION 1.
Page 829 6. Check for oil and coolant leak. INSPECTION OIL COOLER 1. Inspect visually the core for clogging or damage, and replace it if a problem is found. OIL COOLER BY-PASS VALVE 1. Check that the valve operates properly. 2. Verify the temperature at which the valve begins to open. Temperature Lift Item...
Page 831 oil pan COMPONENT...
Page 832 Reassembly 1. Install the bed plate after apply sealant. Clean the foreign material from mating surface before apply sealant. Tightening torque Bolt Size Quantity N-m (kg-m, lb-ft) 6 x 18 3 EA 7.8-11.8 (0.8-1.2, 5.8- 8.7) 6 x 30 13 EA 7.8-11.8 (0.8-1.2, 5.8- 8.7) 8 x 45...
Page 833 oil pump COMPONENTS...
Page 834 DISASSEMBLY 1. Drain engine oil. 2. Remove the timing chain "C" and "B". Refer to "Timing chain". 3. Remove the oil pan. Refer to "Oil pan". 4. Remove the oil feed pipe from the oil pump and bed plate. 5. Remove the oil pump assembly from the cylinder block. 6.
Page 835 * Bolts size = Diameter x Length 3. Install the oil feed pipe to the oil pump and bed plate. Tightening torque : 19.6-26.5 N-m ( 2.0-2.7 kg-m, 14.5-19.5 lb-ft) 4. Install the oil pan. Refer to "Oil pan" 5. Install the timing chain "B" and "C". Refer to "Timing chain". 6.
Page 836 timing systm Components...
Page 838 Component...
Page 840 DISASSEMBLY TIMING CHAIN “C” 1. Rotate the crankshaft pulley to align the timing mark with TDC, in which No.1 piston locates at the top dead center of compression stroke. 2. Remove the timing chain upper front cover. 3. Remove the cylinder head cover. 4.
Page 841 Before removing auto-tensioner “A”, install a set pin (Ø2.5mm wire) after compressing the tensioner. 4. Remove the timing chain lever “A”. 5. Remove the timing chain guide “A”. 6. Set the special tool (09331-4A000) around the high pressure pump sprocket and install a knob. 7.
Page 842 Grade Color Protrusion (mm(in)) Blue 34.2-35.0 (1.3465-1.3780) White 33.4-34.2 (1.3150-1.3465) 35.0-35.8 (1.3780-1.4094) 3. Install the crankshaft sprocket as the timing mark of crankshaft sprocket aligns with the timing mark of lower under cover, at which No.1 piston locates at the top dead center of compression stroke. In installing crankshaft sprocket, apply oil to the O ring inside the sprocket.
Page 843 7. Align the timing marks of sprocket and chain when high-pressure pump sprocket is not installed to pump. 8. Using the chain connected to the high-pressure pump sprocket, install as the timing marks of LH balance shaft sprocket and crankshaft sprocket align with each other. 9.
Page 844 3. Check the RH balance shaft whether it is located at the right position. To prevent the rotation of balance shaft, insertthe screwdriver (or bolt) intothe plughole at the side of cylinder block and check whether it slides more than 60 mm(2.4in). 4.
Page 845 11. Apply the sealant at the timing chain lower front cover. Sealant type : Lotite #5902 Bead width : 2-4 mm(0.08-0.16 in) 12. Install the timing chain lower front cover. Tightening torque Bolt Size Quantity N-m (kg-m, lb-ft) 8 x 80 4 EA 9.8-11.8 (1.0-1.2, 14.5-19.5) 8 x 70...
Page 846 TIMING CHAIN “C” 1. Check the worn of the timing chain, lever, guide and sprocket and replace them if necessary. 2. Install the timing chain “A” and “B”. 3. Apply the sealant at the timing chain upper under cover. Sealant type : Lotite #5902 Bead width : 2-4 mm (0.08-0.16 in) Then apply the sealant additionally to prevent the oil leak to the overlapping part (T-joint : 2 points right and left of the engine), where cylinder head, timing chain cover plate and timing chain upper...
Page 847 5. Assemble the LH camshaft sprocket tentatively, and align the timing mark with that of timing chain upper under cover. 6. Align the RH camshaft dowel pin with the timing mark of the timing chain upper under cover. 7. Align the timing marks of sprocket and chain when RH camshaft sprocket is not installed to the camshaft.
Page 848 64.7-74.5 N·m (6.6-7.6 kg·m, 47.7-55.0 lb·ft) 14. Assemble camshaft sprocket bolt. Tightening torque: 93.2-117.7 N·m (9.5-12 kg·m, 68.7-86.8 lb·ft) Then assemble the damper pulley to the crankshaft tentatively and align the timing mark of the damper pulley to that of chain cover. And check whether timing mark of the camshaft positions at the right place finally.
Page 850 FUEL SYSTEM engine control module ECM ECU TERMINAL LAYOUT Terminal Signal (Associated Function) Connected to BATTERY (-) BATTERY Ground BATTERY (-) BATTERY Ground BATTERY (-) BATTERY Ground BATTERY (+) via FUSE (10A) MAIN RELAY BATTERY (+) via FUSE (20A) MAIN RELAY CAN LOW CAN HIGH SMARTRA IMMOBILIZER System...
Page 851 To A/CON COMPRESSOR RELAY A/CON COMPRESSOR RELAY ACCELERATION PEDAL PWM Signal TOD TOD TOD UNIT AUXILIARY WATER HEATER RELAY AUXILIARY WATER HEATER RELAY CRUISE CONTROL Supply CRUISE CONTROL ACTIVATOR ENGINE SPEED Signal To TACHOMETER TACHOMETER DIAGNOSIS K-LINE SCAN TOOL CONNECTOR (Pin No.7) VEHICLE SPEED Signal VEHICLE SPEED SENSOR...
Page 852 (From VEHICLE SPEED SENSOR) A/CON PRESSURE S/W Input A/CON PRESSURE S/W REDUNDANT BRAKE S/W Input BRAKE S/W MT/AT AUTO RECOGNITION S/W MT/AT AUTO RECOGNITION S/W (MT:Open, (MT:Open, AT:Ground) AT:Ground) Terminal 15 ( IG ON/OFF Signal) IGNITION S/W BRAKE S/W Input BRAKE S/W A/CON ON S/W Input THERMO S/W...
Page 853 ACCELERATION PEDAL SENSOR Signal 1 ACCELERATION PEDAL SENSOR (PWM) ACCELERATION PEDAL SENSOR Supply 1 ACCELERATION PEDAL SENSOR (PWM) ACCELERATION PEDAL SENSOR Ground 2 ACCELERATION PEDAL SENSOR (PGS) ACCELERATION PEDAL SENSOR Signal 2 ACCELERATION PEDAL SENSOR (PGS) ACCELERATION PEDAL SENSOR Supply 2 ACCELERATION PEDAL SENSOR (PGS) WATER TEMPERATURE SENSOR (WTS)
Page 854 CRANKSHAFT POSITION SENSOR (CKP) CRANKSHAFT POSITION SENSOR (CKP) Shield CAMSHAFT POSITION SENSOR (TDC) CAMSHAFT POSITION SENSOR (TDC) Signal CAMSHAFT POSITION SENSOR (TDC) CAMSHAFT POSITION SENSOR (TDC) Ground MPROP (SUCTION THROTTLE) HIGH SIDE MPROP (SUCTION THROTTLE) MPROP (SUCTION THROTTLE) LOW SIDE MPROP (SUCTION THROTTLE) MALFUCTION INDICATOR LAMP (MIL MALFUNCTION INDICATOR LAMP (MIL...
Page 855 REMOVAL 1. IG OFF and wait for 30 seconds. 2. Disconnect the battery groud terminal. 3. Lift the passenger side carpet (for LHD vehicle), and then remove the protection plate. 4. Remove the ECU mounting nuts. 5. Disconnect ECU harness connector. To do this, pull locking clip. 6.
