Kia VISTO Owner's Manual
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Kia VISTO Owner's Manual

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Summary of Contents for Kia VISTO

  • Page 1    ...

  • Page 2: General Information

    GENERAL INFORMATION GENERAL EATC0100 HOW TO USE THIS MANUAL This manual is divided into 21 sections. The first page of each section is marked with a black tab at the edge of the page. You can quickly find the first page of each section without looking through the whole table of contents. Each section includes the essential removal, installation, adjustment and maintenance procedures for servicing all body styles.

  • Page 3: Vehicle Identification Number

    VEHICLE IDENTIFICATION NUMBER The vehicle identification number consists of 17 digits. 1. W.I.C. (World manufacturer's Identification Code) KMH - Hyundai Motor Company, Korea 2. Vehicle Line A : ATOS 3. Model & Series F : Standard (L) G : Deluxe (GL) H : Super deluxe (GLS) 4.

  • Page 4: Protection Of The Vehicle

    ENGINE IDENTIFICATION NUMBER LOCATION The engine identification number is stamped on the right front side of the top edge of the cylinder block. DESCRIPTION OF ENGINE IDENTIFICATION NUMBER The engine identification number consists of 11 digits. 1. Engine fuel G - Gasoline 2.

  • Page 5: A Word About Safety

    CAUTION The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine compartment to prevent the hood from falling and causing passible injury. Make sure that the support rod has been released prior to closing the hood. Always check to be sure the hood is firmly latched before driving the vehicle.
  • Page 6 1. Inspection of parts Each part, when removed, should be carefully inspected for malfunction, deformation, damage, and other problems. 2. Arrangement of parts All disassembled parts should be carefully arranged for effective reassembly. Be sure to separate and correctly identify the parts to be replaced from those that will be used again. 3.
  • Page 7 REPLACEMENT Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. If removed, the following parts should always be replaced with new ones. 1. Oil seals 2. Gaskets 3. O-rings 4. Lock washers 5.

  • Page 8: Electrical System

    ADJUSTMENT Use gauges and testers to adjust correctly the parts to standard values correctly. ELECTRICAL SYSTEM 1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery. 2. Never pull on the wires when disconnecting connectors. 3.
  • Page 9 MEASURING BODY DIMENSIONS 1. Basically, all measurements in this manual are taken with a tracking gauge. 2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending 3. For measuring dimensions, both projected dimensions and actual-measurement dimensions are used in this manual.

  • Page 10: Measurement Point

    MEASUREMENT POINT Measurements should be taken at the center of the hole. CHECKING CABLES AND WIRES 1. Check the terminal for tightness. 2. Check terminals and wires for corrosion from battery electrolyte, etc. 3. Check terminals and wires for open circuits. 4.

  • Page 11: Servicing The Electrical System

    SERVICING THE ELECTRICAL SYSTEM 1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable. NOTE In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble code retained by the computer will be cleared.
  • Page 12 4. If any section of a wiring harness interferes with the edge of a part, or a corner, wrap the section of the harness with tape or something similar in order to protect it from damage. 5. When installing any parts, be careful not to pinch or damage any of the wiring harnesses. 6.
  • Page 13 8. Loose connectors cause problems. Make sure that the connectors are always securely fastened. 9. When disconnecting a connector, be sure to grip only the connector, not the wires. 10. Disconnect connectors which have catches by pressing in the direction of the arrows shown the illustration. 12 ...
  • Page 14 11. Connect connectors which have catches by inserting the connectors until they make a clicking sound. 12. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the harness side. If the connector is a sealed connector, insert the test probe through the hole in the rubber cap until it contacts the terminal, being careful not to damage the insulation of the wires.

  • Page 15: Precautions For Catalytic Converter

    PRECAUTIONS FOR CATALYTIC CONVERTER CAUTION If a large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. 1. Use only unleaded gasoline. 2.
  • Page 16 CAUTION 1. Never use a jack beneath the lateral rod or rear suspension assembly. 2. In order to prevent scarring the sub frame, place a piece of cloth on the jack's contact surface (to prevent corrosion caused by damage to the coating). 3.
  • Page 17 TIGHTENING Torque Nm (kg.cm, Ib.ft) TORQUE TABLE OF STANDARD PARTS Pitch (mm) Head Mark 4 Head Mark 7 Bolt nominal diameter (mm) 3-4 (30-40, 2.2-2.9) 5-6 (50-60, 3.6-4.3) 5-6 (50-60, 3.6-4.3) 9-11 (90-110, 6.5-8.0) 1.25 12-15 (120-150, 9-11) 20-25 (200-250, 14.5-18.0) 1.25 25-30 (250-300, 18-22) 30-50 (300-500, 22-36)

