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Kia SOUL 2010 Manual

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SOUL(AM) > 2010 > G 1.6 DOHC > General Information

General Information > General Information > General Information

Identification Number Locations

Identification Number Description

Vehicle Identification Number

Table of Contents

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Table of Contents

Troubleshooting

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Page 1 Page 1 of 22 SOUL(AM) > 2010 > G 1.6 DOHC > General Information General Information > General Information > General Information Identification Number Locations Identification Number Description Vehicle Identification Number...
Page 2 Page 2 of 22 1. World Manufacturer Identifier (WMI) - KNA : Passenger vehicle, MPV(Multipurpose Passenger Vehicle)/SUV(Sports Utility Vehicle)/RV(Recreational Vehicle) - KNC : Commercial vehicle (Van) - KND: MPV/SUV/RV (For U.S.A, Canada, Mexico) - KNH: Van 2. Vehicle line - J : SOUL 3.
Page 3 Page 3 of 22 - 1 : Wagon 4×2 Class-A - 2 : Wagon 4×2 Class-B - 3 : Wagon 4×2 Class-C - 4 : Wagon 4×2 Class-D - 5 : Wagon 4×2 Class-E - 6 : Wagon 4×2 Class-F - 7 : Wagon 4×2 Class-G - A : Wagon 4×4 Class-A - B : Wagon 4×4 Class-B...
Page 4 Page 4 of 22 6. Engine type - 1 : Gasoline engine 1.6 - 2 : Gasoline engine 2.0 7. Check digit or Driver’s side & Transmission Except U.S.A, Canada, Mexico, Gulf Cooperation Council, China, Yemen - A : LHD & MT - B : LHD &...
Page 5 Page 5 of 22 1. Engine fuel - G : Gasoline 2. Engine range - 4 : 4 cycle 4 cylinder 3 - 4. Engine development order and capacity - FC : Gamma engine, 1592 cc - GC : Beta - engine, 1975 cc 5.
Page 6 Page 6 of 22 6. Gear ratio A. F : 4.267 B. E : 4.188 7. Transaxle production sequence number - 000001 ~ 999999 Automatic 1. Model A. A : A4CF1 B. B : A4CF2 2. Production year - 9 : 2009, A : 2010, B : 2011, C : 2012, D : 2013... 3.
Page 7 Page 7 of 22 1. Coolant level 4. Battery caution caution 5. Air cleaner caution 2. Fan caution 3. Radiator cap caution Battery Caution Label Describtion...
Page 8 Page 8 of 22 WARNING / CAUTION LABEL (CONT'D) Keep lighted cigarettes and all other flames or sparks away from the battery. Wear eye protection when charging or working near a battery. Always provide ventilation when working in an enclosed space. •...
Page 9 Page 9 of 22 An improperly disposed battery can be harmful to the environment and human health. Always confirm local regurations for battery disposal. Handling And Storage The Battery Battery Itself • Batteries should be stored in cool, dry (27 degrees Celsius) places and out of direct sunlight.
Page 10 Page 10 of 22 Towing If the vehicle needs to be towed, call a professional towing service. Never tow vehicle with just a rope or chain. It is very dangerous. Emergency Towing...
Page 11 Page 11 of 22 There are three popular methods of towing a vehicle : - The operator loads the vehicle on the back of truck. This is best way of transporting the vehicle. - The tow truck uses two pivoting arms that go under the tires of the driving axle and lift them off the ground. The other two wheels remain on the ground.
Page 12 Page 12 of 22 1.25 35 ~ 45 (350 ~ 450, 25 ~ 60 ~ 80 (600 ~ 800, 43 ~ 75 ~ 85 (750 ~ 850, 54 ~ 120 ~ 140 (1,200 ~ 1,400, 85 ~ 100) 110 ~ 130 (1,100 ~ 1,300, 180 ~ 210 (1,800 ~ 2,100, 80 ~ 94) 130 ~ 150)
Page 13 Page 13 of 22 Removal Of Parts First find the cause of the problem and then determine whether removal or disassembly before starting the job. Disassembly If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will not affect their performance or external appearance.
Page 14 All parts to be used again should be carefully and thoroughly cleaned by an appropriate method. Parts When replacing parts, use KIA genuine parts. Replacement Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
Page 15 Page 15 of 22 3. O-rings 4. Lock washers 5. Cotter pins (split pins) 6. Plastic nuts Depending on their location. 7. Sealant should be applied to gaskets. 8. Oil should be applied to the moving components of parts. 9. Specified oil or grease should be applied to the prescribed locations (oil seals, etc) before assembly. Adjustment Use gauges and testers to adjust correctly the parts to standard values correctly.
Page 16 Page 16 of 22 Measuring Body Dimensiongs 1. Basically, all measurements in this manual are taken with a tracking gauge. 2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending. 3. For measuring dimensions, both projected dimensions and actual - measurement dimensions are used in this manual.
Page 17 Page 17 of 22 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 18 Page 18 of 22 Serivicing The Electrical System 1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable. In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble code retained by the computer will be cleared.
Page 19 Page 19 of 22 3. If any section of a wiring harness interferes with the edge of a parts, or a corner, wrap the section of the harness with tape or something similar in order to protect if from damage. 4.
Page 20 Page 20 of 22 7. Loose connectors cause problems. Make sure that the connectors are always securely fastened. 8. When disconnecting a connector, be sure to grip only the connector, not the wires. 9. Disconnect connector which have catches by pressing in the direction of the arrows shown the illustration.
Page 21 Page 21 of 22 10. Connect connectors which have catches by inserting the connectors until they make a clicking sound. 11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the harness side.
Page 22 Page 22 of 22 If a large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To prevent this observe the following precations and explain them to your customer. 1. Use only unleaded gasoline. 2.
Page 23 Page 1 of 52 SOUL(AM) > 2010 > G 1.6 DOHC > Automatic Transaxle System Automatic Transaxle System > General Information > Specifications Specifications Transaxle model A4CF1 Engine model Gasoline 1.6L T/con 3 elements 2 phases 1 stage T/con size (Φ) O/PUMP type Parachoid T/M CASE type...
Page 24 Page 2 of 52 Item kgf.m lb-ft Shift cable bracket 15~22 1.5~2.2 10.8~15.9 Input shaft speed sensor 10~12 1.0~1.2 7.2~8.6 Output shaft speed sensor 10~12 1.0~1.2 7.2~8.6 Manual control lever 17~21 1.7~2.1 12.3~15.2 Inhibitor switch 10~12 1.0~1.2 7.2~8.6 Oil pan 10~12 1.0~1.2 7.2~8.6 Oil drain plug...
Page 25 Page 3 of 52 Tool Illustration (Number and name) 09200-38001 Removal and installation of the Engine support fixture transaxle. 09624-38000 Supporting of the crossmember. Crossmember supporter Automatic Transaxle System > Automatic Transaxle System > Description and Operation Description The new small sized automatic transaxle (A4CF1) is for gasoline 1.6 engine. The transaxle (A4CF1) has improved on the durability, fuel consumption and efficiency by the new main features as follows: The new main features...
Page 26 Page 4 of 52 Item Contents Components The full line pressure variable control operates in the valve body to improve the fuel consumption. The long travel damper clutch is applied to the torque converter to improve the engine revolution change reduction capability and the fuel consumption. (17~20°) The oil pump of the trochocentric type is changed to parachoid type to improve the processing and the capacity efficiency at the low RPM range.
Page 27 Page 5 of 52 Oil Pump The oil pump is made of aluminum (the reaction shaft support) to reduce weight and selects the parachoid type to improve the processing and the capacity efficiency at the low RPM range. Brakes The automatic transaxle (A4CF1) uses the low and reverse brake and the second brake. The low and reverse brake is fixed by the low and reverse annulus gear and overdrive planetary carrier.
Page 28: Underdrive Clutch
Page 6 of 52 Clutch The multiple clutches and the one way clutch are used as the transaxle device. The retainer of each clutch is composed of precision sheet metal parts for productivity and the light weight. The hydraulic centrifugal oil pressure balance device resides inside the clutch assembly. Generally, the oil remaining in the piston oil pressure chamber pushes the piston by the centrifugal force.
Page 29 Page 7 of 52 The driving force of input shaft is delivered to the underdrive sun gear. The operating oil pressure in the underdrive clutch components operates between the piston and the retainer and pushes the piston to the clutch discs to deliver the driving force from the retainer to the hub. 2.
Page 30 Page 8 of 52 1. Snap ring 8. Clutch plate 15. Reverse clutch piston 2. Clutch reaction plate 9. Snap ring 16. D-ring 3. Clutch disc 10. Spring retainer 17. D-ring 4. Clutch plate 11. Return spring 18. D-ring 5. Snap ring 12.
Page 31: Main Features
Page 9 of 52 Operation Hydraulic Control System Main Features The VFS (Variable Force Solenoid) installed in the valve body is applied to transaxle. VFS varies the line pressure from 4.5bar to 10.5bar according to throttle open angle and shift range to improve the fuel consumption and shift ability.
Page 32 Page 10 of 52 Sensor And Actuator Function Item Function Input speed sensor Detect the input shaft rpm(TURBINE RPM) at the OD/RVS retainer Output speed sensor Detect the output shaft rpm(T/F DRIVEN GEAR RPM) at the T/F driven gear Engine rpm signal Receive the engine rpm via CAN communication with ECM Fluid temperature sensor Detect the temperature of ATF through the thermistor...
Page 33 Page 11 of 52 ECM- TCM CAN Communication error management Item Error management Engine rpm 3,000 RPM Engine torque Vehicle speed 0 km/h A/C Switch Engine coolant 70°C temperature Shift range hold signal Automatic Transaxle System > Automatic Transaxle System > Repair procedures Basic Inspection Adjustment Transaxle Fluid Level Inspection...
Page 34 Page 12 of 52 5. Check that the fluid level is in the "HOT" mark on the oil level gauge. If fluid level is low, add automatic transaxle fluid until the level reaches the "HOT" mark. Automatic transaxle fluid : DIAMOND ATF SP-III, SK ATF SP-III Automatic transaxle fluid capacity: 6.8liter(7.2 US qt, 5.98lmp.qt)
Page 35 Page 13 of 52 4. Install the drain plug via the gasket, and tighten it the specified torque. Tightening torque : 40~50 Nm (4.0~5.0kgf.m, 28.9~36.2lb-ft) 5. Pour the new fluid in through the oil filler tube. Stop pouring if the full volume of fluid cannot be poured 6.
Page 36 Page 14 of 52 5. Move the select lever to the "D" position, fully depress the accelerator pedal and take a reading of the maximum engine speed at this time. • The throttle should not be left fully open for any more than 5 seconds. •...
Page 37 Page 15 of 52 1. RED pressure 5. DA pressure port port 6. UD pressure port 2. OD pressure port 7. LR pressure port 3. 2/4 pressure port 8. DR pressure port 4. REV pressure port Standard Hydraulic Pressure Table...
Page 38 Page 16 of 52 Automatic Transaxle System > Automatic Transaxle System > Troubleshooting Troubleshooting Diagnostic Trouble Codes (Inspection Procedure) Check the Diagnostic Trouble Codes 1. Turn the ignition switch to OFF. 2. Connect the Hi-scan tool or GDS to the DLC connector for diagnosis. 3.
Page 39 Page 17 of 52 5. Read the output diagnostic trouble codes. Then follow the repair procedures according to the "DIAGNOSTIC TROUBLE CODE DESCRIPTION" on the following pages. Write down the codes and any freeze frame data which show the parameters or conditions of when the code was set. •...
Page 40 Page 18 of 52 19 U0001 High Speed CAN Communication Bus off ● 20 U0100 Lost Communication With ECM/PCM 'A' Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Components and Components Location Components (1)
Page 41 Page 19 of 52 1. Torque converter 13. Parking sprag 25. Accumulator piston 2. Differential oil seal 14. Detent spring 26. Coil spring 3. Converter housing 15. Manual control shaft 27. O-ring 4. Oil pump 16. Spacer 28. Oil filter 5.
Page 42 Page 20 of 52 38. Low & reverse brake piston 49. 2ND brake plate 59. Reverse sun gear 39. 2ND brake return spring 50. 2ND brake disc 60. Thrust bearing 40. Low & reverse brake spring 51. 2ND brake pressure plate 61.
Page 43 Page 21 of 52 3. Remove the battery tray (A). 4. Disconnect the inhibiter switch connector (A), solenoid valve connector (B) and the input speed sensor connector (C). 5. Remove the shift cable assembly (A). 6. Remove the ground cable (A) by removing a bolt.
Page 44 Page 22 of 52 7. Disconnect the output speed sensor connector (A). 8. Remove the oil cooler hoses by moving clamps (A). 9. Install the special tools (09200-38001), the engine support fixture and the adapter on the engine assembly. 10. Remove the transaxle support bracket bolts(3ea).
Page 45 Page 23 of 52 11. Remove the transaxle upper mounting bolts (A-2ea) and the starter motor mounting bolts (B-2ea). 12. Remove the under shield covers(A). 13. Remove the side mud cover (A). 14. Drain the transalxe fluid by removing the drain plug (A).
Page 46 Page 24 of 52 15. Remove the bracket (A). 16. Disconnect the drive shafts from the transaxle. (refer to Front Driveshaft in DS group) 17. Remove the plastic dust cover (A). 18. Remove the torque converter mounting bolts(A-3ea) by rotating the crankshaft. 19.
Page 47 Page 25 of 52 20. Supporting the transaxle with a jack, remove the transaxle lower mounting bolts (A-3ea, B-2ea). 21. Lowering the jack slowly, remove the transaxle. When removing the transaxle assembly, be careful not to damage any surrounding parts or body components.
Page 48 Page 26 of 52 3. Install the roll stopper bracket(A). 4. Install the torque converter assembly mounting bolts (A-3ea). Tightening torque : 46~53 Nm (4.6~5.3 kgf.m, 33.3~38.3 lb-ft) 5. Install the plastic dust cover (A). 6. Connect the drive shafts to the transaxle. (refer to Front Driveshaft in DS group) 7.
Page 49 Page 27 of 52 8. Install the side mud cover (A). 9. Install the under shield covers(A). 10. Install the transaxle upper mounting bolts (A-2ea) the starter motor mounting bolts (B-2ea). Tightening torque : [A] 60~80 Nm (6.0~8.0 kgf.m, 43.4~57.9 lb-ft) [B] 43~55 Nm (4.3~5.5 kgf.m, 31.1~39.8 lb-ft)
Page 50 Page 28 of 52 11. Install the transaxle insulator mounting bracket bolts(3ea). Tightening torque : 90~110 Nm (9~11 kgf.m, 65~79 lb-ft) 12. Remove the special tool (09200-38001). 13. Connect the transaxle oil cooler hoses (A) to the tubes by fastening the clamps. 14.
Page 51 Page 29 of 52 15. Install the ground cable (A) to transaxle. 16. Install the shift cable assembly (A). Tightening torque : 10~14Nm (1.0~1.4kgf.m, 7.2~10.1lb-ft) 17. Connect the inhibiter switch connector (A), solenoid valve connector (B) and the input speed sensor connector(C).
Page 52 Page 30 of 52 19. After installiing the battery (B), install the PCM (A). 20. Connect the air duct (A). 21. After completing the installation perform the following procedure; A. Adjust the shift cable. B. Refill the transaxle fluid. C. Clean the battery posts and cable terminals with sandpaper and grease them to prevent corrosion before installing.
Page 53 Page 31 of 52 ● PWM (Pulse Width Modulation) Solenoid Valve Structure and functions PWM solenoid valve is composed of five solenoid valves and the oil capacity in the solenoid valve is changed by the electric duty value of TCM. The oil pressure of the valve body and the torque converter engages or disengages the damper clutch.
Page 54 Page 32 of 52 PWM (Pulse Width Modulation) Solenoid Valve Control Feature PWM solenoid valve is controlled linearly according to the duty ratio. Oil pressure range: 0~4.3 kgf/cm² (0~422kpa, 0~61.2psi) Type 3way & Normal High Input voltage Coil 3.2±0.2Ω (at 25°C, 77°F) resistance Cycle 50Hz...
Page 55 Page 33 of 52 5. Remove the oil pan. (Refer to Automatic transaxle's disassembly in overhaul manual) 6. Remove the oil filter. 7. Remove the valve body. (Refer to Valve body's disassembly in overhaul manual) 8. Disconnect the main harness(A) from valve body. 9.
Page 56 Page 34 of 52 5. Continue to apply liquid gasket at application points at the oil pan with Ø2.5mm (0.098in) thickness. Liquid gasket Part name : Threebond 1281B 6. Tighten the mounting bolt with the specified torque after installing the oil pan. Tightening torque : 10~12Nm(1.0~1.2kgf.m, 7~8lb-ft) 7.
Page 57 Page 35 of 52 PWM solenoid valve is linear controlled according to the current value. type 3way & Normal High Input voltage Coil resistance 3.5±0.2Ω(at 25°C, 77°F) Operating current 0 ~ 1200 mA Automatic Transaxle System > Valve Body System > VFS(Variable Force Solenoid) Valve > Repair procedures (A4CF2) Removal 1.
Page 58 Page 36 of 52 1. Install the solenoid valve (B). Apply the ATF oil or White Vaseline to the O-ring not to be damaged. 2. Connect the solenoid valve connector (A). When connecting the solenoid valve connector, check the connector for rust, dirt, or oil, then reconnect it.
Page 59 Page 37 of 52 6. Tighten the mounting bolt with the specified torque after installing the oil pan. Tightening torque : 10~12Nm(1.0~1.2kgf.m, 7~8lb-ft) 7. Install the drain plug. Tightening torque : 40~50Nm(4.0~5.0kgf.m, 28.9~36.2lb-ft) 8. Installation is the reverse of the removal. Automatic Transaxle System >...