Page 856 AIR FLOW SENSOR (AFS) CIRCUIT DIAGRAM HOT FILM AFS OUTPUT FEATURES Mass air flow (kg/h) Output voltage (V) 1.2226 - 1.2398 1.3552 - 1.3778 1.6783 - 1.7146 2.1619 - 2.2057...
Page 857 2.7215 - 2.7762 3.4388 - 3.5037 3.8796 - 3.9511 4.1945 - 4.2683 4.5667 - 4.6469 TEST PROCEDURE...
Page 858 TROUBLESHOOTING HINTS 1. When Ignition switch is turned on, if AFS output voltage is not "0" (engine stops), inspect the malfunction of AFS and ECU. 2. Even though AFS output voltage is abnormal, if engine is at idle ,inspect the following conditions. (1) Chect the poor attachment of airflow, cut air duct, and air cleaner filter branched from AFS.
Page 859 ATS (INTAKE AIR TEMPERATURE SENSOR) HARNESS INSPECTION PROCEDURE...
Page 860 TEST PROCEDURE (ATS) SENSOR INSPECTION 1. Inspect the resistance of sensor using a multi-tester. 2. Measure the resistance between ATS and terminal. CONDITION TEMPERATURE (°C) RESISTANCE (kΩ) 39.260 22.960 Ignition switch ON 13.850 8.609...
Page 861 5.499 3.604 2.420 1.662 1.166 0.835 0.609 0.452 0.340 0.261 +100 0.202 +110 0.159 +120 0.127 +130 0.102 3. If resistance value is out of standard, replace the intake air temperature sensor assembly. Intake air temperature sensor is integrated in AFS. WTS (WATER TEMPERATURE SENSOR) CIRCUIT DIAGRAM...
Page 862 TROUBLESHOOTING HINTS When idling speed is not appropriate or blacksmoke arises it is likely to be a defect of water temperature sensor. HARNESS INSPECTION PROCEDURES...
Page 863 SENSOR INSPECTION USING HI-SCAN Set value Check item Data display Check conditions Coolant temp. (HI-SCAN) Water Sensor Ignition switch : ON or engine running -20°C -20°C temperature temperature 0°C 0°C sensor 20°C 20°C 40°C 40°C 80°C 80°C USING MULTITESTER 1. Remove the water temperature sensor from the engine coolant passage of the cylinder head. 2.
Page 864 (2) Gauge unit Temperature (°C) Resistance (Ω) 42.6 ~ 54.2 22.1 ~ 26.2 15.2 3. If the resistance deviates from the standard value greatly, replace the sensor. INSTALLATION 1. Apply sealant LOCTITE 962T or equivalent to threaded portion. 2. Install water temperature sensor and tighten it to specified torque. Tightening torque :2.0 ~ 4.0kg·m 3.
Page 865 HARNESS INSPECTION PROCEDURES...
Page 866 CRANSHAFT POSITION SENSOR (CKP) CIRCUIT DIAGRAM...
Page 867 HARNESS INSPECTION PROCEDURES...
Page 868 INJECTOR CIRCUIT DIAGRAM...
Page 869 HARNESS INSPECTION PROCEDURES INJECTOR OPERATION INSPECTION 1. Using a clip-on ammeter of motor tester, check actuation of injector. Clip-on ammeter must satisty the following conditions. Measuring range >25A Bandwidth > 100kHz 2. Attach the plug to the injector. Fasten clip-on ammeter around lead to pin.2 of corresponding injector. Allow engine to be at idle.
Page 870 3. Check the injector for injecting of fuel. As checking procedure, detach the injector plug from each boxes and connect to replaced injector. If change to enine running results, injector is injecting. If no change to engine running results, injector is not injecting.
Page 871 SENSOR INSPECTION USING HI-SCAN Set value Check item Data display Check conditions Rail pressure (HI-SCAN) Rail pressure sensor Rail pressure Engine at idle 220 - 300bar 260bar HARNESS INSPECTION PROCEDURES...
Page 872 SENSOR REPLACEMENT 1. Replace the RPS if signal voltage exceeds the set value. 2. Note the followings. (1) Always renew the sealing washer (soft iron sealing ring) even if old sensor is re-used. (2) When removing seal, take care not to damage sealing surface. (3) When installing RPS, provide the sealing washer with grease if necessary.
Page 873 CIRCUIT DIAGRAM HARNESS INSPECTION PROCEDURES...
Page 874 EGR SOLENOID VALVE INSPECTION USING HI-SCAN Check item Check condition Engine condition Standard value EGR solenoid valve solenoid valve Ignition switch : ON Check the sound for OFF →ON proper operation USING VOLTMETER Check item Specified value EGR solenoid valve resistance 14 ~ 17Ω...
Page 875 TROUBLESHOOTING HINTS At after run test mode or fuel cut mode, if within set time engine rpm is not dropped below the lower set value, error is detected. The reasons are short circuit, connecting resistance, faulty rail pressure sensor, continuity of fuel pump relay, faulty rail pressure control valve, defective high pressure pump, ECU fault, etc.
Page 876 RAIL RPRESSURE REGULATOR INSPECTION USING VOLTMETER Check item Set value (Ω) Rail pressure control valve resistance 2.9~3.15Ω Replace the faulty fuel rail assembly in case of new model vehicle within a year, or replace the faulty parts of vehicle of which model year is more than a year. DON'T DISASSEMBLE OR DISASSEMBLE Rail Pressure Regulator, because it is NOT SERVICE ITEM.
Page 877 HARNESS INSPECTION PROCEDURES...
Page 879 fuel delivery system common rail COMPONENTS LOCATION...
Page 880 REMOVAL a. Common rail fuel injection system is subject to extremely high pressure (1350 bar). b. Never perform any work on injection system with engine runnin or within 30 seconds after stopping the engine. c. Always pay attention to safety precaution. d.
Page 881 INSTALLATION 1. Tightening the three mounting bolts Tightening torque Rail fixing bolt: 14.7-21.6N·m (150-220 kg·cm, 10.8-15.9 lbf·ft) 2. Assemble intake manifold. Refer to ENGINE MECHANICAL group. 3. Assemble EGR valve. 4. Connect rail pressure sensor connector. 5. Connect high-pressure tube (rail to injector, high pressure pump to rail).
Page 882 fuel filter REMOVAL 1. Remove the inlet hose and outlet hose. 2. Remove connectors (thermoswitch, heater and water sensor connector). 3. Unscrew fixing bolt and nut in bracket, then remove fuel filter. You must be careful of fuel spillage from fuel filter. Tightening torque Fuel filter fixing bolts and nut: 30-35N·m (305.9 - 356.9 kg·cm, 22.1 - 25.8 lbf·ft)
Page 883 fuel line INSTALLATION Tightening torque Fuel tube fitting nut: 24.5-28.4 N·m (250-290 kg·cm, 18.1-21.0 lbf·ft) a. During the installation of the lines, do not use any extreme force, or any tools. b. The high-pressure line must only be installed to the injector when the injector is tightly secured in its position.
Page 884 fuel tank REMOVAL 1. IG OFF. 2. Remove rear seat. 3. Remove carpet, and then disassemble service cover plate. 4. Disconnect the sender connector. 5. Disconnect the main and return tube. 6. Remove breather hose and joint hose in fuel filler pipe. 7.
Page 886 high pressure pump COMPONENTS LOCATION...
Page 887 REMOVAL 1. Disassemble timing chain and high-pressure sprocket. (Refer to Gr: ENGINE MECHANICAL SYSTEM- TIMING SYSTEM) 2. Disconnect fuel tube (HP to rail) and rail pressure regulator(MPROP) connector. 3. Unscrew high-pressure mounting bolts and then disassemble high-pressure pump. Tightening torque High-pressure pump fixing bolt: 12.7-17.7 N·m (130-180 kg·cm, 9.4-13.0 lbf·ft) High-pressure fuel line fixing:...
Page 888 ACCELERATOR PEDAL REMOVAL 1. Unscrew fixing bolts or nuts and disconnect APS sensor connector, which senses position of accelerator pedal. 2. Disassemble APM.