  • Page 18: Recommended Lubricants

    Recommended Lubricants RECOMMENDED LUBRICANTS EATC0200 Parts Specifications Remarks Engine oil API Classification SE Above For further details, refer to SAE viscosity number Manual transaxle API classification GL-4 SAE grade number: SAE 75W/90 Automatic transaxle GENUINE HYUNDAI transaxle oil, GENUINE DIAMOND ATF SP-II Brake DOT 3 or DOT 4 Cooling system...

  • Page 19: Maintenance Information

    Maintenance Information MAINTENANCE EATC0300 CHANGING ENGINE OIL 1. If the engine is cold, run the engine until it reaches normal operating temperature. 2. Turn off the engine. 3. Remove the oil filler cap and drain plug. Drain the engine oil. 4.

  • Page 20: Replacing The Engine Oil Filter

    REPLACING THE ENGINE OIL FILTER 1. Use a filter wrench to remove the oil filter. 2. Before installing a new oil filter on the engine, apply clean engine oil to the surface of the rubber gasket. 3. Tighten the oil filter to the specified torque. Tightening torque Oil filter : 12 -16 N.m (120-160 kg.cm, 9-12 lb.ft) 4.

  • Page 21: Adjusting Belt Tension

    ADJUSTING BELT TENSION Refer to EM Sections. COOLING SYSTEM Check the cooling system for damaged hoses, loose or leaking connections, or other possible causes of coolant leaks. Antifreeze The engine cooling system is provided with a mixture of 50% ethylene glycol anti-freeze and 50% water (For the vehicles of tropical area, the engine cooling system is provided with a mixture of 40% ethylene glycol anti-freeze and 60% water at the time of manufacture.) Since the cylinder head and water pump body are made of aluminum alloy casting, be sure to use a 30 to 60%...
  • Page 22 Replacing the Coolant 1. Set the temperature control lever to the hot position. 2. Remove the radiator cap. CAUTION Remove the cap slowly. The system is pressurized and the coolant may be hot. Do not open the cap when the engine is hot. 3.
  • Page 23 MANUAL TRANSAXLE (Inspect oil level) Inspect for leakage in each component and check the oil level by removing the filler plug. If the oil is contaminated, replace it with new oil. 1. With the vehicle parked on a level surface, remove the filler plug and make sure that the oil level is the same level as the plug hole.

  • Page 24: Front Disc Brake Pads

    2. Check the steering linkage for looseness and damage Tie rod ends must not have excessive play. b. Dust seals and boots must not be damaged. Boot clamps must be not loose. POWER STEERING FLUID LEVEL (Inspect fluid level) 1. Park the vehicle on a level surface, start the engine, and then turn the steering wheel several times to raise the temperature of the fluid to approximately 50°C (122°F).
  • Page 25 NOTE If a squealing or scraping noise occurs from the brake during driving, check if the pad wear indicator is contacting the disc, if it is, the brake pad should be replaced. CAUTION The pads for the right and left wheels should be replaced at the same time. Never split or intermix brake pad sets.

  • Page 26: Checking The Brake Fluid Level

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

  • Page 27: Checking Tire Inflation Pressure

    6. Repeat these steps for the other cylinders. 7. Add fresh brake fluid up to the "MAX" level in the reserve tank. Brake fluid : DOT 3 or DOT4 CHECKING TIRE INFLATION PRESSURE Check the tire inflation pressures as follows. Tire inflation pressure (Check with Tires Cool) Tire size :155/70 R13, 175/60 R13...

  • Page 28: Engine Mechanical

    ENGINE MECHANICAL    GENERAL    ECTC0010 EPSILON ENGINE APPEARANCE       27   ...

  • Page 29: Engine Block

    Engine Block     CYLINDER BLOCK    ECTC0150   COMPONENTS           28   ...
  • Page 30 Main Moving System    COMPONENTS    ECTC0500         29   ...

  • Page 31: Cooling System

    Cooling System     COMPONENTS    ECTC1150         30   ...

  • Page 32: Lubrication System

    Lubrication System     COMPONENTS    ECTC1600     31   ...