Page 60 Page 38 of 52 1. Shift lever knob 4. Shift lock cably 2. Shift lever assembly assembly 3. Control cable assembly 5. Retainer 6. Brake pedal assembly Automatic Transaxle System > Automatic Transaxle Control System > Shift Lever > Repair procedures Removal 1.
Page 61 Page 39 of 52 7. Remove the shift lock cable mounting nut (B). 8. Remove the shift lever assembly by removing the bolts(4ea). 9. Remove the retainer (A) and nuts (B). 10. Remove the shift cable assembly from the transaxle. (refer to Automatic transaxle’s removal) 11.
Page 62 Page 40 of 52 3. Check the boots for wear, abrasion, sticking, restricted movement or damage if boots are applied. 4. Check for the weak or damaged spring. Adjustment Adjusting the shift cable 1. Set the room side lever and the manual lever (A) to N position. 2.
Page 63 Page 41 of 52 3. Install the shift lever assembly (A). Tightening torque : 10~14Nm (1.0~1.4kgf.m, 7.2~10.1lb-ft) 4. Install the shift lock cable mounting nut (B). 5. Install the shift lock cable (A). 6. Install the shift cabble holder. 7. Insert the cotter pin (A) from the shift cable.
Page 64 Page 42 of 52 8. Connect the connector (A). 9. Install the center console. (refer to Console in BD group) 10. Install the center console cover (A). Automatic Transaxle System > Automatic Transaxle Control System > Input Speed Sensor > Description and Operation (A4CF2) Description 1.
Page 65 Page 43 of 52 Item Inspection item Standard value Air gap Input speed sensor 0.035in(0.9mm) Sensor Input speed sensor Over 1 MΩ resistance HIGH Over 4.8V Output voltage Below 0.8V Automatic Transaxle System > Automatic Transaxle Control System > Input Speed Sensor > Repair procedures (A4CF2) Removal 1.
Page 66 Page 44 of 52 6. Remove the input speed sensor(A). Installation 1. Install the new O-ring to the input speed sensor. 2. Install the input speed sensor (A). Tightening torque : 10~12Nm(1.0~1.2kgf.m, 7~8lb-ft) While installing the input shaft speed sensor, do not allow dust or other foreign particles to enter the transaxle.
Page 67 Page 45 of 52 Description 1. Type : HALL SENSOR Sensor type 2. Output voltage : DC 12V 3. Current consumption : 22mA (Max) 1. Output speed sensor : Detect the output shaft rpm(T/F DRIVEN GEAR RPM) at the T/F driven gear Function 2.
Page 68 Page 46 of 52 5. Remove the output speed sensor connector(A). 6. Remove the output speed sensor(A). Installation 1. Install the new O-ring to the output shaft speed sensor. 2. Remove the output speed sensor (A). Tightening torque : 10~12Nm(1.0~1.2kgf.m, 7~8lb-ft) While installing the output speed sensor, do not allow dust or other foreign particles to enter the transaxle.
Page 69 Page 47 of 52 3. Check the connector for dust, dirt, or oil, then connect the output speed sensor connector (A) securely. 4. Installation is the reverse of removal. Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Oil Temperature Sensor >...
Page 70 Page 48 of 52 Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Oil Temperature Sensor > Repair procedures (A4CF2) Removal 1. Remove the battery terminal. 2. Lift the vehicle. 3. Remove the under cover. 4. Loosen the drain plug and drain the transaxle oil. 5.
Page 71 Page 49 of 52 1. Install oil temperature sensor and connect the main harness connector (A) to the valve body. When connecting the oil temperature connector, check the connector for rust, dirt, or oil, then reconnect it. 2. Install the valve body. (Refer to Valve body's reassembly in overhaul manual) Tightening torque : 10~12Nm(1.0~1.2kgf.m, 7~8lb-ft) 3.
Page 72 Page 50 of 52 6. Install the drain plug. Tightening torque : 40~50Nm(4.0~5.0kgf.m, 28.9~36.2lb-ft) 7. Installation is the reverse of the removal. Automatic Transaxle System > Automatic Transaxle Control System > Inhibiter Switch > Description and Operation (A4CF2) Description 1. Type : ROTARY Sensor type 2.
Page 73 Page 51 of 52 5. Disconnect the inhibitor switch connector (A). 6. Remove the control cable(A) from the manual control lever. 7. Remove the inhibitor switch and manual control lever. Installation 1. Set the inhibitor switch to the "N" position. 2.
Page 74 Page 52 of 52 5. Connect the inhibitor switch connector (A). 6. Installation is the reverse of the removal. 7. Turn the ignition switch ON after installation. Move the shift lever from "P" range to "L" range, and verify that the A/T gear position indicator follows the transaxle range switch.
Page 75 Page 1 of 112 SOUL(AM) > 2010 > G 1.6 DOHC > Body (Interior and Exterior) Body (Interior and Exterior) > General Information > Specifications Specifications Hood Type Rear hinged, stay rod type Front Door Construction Front hinged, full door construction Regulator system X-arm type Locking system...
Page 76 Page 2 of 112 Body (Interior and Exterior) > General Information > Special Service Tools Special Service Tools Tool (Number and Illustration name) 09793-21000 Adjustment, removal and installation of the door Door hinge adjusting hinge wrench 09800-21000 Trim removal Ornament remover 09853-31000 Headliner clip removal Headliner clip remover...
Page 77: Troubleshooting
Page 3 of 112 Hog ring clip installer 09840-1M100 Air vent removal Air vent remover 09840-1E100 Center fascia removal Center fascia remover Body (Interior and Exterior) > General Information > Troubleshooting Troubleshooting Symptom Suspect Area Remedy Water leaks from sunroof Dirt accumulation in drain tube Remove dirt from drain Clogged drain tube...
Page 78: Projected Dimensions
Page 4 of 112 Increased sunroof sliding resistanceor interference of sunroof with drive cables, weatherstrip, etc. due tomal adjustment of sunroof Noise in motor (clutch slipping noise Incorrect engagement of motor pinion with Check pinion from motor when sunroofIs fully opened drive cable installation and or closed is not an unusual noise...
Page 79: Actual-Measurement Dimensions
Page 5 of 112 Actual-Measurement Dimensions 1. These dimensions indicate the actual linear distance between measurement points, and are the reference dimensions for use if a tracking gauge is used for measurement. 2. Measure by first adjusting both probes to the same length (A=A'). Check the probes and gauge itself to make sure there is no free play.
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Page 81 Page 7 of 112 Front Body B...
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Page 83 Page 9 of 112 Body (Interior and Exterior) > Body Dimensions > Side Body > Body Repair Side Body A...
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Page 85 Page 11 of 112 Side Body B...
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Page 87 Page 13 of 112 Body (Interior and Exterior) > Body Dimensions > Interior > Body Repair Interior A...
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Page 89 Page 15 of 112 Interior B...
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Page 91 Page 17 of 112 Interior C...
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Page 93 Page 19 of 112 Interior D...
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Page 95 Page 21 of 112 Body (Interior and Exterior) > Body Dimensions > Rear Body > Body Repair...
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Page 97 Page 23 of 112 Body (Interior and Exterior) > Body Dimensions > Under Body > Body Repair Projected Dimensions...
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Page 99 Page 25 of 112 Actual-Measurement Dimensions...
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Page 101 Page 27 of 112 Body (Interior and Exterior) > Exterior > Fender > Repair procedures Replacement • Be careful not to damage the hood and body. • When removing the clips, use a clip remover.
Page 102 Page 28 of 112 1. Remove the front bumper mounting screw (A). 2. Loose the mud guard mounting screws. 3. After loosening the fender mounting bolts, remove the fender (A). 4. Installation is the reverse of removal. Body (Interior and Exterior) > Exterior > Hood > Repair procedures Replacement Hood Assembly Replacement •...
Page 103 Page 29 of 112 1. After loosening the hood hinge (A) mounting bolts, remove the hood (B). 2. Installation is the reverse of removal. • Make sure the hood opens properly and locks securely. • Adjust the hood alignment. Hood Weatherstrip Replacement 1.
Page 104 Page 30 of 112 2. Installation is the reverse of removal. • Make sure the hood latch cable is connected properly. • Make sure the hood locks securely. Hood Latch Replacement 1. Remove the hood latch (A) mounting bolts. 2. Disconnect the hood latch cable and remove the latch. Tightening torque : 6.9~10.8N.m (0.7~1.1kgf.m, 5.1~8.0 lb-ft) 3.
Page 105 Page 31 of 112 3. After loosening the hood latch (D) mounting bolts, adjust the latch by moving it up or down, or right or left. Body (Interior and Exterior) > Exterior > Tailgate > Repair procedures Replacement Tailgate Trim Replacement •...
Page 106 Page 32 of 112 1. After loosening the mounting screws,remove the tailgate trim (A). 2. Installation is the reverse of removal. • Replace and damaged clips. Latch Assembly Replacement 1. Remove the tailgate trim. 2. Disconnect the latch connector (A). 3.
Page 107 Page 33 of 112 1. Using a screwdriver (A), lift up slightly both ends of the socket clips (B), and then remove the lifter from the bracket (C). 2. Push the socket of the lifter onto the bracket for installation. Adjustment 1.
Page 108 Page 34 of 112 Body (Interior and Exterior) > Exterior > Front Door > Components and Components Location Components...
Page 109 Page 35 of 112 1. Body weatherstrip 4. Door glass weatherstrip 7. Door trim 2. Door weatherstrip 5. Door panel 8. Quadrant inner cover 3. Door belt weatherstrip 6. Door screen 9. Door hinge...
Page 110 Page 36 of 112 1. Door outside handle 5. Door striker 8. Door module 2. Key lock cylinder 6. Door panel 9. Door checker 3. Window glass 7. Door latch 10. Glass run 4. Rear channel Body (Interior and Exterior) > Exterior > Front Door > Repair procedures Replacements Door Trim Replacement •...
Page 111 Page 37 of 112 1. Remove the quadrant inner cover (A). 2. Remove the inside handle cover (A). 3. Loosen the door trim (A) mounting screws. 4. Release the clips that hold the door trim. 5. Disconnect the connectors (A) and (B).
Page 112 Page 38 of 112 6. Installation is the reverse of removal. • Make sure of connectors is plugged in properly and each rod is connected securely. • Make sure the door lock and opens properly. Inside Handle Replacement 1. Remove the door trim 2.
Page 113 Page 39 of 112 3. Carefully adjust the glass (A) until you can see the bolts, then loosen them. Separate the glass from the glass run and carefully pull the glass out through the window slot. 4. Installation is the reverse of removal. •...
Page 114 Page 40 of 112 2. After disconnecting the connector (A), remove the power window motor (B). 3. Installation is the reverse of removal. • Grease should be applied to areas where there is rotational parts and springs. • Roll the glass up and down to see if it move freely without binding. Door Module Assembly Replacement 1.
Page 115 Page 41 of 112 5. Disconnect the clip (A). 6. Loosen the door module mounting bolts, remove the door module (A). 7. Disconnect the connector . 8. Disconnect the door module wiring harness, remove the module assembly. 9. Installation is the reverse of removal. •...
Page 116 Page 42 of 112 4. After loosening the mounting bolt, remove the key cylinder (A). 5. After loosening the mounting bolt, remove the outside handle (A). 6. Installation is the reverse of removal. • Make sure the door lock and open properly.
Page 117 Page 43 of 112 2. Carefully move the glass (A) until the glass mounting bolts are visible(B), then loosen them. 3. Check that the glass moves smoothly. 4. Raise the glass fully, and check for gaps. Check that the glass contacts the glass run channel evenly. 5.
Page 118 Page 44 of 112 2. Adjust at the hinges (A): A. Loosen the door mounting bolts slightly, and move the door IN or OUT until it aligns flush with the body. B. Loosen the hinge mounting bolts slightly, and move the door BACKWARD or FORWARD, UP or DOWN as necessary to equalize the gaps.
Page 119 Page 45 of 112 1. Loosen the screws (B), then insert a shop towel between the body and striker. 2. Lightly tighten the screws. 3. Wrap the striker with a shop towel, then adjust the striker by tapping it with a plastic hammer. Do not tap the striker too hard.
Page 120 Page 46 of 112 1. Door weatherstrip 4. Door glass weatherstrip 7. Door screen 2. Body weatherstrip 5. Delta cover 8. Door trim 3. Door belt weatherstrip 6. Door panel 9. Door hinge...
Page 121 Page 47 of 112 1. Door outside handle 4. Door panel 7. Door latch 2. Rear channel 5. Door striker 8. Door module 3. Window glass 6. Door checker Body (Interior and Exterior) > Exterior > Rear Door > Repair procedures Replacement Door Trim Replacement •...
Page 122 Page 48 of 112 1. Remove the inside handle cover (A). 2. Loosen the door trim (A) mounting screws. Release the clips that hold the door trim. 3. Disconnect the connector (B). 4. Installation is the reverse of removal. • Make sure of connectors is plugged in properly and each rod is connected securely.
Page 123 Page 49 of 112 2. After loosening the mounting screw, remove the inside handle (A). 3. Disconnect the lock cable (A) and inside handle cable (B). 4. Installation is the reverse of removal. • Make sure the door locks and opens properly.
Page 124 Page 50 of 112 4. Remove the rear channel (A). 5. Remove the door belt weatherstrip (A). • Take care not to drop to glass and scratch the glass surface. 6. Carefully move the glass (A) until you can see the bolts, then loosen them. Separate the glass from the glass run and carefully pull the glass out through the window slot.
Page 125 Page 51 of 112 3. Disconnect the speaker connector (A). 4. Installation is the reverse of removal. • Use sheet metal screws to secure the speaker. Power Window Motor Replacement 1. Remove the door trim. 2. After disconnecting the connector (A), remove the power window motor (B). 3.
Page 126 Page 52 of 112 3. Remove the outside handle (B). 4. Installation is the reverse of removal. • Make sure door lock operates and door open/closes properly. Module Assembly Replacement 1. Remove the following parts. A. Door trim. B. Door screen. C.
Page 127 Page 53 of 112 5. Detach the clips, then remove the wiring harness. 6. Installation is the reverse of removal. • The area of whole parts should be applied with sufficient grease. • Make sure the connector is plugged in properly and each rod is connected securely.
Page 128 Page 54 of 112 5. Check for water leaks. Run water over the roof and on the sealing area as shown, and note these items: A. Use a 12mm (1/2Iin.) diameter hose (A). B. Adjust the rate of water flow as shown (B). C.
Page 129 Page 55 of 112 3. Check that the door and body edges are parallel. 4. Grease the pivot portions of the hinges indicated by the arrows (A). 5. Check for water leaks. Door Striker Adjustment Make sure the door latches securely without slamming it. If necessary adjust the striker (A): The striker nuts are fixed.
Page 130 Page 56 of 112 Replacement Roof Rack Replacement • When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage. • Put on gloves to protect your hands. • Take care not to scratch the body surface. 1.
Page 131 Page 57 of 112 3. Disconnect the connector (B). 4. Installation is the reverse of removal. Body (Interior and Exterior) > Exterior > Sunroof > Components and Components Location Components...
Page 132 Page 58 of 112 1. Glass 4. Guide assembly 7. Defector 2. Decoration cover 5. Drip rail 8. Motor 3. Drip link 6. Sunshade 9. Set bracket Body (Interior and Exterior) > Exterior > Sunroof > Repair procedures Replacements Glass Replacement •...
Page 133 Page 59 of 112 3. Installation is the reverse of removal. • Make sure to initialize the motor. Deflector Replacement 1. Open the glass fully. 2. Disconnect the deflector link (A) from the frame (B), and then remove the deflector (C). 3.
Page 134 Page 60 of 112 3. After loosening the mounding bolts and nuts, remove the sunroof assembly (B). • Take care not to scratch the interior trims and other parts. 4. Installation is the reverse of removal. Sunshade And Drip Rail Replacement 1.
Page 135 Page 61 of 112 2. Remove a guide assembly (A) after lowering a guide thoroughly by pushing a slide (B) to rear. 3. Remove the guide (A) and slide (B). 4. Installation is the reverse of removal. • Make sure to align the slide with the center of“A” and “B”...
Page 136 Page 62 of 112 Adjustment How To Initialize 1. Check that the glass has been installed. A. Finished height adjustment. 2. Push and hold the up switch. A. The slide moved 5mm forward after 15 seconds. 3. After moving the slide 5mm forward, turn OFF the switch and push the UP switch (Keeping pushing the switch of continuous operation) A.
Page 137 Page 63 of 112 2. Operating method A. Remove the overhead console B. Push the emergency handle up into the hexagonal drive (A) of the sunroof motor. You must push hard enough to disengage the motor clutch; otherwise the emergency handle will slip due to incomplete fit in the motor. C.
Page 138 Page 64 of 112 2. After disconnecting the connector (A), remove the outside rear view mirror (B). 3. Installation is the reverse of removal. Inside Rear View Mirror Replacement 1. Push the inside rear view mirror base (A) down to remove to inside rear view mirror assembly (B). 2.
Page 139 Page 65 of 112 2. Detach the clips, then remove the cowl top cover (A). 3. Installation is the reverse of removal. Body (Interior and Exterior) > Interior > Console > Components and Components Location Components...
Page 140 Page 66 of 112 1. Console side cover 4. Parking brake 2. Front floor console cover 3. Astray 5. Pad 6. Console upper cover Body (Interior and Exterior) > Interior > Console > Repair procedures Replacement Floor Console Replacement • When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage.
Page 141 Page 67 of 112 4. Remove the console side cover (A). 5. After loosening the console mounting screws, remove the floor console assembly (A). 6. Installation is the reverse of removal. • Make sure the connector is plugged in properly. •...
