Page 1: Table Of Contents
Body Electrical System General Windshield Wiper/ Washer Generals ............BE - 3 Component Location ........BE - 40 Specifications ..........BE - 6 Windshield Wiper/Washer Diagnosis ............BE - 7 Removal ..........BE - 41 Inspection ..........BE - 42 Fuses and Relays Circuit Diagram ........
Page 2 Digital Tachograph Specifications ..........BE - 74 Description ............ BE - 74 Components ..........BE - 75 Part Circuit Diaram ........BE - 76 Replacement ..........BE - 77 DTC Chart ............. BE - 77 Audio System Audio Unit Components ........... BE - 78 Replacement ...........
Page 3: General
General 3. When the parts are installed at the vehicle, be careful Generals that the wiring harness is not torn off or damaged. 1. For servicing the electric system, the battery (-) terminal should be disconnected first. KMTBE5003A 4. When the fuse is burn-out, replace it with a new one KMTBE5001A of rated ampere.
Page 4 5. Be careful that the sensors or the relays are not shocked. Do not drop them down to the floor. Do not throw them recklessly. KMTBE5007A 8. When disconnecting the harness, hold the connector and pull it. Do not pull the harness to disconnect it. KMTBE5005A 6.
Page 5 10.When connecting the connector, insert the connector Inspection of Cable and Wire until "Tag" sound can be heard. 1. Check that the connecting portion is loosened or rusted. 2. Check that the terminal or wire is corroded by the battery electrolyte. 3.
Page 6: Specifications
Specifications Item Specifications Indicator and Gauge Fuel gauge type Cross coil type(Scale fixing type) (Except D4GA engine) Unit type Variable resistor type Water temperature gauge type Cross coil type (Middle fixing type) Unit type Thermistor type Tachometer type Cross coil type Sensor type Moving coil type Speedometer type...
Page 7: Diagnosis
Item Specifications Lightening system Lamp capacity Head lamp (Up/Down) 75W70W Turn lamp Position lamp Tail / Brake lamp 5/21W Room lamp Fog lamp Back up lamp License plate lamp Luminescent lamp Horn Type Flat type Nominal voltage DC 24V Frequency 415 ±...
Page 8 Lighting System Symptom Causes Remedy General Light When turning the switch ON, The bulb is short. Replace the lamp is not lightened. The battery is discharged. Charge The switch is faulty. Replace The fuse is short. Replace The wiring circuit is opened or the conta- Repair ct is faulty.
Page 9 Meter and Gauge Symptom Causes Remedy The speedometer does not work. The speed sensor is faulty. Replace The fuse is opened or blow. Replace The speedometer is faulty. Replace The needle of the speedometer is unstable. The speed sensor is faulty. Replace The speedometer is faulty.
Page 10 Symptom Causes Remedy The brake lamp does not work. The bulb is short. Replace The fuse is short. Replace The wiring circuit is opened, or it contact is fa- Repair ulty. During working of engine, the oil warning la- The engine oil pressure is too low. Adjust mp turns on.
Page 11 Washer System Symptom Causes Remedy The washer motor does not work. The washer motor or pump is faulty. Replace The washer switch is faulty. Replace The fuse is short. Replace The wiring circuit is opened, or it contact is fa- Repair ulty.
Page 12: Fuses And Relays
Fuses And Relays Component Location (Except D4GA engine) EMTBE5008A...
Page 13 Component (D4GA engine) SUDBEA0053L...
Page 14 Component(Fuse) Except D4GA engine Fuse box Fuse Amperages Circuit protected Fuse Amperages Circuit protected Working lamp Outside mirror defogger Head lamp relay Blower and A/C control Fuel heater Exhaust brake, tachograph(EC), Cold start switch Tachograph, ETACS, audio, instru- Wiper and washer ment cluster, room lamp ABS control(ECU) Starting...
Page 15: Components
Components(Relay, Fuse blink) EMTBE5009A...
Page 16: Relay Inspection
Relay Type B relay Inspection 1. When an electric power is applied between the power Type A relay relay terminal No.3 and No.5, check that there is an 1. When an electric power is applied between the power electric current between the terminal No.1 and No.2. relay terminal No.2 and No.4, check that there is an electric current between the terminal No.1 and No.5.