  • Page 33: Intake And Exhaust System

    Intake And Exhaust System    COMPONENTS    ECTC1800         32   ...

  • Page 34: Cylinder Head Assembly

    Cylinder Head Assembly     COMPONENTS    ECTC2350     33   ...

  • Page 35: Timing System

    Timing System     COMPONENTS    ECTC2900     34   ...

  • Page 36: Engine Electrical System

    ENGINE ELECTRICAL SYSTEM  General  SPECIFICATIONS EBTC0010 IGNITION COIL Type Mold single coil Primary coil resistance 0.8 ± 0.08Ω Secondary coil resistance 12.1 ± 1.8kΩ   SPARK PLUG   Type UNLEADED BKR5ES-11 Champion RC9YC4, RC10YC4 Plug gap mm (in.) 1.0-1.1 (0.039-0.043)   STARTER MOTOR Type Direct drive type Rated output...
  • Page 37 BATTERY Type MF 40Ah Ampere hours (5HR) 30 Ah or more Ampere hours (20HR) 40 Ah or more Cold cranking [at -17.8°C (0°F)] 354A or more Reserve capacity 52 min. Specific gravity [at 25°C (77°F)] 1.280 ± 0.01 NOTE COLD CRANKING AMPERAGE is the amperage that the battery can delivery for 30 seconds and maintain a terminal voltage of 7.2 volts or greater at a specified temperature.

  • Page 38: Ignition System

    Ignition System  GENERAL INFORMATION EBDA0030 Ignition timing is controlled by the electronic control ignition timing system. The standard reference ignition timing data for the engine operation conditions are pre-programmed in the memory of the engine control module (ECM). The engine condition (speed, load, warm-up condition, etc.) are detected by various sensors. Based upon these sensor signals and the ignition timing data, signals to interrupt the primary current are sent to the ECM.

  • Page 39: Charging System

    Charging System  GENERAL INFORMATION EBDA0240 The charging system includes a battery, a generator with a built-in regulator, and the charging indicator light and wire. The generator has six built-in diodes (three positive and three negative), each rectifying an AC current to DC current.

  • Page 40: Starting System

    Starting System GENERAL INFORMATION EBDA0570 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. The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.

  • Page 41: Emission Control System

    EMISSION CONTROL SYSTEM  General  SPECIFICATIONS EETC0010 Components Function Remarks Crankcase Emission System HC reduction Positive crankcase ventilation (PCV) valve Variable flow rate type Evaporative Emission System HC reduction Evaporative emission canister EVAP Canister Purge Solenoid Valve Duty controlsolenoid valve Exhaust Emission System MFI system (air-fuel mixtrue control CO, HC, NOx reduction Heated oxygen sensor feedback...

  • Page 42: Crankcase Emission Control System

    Crankcase Emission Control System    CRANKCASE EMISSION SYSTEM    EETC0090     41   ...

  • Page 43: Evaporative Emission Control System

    Evaporative Emission Control System    EVAPORATIVE EMISSION SYSTEM    EETC0110       Exhaust Emission Control System     EXHAUST EMISSION CONTROL SYSTEM    EEDA0180 Exhaust emissions (CO,HC,NOx) are controlled by a combination of engine modifications and the addition of special  control components.   Modifications to the combustion chamber, intake manifold, camshaft and ignition system form the basic control  system.   These items have been integrated into a highly effec tive system which controls exhaust emissions while  maintaining good driveability and fuel economy.   42   ...