Page 142 Page 68 of 112 1. Main crash pad 4. Reinforecing panel 2. Crash pad side 5. Switch assembly cover 3. Crash pad lower panel Body (Interior and Exterior) > Interior > Crash Pad > Repair procedures Replacement Cluster Fascia Replacement •...
Page 143 Page 69 of 112 2. Remove the cluster fascia panel (A). 3. After loosening the mounting screws, remove the cluster fascia (A). 4. Disconnect the connector (A). 5. Installation is the reverse the removal. • Make sure the connector is plugged in properly.
Page 144 Page 70 of 112 2. Separate the center facia panel (A) from the crash pad by pulling the SST (09840-1E100). 3. Disconnect the connector (A). 4. Installation is the reverse the removal. Lower Panel Replacement 1. After loosening the crash pad lower panel mounting screws, remove the lower panel (A). 2.
Page 145 Page 71 of 112 3. After loosening the mounting bolts, then remove the reinforcing panel (A). 4. Installation is the reverse of removal. Audio Assembly Replacement 1. Remove the center fascia panel. 2. After loosening the heater control unit mounting screws, remove the heat control unit (A). 3.
Page 146 Page 72 of 112 5. Disconnect the audio connectors (A). 6. Installation is the reverse of removal. • Make sure the connector is plugged in properly. Center Speaker Replacement 1. Remove the grill (A). 2. After loosening the mounting screws, remove the speaker (A).
Page 147 Page 73 of 112 3. Disconnect the speaker connector (A). 4. Installation is the reverse of removal. Speaker Replacement 1. Remove the grill (A). 2. Loosen the mounting screw. 3. Insert the air vent remover (09840-1M100) into the air vent hole and pull the air vent (A) remover. •...
Page 148 Page 74 of 112 4. After loosening the mounting screws, remove the speaker (A). 5. Disconnect the speaker connector (A). 6. Installation is the reverse of removal. Glove Box Replacement 1. Open the glove box. 2. After loosening the mounting screws, remove the glove (A). 3.
Page 149 Page 75 of 112 2. Disconnect the connector (A). 3. Installation is the reverse of removal. Steering Column Shroud Replacement 1. After loosening the mounting screws, remove the shroud (A). 2. Installation is the reverse of removal. Crash Pad Replacement •...
Page 150 Page 76 of 112 2. Remove the switch assembly (A). 3. Disconnect the connector (A). 4. Disconnect the passenger`s air bag connector (A). 5. Remove the passenger’s air bag mounting bolt (A).
Page 151 Page 77 of 112 6. Disconnect the connector (A). 7. Remove the crash pad side pad (A). 8. Loosen the bolts and nuts, then remove the crash pad (B). 9. Installation is the reverse of removal. • Make sure the crash pad fits onto the guide pins correctly. •...
Page 152 Page 78 of 112 6. Disconnect the driver’s connectors. 7. Disconnect the passenger’s connectors. 8. Disconnect the connectors. 9. Disconnect the air bag connector (A).
Page 153 Page 79 of 112 10. After loosening the mounting bolts, remove the cowl cross bar (A). 11. Installation is the reverse of removal. Body (Interior and Exterior) > Interior > Roof Trim > Components and Components Location Components 1. Roof trim 3.
Page 154 Page 80 of 112 Body (Interior and Exterior) > Interior > Roof Trim > Repair procedures Replacement Sunvisor Replacement • When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. • Put on gloves to protect your hands. 1.
Page 155 Page 81 of 112 3. Remove the overhead console. A. Remove the cover (A). B. After loosening the overhead console mounting screws, remove the overhead console lamp (A). C. Disconnect the connector (B).
Page 156 Page 82 of 112 4. Remove the room lamp. A. Remove the lens (A). B. Remove the screws. C. Pull out the room lamp (A). D. Disconnect the connector (B). 5. After loosening the mounting screws, remove the sunglass case (A).
Page 157 Page 83 of 112 6. Disconnect the connector (B). 7. Disconnect the connector (A). 8. Disconnect the sunroof motor connector (B). 9. Remove the roof trim (A). 10. Installation is the reverse of removal. • Replace any damage clips.
Page 158 Page 84 of 112 Body (Interior and Exterior) > Interior > Interior Trim > Components and Components Location Components 1. Front pillar trim 5. Center lower pillar trim 2. Front door scuff trim 6. Rear door scuff trim 3. Cowl side trim 7.
Page 159 Page 85 of 112 1. After loosening the mounting screw, remove the front pillar trim (A). 2. Installation is the reverse of removal. • Replace any damage clips. Door Scuff Trim Replacement • Put on gloves to protect your hands. •...
Page 160 Page 86 of 112 • Put on gloves to protect your hands. • When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. • Take care not to bend or scratch the trim and panels. 1. Remove the front seat belt lower anchor. 2.
Page 161 Page 87 of 112 3. Remove the luggage side trim (A). 4. Remove the rear pillar trim (A). 5. Installation is the reverse of removal. • Replace any damage clips. Luggage Side Trim Replacement • Put on gloves to protect your hands. •...
Page 162 Page 88 of 112 4. Installation is the reverse of removal. 1. Luggage side trim 4. Floor box 2. Transverse trim 5. Floor box cover 3. Floor mat Body (Interior and Exterior) > Interior > Windshield Glass > Components and Components Location Components...
Page 163 Page 89 of 112 1. Windshield 3. Front pillar garnish molding 2. Windshield glass Body (Interior and Exterior) > Interior > Windshield Glass > Repair procedures Replacement Removal • Put on gloves to protect your hands. • Use seat covers to avoid damaging any surfaces. 1.
Page 164 Page 90 of 112 3. Remove the windshield glass upper molding (A).Remove the spacer. 4. Cut out the windshield sealant using the sealant cutting tool (A)(09861-31100). 5. Remove the windshield (A) carefully using the glass holder (B). Installtion 1. With a scraper, scrape the old adhesive smooth to a thickness of about 2mm (0.08 in.) on the bonding surface around the entire windshield opening flange: A.
Page 165 Page 91 of 112 2. Clean the bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the clean surface. 3. Install the winshield (A) upper molding (B) and fasteners (E). 4. Install the spacer (A) install the windshield glass (B) temporarily with marking sure to position them on the center, and then place the alignment mark (C).
Page 166 Page 92 of 112 6. With a sponge, apply a light coat of body primer to the original adhesive remaining around the windshield opening flange. Let the body primer dry for at least 10 minutes. A. Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges. B.
Page 167 Page 93 of 112 9. Use suction cups (A) to hold the windshield over the opening, align it with the alignment marks (B) made in step 15, and set it down on the adhesive. Lightly push on the windshield until its edges are fully seated on the adhesive all the way around.
Page 168 Page 94 of 112 1. Front bumper cover 2. Front bumper side bracket...
Page 169 Page 95 of 112 1. Front bumper 4. Bumper cover 5. Bumper lip 2. Energy absorber 3. Fog lamp Body (Interior and Exterior) > Bumper > Front Bumper > Repair procedures Replacement • Put on gloves to protect your hands. •...
Page 170 Page 96 of 112 1. Remove the radiator upper mounting clips. 2. Remove the screw. 3. Disconnect the fog lamp connector (A). 4. Remove the front bumper cover (A). 5. Installation is the reverse of removal. Body (Interior and Exterior) > Bumper > Rear Bumper > Components and Components Location Components...
Page 171 Page 97 of 112 1. Rear bumper 4. Wiring harness cover 5. Bumper 2. Energy absorber 3. Bumper rail Body (Interior and Exterior) > Bumper > Rear Bumper > Repair procedures Replacement • When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts your hands.
Page 172 Page 98 of 112 1. Remove the combination lamp (A). 2. Disconnect the connector (A). 3. Remove the screw. 4. Remove the mounting bolts. 5. Loosen the rear bumper cover screws and clips.
Page 173 Page 99 of 112 6. Remove the rear bumper cover (A). 7. Disconnect the connector (A). 8. Installation is the reverse of removal. • Replace any damage clips. Body (Interior and Exterior) > Seat & Power Seat > Front Seat > Repair procedures Replacement Seat assembly replacement 1.
Page 174 Page 100 of 112 2. Disconnect the connectors (B), and remove the seat assembly. SEAT MOUNTING BOLT INSTALLATION PROCEDURE (manual seat only) • Set the into the most rearward position. check that each slide is locked, and then tighten the front mounting bolt temporarily.
Page 175 Page 101 of 112 2. Loosen the recliner mounting screw and clip, remove the recliner cover (A). 3. Installation is the reverse of removal. Seat Back Cover Replacement 1. Remove front seat assembly. 2. Remove the headrest. 3. Loosen the armrest mounting bolt, remove the armrest (A). 4.
Page 176 Page 102 of 112 5. Disconnect the connector (A). 6. Disconnect the air bag wiring (A). 7. Remove the seat back panel (B). 8. Disconnect the protector (A) from the back frame.
Page 177 Page 103 of 112 9. Remove the headrest and headrest guide (A). 10. After removing the hogring clip on the front of seat back and remove the seat back cover (A). 11. Installation is the reverse of removal. Seat Cushion Cover Replacement 1.
Page 178 Page 104 of 112 5. Disconnect the air bag wiring (A). 6. After disconnect the protector (A), then remove the seat cushion (B). 7. After removing the hogring clips on the front of seat cushion and remove the seat cushion cover (A). 8.
Page 179 Page 105 of 112 2. After removing the mounting bolts, then disconnect the seat back frame (A) and seat cushion frame (B). • Remove the side air bag for replacing side air bag installation seat. • Before service, be fully aware of precautions and service procedure relevant to air bag (Refer to page RT-Airbag) 3.
Page 180 Page 106 of 112 2. Cut the heater (B) attached to the pad (A), as shown in the picture. • Take care not to damage the slave pad. 3. Install the seat back cover. A. Detach the paper from the back of the heater assembly. B.
Page 181 Page 107 of 112 1. Front seat belt 4. Front seat belt buckle 2. Rear seat belt 5. Rear center 2-point seat belt 3. Rear center 3-point seat belt 6. Rear center seat buckle Body (Interior and Exterior) > Seat Belt > Front Seat Belt > Repair procedures Replacement Front Seat Belt Replacement •...
Page 182 Page 108 of 112 3. After raise the lower anchor cover (A), loosen the lower anchor mounting bolt (B). Tightening torque : 39.2~53.9 N.m (4.0~5.5kgf.m, 28.9~39.8lb-ft) 4. Remove the center pillar lower trim (A). 5. Remove the center pillar upper trim (B). 6.
Page 183 Page 109 of 112 7. After disconnecting the pretensioner connector lock pin, remove the pretensioner squib connector (B), Loosen the mounting bolt, then remove the pretensioner (C). 8. Installation is the reverse of removal. Hight adjuster replacement 1. Remove the following items first. A.
Page 184 Page 110 of 112 3. Remove the seat belt buckle (A). Tightening torque : 39.2~53.9 N.m (4.0~5.5kgf.m, 28.9~39.8lb-ft) 4. Installation is the reverse of removal. Body (Interior and Exterior) > Seat Belt > Rear Seat Belt > Repair procedures Replacement Seat belt relacement •...
Page 185 Page 111 of 112 3. Remove the luggage side trim (A). 4. Remove the rear pillar trim (A). 5. After loosening the retractor (B) mounting bolt, remove the rear seat belt (C). 6. Remove the upper anchor (A). Tightening torque : 39.2~53.9 N.m (4.0~5.5kgf.m, 28.9~39.8lb-ft) 7.
Page 186 Page 112 of 112 2. Remove the seat belt buckle (A). Tightening torque : 39.2~53.9 N.m (4.0~5.5kgf.m, 28.9~39.8lb-ft) 3. Loosen the mounting bolt, remove the center seat belt (A) and buckle (B). Tightening torque : 39.2~53.9 N.m (4.0~5.5kgf.m, 28.9~39.8lb-ft) 4. Installation is the reverse of removal.
Page 187 Page 1 of 258 SOUL(AM) > 2010 > G 1.6 DOHC > Body Electrical System Body Electrical System > General Information > General Information General Troubleshooting Information Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Using the battery checker (MCR-570 KIT), check the battery for damage, state of charge, and clean and tighten connections.
Page 188 Page 2 of 258 7. Always reinstall plastic covers. 8. Before connecting connectors, make sure the terminals (A) are in place and not bent. 9. Check for loose retainer (A) and rubber seals (B). 10. The backs of some connectors are packed with grease. Add grease if necessary. If the grease (A) is contaminated, replace it.
Page 189 Page 3 of 258 12. Position wires so that the open end of the cover faces down. Handling Wires And Harnesses 1. Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. 2. Remove clips carefully; don't damage their locks (A). 3.
Page 190 Page 4 of 258 6. Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing And Repairs 1. Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. 2.
Page 191 Page 5 of 258 3. Isolate the problem by testing the circuit. Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4.
Page 192 Page 6 of 258 Specification Audio Item Specification Radio/CD/MP3 Radio/CD/MP3 Model (Internal Amp) (External Amp) Power supply DC 14.4V Rated output Min 14W Antenna 80PF 75Ω Tuning type PLL synthesized type 87.5~107.9 MHz / 200KHz Frequency range / Channel space 530~1710 KHz (10KHz) Speaker Item...
Page 193 Page 7 of 258 1. Audio unit 7. Antenna feeder cable 2. Tweeter speaker 8. Roof antenna 3. AUX Jack / USB Port 9. Woofer speaker 4. External amplifier 10. Antenna cable connector 5. Front door speaker 11. Advanced lighting 6.
Page 194 Page 8 of 258...
Page 195 Page 9 of 258...
Page 196 Page 10 of 258 Body Electrical System > Audio > Audio Unit > Repair procedures Removal 1. Disconnect the negative (-) battery terminal. 2. Remove the crash pad center facia panel. (Refer to the Body group - "Crash pad")
Page 197 Page 11 of 258 3. Disconnect the connector(A) from the crash pad center facia panel. 4. Remove the heater control unit(A). 5. Remove the mounting bolts then remove the audio unit(A). 6. Disconnect the audio connectors and cable(A). Disassembly...
Page 198 Page 12 of 258 1. Disassemble the front panel(A) then disconnect the connector(B) between the unit and front panel. 2. Remove the top cover(A) after loosening 4 screws. 3. Disassemble the deck (A) from the unit after removing the connector and screws. Reassembly 1.
Page 199 Page 13 of 258 2. Remove the external amplifier(A) after loosening the nuts (2EA), bolt (1EA) and connector (B). Installation 1. Connect the audio unit connectors and cable. 2. Install the audio unit. 3. Install the crash pad center facia panel. 4.
Page 200 Page 14 of 258 Body Electrical System > Audio > Speakers > Schematic Diagrams Circuit diagram...
Page 201 Page 15 of 258 Body Electrical System > Audio > Speakers > Description and Operation Description Advanced lighting speaker The advanced lighting speaker that lights around the front speaker is adjusted by turning the knob. • ON : The light turns on. •...
Page 202 Page 16 of 258 2. Remove the front speaker (B) after removing 4 rivets and connector (A). Rear Speaker 1. Remove the rear door trim. (Refer to the Body group - "Rear door") 2. Remove the rear speaker (B) after removing 4 rivets and connector (A). Tweeter Speaker 1.
Page 203 Page 17 of 258 2. Remove the tweeter speaker cover (A). • To prevent the damage to the air vent, the 09840-1M100 Air Vent Remover should be used to grab the sides of the air vent. 3. Remove the tweeter speaker (A) after removing the screw (2EA) and connector (B). Center Speaker 1.
Page 204 Page 18 of 258 2. Remove the crash pad center facia panel (A). (Refer to the Body group - "Crash pad") 3. Remove the center speaker grill (A). 4. Remove the center speaker (A) after removing the screws (4EA) and connector (B). Woofer Speaker 1.
Page 205 Page 19 of 258 2. Remove the woofer speaker (A) after removing the screws (4EA) and connector (B). Installation Front Speaker 1. Install the front speaker. 2. Install the front door trim. Rear Speaker 1. Install the rear speaker. 2. Install the rear door trim. Tweeter Speaker 1.
Page 206 Page 20 of 258 (2) Case Troubleshooting Case Inspection/Remedy 1. Before replacing the speaker, inspect that the mounting screw is installed normally. Trembling 2. After re-installing the speaker, verify that no trembling sound is heard. sound 3. When hearing a trembling sound again, replace the speaker with new one. 1.
Page 207 Page 21 of 258 2. Check for continuity between the center poles of antenna cable. There sould be continuity. 3. Check for continuity between the outer poles of antenna cable. There should be continuity. 4. If there is no continuity, replace the antenna cable. 5.
Page 208 Page 22 of 258 2. Disconnect the connector and cable (A) and nut (B) from the roof antenna. 3. Remove the roof antenna(A). Installation 1. Connect the roof antenna cables and connectors. 2. Install the rear roof trim. Body Electrical System > Audio > Audio Remote control > Schematic Diagrams Circuit Diagram...
Page 209 Page 23 of 258...
Page 210 Page 24 of 258 Body Electrical System > Audio > Audio Remote control > Repair procedures Removal 1. Disconnect the negative (-) battery terminal.
Page 211 Page 25 of 258 2. Remove the driver airbag module (A). (Refer to the Airbag group - "Airbag module and clock spring") 3. Remove the steering wheel after loosening the nut and disconnecting the connector (A). 4. Loosen the screws (4EA) on the opposite side of the steering wheel.
Page 212 Page 26 of 258 5. Disconnect the audio remote control switch connector(A). 6. Remove the audio remote control switch(B). Installation 1. Install the audio remote control switch on the steering wheel. 2. Connect the audio remote control switch connector. 3. Install the steering wheel. 4.