Page 889 COMPONENTS LOCATION a. Common rail fuel injection system is subject to extremely high pressure (1350 bar). b. Never perform any work on injection system with engine runnin or within 30 seconds after stopping the engine. c. Always pay attention to safety precaution. d.
Page 890 GENERAL INFORMATION GENERAL SPECIFICATION Items Specification sensors Air flow sensor Type HFM5 (Hot film sensor) Intake air temperature sensor Type Thermistor type 2.28~2.56kΩ at 20°C(68°F) Resistance 0.30~0.38kΩ at 80°C (176°F) Water temperature sensor Type Thermistor type (WTS) 2.31~2.59kΩ at 20°C (68°F) Resistance 0.314~0.331kΩ...
Page 891 curv idle speed (rpm) N-range A/CON OFF 800rpm A/CON ON 850rpm D-range A/CON OFF 800rpm A/CON ON 850rpm TIGHTENING TORQUES Item N·m Kg·cm lb·ft Common Rail installation 14.7-21.6 150-220 10.8-15.9 Water temperature sensor 29.4-39.2 300-400 21.6-28.9 Accelerator arm bracket bolts 7.8-11.8 80 -120 5.8-8.7...
Page 892 TROUBLESHOOTING FUEL INJECTION SYSTEM Trouble symptom Probable cause Remedy Engine does not start Cranking speed too low Repair starting system or charge or replace battery so that engine cranks at a minimum of 150 rpm. No voltage at glow plug bus If test light shows no voltage at bus with key at "ON"...
Page 893 Faulty injection pump Try engine at idle with new pump installed. If necessary, replace pump permanently. Engine lugging in too high a gear Observe correct shift speeds. Smoky exhaust (black, Engine not reaching correct operating Check and, if necessary, replace blue or white) temperature cooling system thermostat.
Page 894 tighten all pipes, hoses and connections. Return pipe and hose blocked Check return line for kinks and dents. Replace faulty lines. If line is clogged, blow it out with compressed air, then bleed fuel system. Faulty injection nozzles Check and, if necessary, repair or replace injection nozzles.
Page 895 will not crank Pinion gear teeth broken or starter motor Repair starter motor faulty Ring gear teeth broken Replace flywheel ring gear or torque FUEL TANK AND FUEL LINE Trouble symptom Probable cause Remedy Engine malfunctions due Bent or kinked fuel pipe or hose Repair or replace to insufficient fuel supply Clogged fuel pipe or hose...
Page 899 TROUBLESHOOTING PROCEDURES Communication with SCAN TOOL is not possible. (Communication with all system is not possible)
Page 900 SCAN TOOL COMMUNICATION WITH ECU IS NOT POSSIBLE Comment Probable cause a. Malfunction of ECU power supply circuit One of the following causes may be suspected. b. Malfunction of the ECU a. No power supply to ECU c. Open circuit between ECU and DLC b.
Page 901 ROUGH IDLE OR ENGINE STALLS...
Page 902 ENGINE HESITATES OR ACCELERATES POORLY...
Page 903 WHEN GLOW(PREHEATING) LAMP IS ILLUMINATED AT ALL TIMES (ECU AUTOMATIC RECOGNITION PROCEDURE)
Page 904 a. In the case of the vehicle with 2.5liter A-Engine CRDi, it is normal if the glow lamp with ignition On is illuminated during preheating(max. 10 seconds) according to the ambient temperature and then put off. The glow lamp is illuminated at all times for the vehicle with ECU having not performed automatic recognition procedure.
Page 905 CASE 2) When ECU is incorrectly adapted for transaxle...
Page 907 TROUBLESHOOTING INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES DESCRIPTION Memory CODE CODE ○ 0100 AIR FLOW SENSOR CIRCUIT-MALFUNCTION C001 Signal below lower limit C002 Signal above upper limit C003 General error 0110 INTAKE AIR TEMPERATURE (ATS) CIRCUIT- ○ MALFUNCTION C001 Signal below lower limit C002 Signal above upper limit ○...
Page 908 C018 Line: short circuit C019 Line: open circuit ○ ○ 0204 Injector circuit MALFUNCTION-CYL 4 C018 Line: short circuit C019 Line: open circuit ○ ○ 0220 ACCEL. POSITION SENSOR2-MALFUNCTION C001 Signal below lower limit C002 Signal above upper limit C003 General error C004 Plausibility error...
Page 909 C021 Dataset selection not fit with the EEPROM ○ 0703 Brake switch-MALFUNCTION C004 Plausibility error ○ 0704 Clutch switch-MALFUNCTION C004 Plausibility error ○ 1170 Atmospheric PRESSURE SENSOR-MALFUNCTION C001 Signal below lower limit C002 Signal above upper limit ○ 1180 Rail pressure regulator-MALFUNCTION C018 Line: short circuit C019...
Page 910 ○ 1622 A/C RELAY-MALFUNCTION C018 Line: short circuit C019 Line: open circuit ○ 1623 ENGINE CHECK lamp-MALFUNCTION C018 Line: short circuit ○ 1624 Radiator cooling fan-MALFUNCTION C018 Line: short circuit ○ 1629 Glow indicator lamp-MALFUNCTION C018 Line: short circuit C019 Line: open circuit ○...
Page 911 ○ 1653 Error check after IG off-MALFUNCTION ○ 1660 Cruise control switch-MALFUNCTION C001 Signal below lower limit C002 Signal above upper limit C003 General error C004 Plausibility error a. MIL: Malfunction Indicator Lamp TROBLE AREA RELATED TO DTC DESCRIPTION REMARK Memory CODE CODE...
Page 912 in HFM5 defective c. ECU defective WATER TEMPERATURE ○ SENSOR (WTS) MALFUNCTION a. Short circuit to ground line b. Contact resistance c. Water temperature sensor C001 Signal below lower limit defective 0115 d. ECU defective a. Short circuit to battery (+) line, open circuit in wiring b.
Page 913 DTC 1526 C001 a. Short circuit to battery (+) line b. Rail pressure sensor defective C002 Signal above upper limit c. ECU - sensor supply voltage: DTC 1526 C002 a. Short circuit to battery (+) line or to ground b. ECU - sensor supply voltage: C003 General error DTC 1526 (The CC code from...
Page 914 a. Contact resistance b. Camshaft position sensor defective c. Incorrect installation position or sensor loose C004 Plausibility error d. Camshaft and crankshaft misarrangement e. Interference on signal line from other component (Alternator, injector line) a. Open circuit. Broken line b. Short circuit to ground line c.
Page 915 b. Fuse defective c. Poor connection d. Switch defective CLUTCH SWITCH- ○ MALFUNCTION (MT vehicle only) a. Open circuit in wiring, short 0704 circuit b. Fuse defective C004 Plausibility error c. Poor connection d. Switch defective ATMOSPHERIC PRESSURE ○ SENSOR-MALFUNCTION 1170 C001 Signal below lower limit...
Page 916 a. Rail pressure sensor defective Minimum pressure at engine C006 b. Pressure regulator valve speed too low defective c. Injectors defective C009 Leakage of Fuel d. High pressure pump defective e. Leakage Governor deviation at engine C010 speed too high GLOW RELAY-MALFUNCTION ○...
Page 917 RADIATOR COOLING FAN- ○ MALFUNCTION a. Short circuit to battery line 1624 b. Fuse defective c. Relay defective C018 Line: short circuit d. Resistance continuity defective e. Fan motors defective WATER HEATER RELAY- ○ MALFUNCTION a. Short circuit to battery line, open circuit in wiring 1635 b.
Page 918 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code AIR FLOW SENSOR CIRCUIT-MALFUNCTION No. P0100 a. Short circuit to ground line or open circuit in Related items C001 Signal below lower wiring (according to CC limit b. Contact resistance code) c. HFM5 defective d.