Page 17: Fuse Inspection
Fuse 3. A blade type fuse is identified by the numbered value Inspection in amperes. 1. When a fuse is burnt-out, check that there is any opened or abnormal component before replacing the If the fuse is burnt-out, be sure to replace a fuse with fuse.
Page 18: Indicators And Gauges Instrument Cluster Components
Indicators And Gauges Instrument Cluster Components (Except D4GA engine) SUDBEA0050L 1. Temperature gauge 6. Working lamp 11. 1st Connector 2. Speedometer gauge 7. Tilting lock warning lamp 12. 2nd Connector 3. Tachometer 8. Seat belt warning lamp 13. 3rd Connector 4.
Page 19 Components (D4GA engine) SUDBEA0051L 1.Water temperature gauge 6. Working lamp 2.Speedometer gauge 7. Tilting lock warning lamp 3.Tachometer 8. Seat belt warning lamp 4.Fuel gauge 9. Parking brake warning lamp 5. Fuel warning lamp 10. Door warning lamp...
Page 20: Circuit Diagram
Circuit Diagram (Mechanical engine) EMTBE5002A...
Page 21 Circuit Diagram (D4DD engine) SUDBEA0054L...
Page 22 Circuit Diagram (D4GA engine) SUDBEA0003L...
Page 23: Connector Configuration
Connector Configurations (Except D4GA engine) EMTBE5014A...
Page 24 Connector Configurations (D4GA engine) SUDBEA0004L...
Page 25: Fuel Gauge Inspection
Fuel Gauge 2. Check that the resistor is varying smoothly, when the Inspection float is moving from "F" to "E" position. Inspection of Fuel Gauge Except D4GA engine 1. Disconnection the fuel sender connector. 2. After connecting the test bulb to the connector of the harness in serial, and ground it.
Page 26: Water Temperature Gauge Inspection
Water Temperature Gauge Inspection Inspection of water temperature gauge and water temperature sensor 1. If it is not satisfied the tolerance, replace the cluster and water temperature sensor. Except D4GA engine Temperature ( ° 85 ~ 105 Scale Angle ( ° ) Tolerance ( °...
Page 27: Tachometer Inspection
Tachometer Inspection 1. Connect the tachometer for a tune-up test, start the engine. 2. By comparing the values indicated by the tester and the tachometer, if it is over the tolerance, replace the cluster. Except D4GA engine 1,000 2,000 3,000 3,500 4,000 Tolera-...
Page 28: Speedometer Inspection
Speedometer Inspection 1. Using the speedometer tester, check the tolerance of the speedometer. Except D4GA engine Spee- d (km Toler- ± 3 + 3.5 + 4.5 ance D4GA engine Spee- d (km Toler- ance 2. Check that the needle of the speedometer is vibrating or the speedometer makes an abnormal noise.
Page 29: Door Warning Indicator Inspection
Door Warning Indicator 3. If the checking value of the door switch does not Inspection satisfy the specifications, replace the door switch. 1. Remove the door switch(A). EMTBE5018A KMTBE5027A 2. Check that there is continuity between the switch's terminal and ground. KMTBE5028A...
Page 30: Seat Belt Warning Indicator Inspection
Seat Belt Warning Indicator Inspection of Seat Belt Warning Inspection Check that the following conditions are satisfied when Inspection of seat belt switch the ignition switch is ON. 1. Disconnect the seat belt switch connector (A). Seat Belt Condition Fastened Not fastened Warning Lamp EMTBE5019A...
Page 31: Parking Brake Switch Inspection
Parking Brake Switch Inspection The parking brake is lever type. The parking brake switch (A) is installed under the parking brake lever. For adjusting that, release the parking brake, and turn the switch up and down. 1. When the switch is "ON" (when the lever is pulled), check that there is continuity between the terminal and the switch.