Page 213: Connector Terminal
Page 27 of 258 Connector Resistance Switch terminal (±1%) VOLUME DOWN 6.81 kΩ VOLUME UP 4.61 kΩ MODE 2.11 kΩ SEEK DOWN 1.11 kΩ SEEK UP 430 Ω MUTE 3.11 kΩ Body Electrical System > Audio > AUX(Auxiliary) jack > Schematic Diagrams Circuit Diagram Body Electrical System >...
Page 214 Page 28 of 258 level of the used media does not match the specification of the AUX input. Body Electrical System > Audio > AUX(Auxiliary) jack > Repair procedures Removal Multi Media Jack...
Page 215 Page 29 of 258 1. Remove the multi media jack assembly from main creah pad (A) by using the trim remover tool. 2. Disconnect the jack assembly connector(A) 3. Remove the Multi Media Jack (A). Installation Multi Media Jack 1. Connect the Multi Media Jack connector. 2.
Page 216 Page 30 of 258 2. Disconnect the Multi Media Jack connector after from the floor console. To inspect USB/IPOD port, check the voltage between NO.1 and 4 terminal of USB/iPod input port at AUX input. Standard value : 5V To inspect AUX Jack, check the voltage between NO.14 terminal of Jack output connector and NO.4 terminal of USB/iPod input port at AUX input.
Page 217 Page 31 of 258 Function Activation In order to extend or reactivate your subscription to SIRIUS Satellite Radio, you will need to contact SIRIUS Customer Care at 888-539-7474. Have your 12 digit SID (Sirius Identification Number)/ESN (Electronic Serial Number) ready. To retrieve the SID/ESN, turn on the radio, press the [SAT] button and tune to channel zero.
Page 218 Body Electrical System > Audio > SIRIUS Radio > Troubleshooting Troubleshooting 1. Antenna Error If this message is displayed, the antenna or antenna cable is broken or unplugged. Please consult with your Kia dealership. 2. Acquiring Signal If this message is displayed, it means that the antenna is covered and that the SIRIUS Satellite Radio signal is not available.
Page 219 Page 33 of 258 Chart 1...
Page 220 Page 34 of 258...
Page 221 Page 35 of 258...
Page 222 Page 36 of 258 Chart 2...
Page 223 Page 37 of 258 Chart 3...
Page 224 Page 38 of 258 Chart 4...
Page 225 Page 39 of 258...
Page 226 Page 40 of 258...
Page 227 Page 41 of 258 Chart 5...
Page 228 Page 42 of 258 Chart 6 Chart 7...
Page 229: Specifications
Page 43 of 258 Body Electrical System > Multifunction switch > Specifications Specifications Items Specifications Rated voltage DC 12V Operating temperature range -30°C ~ +80°C (-22 ~ +176°F) Dimmer & High : 0.2A (Relay load) passing Low : 0.2A (Relay load) switch Passing : 0.2A (Relay load) Lighting...
Page 230 Page 44 of 258 Body Electrical System > Multifunction switch > Components and Components Location Component (1) <Installation order : A→B→C→D> 1. Steering column 4. Screw shaft 5. Clock spring 2. Lighting switch 3. Wiper and washer switch Component (2)
Page 231 Page 45 of 258 Body Electrical System > Multifunction switch > Repair procedures Inspection Lighting Switch Inspection 1. With the multi function switch in each position, make sure that continuity exists between the terminals below. If continuity is not as specified, replace the multi-function switch...
Page 232 Page 46 of 258 Lighting Switch (Auto Light) Lighting Switch Dimmer And Passing Switch Turn Signal Switch Front Fog Lamp...
Page 233 Page 47 of 258 Wiper And Washer Switch Inspection 1. With the multi function switch in each position, make sure that continuity exists between the terminals below. If continuity is not as specified, replace the multi-function switch. Wiper Switch Washer Switch Rear Wiper &...
Page 234 Page 48 of 258 2. Remove the steering column upper and lower shrouds (A) after removing 3 screws. 3. Disconnect the light switch connector (A) and the wiper switch connector (B).
Page 235 Page 49 of 258 4. Remove the wiper switch (A) by pushing the lock pin (B). when removing the wiper & washer switch only, release the lock of wiper switch without removing the steering wheel. 5. Remove the clock spring(A). 6.
Page 236 Page 50 of 258 1. Horn switch 4. Horn relay 2. Relay box (Engine room 5. Clock spring compartment) 3. Horn (High pitch - Single) Body Electrical System > Horn > Repair procedures Removal 1. Remove the front bumper. (Refer to the Body group - "Front bumper")
Page 237 Page 51 of 258 2. Remove the bolts and disconnect the horn connectors, then remove the high pitch horn (A) and high pitch (B). Installation 1. Install the horns after connecting the horn connectors. 2. Install the front bumper. (Refer to the Body group - "Front bumper") Inspection Test the horn by connecting battery voltage to the 1 terminal and ground the 2 terminal.
Page 238 Page 52 of 258 1. Operate the horn, and adjust the tone to a suitable level by turning the adjusting screw. After adjustment, apply a small amount of paint around the screw head to keep it from loosening. Body Electrical System > Keyless Entry And Burglar Alarm > Components and Components Location Component Location...
Page 239 Page 53 of 258 1. Hood switch 6. Front door lock actuator & 2. Burglar horn switch 3. Body control module 7. Rear door lock actuator & 4. Key warning switch switch 5. Front door motor 8. Rear door motor 9.
Page 240 Page 54 of 258 not open a door, the light will go off in about 30 seconds, the doors will automatically relock, and the burglar alarm system will rearm. If you relock the doors with the remote transmitter within 30 seconds, the light will go off immediately.
Page 241 Page 55 of 258 10. When Assist Door Key Lock SWITCH ON T1 : 0.9 ± 0.1sec, T2 : 27 ± 3sec Transmitter(TX) Spec 1. Transmission Distance : 30m or more from outside of the car 2. Registration procedure of the transmitter (1) In registration mode, it shall be possible to register up to Max 4EA.
Page 242 Page 56 of 258 Check for continuity between the terminals. 1. There should be continuity between the No.1 terminals in the I/P-F and No.6 terminals in the I/P-H when power and ground are connected to the No.1 terminals in the I/P-F and No.3 terminals in the I/P-H. 2.
Page 243 Page 57 of 258 3. Disconnect the connectors from the actuator. 4. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. Rear Door Lock Actuator 1. Remove the rear door trim. (Refer to the Body group - "Rear door") 2.
Page 244 Page 58 of 258 4. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. Tailgate Lock Actuator Inspection 1. Remove the tailgate trim. (Refer to the Body group - "Tail gate") 2.
Page 245 Page 59 of 258 4. Check for continuity between the terminals in each switch position when inserting the key into the door according to the table. Tailgate Switch 1. Remove the tailgate trim. (Refer to the Body group - "Tail gate") 2.
Page 246: Specification
Page 60 of 258 2. Disconnect the 6P connector from the key warning switch. 3. Check for continuity between the terminals in each position according to the table. Body Electrical System > Keyless Entry And Burglar Alarm > Transmitter > Specifications Specifications Item Specification...
Page 247 Page 61 of 258 2. Remove the battery and check voltage if the red light doesn't flicker. Standard voltage : 3V 3. Replace the transmitter battery with a new one, if voltage is below 3V then try to lock and unlock the doors with the transmitter by pressing the lock or unlock button five or six times.
Page 248 Page 62 of 258 3. After selecting "CODE SAVING" menu, button "OK" key, then the screen will be shown as below. 4. After removing the ignition key from key cylinder, push "OK" key to proceed to the next mode for code saving. Follow steps 1 to 4 and then code saving is completed.
Page 249 Page 63 of 258...
Page 250 Page 64 of 258...
Page 251 Page 65 of 258...
Page 252 Page 66 of 258 Body Electrical System > BCM (Body Control Module) > Body Control Module (BCM) > Specifications Specifications...
Page 253 Page 67 of 258 Item Requirement Remark Rated voltage DC 12V Operating voltage range DC 9 ~ 16V Operating temperature Shall activate normally in these range. -30°C ~ +80°C range Storage temperature -40°C ~ +85°C range 100Mohm or more Specify as well as parts that insulation like PCB, Insulation resistance (measured with 500V moisture-proof COATING is required...
Page 254 Page 68 of 258...
Page 255 Page 69 of 258 Body Electrical System > BCM (Body Control Module) > Body Control Module (BCM) > Description and Operation Description...
Page 256 Page 70 of 258 Body control module (A) receives various input switch signals controlling time and alarm functions for Variant INT wiper, MIST wiper, rear wiper & washer, seat belt warning(reminder), over speed warning, tail lamp auto cut, DRL, front fog lamp, decayed room lamp, rear defoger timer, power window timer, central lock/unlock, tail gate release control, IGN key reminder, crash door unlock, keyless entry, panic.
Page 257 Page 71 of 258 (2) Turn Wiper relay ON after T1 when turning Washer switch ON at the status of IGN2 ON and if the input of Washer switch is more than 0.2sec, turn the output of wiper relay off for 2.5 ~ 3.8sec after turning washer switch OFF.
Page 258 Page 72 of 258 (3) Ignore the input of Mist switch while operating WIPER by INT WIPER, WASHER Interlocking WIPER. T1 : Min 60 ms, T2 : Max 100ms, T3 : 700 ± 100ms, T4 : 700ms 4. Variable INT Wiper Variable INT Wiper is operated by INT volume when the input of INT WIPER switch is ON at the status of IGN2 ON.
Page 259 Page 73 of 258 6. Rear Washer Inter Locking Rear Wiper (1) Rear Wiper Realy is turned ON after T1 When Rear Washer switch is turned ON at the status of IGN2 ON. If input of Rear Washer switch is less than 0.2sec and more than 0.06sec, Rear Wiper Realy is turned OFF after T3.
Page 260 Page 74 of 258 7. Rear Wiper ON (1) IF Rear Wiper ON switch is ON at the status of IGN2 ON, the output of Rear Wiper Relay is turned ON for 700ms. T1 : Min 60ms, T2 : Max 100ms, T3 : 700 ±...
Page 261 Page 75 of 258 2. Tail Lamp Auto Cut (1) Turn IGN KEY OFF when turning Tail Lamp switch ON after turning IGN KEY ON and turn Tail Lamp Relay OFF(automatic blackout) when Driver Door open switch is opened. (2) Also, Tail Lamp Relay OFF(automatic blackout) even though IGN KEY is turned OFF after opening Driver Door open switch at the condition that IGN KEY is ON..
Page 262 Page 76 of 258 3. Daytime Running Lamps (1) If Alt ‘L’is High, DRL control put in operation. (2) If Head Lamp Low Relay is turned ON or Head Lamp High Switch is turned ON during DRL control operating, DRL control is cancelled. 4.
Page 263 Page 77 of 258 1. Interrior Room Lamp Data Flow 2. Decayed Room Lamp & Keyless Unlock Timer When removing or installing the Battery (1) Start Room Lamp on the state of 20min, if the DOOR is OPENED. (2) Start Room Lamp when it is OFF if the DOOR is CLOSED. 3.
Page 264 Page 78 of 258 (3) Condition 3 State Description Initial condition Room Lamp OFF and IGN1 OFF Event IGN1 ON and DOOR OPEN for over 0.1 sec. Action ROOM LAMP ON T1 : 20 ± 1min, T2 :30 ± 3sec 4.
Page 265 Page 79 of 258 (3) Condition 3 State Description Initial condition ROOM LAMP ON for 30s and IGN1 OFF IGN1=ON, or after 30sec, or ALL DOOR UNLOCK → Event LOCKED or TX LOCK & ALL DOORS CLOSED & ALL DOOR LOCKED The state go to ROOM LAMP DECAYING state Action Room Lamp decaying for 2 ±...
Page 266 Page 80 of 258 (3) Condition 3 State Description ROOM LAMP ON for 20min and IGN1 Initial condition Event DOOR CLOSE Action ROOM LAMP ON for 30s T1 :20 ± 1min, T2 : 30 ± 3sec 6. Room Lamp Decaying (1) Condition 1 State Description...
Page 267 Page 81 of 258 (4) Condition 4 State Description Initial condition ROOM LAMP DECAYING Event IGN1 ON and DOOR OPEN for 0.1 sec. Action ROOM LAMP ON T1 : 20 ± 1min, T2 : 30 ± 3sec. 7. Room Lamp On (1) Condition 1 State Description...
Page 268 Page 82 of 258 (3) Condition 3 State Description Room Lamp ON and IGN1 ON and DOOR Initial condition OPEN Event DOOR CLOSE and IGN1 OFF Action ROOM LAMP ON for 30s T1 : 20 ± 1min, T2 : 30 ±3sec 1.
Page 269 Page 83 of 258 (2) Priority : S/BELT WARNING/SEAT BELT REMINDER > OVER SPEED WARNING > KEY OPERATED WARNING (3) Keep the output up to the OFF cycle when turning the output OFF. (4) Measurement distance for sound pressure: 1.0 m Warning Control 1.
Page 270 Page 84 of 258 (2) From State IGN1 On Driver Belted State Description Initial condition IGN1 ON DRIVER BELTED Event IGN1 OFF - Stop Bulb check 6 seconds driver indicator blinking Action - Stop ALT L 6 seconds driver indicator blinking - The automaton state is changed to IGN1 OFF State Description...
Page 271 Page 85 of 258 State Description Initial condition IGN1 ON DRIVER UNBELTED Event Vehicle Speed ≥ 10km/h - Start buzzer and driver indicator Pattern (10 times (6sec ON/24sec OFF) + 6sec ON) Action - The automaton state is changed to PATTERN State Description Initial condition...
Page 272 Page 86 of 258 3. Key Operated Warning (1) When Driver Door Switch is ON at the status of KEY IN ON, Buzzer will be outputted per 0.6sec continuously. (2) If KEY IN turns OFF or Driver Door Switch is CLOSED during Buzzer output, the output will turn OFF. (3) When IGN1 turns ON while outputting, the output will be stopped.
Page 273 Page 87 of 258 (5) Rear Defogger relay should not be outputted when turning Alt’L’ ON while Rear Defogger switch is pressed. T1 : 20 ± 1min 3. Power Window Timer (1) Turn Power window Relay output ON when turning IGN2 ON. (2) Turn Power window Relay output OFF after keeping Power window Relay output for 30sec when IGN2 is OFF.
Page 274 Page 88 of 258 1. Door Lock/unlock Control Data Flow 2. Door Lock/unlock Relay Control (1) NON-APPLICABLE SPEC FOR 2-TURN Unlock Driver Door Unlock Lock Mode Relay Relay Relay CENTRAL LOCK CENTRAL UNLOCK...
Page 275 Page 89 of 258 (2) 2-Turn Unlock Spec (For North America) Driver Unlock Lock Mode Unlock Relay Relay Relay CENTRAL LOCK CENTRAL UNLOCK DRIVER UNLOCK (3) Turn the present output OFF immediately when reciprocal output is requested while outputting and start outputting reciprocally in 100ms.
Page 276 Page 90 of 258 (2) In case of DOOR KEY LOCK (UNLOCK) signal of the passenger seat, handle as KEY LOCK (UNLOCK) of the passenger seat is inputted if the knob in the passenger seat is LOCKED (UNLOCKED) after checking it for 3s. 4.
Page 277 Page 91 of 258 (10) If Power window Lock Switch is ON, turn CENTRAL UNLOCK output ON for T1. (NORTH AMERICA) But, inhibit operating by Power window Unlock Switch at Lock state by TX. *1) CENTRAL LOCK : Refer to control mode for each Spec. *2) CENTRAL LOCK : Refer to control mode for each Spec.
Page 278 Page 92 of 258 T1 : 4 ± 1sec, T2 : 0.5 ± 0.1sec 6. IGN Key Reminder (1) This function will not be operated if the speed of cars exceeds 3km/h. (2) Perform Unlock Relay output for 1s after 0.5s when the condition becomes to be KEY IN = ON& Driver Door open Switch = OPEN &...
Page 279 Page 93 of 258 (13) Output UNLOCK though the condition is not kept for 0.5sec after realizing that of UNLOCK. But, do not output UNLOCK in case that KEY IN is OFF at the point of 0.5s passed after realizing the condition by the change of UNLOCK →...
Page 280 Page 94 of 258 1. Permission Mode State State Description Initial condition No permission state Event DR Door Unlock switch ON Action The state goes to permission state State Description Initial condition 30s permission state Event DR Door Unlock switch ON Action The state goes to permission state State...
Page 281 Page 95 of 258 2. Remove the glove box. (Refer to the Body group - "Crash pad") 3. Remove the BCM (A) after removing the connector (B) and nuts (2EA). Installation 1. Install the BCM after connecting the connector. 2. Install the glove box. Inspection BCM Connectors...
Page 282 Page 96 of 258 Connector A Connector B Connector C Room lamp Assist seat belt IND GND 2 IG 2 Rear wiper ON switch Wiper relay Front fog relay Rear defogger switch Rear wiper relay ALT L Wiper INT switch T/Gate relay Assist seat belt switch Washer switch...
Page 283 Page 97 of 258 PIN Name Capacity Availability in Power DC 12V Horn relay 200mA(indective load) DC 12V Hazard relay 200mA(indective load) Room lamp DC 12V 30W LAMP DC 12V Defogger relay 200mA(indective load) DC 12V Unlock relay 200mA(indective load) DC 12V Lock relay 200mA(indective load)
Page 284 Page 98 of 258 2. To diagnose the BCM function, select the menu of model and body control module. 3. To consult the present input/out value of BCM, "Current DATA". It provides information of BCM input/output conditions of power supply, turn signal/brake lamp, headlamp, door locks, outside mirror, wiper, auto-light and transmitters etc.