  • Page 44: Fuel System

    FUEL SYSTEM  General      SPECIFICATIONS    EFTC0010 Items   Specifications  Fuel tank     Capacity   35 lit. (9.2 U.S. gal., 7.7 lmp.gal.)  Fuel filter   High pressure type   Fuel pump   Electrical, in‐tank type     Throttle body     Throttle position sensor (TP Sensor)   Variable resister type   Resistance   0.7 ‐ 3.0 kΩ     Output voltage at curb idle   0.1 ‐ 0.875V   Input sensors     Manifold absolute pressure (MAP) sensor     Type   Piezo‐Resistivity type     Output voltage   0 ‐ 5V   Knock sensor   Piezoelectric type   Intake Air Temperature sensor (IAT Sensor)   Thermistor type     Resistance   2.0 ‐ 3.0 kΩ at 20°C (68°F)   EVAP Canister Purge solenoid valve   Duty type     Resistance   26Ω   Engine coolant temperature sensor (ECT Sensor) ...
  • Page 45   SERVICE STANDARD   Items   Standard value  Basic ignition timing   BTDC 8° ± 5°  Normal   850 ± 100  Electrical load   900 ± 100  Curb idle speed (rpm)   A/con ON   900 ± 100  Electrical load & A/con ON  1000 ± 100    SEALANT   Engine coolant temperature sensor assembly  LOCTITE 962T or equivalent  Engine coolant temperature sender   Three bond No.2310 or equivalent    TIGHTENING TORQUE   Items   Nm  Kg∙cm  lb∙ft  Delivery pipe installation bolts   10 ‐ 15  100 ‐ 150  7 ‐ 11  Heated oxygen sensor   50 ‐ 60  500 ‐ 600  37 ‐ 44  Crankshaft position sensor installation bolts  9 ‐ 11   90 ‐ 110 ...
  • Page 46 MFI Control System  LOCATION OF MFI COMPONENTS EFTC7010 45   ...
  • Page 47 46   ...
  • Page 48 [BOSCH ECU] 47   ...
  • Page 49 [HEI ECU] 48   ...

  • Page 50: Fuel Delivery System

    Fuel Delivery System    COMPONENTS    EFTC8090         49   ...

  • Page 51: Circuit Diagram

    Troubleshooting for DTC  DIAGNOSTIC ITEM EFTC5020 Diagnostic item P0105 Manifold Absolute Pressure Sensor Circuit Malfunction DESCRIPTION The MAP sensor is essentially a strain gauge used to measure the pressure in the surge tank. Inside the sensor is a metal diaphragm with a small wire attached. The diaphragm flexes according to changes in pressure. When the diaphragm flexes, the wire attached to it stretches, changing the resistance of the wire.
  • Page 52 TEST PROCEDURE 51   ...
  • Page 53 52   ...

  • Page 54: Clutch System

    CLUTCH SYSTEM General SPECIFICATIONS EOTC0010 Item Type Single dry with diaphragm Clutch disc Facing diameter (Outside x Inside) mm (in.) 170 x 125 (6.7 x 4.8) Type Diaphragm spring strap Clutch cover assembly Setting load N (lb) 2,300 - 2,600 (517-584) * I.D : Inside Diameter Clutch System  ...
  • Page 55 3. If the clutch pedal free play is not within the standard value range, turn and adjust the nut.   Clutch cable free play : 3‐4 mm         4. After completing the adjustments, check that the distance between the clutch pedal (the face of the pedal  pad) and the toeboard when the clutch is disengaged, are within the standard value ranges.   Standard value : 33 mm         54   ...
  • Page 56 TRANSAXLE/TRANSMISSION General Automatic Transaxle System SPECIFICATIONS(M/T) EMTC0010 Model M5EF1 Type Forward 5 speed, reverse 1 speed Gear ratio 1.0 MPI First 3.833 Second 2.105 Third 1.310 Fourth 0.919 Fifth 0.784 Reverse 4.000 Final 4.222   GENERAL INFORMATION    EKTC0040 This newly developed automatic transaxle is a light and compact transaxle for small vehicles and provides smooth  operation, swift driving, and improved fuel consumption. Its electronically‐controlled shift point and shift oil  pressure have resulted in delicate gear change control for various driving factors such as throttle position and  vehicle speed. Thus, smooth driving at all speeds has been realized.  ...
  • Page 57         56   ...

  • Page 58: Service Adjustment Procedures

    Manual Transaxle System SERVICE ADJUSTMENT PROCEDURES EMTC0070 TRANSAXLE GEAR OIL LEVEL INSPECTION(M/T) Inspect component for evidence of leakage. Check the gear oil level by removing the filler plug. If the oil is contanminated, it is necessary to replace it with new oil. 1.
  • Page 59 DRIVE SHAFT OIL SEAL REPLACEMENT 1. Disconnect the drive shaft form the transaxle. 2. Using a flat-tip screwdriver, remove the oil seal. 3. Apply a coating of gear oil to the lip of the oil seal. 4. Using the special tool (09431-32000), tap the drive shaft oil seal into the transaxle. 58 ...