Page 32: Tilting Lock Sensor Inspection
Tilting Lock Sensor Inspection 1. Remove the tilting lock sensor. KMTBE5032A 2. Check continuity between the tilting lock sensor and the terminal. If there is no continuity, replace the tilting lock sensor. EMTBE5020A...
Page 33: Hazard Switch Inspection
Hazard Switch Inspection Circuit Diagram 1. Remove the instrument facia panel. EMTBE5021A KMTBE5133A 2. Check the continuity between the terminals(A) during the hazard switch operation. KMTBE5034A...
Page 34: Working Lamp Switch Inspection
Working Lamp Switch 3. Check continuity between the terminals during the Inspection switch operation. 1. Remove instrument facia panel mounting screw(A) and the instrument facia panel. KMTBE5036A KMTBE5133A 2. Remove the working lamp switch(A). SUDBEA0039L KMTBE5134A...
Page 35: Front/Rear Fog Lamp Switch Inspection
Front/Rear Fog Lamp Switch 2. Check continuity between the terminals during Inspection operating the switch. 1. Remove instrument facia panel mounting screw(A) and the instrument facia panel. KMTBE5040A KMTBE5133A EMTBE5024A...
Page 36: Idle Adjust Switch Inspection
Idle Adjust Switch 2. Check continuity between the terminals during Inspection operating the switch. 1. Remove instrument facia panel mounting screw(A) and the instrument facia panel. SUDBEA0006L SUDBEA0005L SUDBEA0007L...
Page 37: Multi Function Switch
Multi Function Switch Components [LHD] SUDBEA0008L...
Page 38: Inspection
[RHD] SUDBEA0009L Inspection LHD type With operating the switch, check continuity between terminals. SUDBEA0011L SUDBEA0010L...
Page 39 RHD type SUDBEA0015L SUDBEA0012L SUDBEA0016L SUDBEA0013L SUDBEA0017L SUDBEA0018L SUDBEA0019L SUDBEA0014L SUDBEA0020L...
Page 40: Windshield Wiper Washer
Windshield Wiper Washer Component Location SUDBEA0021L 1. Wiper link 3. Washer reservoir 2. Washer motor...
Page 41: Windshield Wiper/Washer Removal
Windshield Wiper Washer 3. After taking off the cover (A), loosen the nut (B) and Removal remove the cap and pad (C). 1. Take off the battery (-) cable(A). SUDBEA0040L 2. Remove the wiper arm cap(A). After loosening the wiper arm mounting nut(B), KMTBE5051A remove the washer hose(C).
Page 42: Inspection
6. Remove the washer motor(B) from the washer Circuit Diagram reservoir(A). KMTBE5053A KMTBE5147A Connector Configurations 7. The installation is performed in the reverse order of the removal. Inspection Washer Motor 1. After disconnect the washer motor connector (A) and the check valve (B), connect the battery to the washer motor connector.
Page 43: Power Windows
Power Windows Power Window Motor Connector Configurations Inspection Connect the battery and then check that the power window motor is working. KMTBE5063A Circuit Diagram EMTBE5039A Rotational Direction CCW : Counterclockwise CW : Clockwise NOTICE The rotational direction of the motor is referred to the EMTBE5038A output axis of the motor.
Page 44: Power Window Switch
Power Window Switch Inspection [Sub switch] Check the continuity of switch using multi tester. If needed, replace it. [Main switch] SUDBEA0041L SUDBEA0041L SUDBEA0043L SUDBEA0042L...
Page 45 Circuit Diagram [Main Switch] SUDBEA0044L [Sub Switch] SUDBEA0045L...
Page 46: Lighting System
Lighting System Components SUDBEA0052L 1.Room lamp mounting bracket 4.License plate mounting bracket 7.Bulb 2.Body assembly 5.License plate lamp assembly 8.Head lamp wiring assembly 3.Room lamp lens 6.Head lamp 9.Front turn signal lamp 10.Side turn signal lamp...
Page 47: Head Lamp Replacement
Head Lamp 3. After taking off the bolt (A), remove the bumper (B). Replacement 1. Take off the battery (-) terminal. KMTBE5067A 4. Remove the front grill (A). KMTBE5065A 2. Take off the connectors (A) of the both fog lamps. KMTBE5068A KMTBE5066A...