Page 285 Page 99 of 258 4. To perform functional test on BCM outputs, select "ACTUATION TEST" Body Electrical System > Seat Electrical > Components and Components Location Component Location...
Page 286 Page 100 of 258 1. Seat warmer 3. Seat warmer switch 2. Seat warmer switch (LH) (RH) Body Electrical System > Seat Electrical > Seat Heater Switch > Repair procedures Inspection Front Seat Warmer Switch 1. Disconnect the negative (-) battery terminal. 2.
Page 287 Page 101 of 258 3. Disconnect the seat heater switch connectors. 4. Check for continuity between the terminals (A) in each switch position according to the table. Body Electrical System > Seat Electrical > Seat Heater > Repair procedures Inspection...
Page 288: Standard Value
Page 102 of 258 1. Check for continuity and measure the resistance between No.1 terminal and No.3 terminal of connector. Standard value Leather seat : 2.4Ω ± 10% / set Fabric seat : 3.24Ω ± 10% / set 2. Operate the seat warmer after connecting the connectors, and then check the thermostat by measuring the temperature of seat surface.
Page 289 Page 103 of 258 1. Wiper relay (Front) 7. Head lamp relay (High) 2. Blower relay 8. Head lamp relay (Low) 3. Fuel pump relay 9. Start relay 4. Main relay 10. A/C relay 5. Condenser fan relay 11. Horn relay (High) 6.
Page 290 Page 104 of 258 1. Tail lamp relay, Power window relay, Rear heater relay, Door unlock relay, Door lock relay, Hazard relay, Rear wiper relay, Front fog relay, Tailgate relay, DRL relay Body Electrical System > Fuses And Relays > Relay Box (Engine Compartment) > Components and Components Location Component Location...
Page 291 Page 105 of 258...
Page 292 Page 106 of 258 Body Electrical System > Fuses And Relays > Relay Box (Engine Compartment) > Repair procedures Inspection 1. Disconnect the negative (-) battery terminal. 2. Pull out the relay from the engine compartment relay box. Power Relay (Type A) Check for continuity between the terminals.
Page 293 Page 107 of 258 C : Start relay D : Head lamp relay (Low) E : Head lamp relay (High) F : Condenser pan relay (Low) G : Condenser pan relay (High) 1. There should be continuity between the No.30 and No.87 terminals when power and ground are connected to the No.85 and No.86 terminals.
Page 294 Page 108 of 258 2. There should be continuity between the No.30 and No.87 terminals when power is disconnected. Power Relay (Type C) Check for continuity between the terminals. A : Blower relay B : Fuel pump realy C : Main relay 1.
Page 295 Page 109 of 258 Fuse 1. Be sure there is no play in the fuse holders, and that the fuses are held securely. 2. Are the fuse capacities for each circuit correct? 3. Are there any blown fuses? If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why the fuse blew first and completely eliminate the problem before installing a new fuse.
Page 296 Page 110 of 258...
Page 297 Page 111 of 258 Body Electrical System > Fuses And Relays > Relay Box (Passenger Compartment) > Repair procedures Inspection Fuse 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.
Page 298 Page 112 of 258 2. Remove the crash pad lower panel. (Refer to the Body group - "Crash pad") 3. Remove the junction box. Power Window Check for continuity between the terminals. 1. There should be continuity between the No.2 terminal in the I/P-F and the No.8 or 14 terminal in the I/P-H when power and ground are connected to the No.2 terminal in the I/P-F and the No.9 terminal in the I/P-A.
Page 299 Page 113 of 258 Front Fog Check for continuity between the terminals. 1. There should be continuity between the No.1 terminals in the I/P-F and No.11 terminals in the I/P-G when power and ground are connected to the No.1 terminals in the I/P-F and No.3 terminals in the I/P-A. 2.
Page 300 Page 114 of 258 1. Cluster assembly 6. Brake fluid level warning switch 2. Seat belt switch 7. Parking brake switch 3. Vehicle speed sensor 8. Door switch 4. Engine coolant temperature 9. Fuel gauge sender sender 10. Tailgate switch 5.
Page 301: Instrument Cluster
Page 115 of 258 Instrument Cluster...
Page 302 Page 116 of 258 Connector B Connector C Connector A Detent Power GND O/D OFF ILL+ TPMS Diagnosis Battery charge TPMS TREAD Oil pressure Head lamp (Low) Check engine Tail lamp ON Washer Low P brake Seat belt Immobilizer Airbag input - Front fog Trunk open Airbag supply +...
Page 303 Page 117 of 258 2. Remove the cluster fascia panel (A). (Refer to the Body group - "Crash pad") 3. Remove the cluster fascia (A) from the housing after removing 4 screws. 4. Disconnect the cluster fascia connecters(A) and then remove the cluster. Installation 1.
Page 304 Page 118 of 258 2. Drive the vehicle onto a speedometer tester. Use wheel chocks(A) as appropriate. 3. Check if the speedometer indicator range is within the standard values. Do not operate the clutch suddenly or increase/ decrease speed rapidly while testing.
Page 305 Page 119 of 258 2. With the engine started, compare the readings of the tester with that of the tachometer. Replace the tachometer if the tolerance is exceeded. 1) Reversing the connections of the tachometer will damage the transistor and diodes inside. 2) When removing or installing the tachometer, be careful not to drop it or subject it to severe shock.
Page 306: Resistance(Ω)
Page 120 of 258 2. Also check that the resistance changes smoothly when the float is moved from "E" to "F". Position Resistance(Ω) 184 ± 1Ω Warning lamp 170 ± 1Ω 66.2 ± 1Ω Sender (F) 15 ± 1Ω 3. If the height resistance is unsatisfied, replace the fuel sender as an assembly. After completing this test, wipe the sender dry and reinstall it in the fuel tank.
Page 307 Page 121 of 258 2. If the resistance value is not as shown in the table, replace the temperature sender. Temp °F(°C) (60) (85) (110) (125) Resistance (Ω) Oil Pressure Switch 1. Check that there is continuity between the oil pressure switch terminal and ground with the engine off. 2.
Page 308 Page 122 of 258 2. Release the parking brake. 3. Remove the connector from the brake fluid level warning switch. 4. Ground the connector at the harness side. 5. Verify that the warning lamp lights. Parking Brake Switch The parking brake switch is a pull type. It is located at the side of the parking brake lever. 1.
Page 309: Warning Lamp
Page 123 of 258 2. Check for continuity between terminals. Seat belt condition Continuity Non-conductive Fastened (∞Ω) Not fastened Conductive (Ω) Seat Belt Warning Lamp With the ignition switch turned ON, verify that the lamp glows. Seat belt Warning lamp condition Fastened Not fastened...
Page 310: Troubleshooting
Page 124 of 258 3. Remove the trip switch connector (A) from the main crash pad. 4. Remove the trip switch (A). 5. Check for continuity between the terminals in each switch position according to the table. Body Electrical System > Indicators And Gauges > Troubleshooting Troubleshooting Symptom Possible cause...
Page 311 Page 125 of 258 Tachometer does not operate Check for short and Cluster fuse (10A) blown replace fuse Tachometer faulty Check tachometer Wiring or ground faulty Repair if necessary Fuel gauge does not operate Check for short and Cluster fuse (10A) blown replace fuse Fuel gauge faulty Check gauge...
Page 312 Page 126 of 258 Bulb burned out Replace bulb Seat belt switch faulty Check switch Wiring or ground faulty Repair if necessary Body Electrical System > Power Door Locks > Components and Components Location Component Location 1. Passenger compartment junction box 5.
Page 313 Page 127 of 258 Front Door Lock Actuator 1. Remove the front door trim. (Refer to the Body group - "Front door") 2. Remove the front door module. (Refer to the Body group - "Front door") 3. Disconnect the connectors from the actuator. 4.
Page 314 Page 128 of 258 4. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. Tailgate Lock Actuator Inspection 1. Remove the tailgate trim. (Refer to the Body group - "Tail gate") 2.
Page 315 Page 129 of 258 4. Check for continuity between the terminals in each switch position when inserting the key into the door according to the table. Tailgate Switch 1. Remove the tailgate trim. (Refer to the Body group - "Tail gate") 2.
Page 316 Page 130 of 258 Check for continuity between the terminals. 1. Disconnect the negative (-) battery terminal. 2. Remove the passenger compartment junction box. 3. Check for continuity between the terminals. 4. There should be continuity between the No.1 terminals in the I/P-F and No.6 terminals in the I/P-H when power and ground are connected to the No.1 terminals in the I/P-F and No.3 terminals in the I/P-H.
Page 317 Page 131 of 258 3. Remove the screws from the switch module (A). 4. Remove the power door switch module (A). 5. Check for continuity between the terminals in each switch position according to the table. Body Electrical System > Power Door Mirrors > Components and Components Location Component Location...
Page 318 Page 132 of 258 1. Power door mirror 2. Power door mirror switch Body Electrical System > Power Door Mirrors > Power Out Side Mirror Switch > Components and Components Location Components...
Page 319 Page 133 of 258 Body Electrical System > Power Door Mirrors > Power Out Side Mirror Switch > Repair procedures Inspection 1. Disconnect the negative (-) battery terminal.
Page 320 Page 134 of 258 2. Remove the front door trim and power window switch module. (Refer to the Body group - "Front door") 3. Remove the power door switch module (A) after removing the screws. 4. Remove the power door mirror switch (A). 5.
Page 321 Page 135 of 258 6. Check for continuity between the terminals in each switch position according to the table. Body Electrical System > Power Door Mirrors > Power Door Mirror Actuator > Repair procedures Inspection 1. Remove the front door quadrant inner cover. Take care not to damage fixing clips. (Refer to the Body group - "Front door") 2.
Page 322 Page 136 of 258 Body Electrical System > Power Windows > Components and Components Location Component Location 1. Instrument panel junction box (Power 6. Front window motor window relay) 7. Rear window motor 2. Passenger window switch 8. Driver power window main switch 3.
Page 323 Page 137 of 258 2. Remove the front door trim. (Refer to the Body group - "Front door") 3. Disconnect the connector from the motor. 4. Connect the motor terminals directly to a 12 volt battery and check that the motor operates smoothly. Next, reverse the polarity and check that the motor operates smoothly in the reverse direction.
Page 324 Page 138 of 258 4. Connect the motor terminals directly to a 12 volt battery 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 325 Page 139 of 258...
Page 326 Page 140 of 258 Rear Power Window Switch...
Page 327 Page 141 of 258 Body Electrical System > Power Windows > Power Window Switch > Repair procedures Inspection Power Window Main Switch Inspection 1. Disconnect the negative (-) battery terminal. 2. Remove the front door trim. (Refer to the Body group - "Front door") 3.
Page 328 Page 142 of 258 4. Check for continuity between the terminals in each switch position according to the table. If the continuity condition is not normal, replace the switch. Passenger Power Window Switch Inspection 1. Disconnect the negative (-) battery terminal. 2.
Page 329 Page 143 of 258 3. Disconnect the connector from the switch. 4. Check for continuity between the terminals in each switch position according to the table. If the continuity condition is not normal, replace the switch. [Manual Power Window] Rear Power Window Switch Inspection 1.
Page 330 Page 144 of 258 4. Check for continuity between the terminals in each switch position according to the table. If the continuity condition is not normal, replace the switch. [Manual Power Window] Body Electrical System > Power Windows > Power Window Relay > Repair procedures Inspection 1.
Page 331 Page 145 of 258 1. No windows operate from the main switch on the driver's door. 2. Driver's side window does not operate.
Page 332 Page 146 of 258 3. Passenger's side window does not operate. Body Electrical System > Rear Glass Defogger > Components and Components Location Component Location...
Page 333 Page 147 of 258 1. Rear window defogger switch 3. Passenger compartment junction 2. Rear window defogger Body Electrical System > Rear Glass Defogger > Rear Glass Defogger Printed Heater > Repair procedures 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.
Page 334 Page 148 of 258 1. Turn on the defogger switch and use a voltmeter to measure the voltage of each heater line at the glass center point. If a voltage of approximately 6V is indicated by the voltmeter, the heater line of the rear window is considered satisfactory.
Page 335 Page 149 of 258 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 336 Page 150 of 258 Body Electrical System > Rear Glass Defogger > Rear Glass Defogger Switch > Repair procedures Inspection 1. Disconnect the negative (-) battery terminal. 2. Remove the center facia panel after removing upper tray. Take care not to damage fixing clips. (Refer to the Body group - "Crash pad") 3.
Page 337 Page 151 of 258 5. Using an ohmmeter, inspect the continuity between the terminals after removing controller. Body Electrical System > Windshield Wiper/Washer > Components and Components Location Component Location...
Page 338 Page 152 of 258 1. Windshield wiper arm & blade 5. Washer motor 2. Wiper & washer switch 6. Washer reservoir 3. Windshield washer hose 7. Wiper relay (Engine room relay 4. Windshield wiper motor & linkage box) 8. Rear washer hose Body Electrical System >...
Page 339 Page 153 of 258 1. Cap 5. Cowl top cover 2. Nut 6. Bolt 3. Wiper arm & blade 7. Wiper motor & linkage 4. Retainer assembly 8. Wiper motor connector Body Electrical System > Windshield Wiper/Washer > Windshield Wiper-Washer Switch > Repair procedures Removal 1.
Page 340 Page 154 of 258 2. Remove the steering column upper and lower shrouds (A) after loosening 3 screws. 3. Remove the wiper switch (A) after disconnecting the connector(B) with pushing the lock pin (C).
Page 341 Page 155 of 258 Installation 1. Install the windshield wiper switch. 2. Connect the wiper switch connector. 3. Install the steering column upper and lower shrouds. Inspection 1. With the multi function switch in each position, make sure that continuity exists between the terminals below. If continuity is not as specified, replace the multi-function switch.
Page 342 Page 156 of 258 Body Electrical System > Windshield Wiper/Washer > Front Wiper Motor > Repair procedures Removal 1. Remove the windshield wiper arm and blade after removing a nut (A). 2. Remove the weather strip and the cowl top cover (A) after removing 5 retainers. 3.
Page 343 Page 157 of 258 Installation 1. Install the wiper motor and linkage assembly and then connect the wiper motor connector. TORQUE : 7-11Nm (0.7-1.1, kgf.m, 5.0-7.9 lbf.ft) 2. Install the cowl top cover. 3. Install the windshield wiper arm and blade. TORQUE : 22.5~26.5 Nm (2.3~2.7 kgf.m, 16.6~19.5 lbf.ft) - The windshield wiper motor must be cycled to make sure that it is in the park position.
Page 344 Page 158 of 258 5. Set the cowl top cover on the specified spray position. Specified Distance (mm) Distance (in) position 111~171 4.37~6.73 326~426 12.8~16.7 9.68 12.2 Inspection Speed Operation Check 1. Remove the connector(A) from the wiper motor. (1. Blank, 2. Battery+, 3. Parking, 4. High, 5. GND, 6. Low) 2.
Page 345 Page 159 of 258 5. Check that the motor stops running at the off position. Body Electrical System > Windshield Wiper/Washer > Front Washer Motor > Repair procedures Removal - When servicing the washer pump, be careful not to damage the washer pump seal. - Do not operate the washer pump before filling the washer reservoir.
Page 346 Page 160 of 258 4. Remove the washer reservoir (A) after removing bolts. Installation 1. Install the washer reservoir. Before installing the pump motor, check the filter for foreign material or contamination. if necessary, clean the filter into the pump motor. 2.
Page 347: Front & Rear
Page 161 of 258 4. If they are abnormal, replace the washer motor (A). Front Front & Rear washer (A) washer (B) Windshield washer Windshield washer Ground Ground Rear washer (+) Body Electrical System > Windshield Wiper/Washer > Troubleshooting Troubleshooting...
Page 348 Page 162 of 258 1. Wiper low and wiper high do not work. 2. When washer switch is on, wiper does not work. Body Electrical System > Rear Wiper/Washer > Components and Components Location Component Location...
Page 349 Page 163 of 258 1. Head cap 4. Packing (rubber) 2. Nut 5. Rear wiper motor 3. Rear wiper arm & Blade assembly 6. Bolt Body Electrical System > Rear Wiper/Washer > Rear Wiper Motor > Repair procedures Removal 1. Detach the wiper cap (A), then remove the rear wiper arm (C) after removing a nut (B).
Page 350 Page 164 of 258 2. Open the tailgate then remove the tailgate trim. 3. Disconnect the rear wiper motor connector (4P) (B) then remove the rear wiper motor (A) after removing 3 bolts.
Page 351: Tightening Torque
Page 165 of 258 4. Remove the rubber packing (A). Installation 1. Install the rubber packing. 2. Install the rear wiper motor assembly. Tightening torque : 6.86 ~ 9.81N.m (0.7 ~ 1.0kgf.m, 5.0 ~ 7.2lb-ft) 3. Intall the tailgate trim. 4.
Page 352 Page 166 of 258 Inspection Rear Wiper Motor 1. Remove the 4P connector from the rear wiper motor. 2. Connect battery positive (+) and negative (-) cables to terminals 4 and 1 respectively. 3. Check that the motor operates normally. Replace the motor if it operates abnormally. (1.
Page 353 Page 167 of 258 Body Electrical System > Rear Wiper/Washer > Rear Wiper Relay > Repair procedures Inspection Check for continuity between the terminals. 1. Disconnect the negative (-) battery terminal. 2. Remove the passenger compartment junction box. 3. Check for continuity between the terminals. 4.
Page 354 Page 168 of 258 1. With the rear wiper & washer switch in each position, make sure that continuity exists between the terminals below. If continuity is not as specified, replace the multifunction switch. Rear Wiper & Washer Switch Body Electrical System > Rear Wiper/Washer > Rear Washer Motor > Repair procedures Inspection 1.