Page 920 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code INTAKE AIR TEMPERATURE SENSOR CIRCUIT (ATS) - No. P0110 MALFUNCTION a. Short circuit to ground line Related items C001 Signal below lower b. Contact resistance (according to CC limit c. HFM5 defective code) d.
Page 922 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code WATER TEMPERATURE SENSOR (WTS) - MALFUNCTION No. P0115 a. Short circuit to ground line Related items C001 Signal below lower b. Contact resistance (according to CC limit c. Water temperature sensor defective code) d.
Page 924 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code ACCEL. POSITION SENSOR 1-MALFUNCTION No. P0120 ACCEL. POSITION SENSOR 2-MALFUNCTION No. P0220 a. Short circuit to ground line Related items C001 Signal below lower b. Accel. position sensor defective (according to CC limit code) c.
Page 925 pin 1(+) and pin 6(-) a. Specification 0.2475~0.5225 at IDLE Stroke 1.575~2.585 at FULL Stroke...
Page 926 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code FUEL RAIL PRESSURE SENSOR-MALFUNCTION No. P0190 a. Open circuit, contact resistance or short circuit Related items C001 Signal below lower to ground line (according to CC limit b. Rail pressure sensor defective code) c.
Page 927 Replace RPS if signal voltage set value are not attained. a. Tightening torque: 35±2 N·m. a. When removing seal, take care not to damage sealing surface. b. When installing RPS, bond on sealing washer with grease if necessary. c. Replace whole FUEL-RAIL ASSEMBLY if vehicle was produced within a year and replace the parts of that if vehicle was produced more than a year ago.
Page 929 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code EGR SOLENOID VALUE CIRCUIT-MALFUNCTION No. P0403 a. Short circuit to battery line, open circuit in wiring Related items C018 Line: short circuit (according to CC a. Short circuit to ground line C019 Line: open circuit code) Step Inspection...
Page 931 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code VEHICLE SPEED SENSOR-MALFUNCTION No. P0500 a. Vehicle speed sensor defective Related items C002 Signal above upper (according to CC limit code) a. Clutch switch defective C004 Plausibility error b. Vehicle speed sensor defective Step Inspection Check wiring between ECU pin 49 and vehicle speed sensor.
Page 932 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code BATTERY VOLTAGE No. P0560 a. Open circuit in wiring. Short circuit to ground line Related items C001 Signal below lower b. Contact resistance (according to CC limit c. Fuse defective code) d. Plug contacts e.
Page 934 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code BRAKE SWITCH-MALFUNCTION No. P0703 a. Open circuit wiring, short circuit Related items C004 Plausibility error b. Fuse defective (according to CC c. Poor connection code) d. Switch defective Step Inspection [Brake switch 1] Measure voltage supply at switch pin 2 to GND with IG ON.
Page 936 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code CLUTCH SWITCH-MALFUNCTION (MT vehicle only) No. P0704 a. Open circuit in wiring, short circuit Related items C004 Plausibility error b. Fuse defective (according to CC c. Poor connection code) d. Switch defective Step Inspection Measure voltage at switch pin (ECU side) to GND with IG ON.
Page 938 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code ATMOSPHERIC PRESSURE SENSOR-MALFUNCTION No. P1170 a. Defective atmospheric pressure sensor in ECU Related items C001 Signal below lower (according to CC limit code) C002 Signal above upper limit Step Inspection Check possible actual value a.
Page 939 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code RAIL PRESSURE REGULATOR-MALFUNCTION No. P1180 a. Short circuit to battery line, open circuit in wiring Related items C018 Line: short circuit b. Water temperature sensor defective (according to CC code) a. Short circuit to ground line, open circuit C019 Line: open circuit a.
Page 941 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code FUEL PRESSURE MONITORING-MALFUNCTION No. P1181 a. Rail pressure sensor defective Related items C005 Maximum pressure b. Pressure regulator valve defective (according to CC exceeded c. Injectors defective code C008 PRV sticking d. High pressure pump defective a.
Page 942 CASE B: The rail pressure setpoint value is greater than actual value by 250-350bar a. Check leakage in the rail: pull out all the fuel tubes (injector return & hose to pump) and check whether the fuel flow out through the limiting valve on the rail, if leakage detected and limiting valve failure, replace limiting valve b.
Page 943 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code GLOW RELAY-MALFUNCTION No. P1325 GLOW INDICATOR LAMP-MALFUNCTION No. P1629 a. Short circuit to battery line, open circuit Related items C018 Line: short circuit b. Fuse defective (according to CC code) c. Contact resistance d.
Page 945 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code MAIN RELAY-MALFUNCTION No. P1616 a. Open circuit in wiring, short circuit Related items C004 Plausibility error b. Contact resistance (according to CC c. Fuse defective code) d. Main relay defective Step Inspection After IG ON, check supply voltage ECU pin 4 to GND and ECU pin 5 to GND. a.
Page 947 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code A/C RELAY-MALFUNCTION No. P1622 a. Short circuit to battery line Related items C018 Line: short circuit b. A/C compressor relay defective (according to CC code) a. Short circuit to ground line, open circuit C019 Line: open circuit b.
Page 949 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code ENGINE CHECK LAMP-MALFUNCTION No. P1623 a. Short circuit to battery line Related items C018 Line: short circuit (according to CC code) Step Inspection Perform the actuator diagnosis. If lamp does not flash, measure supply voltage at engine check to GND with IG ON. a.
Page 951 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code WATER HEATER RELAY-MALFUNCTION No. P1635 a. Short circuit to battery line, open circuit in wiring Related items C018 Signal below lower b. Fuse defective (according to CC limit c. Open circuit. Contact resistance code) d.
Page 953 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code INJECTOR SUPPLY VOLTAGE-MALFUNCTION No. P1645 Related items C002 Signal above upper (according to CC limit code) C001 Signal below lower limit Step Inspection Capacitor in the ECU charges for activating the injectors. Check wiring of injectors to ECU. Rectify additional faults stored.
Page 954 TROUBLESHOOTING PROCEDURE FOR DTC Diagnostic trouble code CAMSHAFT POSITION SENSOR(TDC)-MALFUNCTION No. P0340 a. Camshaft position sensor defective Related items C002 Signal above upper b. Interference on signal line from other component (according to CC limit (Alternator, injector lines) code) a. Camshaft position sensor defective C003 General error b.
Page 956 FUNDAMENTAL PROCEDURES SYMBOLS Symbol Meaning Type New engine oil, gear oil, etc. as Apply oil appropriate Apply brake fluid Only brake fluid Apply automatic transmission fluid Only ATF (ATF) Apply grease Appropriate grease Apply sealant Appropriate sealant Apply petroleum jelly Appropriate petroleum jelly Whenever special oil or grease is required, it will be identified in figure.
Page 957 A WORD ABOUT SAFETY 1. Block the wheels. 2. Use only the specified jacking positions. 3. Support the vehicle with safety stands. PREPARATION OF TOOLS AND MEASURING EQUIPMENT SPECIAL SERVICE TOOLS (SST'S) REMOVAL OF PARTS...
Page 958 DISASSEMBLY INSPECTION OF PARTS ARRANGEMENT OF PARTS CLEANING PARTS FOR REUSE...
Page 959 REASSEMBLY a. Oil seals b. O-rings c. Cotter pins d. Gaskets e. Lock washers f. Nylon nuts DEPENDING ON LOCATION: 1. Sealant should be applied or new gaskets installed. 2. Oil should be applied to the moving components of parts. 3.
Page 960 RUBBER PARTS AND TUBING ELECTRICAL TROUBLESHOOTING TOOLS (TEST LIGHT) The test light is used for simple voltage checks and in checking for short circuits. When checking the engine control module (ECM), never use a bulb exceeding 3.4W. ELECTRICAL TROUBLESHOOTING TOOLS(JUMPER WIRE) Do not connect a jumper wire from the power source line to a body ground.
Page 961 VOLTMETER OHMMETER Do not attempt to connect the ohmmeter to any circuit in which voltage is applied. Such a connection may damage the ohmmeter. ELECTRICAL PARTS...