  • Page 60: Speedometer Cable Replacement

    SPEEDOMETER CABLE REPLACEMENT 1. Correctly insert the adapter into the instrument panel, and fasten the new speedometer cable. 2. Install the grommet so the cable attachment part and the projecting part are horizontal, as shown in the illustration. CAUTION  The cable should be installed so that the radius of the cable bend is 150 mm (5.9 in.) or more. 3.
  • Page 61 DRIVE SHAFT AND AXLE  General  SPECIFICATIONS EITC0100 Driveshaft Joint type Outer B.J. B.J. Inner T.J. T.J. Length (Joint to joint) mm (in.) Left 380 (14.96) 349 (13.74) Right 593 (23.35) 623 (24.53) Maximum permissible joint angle B.J. 45.3° or more 45.3° or more T.J.
  • Page 62 Driveshaft    COMPONENTS    EITC0700           61   ...

  • Page 63: Front Axle

    Front Axle    COMPONENTS    EITC1500         62   ...
  • Page 64 Rear Axle    COMPONENTS    EITC2100         63   ...
  • Page 65 SUSPENSION  General    SPECIFICATIONS    EHTC0100     64   ...

  • Page 66: Front Suspension System

      Front Suspension System    COMPONENTS    EHTC0700       65   ...

  • Page 67: Rear Suspension System

    Rear Suspension System     COMPONENTS    EHTC2300     66   ...
  • Page 68 SERVICE ADJUSTMENT PROCEDURES FRONT WHEEL ALIGNMENT EHTC2800 When using a wheel alignment tester to inspect front wheel alignment, always position the car on a level surface and the front wheels in the straight ahead position. Prior to inspection make sure that the front suspension and steering system are in normal operating condition and that wheels and tires are free of deflection and tires are inflated to specification.
  • Page 69 CAMBER The steering knuckle which is integral with the strut assembly is pre-adjusted to the specified camber at the factory and requires no adjustment. Standard value Camber General suspension : 32′ ± 30′ High suspension : 34′ ± 30′ CASTER Caster is pre-set at the factory and can not be adjusted.

  • Page 70: Steering System

    STEERING SYSTEM  General  SPECIFICATIONS EPTC0100 MANUAL STEERING Specifications Items Steering wheel diameter (Outer) 370 ± 2mm Steering gear type Rack and pinion Pinion tooth Rack stroke 136 ± 1.5mm POWER STEERING Specifications Items Steering gear type Rack and pinion Rack stroke 136 ±...

  • Page 71: Manual Steering System

    Manual Steering System  SERVICE ADJUSTMENT PROCEDURE EPTC0700 CHECKING STEERING WHEEL FREE PLAY 1. Place the steering wheel in the straight ahead position. 2. Measure the steering wheel free play by turning the steering wheel left and right. Limit Steering wheel free play : 0-30 mm 3.
  • Page 72 Mechanical Power Steering System  CHECKING STEERING WHEEL FREE PLAY EPTC1000 1. Start the engine with the steering wheel in the straight ahead position. 2. Measure the play while turning the steering wheel to the left and right Limit Steering wheel free play : 0-30 mm 3.
  • Page 73   SRSCM (Supplemental Restraints System Control  Module)  INFLATOR MODULE (DAB, PAB) ERTC0070 DAB (Driver airbag), PAB (Passenger airbag) module all consist of an inflator and cushion. The initiator (a gas generator igniting device) is port of the inflator. When the vehicle is in a frontal or side crash of sufficient force to close the sensor of the SRSCM, current flows through the deployment loop.
  • Page 74 Air Bag Module (Drive Side) And Clock Spring    COMPONENTS    ERDA0160                 73   ...
  • Page 75 Air Bag Module (Passenger Side)    REMOVAL ERKB0250 NOTE 1. Never attempt to disassemble or repair the airbag module. 2. Do not drop the airbag module or allow contact with water, grease or oil. Replace it if a dent, crack, deformation or rust are detected. 3.

  • Page 76: Airbag Module Disposal

    Troubleshooting  DIAGNOSIS WITH SCAN TOOL ERFB0100 CHECK PROCEDURES ERFB0100 1. Connect the Hi-Scan Pro DLC to the vehicle's data link connector located underneath the dash panel. 2. Turn the ignition key to the "ON" position and turn the Hi-Scan Pro ON. 3.