Page 355 Page 169 of 258 Body Electrical System > Electro chromic Inside Rear View Mirror > Description and Operation Description The ECM (Electro Chromic inside rear view Mirror) is for dimming the reflecting light from a vehicle behind at night, in order the user not to be dazzled by the light. The front looking sensor detects brightness of the surroundings, while the rearward looking sensor the strength of the reflecting light so that adjusts the reflexibility of the mirror in the range of 10~70%.
Page 356 Page 170 of 258 1. The front looking sensor sees if the brightness of the surroundings is low enough for the mirror to operate its function. 2. The rearward looking sensor detects glaring of the reflecting light from a vehicle behind. 3.
Page 357 Page 171 of 258 cleaner. If the back view camera system image is not clear or seems distorted, it may be covered with water droplets, snow, mud or any other substance. If this occurs, clean the camera lens before using the reverse camera system. The back view camera system is a reverse aid supplement device that still requires the driver to use it in conjunction with the back view mirror and the side mirrors for maximum coverage.
Page 358 Page 172 of 258 4. The ECM should be darkened as soon as the rearward looking sensor detects the light. If this test is performed in daytime, the ECM may be darkened as soon as the forward looking sensor is covered.
Page 359 Page 173 of 258 Body Electrical System > Hands Free System > Components and Components Location Components 1. Hands free call switch 4. Front right speaker 2. Mic 5. Audio head unit (hands free 3. Front left speaker control) There is no hands free jack. This system supports Bluetooth(wireless system). Body Electrical System >...
Page 360 Page 174 of 258 • The phone must be paired to the system before using the hands-free feature. Only one linked cellular phone can be used with the system at a time. The system is available in English, US Spanish, or Canadian French languages. If the vehicle is moving do not use a cellular phone or connect the Bluetooth phone.
Page 361 Page 175 of 258 7. The Pairing procedure of the cellularphone varies according to each cellularphone. The system may not function in the following cases: If 5 phones have already been registered.If the system cannot communicate with the phone. To connect phone The registered phones can be selected.
Page 362 Page 176 of 258 In the following situations, your voice may not reach the other party: 1. Talk alternately with the other partyon the phone. If you talk at the sametime, the voice may not reach eachother parties. (This is not a malfunction.)(It is not a malfunction.) 2.
Page 363 Page 177 of 258...
Page 364 Page 178 of 258 Body Electrical System > Hands Free System > Hands Free Switch > Repair procedures Inspection...
Page 365 Page 179 of 258 1. Check the hands free remote control switch for resistance between No.3 and No.4 terminals in each switch position. Connector Resistance Switch terminal (±5%) HANG UP 6 - 7 (RH) 18.91 kΩ CALL 6 - 7 (RH) 10.71 kΩ...
Page 366 Page 180 of 258 5. Remove the hands free remote control switch(A) after removing the steering wheel remote control switch connector(B) and 2 screws. Installation 1. Reassemble the steering wheel remote control switch after connecting the connector. 2. Reassemble the steering wheel. 3.
Page 367 Page 181 of 258 3. Remove the hands free mic(A) after loosening the connector and screw(3EA) from loof top. 4. Check the continuity of Mic between terminals. Body Electrical System > Hands Free System > Troubleshooting Troubleshooting...
Page 368 Page 182 of 258 Problem Possible cause Solution Not pairing Bluetooth device of Car is not discoverable Enter Bluetooth pairing (searching) mode mode User’s phone is Bluetooth off mode User’s phone set Bluetooth on Making an attempt pairing others bluetooth Check Bluetooth device name and address system (12 word) to attempt paring...
Page 369 Page 183 of 258 1. Sunroof 3. Sunroof motor & 2. Sunroof switch controller Body Electrical System > Sun Roof > Schematic Diagrams Circuit Diagram...
Page 370 Page 184 of 258 Body Electrical System > Sun Roof > Sunroof Switch > Repair procedures Inspection 1. Disconnect the negative (-) battery terminal. 2. Detach the lamp lens (A) from the overhead console lamp with a flat-tip screwdriver.
Page 371 Page 185 of 258 3. Remove the over head console lamp (A) after removing the screws (2EA). 4. Check for continuity between the terminals. If the continuity is not as specified, replace the sunroof switch. Body Electrical System > Sun Roof > Sunroof Motor > Repair procedures Inspection 1.
Page 372 Page 186 of 258 3. Remove the sunroof motor after removing the screws (3EA) and connector (10P). 4. Ground the terminals as below table, and check that the sunroof unit operates as below table. 5. Make these input tests at the connector if any test indicates a problem, find and correct the cause, then recheck the system.
Page 373 Page 187 of 258 the Run-time and Cool-time of the motor as follows: 1. The Sunroof ECU detects the Run- time of motor 2. Motor can be operated continuously for the 1st run-time(120 ± 10sec.). 3. The continuous operation of motor stops after the 1st Run-time(120 ± 10sec.). 4.
Page 374 Page 188 of 258 Component Location 1. Engine room junction box 7. Over head lamp (Head lamp Low/High, Fog 8. Room lamp(Center) lamp relay) 9. Tail/Stop lamp 2. Passenger compartment 10. Rear turn signal lamp junction box 11. Back up lamp (Tail lamp relay,Hazard relay) 12.
Page 375 Page 189 of 258 Head Lamp Relay / Front Lamp Relay 1. Disconnect the negative(-) battery terminal. 2. Pull out the relay from the engine compartment relay box. A : Head lamp(Low) relay B : Head lamp (High) relay 3. Check for continuity between terminals. There should be continuity between the No.87 and No.30 terminals when power and ground are connected to the No.86 and No.85 terminals.
Page 376 Page 190 of 258 4. Check for continuity between the terminals. (1) There should be continuity between the No.1 terminal in the I/P-F and the No.17(LH) or 16(RH) terminal in the I/P-I when power and ground are connected to the No.1 terminal in the I/P-F and the No.18 terminal in the I/P-A.
Page 377 Page 191 of 258 4. With the head lamp and battery in normal condition, aim the head lamps so the brightest portion falls on the horizontal and vertical lines. Make vertical(A) adjustments to the lower beam using the adjusting wheel. Aiming Direction Condition Turning Clockwise...
Page 378 Page 192 of 258 1. Turn the low beam on with driver. The cut-off line should be projected in the allowable range shown in the picture. In case of equipping with the manual leveling device, set the leveling device switch on the "O" position.
Page 379 Page 193 of 258 2. Turn the front fog lamp on with driver. The cut-off line should be projected in the allowable range shown in the picture. Removal Head lamps become very hot during use; do not touch them or any attaching hardware immediately after they have been turned off.
Page 380 Page 194 of 258 3. Loosen the mounting bolts (2EA) of head lamp. Remove the head lamp assembly (A) after disconnecting the lamp connectors. Take care that retaining clip (A) is not to be damaged. 4. Remove the bulb caps from the head lamp assembly after turning in the counter clock-wise direction. A : Head lamp low/high bulb B : Turn signal bulb cab...
Page 381: Side Marker
Page 195 of 258 5. Remove the head lamp bulbs after releasing the lock of the set spring. A : Head lamp low/high bulb, B : Turn signal bulb Installation 1. Install the head lamp bulbs. 2. Install the head lamp bulb caps. 3.
Page 382 Page 196 of 258 2. Detach the lamp lens (A) from the room lamp with a flat-tip screwdriver then remove the bulb (B). 3. Loosen the fixing screw (2EA) and disconnect the 3P connector(B). And then remove the room lamp assembly (A).
Page 383 Page 197 of 258 1. Remove the room lamp assembly then check for continuity between terminals. Body Electrical System > Lighting System > Overhead Console Lamp > Repair procedures Removal 1. Disconnect the negative (-) battery terminal. 2. Detach the lamp lens (A) from the room lamp with a flat-tip screwdriver. 3.
Page 384 Page 198 of 258 4. Disconnect the sunroof switch and lamp connector (B) and then remove the overhead console lamp (A). Installation 1. Install the overhead console lamp after connecting the sunroof switch and lamp connector. 2. Install the lens after tightening 2 screws. Inspection Remove the overhead console lamp assembly then check for continuity between terminals.
Page 385 Page 199 of 258 Body Electrical System > Lighting System > Hazard Lamp Switch > Repair procedures Inspection Hazard Lamp Switch 1. Disconnect the negative (-) battery terminal. 2. Remove the crash pad center facia panel. (Refer to the Body group - "Crash pad") 3.
Page 386 Page 200 of 258 2. There should be no continuity between the No.2 terminals in the I/P-F and No.5 or 6 terminals in the I/P-A when power is disconnected. Body Electrical System > Lighting System > Flasher Unit > Repair procedures Inspection 1.
Page 387 Page 201 of 258 5. Connect the two turn signal lamps in parallel to terminals 1 and 3. Check that the bulbs turn on and off. The turn signal lamps should flash 60 to 120 times per minute. If one of the front or rear turn signal lamps has an open circuit, the number of flashes will be more than 120 per minute.
Page 388 Page 202 of 258 4. Check for intensity of new rheostat switch. If the light intensity of the lamps changes smoothly without any flickering when the rheostat is turned, it can be assumed that the rheostat is normal. Body Electrical System > Lighting System > Front Fog Lamps > Repair procedures Removal 1.
Page 389 Page 203 of 258 4. There should be no continuity between the No.87 and No.30 terminals when power is disconnected. Body Electrical System > Lighting System > License Lamps > Repair procedures Removal License Lamp 1. Disconnect the negative (-) battery terminal. 2.
Page 390 Page 204 of 258 3. Replace the bulb (A). Luggage Room Lamp 1. Disconnect the negative(-) battery terminal. 2. Remove the luggage room lamp lens(A) from the luggage side trim. 3. Remove the bulb(A). Installation License Lamp 1. Install the bulb. 2.
Page 391 Page 205 of 258 2. Remove the high mounted stop lamp cover (A). 3. Remove the connector (A) and bolts. 4. Replace the bulbs (A). Installation 1. Install the high mounted stop lamp and connector. 2. Install the high mounted stop lamp cover. Body Electrical System >...
Page 392 Page 206 of 258 2. Remove the rear combination lamp assembly (B) after removing connector (A) and screw (3EA). 3. Replace the lamp bulbs after turning in the counter clock-wise direction. A: Turn signal lamp B: Back up lamp C: Tail / Stop lamp Installation 1.
Page 393: Troubleshooting
Page 207 of 258 Troubleshooting Symptom Possible cause Remedy Bulb burned out Replace bulb One lamp does not light (all exterior) Socket, wiring or ground faulty Repair if necessary Head lamps do not light Bulb burned out Replace bulb Head lamp fuse (LOW:10A, HIGH:20A) Check for short and replace blown fuse...
Page 394 Page 208 of 258 Flasher unit faulty Check flasher unit Hazard switch faulty Check switch Wiring or ground faulty Repair if necessary Flasher rate too slow or too fast Lamps' wattages are smaller or larger than Replace lamps specified Flasher unit faulty Check flasher unit Back up lamps do not light Bulb burned out...
Page 395 Page 209 of 258 Check for short and replace Room lamp fuse (10A) blown fuse Tailgate room lamp switch faulty Check switch Wiring or ground faulty Repair if necessary Body Electrical System > Daytime Running Lights > DRL Control Module > Repair procedures Inspection 1.
Page 396 Page 210 of 258 Body Electrical System > Immobilizer System > Description and Operation Description The immobilizer system will disable the vehicle unless the proper ignition key is used, in addition to the currently available anti-theft systems such as car alarms, the immobilizer system aims to drastically reduce the rate of auto theft.
Page 397 Page 211 of 258 Components Operations PCM (Power Train Control Module) 1. The PCM(ECM) (A) carries out a check of the ignition key using a special encryption algorithm, which is programmed into the transponder as well as the PCM(ECM) simultaneously. Only if the results are equal, the engine can be started.
Page 398 Page 212 of 258 TRANSPONDER (Built-in keys) The transponder (A) has an advanced encryption algorithm. During the key teaching procedure, the transponder will be programmed with vehicle specific data. The vehicle specific data are written into the transponder memory. The write procedure is once only;...
Page 399 Page 213 of 258 The attempt to repeatedly teach a key, which has been taught already during the same teaching cycle, is recognized by the PCM(ECM). This rejects the key and a message is sent to the tester. The PCM(ECM) rejects invalid keys, which are presented for teaching. A message is sent to the tester. The key can be invalid due to faults in the transponder or other reasons, which result from unsuccessful programming of data.
Page 400 Page 214 of 258 (1) PCM(ECM) learnt status.
Page 401 Page 215 of 258...
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Page 403 Page 217 of 258...
Page 404 Page 218 of 258...
Page 405 Page 219 of 258 (2) PCM(ECM) virgin status. After replacing new "PCM(ECM)" scan tool displays that PCM(ECM) is virgin status in Key Teaching mode. "VIRGIN" status means that PCM(ECM) has not matched any PIN code before. Password Teaching/changing 1. User Password Teaching Procedure The user password for limp home is taught at the service station.
Page 406 Page 220 of 258...
Page 407 Page 221 of 258...
Page 408 Page 222 of 258 In case of putting wrong password, retry from first step after 10 seconds. 3. User password changing...
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Page 410 Page 224 of 258...
Page 411 Page 225 of 258 Limp Home Function 1. Limp Home By Tester If the PCM(ECM) detects the fault of the SMARTRA or transponder, the PCM(ECM) will allow limp home function of the immobilizer. Limp home is only possible if the user password (4 digits) has been given to the PCM(ECM) before.
Page 412 Page 226 of 258...
Page 413 Page 227 of 258 2. Limp Home By Ignition Key The limp home can be activated also by the ignition key. The user password can be input to the PCM(ECM) by a special sequence of ignition on/off. Only if the PCM(ECM) is in status "learnt" and the user password status is "learnt" and the user password is correct, the PCM(ECM) will be unlocked for a period of time (30 sec.).
Page 414 Page 228 of 258 Replacement Problems And Replacement Parts: Scan tool Problem Part set required? All keys have been lost Blank key (4) Antenna coil unit does not work Antenna coil unit ECM does not work PCM(ECM) Ignition switch does not work Ignition switch with Antenna coil unit Unidentified vehicle specific data Key, PCM(ECM)
Page 415 Page 229 of 258 to the new ECM. Keys, which are not taught to the ECM, are invalid for the new ECM (Refer to key teaching procedure). The vehicle specific data have to be left unchanged due to the unique programming of transponder. In case of a defective SMARTRA, it needs teaching the smartra.
Page 416 Page 230 of 258 1. When there is only one key registered and you wish to register another key, you need to re-register the key which was already registered. 2. When the key #1 is registered and master key #2 is not registered, Put the key #1 in the IG/ON or the start position and remove it.
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Page 420 Page 234 of 258 Neutralizing Of SMARTRA The EMS can be set to the status "neutral" by tester Ignition key (regardless of key status) is inserted and after IGN ON. If receiving the correct vehicle password from GST, SMARTRA can be neutralized. The neutralization of SMARTRA is possible if DPN is same as the value inputted by GST.
Page 421 Page 235 of 258 • Neutralizing Setting condition : - In case of "SMARTRA status", "Learnt" - Input correct Pin code by tester • Neutralizing meaning : - Vehicle password(DPN Code) & SEK Code deletion. - Permission of New DPN Learning.
Page 422 Page 236 of 258...
Page 423 Page 237 of 258...
Page 424: Fault Types
Page 238 of 258 Body Electrical System > Immobilizer System > Troubleshooting Diagnosis Of Immobilizer Faults - Communication between the ECM and the SMARTRA. - Function of the SMARTRA and the transponder. - Data (stored in the ECM related to the immobilizer function. The following table shows the assignment of immobilizer related faults to each type: Immobilizer Related Fault types...
Page 425 Page 239 of 258 1. Corrupted data from transponder 2. More than one transponder in the magnetic field P1693 Transponder key fault (Antenna coil) (Transponder no response error/invalid response) 3. No transponder (Key without transponder) in the magnetic field (Antenna coil) 1.
Page 426 Page 240 of 258 3. Disconnect the 5P connector of the SMARTRA unit and then remove the SMARTRA unit (A) after loosening a nut. Installation 1. Install the immobilizer control unit after connecting the unit connector. 2. Install the crash pad. Body Electrical System >...
Page 427 Page 241 of 258 Body Electrical System > Rear Parking Assist System > General Safety Information and Caution Warning 1. Range detected by back sensors is limited. Watch back before reversing. 2. There is a blind spot below the bumper. Low objects (for example boundary barrier) may be detected from minimum 1.5m away unable to detect at nearer.
Page 428 Page 242 of 258 6. False alarm may operate in the following condition: irregular road surface, gravel road, sloped road and grass. Upon alarm generation by grass the alarm may be generated by rock behind grass. Be sure to check for the safety.
Page 429: Specification
Page 243 of 258 Item Specification Rear parking assist system Voltage rating DC 12V control unit Operation voltage DC 9 ~ 16 V Operation temperature -30°C ~ + 80°C Operation current MAX 600 mA Operation frequency 40 ± 5 KHz Detective method Direct and indirect detection Ultrasonic sensor...
Page 430 Page 244 of 258 1. Rear parking assist 3. Buzzer system control unit 2. Ultrasonic sensor Body Electrical System > Rear Parking Assist System > Schematic Diagrams Circuit Diagram...
Page 431 Page 245 of 258 Body Electrical System > Rear Parking Assist System > Description and Operation Description When reversing, the driver is not easy to find objects in the blind spots and to determine the distance from the object. In order to provide the driver safety and convenience, rear parking assist system will operate upon shifting to "R"...