Page 962 < REMOVAL OF CONNECTOR > 1. Never pull on the wiring harness when disconnecting connectors. 2. Connectors can be removed by pressing or pulling lock lever. < LOCKING A CONNECTOR > Listen for a click when locking connectors. This sound indicates that they are securely locked. <...
Page 963 2. Check terminals of waterproof connectors from connector side because they cannot be accessed from harness side. a. Use a fine wire to prevent damage to the terminal. b. Do not damage the terminal when inserting the tester lead. Pull lightly on individual wires to ensure that they are secured in the terminal. REPLACEMENT OF TERMINALS <...
Page 964 SENSORS, SWITCHES, AND RELAYS Do not drop them or accidentally strike them against other parts. WIRING COLOR CODES CODE COLOR CODE COLOR BLACK PINK BROWN GREEN SILVER(LIGHT BLUE) GRAY TAWNY BLUE VIOLET LIGHT GREEN WHITE ORANGE TELLOW VEHICLE LIFT (2-SUPPORT TYPE) AND SAFETY STAND POSITIONS...
Page 965 TOWING If emergency towing is necessary, we recommend having it done by an authorized KIA dealer or a commercial tow-truk service. Proper lifting and towing procedures are necessary to prevent damage to the vehicle. It is recommended that your vehicle be towed with a wheel lift or flatbed eguipment. Do not tow with a slingbelt.
Page 966 × × × × 1 - 3 : World Manufacturer's Identification KNA = Kia Motors Corporation 4 - 5 : Vehicle Type JC = Kia SORENTO 6 -7 : Body Type 52 = 4 door wagon 8 : Engine Type 1 = 2.5L Diesel, 2 = 2.4L Gasoline, 3 = 3.5L Gasoline...
Page 967 KNA = Kia Motors Corporation 4 - 5 : Vehicle Type JC = Kia SORENTO 6 -7 : Body Type 52 = 4 door Wagon 8 : Engine Type 1 = 2.5L Diesel, 2 = 2.4L Gasoline, 3 = 3.5L Gasoline...
Page 968 ENGLISH/METRIC CONVERSION TABLE...
Page 969 UNITS...
Page 970 ABBREVIATIONS...
Page 971 MAINTENANCE SCHEDULE...
Page 972 MAINTENANCE UNDER SEVERE USAGE CONDITIONS...
Page 974 HVAC a/c system DEFROST LOGIC 1. Defrost logic Mode Intake IG ON System ON Vent, B/L, Floor Previous Previous Fresh (Except auto) Mix, Defrost Previous Fresh a. At initial the battery on, the A/C is off and the intake is changed to fresh status. b.
Page 975 SCHEMATIC DIAGRAM (FULL AUTO) BLOWER AND A/C CONTROLS (FULL AUTO) FULL AUTOMATIC AIR CONDITIONER (FATC) CONTROL PANEL...
Page 976 Connector Pin Description...
Page 977 Item PIN NO. PIN Name Item PIN NO. PIN Name Main Connector IG1 (METER Main Connector MAX HI RELAY 10A) MODE BI/L CHECKER COUPLER(DCC : GND) MODE D/H A/C SELECT HIGH MIX PBR MIX HOT AQS SENSOR SENSOR GND AMB SENSOR INTAKE FRE BATT 3B JOINT...
Page 979 SWITCH OPERATION AND FEATURES 1. Full auto air conditioning system: One-touch button type. 2. Manual air conditioning system: Combination of dial switch and one-touch button. CONTROL PANEL SWITCHES WILL GENERATE BUZZER SOUND ON OPERATION Replacing switch Button Function Display System operation and system operation 1.
Page 980 shift) a. Off→System Off AUTO Auto control "AUTO" will be b. Blower switch : (Auto control) of air displayed on 1. The system will provide Manually control conditioning control panel. auto control of the below blower system features on the basis of c.
Page 981 b. "AUTO" lamp b. OFF S/W : FRE. will go out. c. AUTO : Auto a. Fresh air lamp Fresh air Fix intake door at the fresh air Control will come on. position. b. "AUTO" lamp will go out. 1. The speed will shift a.
Page 982 2. Intake door: Fresh air moisture/frost b. DEF indication b. MODE: Discharge control (Selecting mode, manual recirculation is enabled). windshield. control (release c. A/C lamp on the defroster d. INTAKE 3. A/C: on (Compressor will control). indicator lamp be controlled on/off based c.
Page 983 control. b. Others: Return to the previous condition before system off. AUTO A/CON OPERATION TABLE...
Page 984 ambient sensor DESCRIPTION 1. The air temperature sensor is located at the front of the engine radiator and detects ambient air temperature. It is a negative type thermistor; resistance will increase with lower temperature, and decrease with higher temperatures. 2. The sensor output will be used for discharge temperature sensor, sensor fail-safe, temperature regulation door control, blower motor level control, mix mode control and in-car humidity control.
Page 986 compressor COMPONENTS 2.5D ENGINE 2.4G ENGINE 3.5G ENGINE...
Page 988 REMOVAL AND INSTALLATION 1. Remove the drive belt by referring to the "EM Group" (2.5D) Remove the drive belt after loosening the tension pulley.(2.4G, 3.5G) 2. Discharge the refrigerant. 3. Remove the discharge and suction hoses. 4. Remove the compressor. 5.
Page 989 compressor oil DESCRIPTION Oil lubricates the compressor and circulates in the system while the compressor is operating. Whenever replacing any component of the system, or when a large amount of gas leakage occurs, add oil to maintain the original total amount of oil. HANDLING OF OIL 1.
Page 990 condensor fan and relay CHECKING CONDENSER 1. Check the condenser fins for clogging and damage. If clogged, clean them with water, and blow them with compressed air. If bent, gently bend them using a screwdriver or a pliers. 2. Check the condenser connections for leakage, and repair or replace it, if required. CONDENSER FAN 1.
Page 991 dual pressure switch DESCRIPTION (2.5D) The dual swith is composed a low pressure and high pressure switches. The low pressure switch will be turned off to stop compressor operation if refrigerant pressure is low. The high pressure switch will be turned off to stop compressor operation if refrigerant pressure is too high.
Page 992 in-car sensor INSPECTION In-car air temperature sensor is located at crash pad. It is installed with humidity sensor. It will detect interior temperature, which will be used for discharge temperature control, sensor failsafe, temperature door control, blower motor level control, A/C auto control. Check resistance of the sensor Resistance between 1 and 2 (Ω...
Page 994 CHECKING THE CLUTCH AIR GAP 1. Check the air gap between the clutch hub and pulley contact surface using a filler gauge. Clutch air gap : 0.35 - 0.65mm (0.0138 - 0.0256 in) 2. Check the gap around the pulley at 3 points. 3.
Page 995 photo-sensor DESCRIPTION The photo sensor is located by the driver side defrost nozzle. In response to photo intensity level in vehicle, the sensor will send signal to control module to control the blower level and discharge temperature. Emit intensive light toward driver side and passenger side using a lamp, and check the voltage change between terminals 1 2.
Page 996 receiver-driver check Check 1. Check the fusible plug and the fittings for leakage, using a leak detector. 2. Run the engine at fast idle with the air conditioning "ON", and check both the inlet and outlet temperatures. If the difference in temperatures between the inlet and outlet is large, replace the receiver-drier.
Page 997 HUMIDITY SENSOR 1. Humidity sensor is located at crush pad and detected in-car humidity for in-car humidity control. 2. If ambient air temperature or in-car humidity is outside certain range, it will turn on A/C to control incar humidity preventing incar fogging. Air conditioner operation depending on ambient temperature and humidity SENSOR OUTPUT Humidity (%)
Page 998 0.98 0.94...
Page 999 thermistor sensor checking SENSOR CHECKING The thermistor will detect the core temperature and interrupt compressor relay power, in order to prevent evaporator freezing by excessive cooling. The thermistor is an NTC device. Thermistor check 1. Remove the glove box. 2. Start the engine. 3.