  • Page 77: Brake System

    PAB : 0957A-38100 DISPOSAL PLAN Take the following disposal steps. CASE DISPOSAL PLAN Abnormal problems in airbag module Deploy and discard Car scrapping DAB, PAB Deploy the airbag module with the SST Crash (Deployed) Discard     BRAKE SYSTEM  General  SPECIFICATIONS EJTC0010 Master cylinder Type...
  • Page 78 Pad thickness 10 mm (0.39 in.) Pad effective thickness 8 mm (3.15 in.) Cylinder I.D. 51.1 mm (2.01 in.) Rear brake Type Leading trailing drum Drum I.D. 180 mm (7.09 in.) Brake lining thickness-Leading 4.6 mm (0.181 in.) Brake lining thickness-Trailing 4.6 mm (0.181 in.) Cylinder I.D.

  • Page 79: Parking Brake System

    Parking Brake System      components    EJTC0360       ABS (Anti‐Lock Brake System)  SPECIFICATION (ABS) EJTC5010 Part Item Standard value Remarks Operating voltage 10V - 16V ABS, EBD Integrated control unit Operating temp -40° - 110°C Warning Lamp Operating voltage BRAKE : Parking, Brake oil, EBD fail BRAKE (EBD) Consumption current...
  • Page 80 Motor power 108W LPA : Low Pressure Accumulator Pump capacity 5.5cc/sec HPA : High Pressure Accumulator Accumulator amount LPA:2.1cc, HPA : 6cc Valve 6Ω (at 20°C) Operating voltage :   BODY (INTERIOR/EXTERIOR)  General  SPECIFICATIONS ESTC0010 Hood Type Rear hinged, front opening type Front door Construction Front hinged, full door construction...
  • Page 81 Exterior      COMPONENTS    ESTC0100         80   ...
  • Page 82 Interior    COMPONENTS    ESTC0650           81   ...
  • Page 83 Bumper    COMPONENTS    ESTC1200         82   ...
  • Page 84 Seat    COMPONENTS    ESTC1400         83   ...
  • Page 85             84   ...

  • Page 86: Body Electrical System

    BODY ELECTRICAL SYSTEM  General  SPECIFICATIONS ETTC0050 MULTIFUNCTION SWITCH Specifications Items Rated Voltage DC 12V Operating temperature range -30°C - +80°C (-22 - +176°F) Rated load Dimmer & passing switch High : 121.4W (Lamp load) Low : 110W (Lamp load) Passing : 121.4W (Lamp load) Lighting switch Lighting : 121.4W (Lamp load) Tail : 40W (Lamp load)

  • Page 87: Audio System

    Audio System    COMPONENTS    ETTC0200           86   ...

  • Page 88: Multifunction Switch

    Multi Function Switch    COMPONENTS    ETTC0450       87   ...
  • Page 89           88   ...

  • Page 90: Keyless Entry System

    Horns  REMOVAL AND INSTALLATION ETCC0600 1. Remove the bolt holding the horn and remove the horn assembly. 2. Installation is the reverse of removal. Keyless Entry System  DESCRIPTION ETTC0650 The keyless entry system consists of transmitter, receiver and some other parts. The keyless entry system is able to lock and unlock all the doors at a distance, transmitting a weak radio wave from a transmitter.

  • Page 91: Fuses And Relays

    Fuses And Relays    SPECIFICATIONS    ETTC0850         90   ...
  • Page 92 Indicators And Gauges    COMPONENTS    ETTC0950           91   ...

  • Page 93: Power Door Locks

    Power Door Locks    COMPONENTS    ETTC1150         92   ...

  • Page 94: Power Windows

    Power Windows    COMPONENTS    ETTC1250           93   ...

  • Page 95: Rear Window Defogger

    Rear Window Defogger  INSPECTION ETA91650 CAUTION 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 96 3. If a heater line is burned out between the center point and (-) terminal, the voltmeter will indicate 0V. 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.
  • Page 97 5. Thin brush. Wipe the glass adjacent to the broken heater line, clean with silicone remover and attach the masking tape as shown. Shake the conductive paint container well, and apply three coats with a brush at intervals of about 15 minutes apart. Remove the tape and allow sufficient time for drying before applying power. For a better finish, scrape away excess deposits with a knife after the paint has completely dried.

  • Page 98: Windshield Wiper/Washer

    Windshield Wiper/Washer    COMPONENTS    ETTC1450             97   ...

  • Page 99: Rear Wiper/Washer

    Rear Wiper/Washer    COMPONENTS    ETTC1850           98   ...