Page 432 Page 246 of 258 alarm. First alarm : Object comes near to the sensor located at the rear of vehicle, within 81-120cm ± 15cm Second alarm : Object comes near to the sensor located at the rear of vehicle, within 41-80cm ± 10cm Third alarm : Object comes near to the sensor located at the rear of vehicle, within 40cm ±...
Page 433 Page 247 of 258 4. Effective operation range is 10km/h or less for the vehicle speed. Body Electrical System > Rear Parking Assist System > Rear Parking Assist System Control Unit > Repair procedures Removal 1. Disconnect the negative (-) battery terminal. 2.
Page 434 Page 248 of 258 Body Electrical System > Rear Parking Assist System > Parking Assist Sensor > Description and Operation Operation Principle The sensor emits ultrasonic wave to the objects, and it measures the time until reflected wave returns, and calculates the distance to the object.
Page 435 Page 249 of 258 Sensor Detection Range...
Page 436 Page 250 of 258 1. 14cm (dia.) plastic rod is used for the test target. 2. The test result may differ by a different target object. 3. Detection range may be reduced by dirt accumulated on sensor, and extremely hot or cold weather. 4.
Page 437 Page 251 of 258 Body Electrical System > Rear Parking Assist System > Parking Assist Sensor > Repair procedures Removal 1. Disconnect the negative (-) battery terminal. 2. Remove the rear bumper. (Refer to the Body group - "Rear bumper") 3.
Page 438 Page 252 of 258 The buzzer should make a sound. If the buzzer fails to make a sound, replace it. Removal 1. Disconnect the negative (-) battery terminal. 2. Remove the main crash pad (A). (Refer to the Body group - "Crash pad") 3.
Page 439 Page 253 of 258 1. Disconnect the ignition switch connector (B) and key warning switch connector (A) from under the steering column. 2. Check for continuity between the terminals. 3. If continuity is not specified, replace the switch. Removal 1. Disconnect the negative (-) battery terminal.
Page 440 Page 254 of 258 2. Remove the steering column upper and lower shrouds (A). 3. Remove the ignition switch (A) after loosening the screw (B) with IG ON and disconnecting the 6P connector (C). 4. Remove the door warning switch and key illumination lamp (A) after loosening the screw and disconnecting the 6P connector (B).
Page 441 Page 255 of 258 1. Install the key lock cylinder. 2. Install the interlock cable. Install procedure for interlock cable 1. After setting key interlock cable and IGN lock assembly, fix the key interlock cable with pre- assembled set screw. 2.
Page 442 Page 256 of 258 1. Back view 2. ECM mirror camera Body Electrical System > Back View Camera System > Schematic Diagrams Circuit Diagram...
Page 443 Page 257 of 258 Body Electrical System > Back View Camera System > Description and Operation Description Back view camera will activate when the backup light is ON with the ignition switch ON and the shift lever in the R position.
Page 444 Page 258 of 258 2. Remove the connector and nuts(2EA). 3. Remove the back view camera(A). Installation 1. Install the back view camera. 2. Install the tailgate trim.
Page 445: Specification
Page 1 of 100 SOUL(AM) > 2010 > G 1.6 DOHC > Brake System Brake System > General Information > Specifications Specifications Item Specification Master cylinder Type Tandem type Piston stroke 45 mm (1.77 in) Fluid level warning sensor Provided Proportioning valve (CBS) Cut-in pressure (Split point) 20 kg/cm²...
Page 446 Page 2 of 100 Specification(ABS) Part Item Standard value Remark System 4 Channel 4 Sensor (Solenoid) Motor, valve relay intergrated Type type HECU Operating Voltage 10 ~ 16 V Operating -40 ~ 120 °C (-40 ~ 248°F) Temperature Motor power 210 W Min.
Page 447 Page 3 of 100 Steering Wheel Current consumption Max. 100mA Angle Output measurement range -780 ~ +799.9° Sensor Operating Angular velocity 1500°/sec Operating Voltage 10 V ~ 16V Current Consumption Max. 150mA Yaw rate& Yaw rate sensor Lateral G sensor -75 ~ 75°/sec measurement range (CAN TYPE)
Page 448: Recommended Lubricant
Page 4 of 100 Item kgf.m lb-ft Master cylinder to booster mounting nut 12.7 ~ 16.7 1.3 ~ 1.7 9.4 ~ 12.3 Brake booster mounting nut 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8 Bleeder screw 6.9 ~ 12.7 0.7 ~ 1.3 5.1 ~ 9.4 Brake tube to HECU-CBS/ABS...
Page 449: Troubleshooting
Page 5 of 100 Tool (Number and Name) Illustration 09581 - 11000 Pushing back of the front disc and rear Piston expander disc brake piston Brake System > General Information > Troubleshooting Troubleshooting Problem Symptoms Table Use the table below to help you find the cause of the problem. The numbers indicate the priority of the possible cause of the problem.
Page 450 Page 6 of 100 3. Disc (Scored) Replace 4. Sliding pin (Worn) Replace 5. Pad or lining (Dirty) Clean Replace 6. Pad or lining (Glazed) Replace 7. Return spring (Faulty) Replace 8. Brake pad shim (Damage) Replace 9. Shoe hold-down spring (Damage) Brake fades 1.
Page 451 Page 7 of 100 Brake System Bleeding • Do not reuse the drained fluid. • Always use genuine DOT3/DOT4 brake Fluid. Using a non-genuine DOT3/DOT4 brake fluid can cause corrosion and decrease the life of the system. • Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. •...
Page 452 Page 8 of 100 3. Loosen the right-rear brake bleed screw (A) to allow air to escape from the system. Then tighten the bleed screw securely. Front Rear 4. Repeat the procedure for wheel in the sequence shown below until air bubbles no longer appear in the fluid. 5.
Page 453 Page 9 of 100 1. Brake booster 2. Master cylinder assembly 3. Vacuum hose Brake System > Brake System > Brake Booster > Repair procedures Brake Booster Operating Test For simple checking of the brake booster operation, carry out the following tests.
Page 454 Page 10 of 100 1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains unchanged, the booster is inoperative.
Page 455: Tightening Torque
Page 11 of 100 2. Disconnect the vacuum hose (A) from the brake booster. 3. Remove the master cylinder. (Refer to Master cylinder) 4. Remove the snap pin (A) and clevis pin (B). 5. Remove the mounting nuts. Tightening torque : 16.7 ~ 25.5N.m (1.7 ~ 2.6kgf.m, 12.3 ~ 18.8lb-ft) 6.
Page 456 Page 12 of 100 Inspection 1. Inspect the check valve in the vacuum hose. Do not remove the check valve from the vacuum hose. 2. Check the boot for damage. Installation 1. Installation is the reverse of removal. • Before installing the pin, apply the grease to the joint pin.
Page 457 Page 13 of 100 1. Reservoir cap 4. Master cylinder 2. Reservoir body 3. Grommet 5. O-Ring Brake System > Brake System > Master Cylinder > Repair procedures Removal 1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
Page 458 Page 14 of 100 2. Remove the cowl top cover. (Refer to the Body group-Cowl top Cover) 3. Disconnect the brake fluid level switch connector (A) from the reservoir. 4. Remove the brake fluid from the master cylinder reservoir with a syringe. •...
Page 459 Page 15 of 100 7. Remove the reservoir (C) from the master cylinder (B), after removing mounting screw (A). 8. Remove the two grommets. 9. Remove the master cylinder (B) from the brake booster after loosening the mounting nuts (A). Tightening torque : 12.7 ~ 16.7N.m (1.3 ~ 1.7kgf.m, 9.4 ~ 12.3lb-ft) Installation...
Page 460 Page 16 of 100 2. Connect two pressure gauges (D); one to the output valve of the front (B) and rear (C) brake. Be sure to bleed the system after connecting the pressure gauges. 3. With the brake applied, measure the front pressure and the rear pressure. If the measured pressures are within the specified range as illustrated, the proportioning valve is good.
Page 461 Page 17 of 100 When installing brake hose, be sure to comply with the torque specification to prevent twisted hose. Brake System > Brake System > Brake Line > Repair procedures Removal 1. Remove the wheel & tire.
Page 462 Page 18 of 100 2. Remove the brake hose clip (C). 3. Disconnect the brake tube by loosening the tube flare nut (B). Tightening torque : 12.7 ~ 16.7N.m (1.3 ~ 1.7kgf.m, 9.4 ~ 12.3lb-ft) 4. Disconnect the brake hose from the brake caliper by loosening the bolt (A). Tightening torque : 24.5 ~ 29.4N.m (2.5 ~ 3.0kgf.m, 18.1 ~ 21.7lb-ft) Front...
Page 463 Page 19 of 100 4. Check the brake hose mounting bracket for crack or deformation. Installation 1. Installation is the reverse of removal. Use a new washer(A) whenever installing. 2. After installation, bleed the brake system. (Refer to Brake system bleeding) 3.
Page 464 Page 20 of 100 1. Brake pedal member 3. Brake pedal assembly 4. Mounting bracket 2. Stop lamp switch Brake System > Brake System > Brake Pedal > Repair procedures Removal 1. Remove the lower crash pad. (Refer to the Body group- crash pad).
Page 465 Page 21 of 100 2. Disconnect the stop lamp switch connector (A). 3. Remove the mounting bracket bolt (B). Tightening torque : 16.7 ~ 25.5N.m (1.7 ~ 2.6kgf.m, 12.3 ~ 18.8lb-ft) 4. Remove the snap pin (A) and clevis pin (B). 5.
Page 466 Page 22 of 100 4. Check the stop lamp switch. (1) Connect a circuit tester to the connector of stop lamp switch, and check whether or not there is continuity when the plunger of the stop lamp switch is pushed in and when it is released. (2) The stop lamp switch is in good condition if there is no continuity when plunger(A) is pushed.
Page 467 Page 23 of 100 1. Guide rod bolt 5. Inner pad shim 2. Bleed screw 6. Brake pad 3. Caliper 7. Pad retainer bracket 4. Caliper body Brake System > Brake System > Front Disc Brake > Repair procedures Removal 1.
Page 468 Page 24 of 100 2. Loosen the hose eye-bolt (B) and caliper mounting bolts (C), then remove the front caliper assembly (A). Tightening torque Brake hose to caliper(B): 24.5 ~ 29.4N.m (2.5 ~ 3.0kgf.m, 18.1 ~ 21.7lb-ft) Caliper assembly to knuckle(C): 78.5 ~ 98.1N.m (8.0 ~ 10.0kgf.m, 57.9 ~ 72.3lb-ft) 3.
Page 469 Page 25 of 100 2. Loosen the guide rod bolt (B) and pivot the caliper up out of the way. Tightening torque : 21.6 ~ 31.4N.m (2.2 ~ 3.2kgf.m, 15.9 ~ 23.1lb-ft) 3. Replace pad shim (B), pad retainers (C) and brake pads (B) in the caliper bracket (A). Inspection Front Brake Disc Thickness Check 1.
Page 470 Page 26 of 100 4. If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle. Front Brake Pad Check 1. Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value. Pad thickness Standard value : 11mm (0.43in) Service limit : 2.0mm (0.0787in)
Page 471 Page 27 of 100 Components 1. Guide rod bolt 5. Inner pad shim 2. Bleed screw 6. Brake pad 3. Caliper 7. Pad retainer bracket 4. Caliper body Brake System > Brake System > Rear Disc Brake > Repair procedures Removal...
Page 472 Page 28 of 100 1. Remove the rear wheel & tire. Tightening torque : 88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft) 2. Loosen the hose eye-bolt (B) and caliper mounting bolts (C), then remove the rear caliper assembly (A). Tightening torque Brake hose to caliper(B): 24.5 ~ 29.4N.m (2.5 ~ 3.0kgf.m, 18.1 ~ 21.7lb-ft)
Page 473 Page 29 of 100 1. Loosen the guide rod bolt (B) and pivot the caliper up out of the way. Tightening torque : 21.6 ~ 31.4N.m (2.2 ~ 3.2kgf.m, 15.9 ~ 23.1lb-ft) 2. Replace pad shim, pad retainers (C) and brake pads (B) in the caliper bracket (A). Inspection Rear Brake Disc Thickness Check 1.
Page 474 Page 30 of 100 Rear Brake Pad Check 1. Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value. Pad thickness Standard value: 10mm (0.39 n) Service limit: 2.0 mm (0.0787 in) 2.
Page 475 Page 31 of 100 1. Shoe hold down pin 6. Adjusting lever 2. Shoe 7. Adjusting lever 3. Shoe hold spring spring 4. Upper return spring 8. Lower return spring 5. Shoe adjuster 9. Brake drum Brake System > Brake System > Rear Drum Brake > Repair procedures Removal •...
Page 476 Page 32 of 100 1. Release the parking brake. 2. Remove the rear tire and wheel. 3. Remove the rear brake drum (A). 4. Remove the shoe hold spring and shoe hold pin (B). 5. Remove the upper return spring (A). 6.
Page 477 Page 33 of 100 10. Remove the bolt (C) and the wheel cylinder (B) from the backing plate (D). Installation • Do not spill brake fluid on the vehicle: it may damage the paint; if brake fluid does contact the paint. Wash it off immediately with water.
Page 478 Page 34 of 100 4. Clean the threaded portions of adjuster sleeve (A) and push rod female (B). Coat the threads of the adjuster assembly with grease. To shorten the clevises, turn the adjuster bolt (C). 5. Hook the shoe adjuster lever (A), then install it to the brake shoe. 6.
Page 479 Page 35 of 100 9. Apply brake cylinder grease or equivalent rubber grease to the brake shoe ends and opposite edges of the shoes shown. Don't get grease on the brake linings. 10. Install the brake shoes (A) onto the backing plate. Be careful not to damage the wheel cylinder dust covers. 11.
Page 480 Page 36 of 100 1. Raise the rear of the vehicle, and make sure it is securely supported. 2. Release the parking brake, and remove the rear brake drum. 3. Check the wheel cylinder (A) for leakage. 4. Check the brake linings (B) for cracking, glazing, wear, and contamination. 5.
Page 481 Page 37 of 100 11. Inspect the brake lining and drum for proper contact. 12. Inspect the wheel cylinder outside for excessive wear and damage. 13. Inspect the backing plate for wear or damage. Brake System > Parking Brake System > Parking Brake Assembly > Components and Components Location Component Location...
Page 482 Page 38 of 100 1. Parking brake 3. Parking brake 2. Parking brake lever cable 4. Equalizer assembly Component Disc Brake Type...
Page 483 Page 39 of 100 1. Back plate 6. Return spring 2. Strut spring 7. Adjuster 3. strut 8. Return spring 4. Shoe & lining 9. Cup washer 5. Shoe guie 10. Shoe hold down spring Drum Brake Type...
Page 484 Page 40 of 100 1. Shoe hold down pin 6. Adjusting lever 2. Shoe 7. Adjusting lever 3. Shoe hold spring spring 4. Upper return spring 8. Lower return spring 5. Shoe adjuster 9. Brake drum Brake System > Parking Brake System > Parking Brake Assembly > Repair procedures Removal Parking Brake Lever...
Page 485 Page 41 of 100 The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature failure. 1. Remove the floor console. (Refer to Body group. -"Floor console") 2. Loosen the adjusting nut (A) and the parking brake cables. 3.
Page 486 Page 42 of 100 3. Remove the brake Disc (A). 4. Remove the rear hub unit bearing (A). 5. Remove the shoe hold down pin (A) and the spring (B) by pushing the retainer spring and turning the pin. 6. Remove the adjuster assembly (A) and the return spring (B).
Page 487 Page 43 of 100 7. Remove the parking brake cable (B) from the brake shoe (A). 8. Remove the strut (C) and the strut spring (D). 9. Remove the brake shoe. 10. Remove the parking brake cable retaining (B), from the parking brake cable (A). Parking Brake Shoe (Drum Brake Type) 1.
Page 488 Page 44 of 100 3. Remove the brake shoe (A). (Refer to "Rear drum brake removal") Installation Parking Brake Shoe (Disc Brake Type) 1. Install the brake shoe(A) to the back plate(B). 2. Install the shoe hold down pin(C) and the spring(D) by pushing the retainer spring (D) and turning the pins. 3.
Page 489 Page 45 of 100 5. Apply a coating of the specified grease to each sliding parts of parking brake as shown. Specified grease : Multi purpose grease SAE J310, NLGI No.2 6. Install the rear brake disc, then adjust the rear brake shoe clearance. (1) Remove the plug from the disc.
Page 490 Page 46 of 100 1. Install the brake shoe (A). (Refer to "Rear drum brake installation") 2. Install the brake drum (A). 3. Depress the brake pedal several times to set the self-adjusting brake. 4. Adjust the parking brake lever. Parking Brake Lever 1.
Page 491: Parking Brake Lever Stroke
Page 47 of 100 2. Apply a coating of the specified grease to each sliding parts (A) of the ratchet plate or the ratchet pawl. Specified grease : Multi purpose grease SAE J310, NLGI No.2 3. Install the parking brake cable adjuster, then adjust the parking brake lever stroke by turning adjusting nut (A). Parking brake lever stroke : 5 ~ 7 cliks (Pull the lever with 20kg) After repairing the parking brake shoe, adjust the brake shoe clearance, and then adjust the parking brake...
Page 492: Disc Brake Type
Page 48 of 100 6. Reconnect the connector (A) of parking brake switch. Inspect the continuity of parking brake switch. When the brake lever is pulled : continuity When the brake lever is released : no continuity 7. Install the floor console. (Refer to Body group - "Floor console") Adjustment Parking Brake Shoe Clearance Adjustment Disc Brake Type...