Page 48: Inspection
5. Check that the width(H1) between the head lamp satisfies the specifications. KMTBE5070A 7. The installation is performed in the reverse order of the removal. EMTBE5057A Model H1(mm) HD65 1240 HD72, HD78 1240 NOTICE H1: Width between the head lamps...
Page 49: Adjustment
1. Setup the tire pressure to the specifications, park the HD65 vehicle on the even ground. Do not tilt the vehicle. HD72, HD78 2. Do not apply any additional load except for the driver. 3. Check that the leaf spring or the shock absorber is CAUTION damaged.
Page 50 + driver. EMTBE5057A KMTBE5077A Model H1(mm) H2(mm) HD65 1240 HD72, HD78 1240 CAUTION The tolerance of the height tolerance should be within ± 30mm. NOTICE H1: Width between the head lamps H2: Height of the head lamp from the ground...
Page 51: Turn Signal Lamp Replacement
Turn Signal Lamp 2. Remove the combination lamp (A). Replacement 1. Remove the battery (-) terminal. KMTBE5078A KMTBE5065A...
Page 52: Room Lamp Replacement
Room Lamp 3. After disconnecting the room lamp connector(B), Replacement remove the room lamp (A). 1. Take off the battery (-) terminal. KMTBE5080A KMTBE5065A 2. After removing the room lamp lens (A), remove the fixing screw. KMTBE5079A...
Page 53: Fog Lamp Replacement
2. After disconnecting the fog lamp connector (A) and the fixing bolt (B), remove the fog lamp (C). KMTBE5141A 5. Check that the width(A) between the fog lamp satisfies the specifications. KMTBE5081A SUDBEA0046L Model A(mm) HD65 1150 HD72, HD78 1150...
Page 54: Adjustment
4. Set a screen at 3m from the fog lamp. KMTBE5143A Model A(mm) HD65 HD72, HD78 KMTBE5144A CAUTION 5. Check that the width between the fog lamp satisfies The tolerance of the height tolerance should be the specifications. within ± 30mm.
Page 55 6. Adjust by turning the adjusting screw(A) to clockwise direction or counter clockwise direction using a + driver. KMTBE5083A...
Page 56: Head Lamp Leveling Device
Head Lamp Leveling Device Description According to driving environment and loading state of vehicle, head lamp lighting direction is changed to keep the driver's visibility range and to protect the driver's vision from glare, aiming at safety driving. If needed, a driver can change the height of head lamp lighting with operating the head lamp leveling device switch.
Page 57: Part Circuit Diagrams
Part circuit diagrams Head lamp leveling switch SUDBEA0033L...
Page 58 Head lamp leveling actuator SUDBEA0034L...
Page 59: Keyless Entry System
Keyless Entry System Components ETACS SUDBEA0024L...
Page 60: Description
Transmitter assembly DESCRIPTION The burglar alarm system is armed automatically after the doors are closed and locked by transmitter. The alarm activates when any of these things occurs : • A door is forced open. • A door is unlocked without using the transmitter. •...
Page 61: Operation
2. CODE SAVING conditions Operation 1. Keyless entry 1) When KEY is ACC OFF and TX REGISTER switch is ON(GND) 1) Security code memory 2) In other way, after ACC is to do ON/OFF three 1. Memory method by CODE SAVING mode entry times within 10 seconds, TAIL switch is ON/OFF Entering the CODE SAVING mode, write the three times.
Page 62 STRBE3024L 1) KEYLESS ENTRY operating specification. In the ACC OFF state, according to requesting of LOCK or UNLOCK from the TX, it operates the same sequence as the CENTRAL DOOR LOCK. STRBE3025L 2. Burglar alarm function 1) ARM FUNCTION 1. In case LOCK signal of Tx is received when both Doors are Closed and ACC is OFF as well, output the LOCK state.
Page 63 5. And otherwise, relock doesn't output by Tx LOCK in all doors locked, HAZARD LAMP only turns on/off twice for T_ARM cycle. STRBE3027L...