  • Page 100: Seat Warmer

    Seat Warmer  INSPECTION ETTC1950 1. Disconnect the negative(-) battery terminal. 2. Remove the seat warmer switch from the floor console upper cover. 3. Check for continuity between the terminals.       99   ...
  • Page 101 Shift And Key Lock Control System  COMPONENTS ETTC2000 A. A/T INTERLOCK CONTROL MODULE B. A/T SHIFT LOCK SOLENOID C. KEY INTERLOCK SOLENOID D. “P” POSITION SWITCH   100   ...

  • Page 102: Lighting System

    Lighting System  REMOVAL AND INSTALLATION ETTC2250 HEAD LAMP / TURN SIGNAL LAMP 1. Disconnect the battery negative terminal and loosen the head lamp mounting bolts. 2. Disconnect the head lamp connector. 3. Installation is the reverse of removal. CAUTION Do not touch the surface of the bulb with hands or dirty gloves. If the surface does become dirty, clean it with alchol or thinner, and let it dry thoroughly before installing.
  • Page 103 ROOM LAMP 1. Disconnect the battery negative terminal and detach the room lamp lens. 2. Loosen the room lamp mounting screws and disconnect the connector. 3. Installation is the reverse of removal. FOG LAMP 1. Remove the wheel cover. 2. Remove the fog lamp mounting screws. 3.

  • Page 104: Daytime Running Lights

    Daytime Running Lights    CIRCUIT DIAGRAM    ETTC2400         103   ...
  • Page 105 Head Lamp Levelling Device    CIRCUIT DIAGRAM    ETTC2500         104   ...

  • Page 106: Immobilizer Control System

    Immobilizer Control System  GENERAL ETTC2600 The immobilizer system consists of a passive challenge-response (mutual authentication) transponder inside the key head and the SMARTRA (SMARt TRansponder Antenna) unit. The SMARTRA unit contains an integrated inductive antenna and electronics. The SMARTRA communicates to the ECM (Engine Control Module) via a dedicated communications line.
  • Page 107 COMPONENT A. TRANSPONDER KEY B. IMMOBILIZER ANTENNA UNIT (SMARTRA) C. ENGINE CONTROL MODULE DESCRIPTION The vehicle immobilizer system consists of the ECM, the SMARTRA and ignition keys with built-in TRANSPONDER. COMPONENT DESCRIPTION The ECM carries out a check of the ignition key using a special encryption algorithm, which is programmed into the transponder as well as the ECM simultaneously.

  • Page 108: Teaching Procedures

    TEACHING PROCEDURES 1. Key Teaching Procedure Key teaching must be done after replacing a defective ECM or when providing additional keys to the vehicle owner. The procedure starts with an ECM request for vehicle specific data from the tester. The “virgin” ECM stores the vehicle specific data and the key teaching can be started.
  • Page 109 LIMP HOME FUNCTION 1. By tester If the ECM detects the fault of the SMARTRA or transponder, the ECM will allow limp home function of the immobilizer. Limp home is only possible if the user password (4 digits) has been given to the ECM before. This password can be selected by the vehicle owner and is programmed at the service station.
  • Page 110 2. By ignition key The limp home can be activated also by the ignition key. The user password can be input to the ECM by a special sequence of ignition on/off. Only if the ECM is in status “learnt” and the user password status is “learnt” and the user password is correct, will the ECM be unlocked for a period of time (30 sec.).

  • Page 111: Air Conditioning System

    The teaching of keys follows the procedure described for the virgin ECM. The vehicle specific data have to be unchanged due to the unique programming of the transponder. If data should be changed, new keys with a virgin transponder are requested.  ...
  • Page 112 Air Conditioning System  INSTRUCTIONS EQTC0110 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. If the refrigerant splashes into your eyes, wash them with clean water immediately. It is standard practice to wear goggles or glasses to protect your eyes, and gloves to protect your hands.
  • Page 113 5. Because of the differences in the physical properties and characteristics between the R12 and R134a refrigerants, the compressor oil for lubricating the air compressor and other system parts are not interchangeable between the R12 and R134a system. Use the utmost care to avoid using the wrong one. The compressor oils and some other materials are not visually distinguishable.
  • Page 114 Manual A/C Compressor Controls    COMPONENTS    EQTC0370           113   ...

  • Page 115: Vacuum System

    Vacuum System       EQTC0040           114   ...
  • Page 116 Heater    COMPONENTS    EQTC0050     115   ...