Page 1000 triple pressure switch DESCRIPTION(2.4G, 3.5G) The triple switch is a combination of a medium switch as well as conventional low pressure and high pressure switches. The low pressure switch will be turned off to stop compressor operation if refrigerant pressure is low. The high pressure switch will be turned off to stop compressor operation if refrigerant pressure is too high.
Page 1002 INSTRUCTIONS WHEN HANDLING REFRIGERANT 1. R-134a liquid refrigerant is highly volatile. A drop on the skin of your hand could result in localized frostbite. When handling the refrigerant, be sure to wear gloves. 2. It is standard practice to wear goggles or glasses to protect your eyes, and gloves to protect your hands.
Page 1003 WHEN INSTALLING CONNECTING PARTS FLANGE WITH GUIDE PIN Check the new O-ring for damage (use only the specified) and lubricate it using compressor oil. Tighten the nut to specified torque. Tightening torque (N·m (kg·m, lb-ft)) Size General bolt, nut 4 - 6 (0.4 - 0.6, 2.9 - 4.3) 7 - 11 (0.7 - 1.1, 5.0 - 7.9) 9 - 14 (0.9 - 1.4, 6.5 - 10) 17 - 26 (1.7 - 2.6, 12 - 18)
Page 1004 T means tensile intensity, and it is stamped on the head of bolt only numeral. HANDLING TUBING AND FITTINGS The internal parts of the refrigeration system will remain in a state of chemical stability as long as pure moisture-free refrigerant and refrigerant oil are used. Abnormal amounts of dirt, moisture or air can upset the chemical stability and cause problems or serious damage.
Page 1005 REFRIGERANT SYSTEM SERVICE BASICS REFRIGERANT RECOVERY Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a(R-134a)from the air conditioning system. a. Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. b.
Page 1006 3. If the low-pressure does not reach more than 93.3 kPa(700 mmHg, 27.6 in.Hg) in 15 minutes, there is probably a leak in the system. Partially charge the system, and check for leaks (See Leak Test.) SYSTEM CHARGING Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a(R-134a)from the air conditioning system.
Page 1007 R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air. a. Compressed air mixed with R-134a forms a combustible vapor. b. The vapor can burn or explode causing serious injury. c. Never use compressed air to pressure test r-134a service equipment or vehicle air conditioning systems.
Page 1008 9. Measure the dry-bulb temperature at the cool air outlet, and calculate the difference between the inlet dry-bulb and outlet dry-bulb temperatures. 10. Check that the intersection of the relative humidity and temperature difference falls within the block below. If the intersection is within the block, cooling performance is satisfactory. PERFORMANCE TEST DIAGNOSIS USING MANIFOLD GAUGE STANDARD VALUE If cooling cycle is operating normally, the manifold gauge reading will be approx.1.5-2.0kg/cm²(21-28psi)
Page 1009 DIAGNOSIS PROBABLE SYMPTOMS REMEDY MANIFOLD GAUGE READINGS CAUSES a. Low pressure and a. Gas leak. a. Check and high pressure are repair. low. b. Add refrigerant. b. Cooler outlet air is a little cooler. a. Low pressure and a. Faulty cooling or a.
Page 1010 b. Frost or dew on pipes expansion valve connected with if the receiver- receiver or expansion drier is faulty. valve. a. Low pressure side a. Intaken moisture a. Repair and pressure sometimes is frozen at bleed receiver goes to negative expansion valve drier pressure or normal.
Page 1011 REFRIGERATION CYCLE...
Page 1013 REFRIGERATION LINE...
Page 1014 BLOWER CHECK 1. Connect the battery voltage and check the blower motor rotation...
Page 1015 blower speed control CHECK (MANUAL CONTROL) 1. Check for continuity and resistance between terminals. Resistance (Ω ± 10%) Terminal 3 - 1 0.33 3 - 2 0.85 3 - 4 2.07...
Page 1016 CONTROL PANEL Connector Pin Description...
Page 1017 Item Pin NO. Pin name Item Pin NO. Pin name Main ILL (-) Main Battery connector connector C3 joint (Blower common) Intake (Fresh) Sensor ground Mix (Hot) Mix (Feedback) A/C select high Check coupler Mode (Floor - defrost) Mode (Face - floor) IG 1 ILL (+) Intake (Recirculation)
Page 1018 DEFROST LOGIC 1. IG ON/OFF logic Condition Mode Intake Face, Face - floor, Floor Memory Fresh IG ON Defrost, Floor - defrost Fresh Memory function a. When moving blower switch off to on, A/C and intake are changed to previous status. b.
Page 1019 SCHEMATIC DIAGRAM (MANUAL) BLOWER AND A/C CONTROLS (MANUAL)
Page 1020 intake actuator DESCRIPTION The intake selection switch is located on the control panel. Pressing the switch will shift between recirculation and fresh air modes. CHECK Input Output Fresh/recirculation shifting Recirculation fresh...
Page 1021 power transistor CHECK (AUTO CONTROL) 1. Manually operate the control switch and measure the voltage of blower motor between pin 1 and 2. 2. Select the control switch to raise voltage until high relay operates. CHECK Motor Voltage First speed 4.0V Second speed 5.6V...
Page 1023 DIAGNOSIS SYSTEM OPERATION METHOD (SELF-DIAGNOSIS) The F.A.T.C. module self test feature will detect electrical malfunction and provide error codes for system components with suspected failures. FAIL SAFE FUNCTION Item Failure FAIL SAFE Function...
Page 1024 In-car temperature sensor Open/Short 25°C (77°F) alternate value control Ambient temperature sensor Open/Short 25°C (77°F) alternate value control Thermistor -2°C (28.4°F) alternate value control Photo sensor (Sun sensor) Open/Short Temperature door Open/Short setup For 17°C (62°F) to 24.5°C (76°F), Set to potentiometer temperature maximum cooling position.
Page 1025 DTC code Detection item Trouble area Normal a. Incar sensor Open/Shorted incar sensor b. Harness or connector between incar sensor circuit. and A/C control assembly c. A/C control assembly a. Ambient sensor Open/Shorted Ambient b. Harness or connector between ambient sensor sensor circuit.
Page 1026 Since FATC controller is complicated in functions as shown in the above chart, it is impossible to conclude its reason at the occurrence of failure. All possibilities of failure shall be considered for the purpose of efficient How to check. 1.
Page 1027 function error occurs IG. If 10V and more, check FATC connector and if no problem, check the inside of controller. If 10V and less, check fuse or wiring state of battery power source. When IG is ON, system IG1 power supply error Check voltage of IG1 after turning on IG.
Page 1028 10.5V, Level 6 :12.0V [high-relay operation]) Measure voltage of each terminal and if there is difference more than ± 0.6V, check power TR. Blower wind is Power TR error Power TR change discharged despite pressing OFF switch. AIR CONDITIONER CHECK 11V is outputted from connector A-15 terminal in turning on IG and pressing air conditioner switch.
Page 1029 INTAKE CHECK In turning on IG and selecting outdoor mode with indoor switch, 12V is outputted from FATC connector A- 8 terminal, 0V is supplied for A-19 terminal and motor works in direction of outdoor. In selecting indoor mode with indo or switch, 12V is outputted from FATC connector A-19 terminal, 0V is supplied for A-8 terminal and motor works in direction of indoor.
Page 1030 in direction of vent mode setup. Vent, Built-in-level, Blower, Mix and Defrost mode can be selected in the method described below. ERROR DIAGNOSTICS Symptoms Causes How to check Specific mode isn't Signal transmission error of Measure voltage of selected mode wiring selected.
Page 1031 TEMP CHECK In adjusting temp switch from 32°C(90°F) to 17°C(62°F), 11V is outputted from FATC connector A-16 terminal, 0V is supplied for A-6 terminal and temp motor works in direction of COOL. In adjusting temp switch from 17°C(62°F) to 32°C(90°F), 11V is outputted from FATC connector A-6 terminal, 0V is supplied for A-16 terminal and temp motor works in direction of WARM.