Page 64 6. In the states of ACC OFF & ALL DOOR CLOSE & DOOR LOCK, after processing UNLOCK signal from Tx, if there's not the ACC ON, DOOR OPEN or LOCK output (LOCK by Tx, KNOB SW) within 30 seconds, door will be relocked automatically.
Page 65 3. If the ACC is ON in the ARM stage, there should be the DISARM stage. STRBE3029L 3) ALARM FUNCTION 1. All Doors are Unlocked regardless of Tx in the 3. The START INHIBIT turns off after turning on ARM MODE. In case Doors is opened more than for T_INH.
Page 66 STRBE3030L 4. If there is received the ACC input within 15 seconds after alarm is starting, and when it is passed by 30 seconds after ACC ON at first, the alarming and warning should be canceled and then ignore ACC input after 15 seconds.
Page 67 STRBE3031L 5. In case it is received the LOCK of Tx after closed the invaded DOOR during an alarm, the LOCK output is turned on for T_LCK. The HORN alarm output and START INHIBIT output are turned off. It confirms the two DOOR LOCK SW and turning ON/OFF the HAZARD LAMP one times for T_ARM cycle, the HORN is turned on for T_ACK and remains to the ARM stage.
Page 68 6. In case of Tx LOCK in the DOOR OPEN state during an alarm. When the invaded DOOR is Opened during alarm and the LOCK of Tx is received, turn ON the LOCK output for T_LCK and turn off the HORN alarm output and START INHIBIT output.
Page 69 7. In case of removing the BATTERY(ARM state, NO ALARM state) BATTERY removed then re-connected in ARM stage, START INHIBIT should be ON. Alarm the HORN and HAZARD LAMP. If UNLOCK of Tx is to input during an alarm, the state will be the DISARM and immediately stop the HORN.
Page 70 8. In case of removing the BATTERY(ALARM state) BATTERY removed then re-connected during an alarm, START INHIBIT will be ON and alarm the HORN and the HAZARD LAMP. If UNLOCK of Tx is to input during an alarm, the state is the DISARM and the HORN is immediately stopped.
Page 71: Inspection
INSPECTION TRANSMITTER 1. Check that the red light flickers when the door lock or unlock button is pressed on the transmitter. 2. Remove the battery and check voltage if the red light doesn't flicker. Standard voltage : 3V SUDBEA0048L 3. Replace the battery after removing the battery cover. 4.
Page 72: Adjustment
ADJUSTMENT STRBE3009L Specifications Items Specifications Keyless entry transmitter power source Lithium 3V battery (1EA) Transmissible distance 10m or more Life of battery 2 years or more (at 20 times per day) Button Door lock Door unlock Transmission frequency 433.92 MHz...
Page 73: Door Lock Actuator Inspection
Door Lock Actuator Inspection 1. After disconnect the door lock actuator connector(A), remove the door lock actuator mounting bolts(B) 2. After connecting the battery power to each terminals, check that the door lock actuator is normal operating. KMTBE5104A EMTBE5043A...
Page 74: Digital Tachograph
Digital Tachograph Specification Items Specification Rated voltage 24 V DC Range of voltage 18 ~ 32 V DC Range of temperature -30 ~ + 80 ℃ -35 ~ + 85 ℃ Range of storage temperature Operating current 500 mA or low Insulation resistance 100 ㏁...
Page 75: Components
Components SUDBEA0036L 1. Upper case 4. LCD monitor 2. Select switch 5. Front case 3. Switch 6. USB terminal...
Page 76: Part Circuit Diaram
Part circuit diagram SUDBEA0037L...
Page 77: Replacement
Replacement 1. Remove the center facia panel. 2. Disconnect the connector and remove the digital tacho graph. 3. The installation is in the reverse order of removal. DTC chart DTC code Description C1271 Engine rpm sensor open/short C1212 Vehicle speed sensor open/short...
Page 78: Audio System
Audio System Audio Unit Components SUDBEA0022L...
Page 79 SUDBEA0023L...
Page 80: Replacement
Replacement Cleaning 1. Disconnect the battery (-) cable. 1. To maintain the best condition, clean the head and capstan periodically. 2. Remove the left overhead facia panel. 3. Loosen the mounting bolt of audio unit. Disconnect the connector on the rear side and remove the audio unit.