  • Page 117: Schematic Diagram

    ELECTRICAL TRHOUBLESHOOT  [General] INTRODUCTION E1KB0010 This Manual consists of five major diagnostic sections for electrical problem troubleshooting. Schematic diagrams Component location indexes Component locations Connector configurations Harness layouts SCHEMATIC DIAGRAM The starting point of each system section is the schematic diagram. These diagrams show how all the components work together, such as electrical current paths from power source to ground (via electrical load), switch connections at each position, and other related circuit functions.
  • Page 118 COMPONENT LOCATION INDEXES When you want to locate the schematic components on the vehicle, use the Component Location Index which follows each schematic. A Component Location Index lists major components, connectors, grounds, diodes, and their physical location and page reference. Almost all components, connectors or grounds, and diodes shown on a schematic can be pinpointed visually by using the Component Location Illustrations.

  • Page 119: Component Locations

    COMPONENT LOCATIONS Component Locations make it easy to find the schematic components on the vehicle shown in the Component Location Index. CONNECTOR CONFIGURATIONS This section shows the cavity or terminal locations in all the multi-pin connectors shown in the schematic diagrams. It will help you to locate check points, together with the wire colors and terminal numbers in the schematic.
  • Page 120 CONNECTOR VIEW AND NUMBERING ORDER 1. CONNECTOR VIEW Female Male Remarks Actual It is not the shape of the connector Illustration housing, but the connector pin that distinguishes between male or female connectors. When numbering female and male connectors, refer to the numbering order in the following table.
  • Page 121     120   ...
  • Page 122 [Schematic Diagram]    FUSE & RELAY INFORMATION    E21C0010 PASSENGER COMPARTMENT RELAY & FUSE BOX   LAYOUT         CIRCUIT Fuse Amperages Circuit Horn Power window 10A/15A Left head lamp, rear fog lamp, DRL control Right head lamp, DRL control Blower, rear window defogger Wiper, washer Power door lock, door warning control Hazard warning, data link connector Stop lamp, shif &...
  • Page 123 ENGINE COMPARTMENT RELAY & FUSE BOX LAYOUT FUSE & RELAY INFORMATION Description Amperages Circuit protected Remark Fusible link Generator ABS control Blower control Ignition power source Battery power source H/LP Lamps ABS control Radiator fan control Fuse A/CON A/CON controls LH LP Left tail lamps RH LP...
  • Page 124 [Component Location]  MAIN HARNESS E31B0010 MAIN HARNESS (1) M01, M02, M05, M06 M09, M10 M11–1, M11–3, M11–4 M11–2, M13 123   ...

  • Page 125: Main Harness

    MAIN HARNESS (2) M15-1,M15-2,M15-3,M15-4 M23,M32-1,M32-2 M16,M18 M26,M27,M28,M29,M30,M32-1,M32-2 M20-1,M20-2,M20-3 124   ...
  • Page 126 MAIN HARNESS (3) 125   ...
  • Page 127 MAIN HARNESS (4) M41, M42 M37, M38 126   ...
  • Page 128 MAIN HARNESS (5) M50, M51 MC01 127   ...
  • Page 129 MAIN HARNESS (6) MC02 MI01, MI02, MI03 MD01, MD02 MM01 MD03, MD04 MR01   [Connector Configurations]  128   ...
  • Page 130 MAIN HARNESS E41C0010 MAIN HARNESS (1) M11–1 M11–2 M11–3 M11–4 BLANK 129   ...
  • Page 131 MAIN HARNESS (2) BLANK BLANK 130   ...
  • Page 132 MAIN HARNESS (3) BLANK BLANK MC01 MC02 BLANK MD01 BLANK 131   ...
  • Page 133 MAIN HARNESS (4) MD02 MD03 MD04 MI01 BLANK MI02 MI03 MM01 MR01         132   ...
  • Page 134 [Harness Layouts]  MAIN HARNESS E51C0010 MAIN HARNESS (1) 133   ...
  • Page 135 Flasher unit Luggage room lamp EBD relay Left rear combination lamp Blower relay SRS control module (DAB+PAB) Rear defogger relay SRS control module (DAB) Horn relay Steering wheel (Contact coil) ABS relay Passenger air bag Right side repeater lamp Left rear door switch Thermostatic switch Right rear door switch Blower motor...
  • Page 136   135   ...

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