Page 1032 terminal. If both of them are 9V and more, check temp actuator and peripheral wiring state and if one or both of them are 5V and less, its cause is internal failure of FATC. Sensor (+5) power supply error If automatic control isn't operated smoothly, measure voltage of FATC connector A-18 terminal.
Page 1033 SPECIFICATIONS A/CON DIESEL GASOLINE ITEM 2.5D 2.4G 3.5G ← ← COMPRESSOR TYPE 10 PA17C ← ← Oil type & Capacity ND-OIL8 200cc COMP.PULLEY TYPE 7PK-TYPE 5PK-TYPE 4PK-TYPE PULLELY Ø123 Ø125 Ø110 ← ← CONDENSER TYPE Corrugated ← TRIPLE S/W High (Kg/cm²G) 32.0 ±...
Page 1034 Selection ← HEATING efficient 325.4cm² area ← Operating method ACTUATOR ← TEMP selection Operating method ACTUATOR Control unit ITEM MANUAL AUTO INCAR SENSOR AMBIENT SENSOR PHOTO SENSOR HUMIDITY SENSOR...
Page 1035 TROUBLESHOOTING MALFUNCTION CAUSES AND REMEDIES (Numbers Indicate checking/inspection order.)
Page 1037 HEATER fuel fired heater DESCRIPTION The fuel fired heater has been applied to the diesel engine (CRDi) to increase heating capability by using diesel only in cold weather. a. Follow the procedures specified in this bulletin during service or it may cause personal injury. b.
Page 1038 1. This fuel fired heater supplies additional heat to the interior compartment with a low fuel consumption to compensate the heat provided by engine alone. 2. The fuel fired heater has been adopted to warm up the interior compartment in a short time. 3.
Page 1039 The fuel fired heater operating at idle mode turns into the half load when the coolant temperature is 74°C. At this time, if the coolant temperature drops again below 68°C, the heater operates with full load and turns into the idle mode if the temperature is 78°C. This serial operating process is performed automatically.
Page 1040 EXPLODED VIEW COMPONENT...
Page 1041 Fuel fired heater assembly a. It is mounted in the engine room under the coolant reserve tank. Exhaust pipe a. It is mounted to the right side member in front of the front tire. Dosing pump a. It is located at the right frame under body. Ambient temperature switch a.
Page 1042 2. Burner assembly This is composed of a glow plug, an evaporator and a housing which air is provided directly. The fuel fired heater is operated when air and fuel supplied through the air and fuel inlet ports are ignited by the glow plug. 3.
Page 1043 dosing pump. The fuel is supplied from the fuel return line. 5. Ambient temperature switch. The ambient temperature switch is a bimetal type and the switch is turned on when the temperature is 0°C ~ 5°C and turned off when the temperature is 5°C ~ 10°C. This switch is consisted of 2 terminals and one terminal receives signal from the alternator and the other one sends signal to the fuel fired heater.
Page 1044 OPERATION TEST Fuel-fired heater operation test by force using Hi-Scan 1. Start the engine. 2. Connect the Hi-Scan to the vehicle. 3. Select "SORENTO" and then select "FUEL FIRED HEATER". 4. Select "04. ACTUATION TEST" mode. 5. Select "PREFILLING + HEATING" to conduct the performance test after replacing the fuel fired heater system.
Page 1045 7. Select "02. CURRENT DATA" to view the current status of the components. Component test 1. Using the Hi-Scan, conduct component test after selecting "FUEL FIRED HEATER" and "ACTUATION TEST" mode. 2. After conducting component test, perform self-diagnosis test. 3. It is recommended to conduct the fuel fired heater system test after completing the component test. 4.
Page 1046 4. Disconnect the fuel fired heater main connector. Care should be taken when removing hot coolant. 5. Remove the coolant hose after loosening the water hose clamp connected to the fuel fired heater. Care should be taken when removing hot coolant. 6.
Page 1047 INSTALLATION 1. Install the sub exhaust pipe to the fuel fired heater. 2. Install the fuel fired heater to the body with mounting hardware. 3. Connect the fuel fired heater main connector. 4. Assemble the fuel hose and water hose. 5.
Page 1048 3. Remove the glow plug and connector. 4. Remove the rubber grommet in the burner assembly wire. 5. Remove the screw and burner assembly. 6. Remove the gasket. Assembly 1. Install the new gasket. 2. Insert the burner assembly, rubber grommet in the wire and then tighten the screw. Tightening torque : 3.2 ~ 3.8N·m ( 0.32 ~ 0.38 kg·m, 2.4~2.8 lb·ft).
Page 1049 SCHEMATIC DIAGRAM FOR FUEL-FIRED HEATER...
Page 1050 SPECIFICATIONS ITEM OPERATION STATE SPECIFICATION Full load 5.0kw Heater discharge Half load 2.5kw Full load Diesel Full load 0.63 l/h Fuel consumption Half load 0.32 l/h Rated voltage 12.0V Fuel Operation voltage range 9.5V~15.0V fired heater Full load 37w(Normal) body Power consumption Half load 13w(Normal)
Page 1051 TROUBLESHOOTING SYMPTOM REMEDY a. Check fuel system on vehicle. a. Check the fuel supply line in the fuel fired heater for fuel leaking and fuel hose for twisting or clogging. Fuel smell a. If none of above is affected, there is likelihood of fuel leaking from the heater inner.
Page 1053 temperature control actuator INSPECTION 1. Temperature control actuator is installed in the heater unit case. The control switches and the vent duct switch will operate actuator to regulate the temperature and discharge air. 2. Verify that the temp actuator operates to the hot position when connecting 12V to the terminal 7 and grounding terminal 5.
Page 1054 MANUAL TRANSAXLE SYSTEM SPECIAL SERVICE TOOL Tool (P/NO & P/Name) Illustration Removal of main shaft 3rd-4th sleeve 09432-3E000 hub. Sleeve hub remover Removal of main shaft 5th reverse (3rd-4th) sleeve hub. 09432-3E100 Removal of main shaft 1st-2nd sleeve Sleeve hub remover hub.
Page 1055 09432-3E400 Removal of main shaft double ball Double ball bearing bearing. remover 09432-3E500 Removal of counter shaft taper roller Counter shaft bearing bearing. remover 09432-3E600 Removal of main shaft 3rd sleeve. 3rd sleeve remover 09431-2C200 Removal of adapter housing taper roller Taper roller bearing bearing outer race.
Page 1056 0K552 171 AA0 Installation of main shaft 5th-Reverse Sleeve hub installer sleeve hub. 09432-22000 Installation of main shaft ball bearing. Ball bearing installer Installation of counter shaft taper roller bearing. 0k9A1 190 004 Installation of main shaft 3rd-4th sleeve 3rd-4th sleeve hub hub.
Page 1058 SPECIFICATION TIGHTENING TORQUE Model Item N·m Kg·cm Ib·ft Engine(A2.5 ENG.) to transmission 43 - 55 430 - 550 31 - 40 (12 X 45, 50, 70, 90) Engine(S2.4 ENG.) to transmission 43 - 55 430 - 550 31 - 40 (12 X 50, 60, 40, 55) Poppet plate bolt 10 - 12...
Page 1059 8X80) 20 - 27 200 -270 14 - 15 Shift control housing assembly 60 - 65 600 -650 43 - 48 Oil drain plug 60 - 65 600 -650 43 - 48 Oil filler plug SERVICE STANDARD Model Item Standard Value mm(in) Front retainer bearing end play 0-0.1L (0-0.0039) 3rd&4th snap ring end play...
Page 1060 TROUBLESHOOTING Symptom Probable cause Remedy Gear will not be shifted or is Bent shift lever Repair or replace hard to be shifted Faulty control cable Replace parts Excessively worn return spring Replace Clutch dose not release correctly Adjust or replace Jumps out of gear or has too Shift rod malfunction Replace...
Page 1061 MANUAL TRANSAXLE SHIFT CONTROL COMPONENTS...