Page 81: Speaker Replacement
Speaker 3. Loosen the tightening screw (A) of the inside handle Replacement housing. Disassemble the inside handle housing (B) 1. Remove the tightening screw (A) for the power from the door trim (C). window switch assembly. KMTBE5112A KMTBE5110A 4. Taking off the tightening screw (A) and bolt (B) from 2.
Page 82: Inspection
5. Disconnect the speaker connector (A) and loosening Inspection the tightening screw (B), remove the speaker (C). 1. Check the speaker using a resistance meter. When checking the ( + ) and the (-) of the same channel speaker, if the resister meter indicates the impedance value, the speaker is normal.
Page 83: Horns Horns
Horns Horns Component Location SUDBEA0049L 1. Horn 3. Bumper 2. Bracket...
Page 84: Replacement
KMTBE5117A Replacement 4. The installation is performed in the reverse order of 1. Disconnect the both fog lamp connectors (A). the removal. NOTICE Be ensure that the connector should be firmly connected. Inspection 1. After connecting the battery power to the horn connector, check that the horn makes the sound.
Page 85: Electronic Time And Alarm Control System
Electronic Time and Alarm Control System Components SUDBEA0024L...
Page 86: Circuit Diagram
Circuit Diagram Except D4DD, D4GA engine ECOBE5025A...
Page 87 D4DD, D4GA engine SNBBE9017L...
Page 88: Connector
Connector Except D4DD, D4GA engine ECOBE5027A EMTBE5048A...
Page 89 D4DD, D4GA engine KMTBE5130A KCOBE5027A...
Page 90: Specifications
Specifications Item Specifications Nominal Voltage DC 24V Operating Voltage DC 20 ~ 32V Operating Temperature -30 ~ + 80 ° C (-22 ~ + 176 ° F) Dark Current 5mA or less Nominal Load Seat Belt Warning Indicator 1.4W (Lamp Load) Coolant Level Warning Lamp 1.4W (Lamp Load) Wiper Relay...
Page 91: Generals
3) This function is prior to the intermittent wiper Generals function. The ETACS is the system for automatic controlling the seat belt warning lamp, the pre-heating indicator, the pre-heater relay, the intermittent wiper relay, the mirror-heater relay, the door lock/unlock relay, the power window relay, and the tail relay.
Page 92 4) At the ON state of the ignition, if the seat belt is 6. Water level warning fastened and then released again, the warning 1) At the ON state of the ignition switch, if the lamp is output for T1. coolant level sensor is maintained over T1 with 30kΩ...
Page 93 2. Washer related Wiper 4. Ignition key reminder 1) At the ON of the ignition switch, if the washer 1) When ACC is ON, open the driver's door and switch is ON, after 1 sec, the wiper output is ON. then if door is locked by pushing DOOR LOCK When the washer switch input is within T3, after KNOB,...
Page 94 5. Ignition key hole illumination control 7. Seat belt warning timer 1) When the driver's door(or passenger's door) is 1) At the ON state of the ignition switch, if the seat opened and the ignition switch is OFF, the belt is released, the seat belt warning lamp is ignition key hole illumination turns on.
Page 95 9. Tail auto cut 10.Parking start warning 1) After ACC SW is On, if Tail SW is On, then ACC 1) In the state that the ignition switch is ON, if the SW shall be OFF; when the driver's door is parking switch is ON and the speed of vehicle is opened, then the Tail Lamp shall be OFF maintained over 7 ±...
Page 96 11.Vehicle speed calibration 1) When IGN is ON, according to input PULSE, output the calibrated SPEED PULSE using the following form. OUTPUT PULSE = INPUT PULSE x K K = [2πx TR x 5,096]/[1,000 x AR x N] ( if N = 1, fix the K = 1, when goods is delivered, initialize.) •...
Page 97 3) when OFF, CALIBRATED SPEED_POS and CALIBRATED SPEED_NEG maintain the reverse phase each other. SPYBE7040L...

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