Page 1062 DISASSEMBLY 1. Remove cap sealing. 2. Remove both of plunger rolling assembly in shift control housing. 3. Remove pin-detent and change shifter. 4. Loosen the stopper bracket bolt. 5. Loosen the shift control finger bolt.
Page 1063 6. Remove the control shaft.
Page 1064 manual transaxle gear system count shaft ASSEMBLY NOTICE 1. Using SST(09432-22000), install taper bearing onto both side of counter shaft.
Page 1065 COMPONENTS...
Page 1066 main shaft COMPONENTS...
Page 1068 DISASSEMBLY Use care to prevent the main shaft from falling when pressing fears and assemblies from it. 1. Remove 4th gear sleeve snap ring. 2. Using SST(09432-3E000), remove 3rd&4th synchronizer hub, sleeve, 3rd speed gear and synchronizer ring (3rd). 3. Remove 3rd speed gear needle bearing. 4.
Page 1069 7. Remove synchronizer ring (1st). 8. Remove 1st speed gear needle bearing. 9. Using SST(09432-3E200), remove main shaft rear ball bearing after removing snap ring. 10. Using SST(09432-H1100/09432-3E300), remove lock nut after releasing calking of lock nut. 11. Using SST(09432-3E400), remove space after removing double bearing. 12.
Page 1070 13. Using SST(09432-3E000), remove 5th&R synchronizer sleeve and hub and reverse gear. 14. Remove synchronizer ring (Reverse). ASSEMBLY Clean perfectly every part before assembly. 1. Install reverse needle bearing onto the main shaft. Apply grease to reverse needle bearing. 2. Install reverse gear and synchronizer ring (Reverse). Check and separate synchronizer ring of each gear before assembly as shown below.
Page 1071 3. Using SST(0K552 171 AA0), install 5th&R sleeve hub assembly. 4. Install snap ring. 5. Measure the clearance between sleeve hub and snap ring with feeler gage after installing snap ring. End play: 0.0~0.08mm (0-0.0031 in) 6. Install 5th needle bearing and 5th synchronizer ring (Single cone).
Page 1072 Apply transmission oil to needle bearing. 7. Insert ball as shown below picture after installing 5th gear. 8. Install space with suitable tool after applying transmission oil to space. 9. Install the double bearing using SST(09432-3A100) after install double bearing support bracket with flat face up.
Page 1073 10. Tighten hub lock nut. Tightening torque: 170-190N·m (1700-1900 kg·cm, 120-140 lb·ft) 11. Calk one part of lock nut using suitable tool. 12. Install snap ring under the rear ball bearing of main shaft.
Page 1074 13. Using SST(09432-22000), install the rear ball bearing of main shaft, then install snap ring at the upper end of rear ball bearing. 14. Rotate main shaft to reverse direction and install 1st needle bearing. Apply transmission oil to 1st needle bearing. 15.
Page 1075 17. Install snap ring. 18. Measure the clearance between sleeve and snap ring using feeler gage after installing 1st&2nd sleeve and snap ring. End play: 0.0-0.08mm (0-0.0031 in) 19. Install 2nd needle bearing and synchronizer ring (2nd). Apply transmission oil to 2nd needle bearing.
Page 1076 20. Install 2nd gear snap ring after installing snap ring guide. (09432-3E800) 21. Install 2nd gear onto the main shaft. 22. Using SST(09432-22000), install 3rd speed gear bearing sleeve. 23. Measure the clearance between 2nd gear and main shaft sleeve using feeler gage. End play: 0.13~0.28mm (0.0051-0.0110 in)
Page 1077 24. Install 3rd needle bearing. Apply transmission oil to 3rd needle bearing. 25. Install 3rd gear onto the main shaft. End play: 0.1-0.2mm (0.0039-0.0079 in) 26. Install 3rd synchronizer ring (3rd).
Page 1078 27. Using SST(0K9A1 190 004), install 3rd&4th synchronizer sleeve and hub. 28. Measure the clearance between sleeve and snap ring using feeler gage after installing snap ring. End play: 0.0~0.08mm (0-0.0031 in) 29. Install 4th synchronizer ring (4th). 30. Install 4th needle bearing.
Page 1079 Apply transmission oil to 4th needle bearing. 31. Install main drive pinion gear onto the main shaft. 32. Measure the clearance of 1st and reverse gear. End play : 1st: 0.10~0.20mm (0.0039-0.0079 in) R: 0.08~0.18mm (0.0031-0.0071 in) 33. Measure the clearance of 2nd and 3rd gear. End play : 2nd: 0.1~0.25mm (0.0039-0.0098 in) 3rd: 0.1~0.2mm (0.0039-0.0079 in)
Page 1080 34. Measure the clearance of 5th gear. End play: 0.13~0.28mm (0.0051-0.0110 in) 35. Measure the length of main shaft. 558.6 - 559 mm (21.99 - 22.00 in) Main shaft length 490 - 490.4 mm (19.29 - 19.30 in)
Page 1081 reverse idle gear assembly COMPONENTS...
Page 1082 manual transaxle COMPONENTS (1)
Page 1084 COMPONENTS (2)
Page 1087 REMOVAL 1. Remove the battery (-) terminal. 2. Remove the knob and the control lever. 3. Raise the vehicle. 4. Remove the transmission under cover. 5. Remove the clutch release cylinder. 6. Remove the front propeller shaft (4WD vehicle). 7. Remove the front muffler and the heater protector. 8.
Page 1088 12. Remove the transmission with transfer case (4WD vehicle). DISASSEMBLY PRECAUTION a. Clean the transaxle exterior thoroughly with a steam cleaner or clear or cleaning solvent before disassembly. b. Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with compressed air.
Page 1089 4. Remove transmission shift control housing. 5. Remove back up lamp switch. 6. Using the pin punch, remove shift rail roll pin. Do not use old roll pin again.
Page 1090 7. With a magnet, remove springs and ball after loosing interlock puppet plate bolts. 8. Loose a reverse idle shaft bolt on the transmission case housing side. 9. Remove retainer after loosing the front retainer bolt. 10. Remove snap ring. 11.
Page 1091 12. Remove transmission case housing after loosing case housing bolt. 13. Remove bearing retainer bolt. In case of 4WD, remove bearing retainer bolt after loosing the transfer case bolt. 14. Remove reverse idle shaft after loosing a reverse idle shaft bolt on the adapter side.
Page 1092 15. Using the pin punch, remove 3th shift fork pin. Do not use old roll pin again. 16. Remove 3rd shift rail after setting each gear to the neutral position. 17. In order to disassemble main shaft assembly, counter shaft assembly and shift rail from adapter, heat double bearing installed part of adapter with electrical heater(Leister 4000) or SST(09432-3E000) as shown picture below.
Page 1093 18. Disassemble it tapping adapter with rubber hammer lightly after heating. REASSEMBLY 1. Measure the depth (A) between the bottom of the main shaft double bearing seat in the adapter and the sealing surface of the adapter. 2. Measure the thickness (B) of main shaft double bearing. Measured value: A-B End play: 0~0.1mm (0-0.0039 in) 3.
Page 1094 5. Install the counter shaft and temporarily taper bearing outer race. Measure the height (B) between the sealing surface of adapter and the upper face of the bearing race (located on the counter shaft). Measured value: A-B End play: 0.02~0.12mm (0.0008-0.0047 in) Select a shim that is equal to the measured value considering the end play.
Page 1095 8. Install two dowel pins into the grooves of the sealing surface of the adapter. 9. Insert two interlock balls into the grooves in the rail holes. 10. In order to secure two interlock balls, temporarily install flexible hoses into the rail holes. 11.
Page 1096 Do not install 3rd&4th shift fork and rail. 12. Heat the main shaft double bearing seat part in adapter with electrical heater(Leister 4000) or SST(09432-3E000). 13. Install the main shaft, counter shaft and shift fork assembly into the adapter after removing two flexible hoses installed temporarily.

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