Page 493: Drum Brake Type
Page 49 of 100 Parking Brake Shoe Clearance Adjustment Drum Brake Type 1. Depress the brake pedal several times to set the self-adjusting brake. For Drum Brake type, shoe clearance is automatically adjusted by the adjuster and adjusting lever. Parking Brake Lever Stroke Adjustment 1.
Page 494 Page 50 of 100 4. Release the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are turned. Readjust if necessary. 5. Make sure that the parking brakes are fully applied when the parking brake lever is pulled up fully. 6.
Page 495 Page 51 of 100 1. Front right wheel speed 4. Hydraulic line sensor 5. Rear right wheel speed sensor 2. ABS control module (HECU) 6. Rear left wheel speed sensor 3. Front left wheel speed sensor Brake System > ABS(Anti-Lock Brake System) > Description and Operation Description This specification applies to HCU(Hydraulic Control Unit) and ECU(Electronic Control Unit) of the HECU.(Hydraulic and Electronic Control Unit)
Page 496 Page 52 of 100 - Failsafe function. - Self diagnosis function. - Interface with the external diagnosis tester. Installation position : engine compartment - Brake tube length from Master cylinder port to HECU inlet port should be max. 1m - The position should not be close to the engine block and not lower than the wheel. Operation The ECU shall be put into operation by switching on the operating voltage (IGN).
Page 497 Page 53 of 100 1. ABS Warning Lamp The active ABS warning lamp indicates the self-test and failure status of the ABS. The ABS warning lamp shall be on: A. During the initialization phase after IGN ON. (continuously 3 seconds). B.
Page 498 Page 54 of 100 2. Dump Mode Under the emergency braking, if the wheels start to lock up, HECU sends a signal to the solenoid valve to decrease the brake fluid, then voltage is supplied to each solenoid. At this time inlet valve is closed and brake fluid is blocked from the master cylinder.
Page 499 Page 55 of 100 3. Hold Mode When the brake fluid pressure is maximally decreased in wheel cylinder, HECU sends a signal to solenoid valve to keep the fluid pressure, voltage is supplied to inlet valve but it is not supplied to outlet valve. At this time inlet and outlet valves are closed and brake fluid is kept in wheel cylinder.
Page 500 Page 56 of 100 4. Increase Mode If HECU determines there's no lock-up in the wheel, HECU cuts voltage to solenoid valve. So voltage is not supplied to each solenoid valve, brake fluid passes through the inlet valve to wheel cylinder, resulting in pressure increase.
Page 501 Page 57 of 100 ABS HECU External Diagram...
Page 502 Page 58 of 100 Hydraulic System Diagram tomsn048@gmail.com...
Page 503 Page 59 of 100 Brake System > ABS(Anti-Lock Brake System) > Schematic Diagrams Circuit Diagram - ABS(1)
Page 504 Page 60 of 100 Circuit Diagram - ABS(2) tomsn048@gmail.com...
Page 505 Page 61 of 100 ABS Connector Input / Output...
Page 506 Page 62 of 100 Connector Terminal Specification Remark Description Over voltage range: 17 ± 0.5V Operating voltage range: 9.5 ± 0.5V < V < 17 ± 0.5V IGNITION1( ) Low voltage range: 7.0 ± 0.5V < V < 9.5 ± 0.5V Nominal current : I <...
Page 507 Page 63 of 100 Brake System > ABS(Anti-Lock Brake System) > Troubleshooting Standard flow of diagnostic troubleshooting Notes with regard to diagnosis The condition listed in the following table are not abnormal. Condition Explanation System check sound When starting the engine, a thudding sound can sometimes be heard coming from inside the engine compartment.
Page 508 Page 64 of 100 Problem symptoms table tomsn048@gmail.com...
Page 509: Dtc Inspection
Page 65 of 100 Symptom Suspect Area ABS does not operate. Only when 1.~4. are all normal and the problem is still occurring, replace the HECU. 1. Check the DTC reconfirming that the normal code is output. 2. Power source circuit. 3.
Page 510 Page 66 of 100 1. Connect the GDS with the data link connector and turn the ignition switch ON. 2. Verify that the normal code is output. 3. Is the normal code output? Check the power source circuit. Erase the DTC and recheck using scan tool.
Page 511 Page 67 of 100 Check the wheel speed sensor circuit 1. Refer to the DTC troubleshooting procedures. 2. Is it normal? Check the hydraulic circuit for leakage. Repair or replace the wheel speed sensor. Check the hydraulic circuit for leakage 1.
Page 512 Page 68 of 100 2. Measure the voltage between terminal 14 of the ABS control module harness side connector and body ground when brake pedal is depressed. Specification : approximately B+ 3. Is the voltage within specification? Check the hydraulic circuit for leakage. Repair the stop lamp switch.
Page 513 Page 69 of 100 2. Is voltage within specification? Check the ground circuit for the diagnosis. Repair an open in the wire. Check and replace fuse (15A) from the engine compartment junction block. Check the ground circuit for the diagnosis 1.
Page 514 Page 70 of 100 Check the power source of ABS control module 1. Disconnect the connector from the ABS control module. 2. Turn the ignition switch ON, measure the voltage between terminal 3 of the ABS control module harness side connector and body ground.
Page 515 Page 71 of 100 Inspection procedures Problem verification 1. Disconnect the connector from the ABS control module and turn the ignition switch ON. 2. Does the ABS warning lamp light up? Inspect again after replacing the ABS HECU. Check the power source for the ABS warning lamp.
Page 516 Page 72 of 100 1. Connect the GDS to the 16P data link connector located behind the driver's side kick panel. 2. Check the DTC output using Scan Tool. 3. Is DTC output? Repair circuit indicated by code output. Check instrument cluster. Check instrument cluster 1.
Page 517 Page 73 of 100 (3) Select HCU air bleeding mode. (4) Press "OK" to operate motor pump and solenoid valve.
Page 518 Page 74 of 100 (5) Wait 60 sec. before operating the air bleeding. (If not, you may damage the motor.) tomsn048@gmail.com...
Page 519 Page 75 of 100 (6) Perform the air bleeding.
Page 520 Page 76 of 100 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(A). Front Rear tomsn048@gmail.com...
Page 521 Page 77 of 100 6. Repeat step 5 until there are no more bubbles in the fluid for each wheel. 7. Tighten the bleeder screw. Bleed screw tightening torque: 6.9 ~ 12.7N.m (0.7 ~ 1.3kgf.m, 5.1 ~ 9.4lb-ft) Brake System > ABS(Anti-Lock Brake System) > ABS Control Module > Components and Components Location Components...
Page 522 Page 78 of 100 1. Front-left tube 6. MC1 2. Rear -right tube 7. ABS control module 3. Rear-left tube connector 4. Front-right tube 8. ABS control module 5. MC2 (HECU) 9. Bracket Brake System > ABS(Anti-Lock Brake System) > ABS Control Module > Repair procedures Removal 1.
Page 523: Tightening Torque
Page 79 of 100 2. Pull up the lock of the ABS control unit connector, then disconnect the connector. 3. Disconnect the brake tubes from the HECU by unlocking the nuts counterclockwise with a spanner. Tightening torque: ABS : 12.7 ~ 16.7N.m(1.3 ~ 1.7kgf.m, 9.4 ~ 12.3lb-ft) ESP : 18.6 ~ 22.6N.m(1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lb-ft) 4.
Page 524 Page 80 of 100 5. Remove the 3 bolts, then remove the bracket from HECU. Tightening torque: 10.8 ~ 13.7N.m (1.1 ~ 1.4kgf.m, 8.0 ~ 10.1lb-ft) Installation 1. Installation is the reverse of removal. 2. Tighten the HECU mounting bolts and nuts to the specified torque. Brake System >...
Page 525 Page 81 of 100 Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Repair procedures Removal 1. Remove the front wheel speed sensor mounting bolt (A). Tightening torque: 6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft) 2.
Page 526 Page 82 of 100 2. Compare the change of the output voltage of the wheel speed sensor to the normal change of the output voltage as shown below. V_low : 0.59V ~ 0.84V V_high : 1.18V ~ 1.68V Frequency range : 1 ~ 2,500Hz Brake System >...
Page 527 Page 83 of 100 1. Rear wheel speed sensor cable 2. Rear wheel speed sensor Brake System > ABS(Anti-Lock Brake System) > Rear Wheel Speed Sensor > Repair procedures Removal...
Page 528 Page 84 of 100 1. Remove the connector after(A) removing the rear wheel speed sensor clip. 2. Remove the rear wheel speed sensor. (Refer to Driveshaft and axle group - Rear axle assembly) 3. Installation is the reverse of removal. Inspection 1.
Page 529 Page 85 of 100 Brake System > ABS(Anti-Lock Brake System) > EBD(Electronic Brake-force Distribution) > Description and Operation EBD (Electronic brake-force distribution) Operation The EBD system (Electronic Brake force Distribution) as a sub-system of the ABS system is to control the Maximum braking effectiveness by the rear wheels.
Page 530 Page 86 of 100 1. HECU module 6. ESC OFF lamp 2. Yaw rate & Lateral G sensor 7. Front wheel speed sensor 3. Parking brake/EBD warning 8. Steering angle sensor lamp 9. Rear wheel speed sensor 4. ABS warning lamp 5.
Page 531 Page 87 of 100 ESC adds a further function known as Active Yaw Control (AYC) to the ABS, TCS, EBD and EDC functions. Whereas the ABS/TCS function controls wheel slip during braking and acceleration and, thus, mainly intervenes in the longitudinal dynamics of the vehicle, active yaw control stabilizes the vehicle about its vertical axis. This is achieved by wheel individual brake intervention and adaptation of the momentary engine torque with no need for any action to be taken by the driver.
Page 532 Page 88 of 100 Input and output diagram tomsn048@gmail.com...
Page 533 Page 89 of 100 ESC Operation mode ESC Hydraulic system diagram...
Page 534 Page 90 of 100 1. ESC Non-operation : Normal braking. Solenoid Motor Continuity Valve TC Valve valve pump IN (NO) OPEN OUT (NC) CLOSE 2. ESC operation Motor Solenoid valve Continuity Valve pump Valve Understeering IN(NO) OPEN (Only inside of OUT(NC) CLOSE rear wheel)
Page 535 Page 91 of 100 ABS Warning lamp The active ABS warning lamp indicates the self-test and failure status of the ABS .The ABS warning lamp shall be - During the initialization phase after IGN ON. (continuously 3 seconds). - In the event of inhibition of ABS functions by failure. - During diagnostic mode.
Page 536 Page 92 of 100 Circuit Diagram - ESC(2) tomsn048@gmail.com...
Page 537 Page 93 of 100 Circuit Diagram - ESC(3)
Page 538: Specification
Page 94 of 100 ESC Connector Input/Output Connector Terminal Specification Remark Description Over voltage range : 17 ± 0.5V Operating voltage range : 9.5 ± 0.5V < V < 17 ± 0.5V IGNITION1(+) Low voltage range : 7.0 ± 0.5V < V < 9.5 ± 0.5V tomsn048@gmail.com...
Page 539 Page 95 of 100 Nominal current : I < 500mA Max leakage current : I < 0.8mA Operating voltage range : POS.BATTERY.(SOLENOID) 9.5 ± 0.5V < V < 17 ± 0.5V Nominal current : I < 40A Hardware shutdown voltage : V < 6.0V Operating voltage range: 9.5 ±...
Page 540 Page 96 of 100 SENSOR CAN BUS LINE (High) SENSOR CAN BUS LINE (Low) ESC OFF LAMP DRIVE Nominal current : I < 200mA (12V) Voltage range : 0 ~ 18 V AS/EBS W/LAMP DRIVE Min. shunt resistance : 500KΩ ESC FUNCTION W/LAMP DRIVER Max Output voltage (Low) : 0.5V Brake System >...
Page 541 Page 97 of 100 Specifications Description Specification Remarks Operating voltage 10 ~ 16V Output signal CAN Interface Operating temperature -40 ~ 85°C(-40 ~ 185°F) Measurement -75 ~ 75°/sec range Yaw-rate sensor Frequency 18 ~ 22Hz response Measurement -1.5 ~ 1.5g range Lateral G sensor...
Page 542: Tightening Torque
Page 98 of 100 3. Clear away the floor mat. 4. Disconnect the yaw rate & lateral G sensor connector. 5. Remove the mounting bolts (A). Tightening torque: 7.9 ~ 10.8N.m (0.8 ~ 1.1kgf.m, 5.8 ~ 8.0Ib-ft) 6. Installation is the reverse of removal. Brake System >...
Page 543 Page 99 of 100 Brake System > ESC(Electronic Stability Control) System > Steering Wheel Angle Sensor > Description and Operation Description Steering Wheel Angle Sensor detects rotating direction of the vehicle. Rotating direction detected by the sensor is communicated with HECU as CAN signal involving information about the angle through CAN communication line. HECU detects speed of the steering wheel handling and the angle with this CAN signal.
Page 544 Page 100 of 100 - Replacement or repair of the Steering column - Detection of DTC codes (C1260, C1261) - Replacement of the sensor cluster - Replacement of HECU Calibration procedure Perform wheel alignment and stand the steering wheel in a line within ±3°error. 1.
Page 545 Page 1 of 21 SOUL(AM) > 2010 > G 1.6 DOHC > Clutch System Clutch System > General Information > Specifications Specifications Item Specification Clutch operation method Hydraulic type Clutch disc Type Single dry with diaphragm Facing diameter (outside x inside)mm (in) •...
Page 546 Page 2 of 21 Item kgf.m lb-ft Clutch pedal to pedal support member 25 ~ 35 2.5 ~ 3.5 12.3 ~ 18.8 (Clutch pedal bracket) Clutch pedal support member to master 17 ~ 26 1.7 ~ 2.6 12.3 ~ 18.8 cylinder Clutch tube flare nut 13 ~ 17...
Page 547 Page 3 of 21 Tool (Number and Illustration name) 09411-11000 Installation of the clutch Clutch disc guide disc. Clutch System > General Information > Troubleshooting Troubleshooting Trouble symptom Suspect area Remedy Clutch slipping Insufficient pedal free play Adjust • Car will not respond to engine Clogged hydraulic system Correct or replace parts speed during acceleration...
Page 548 Page 4 of 21 Faulty of the clutch release cylinder Repair the release cylinder Clutch disc out of place, runout is excessive Inspect the clutch disc or lining broken Spline on the input shaft or clutch disc dirty Repair as necessary or burned Faulty of the clutch pressure plate Replace the clutch cover...
Page 549 Page 5 of 21 1. Clutch Pedal Assembly 4. Ignition Lock Switch 2. Clutch Master Cylinder 5. Clutch Fluid Hose Assembly 6. Brake Fluid Reservoir Tank 3. Clutch Tube Assembly Clutch System > Clutch System > Repair procedures Service Adjustment Procedure Clutch Pedal Inspection And Adjustment...
Page 550 Page 6 of 21 1. Measure the clutch pedal height (from the face of the pedal pad to the floorboard) and the clutch pedal clevis pin play (measured at the face of the pedal pad.) Standard value (A) : 6 ~ 13 mm (0.24~0.51 in) (B) : 168.7 mm (6.64 in) 2.
Page 551 Page 7 of 21 Specified fluid: SAE J1703 (DOT 3 or DOT 4) 1. Loosen the bleeder screw(A) at the clutch release cylinder. 2. Depress the clutch pedal slowly until all air is expelled. 3. Hold the clutch pedal down until the bleeder is retightened. 4.
Page 552 Page 8 of 21 1. Clutch release fork 3. Clutch disk assembly 2. Clutch assembly 4. Clutch release bearing cover Clutch System > Clutch System > Clutch Cover And Disc > Repair procedures Removal 1. Remove the transaxle assembly. (Refer to Manual transaxle's removal in MT group) tomsn048@gmail.com...
Page 553: Clutch Release Bearing
Page 9 of 21 2. Insert the special tool (09411-11000) in the clutch disc to prevent the disc from shifting. 3. Loosen the bolts(Gasoline : 6ea, Diesel : 9ea) 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.
Page 554 Page 10 of 21 The release bearing is packed with grease. Do not use cleaning solvent or oil. Standard grease : CASMOLY L9508 1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for wear.
Page 555: Tightening Torque
Page 11 of 21 3. Tighten the bolts one or two steps at a time in a star pattern. Tightening torque : 15 ~ 22 Nm (1.5 ~ 2.2 kgf.m, 10.9 ~ 16.0 lb-ft) 4. Remove the clutch disc guide (09411-11000). 5.
Page 556 Page 12 of 21 1. Cluch pedal 3. Washer assembly 4. Snap pin 2. Cluch master cylinder assembly Clutch System > Clutch System > Clutch Master Cylinder > Repair procedures Removal tomsn048@gmail.com...
Page 557 Page 13 of 21 1. Remove the flexible hose (A) connected to brake reserve tank from the master cylinder. In advance remove the ECU and battery. Put aside the fuel pump by disconnecting the connectors and remove the mounting nuts. 2.
Page 558 Page 14 of 21 3. Remove the reserve tank band, reserve tank cap, and reserve tank. Use care not to damage the master cylinder body and piston assembly. Do not disassemble the piston assembly. Inspection 1. Check the inside of the cylinder body for rust, pitting or scoring. 2.
Page 559 Page 15 of 21 2. Install the clutch pedal mounting nuts. Tightening torque : 17 ~ 26Nm (1.7 ~ 2.6kgf.m, 12.3 ~ 18.8Ib-ft) 3. Connect the push rod to the clutch pedal by installing the snap pin (A) and washer (B). 4.
Page 560 Page 16 of 21 1. Cluch pedal 3. Washer assembly 4. Snap pin 2. Cluch master cylinder assembly Clutch System > Clutch System > Clutch Pedal > Repair procedures Removal 1. Remove the driver lower cover. (refer to BD group) 2.
Page 561 Page 17 of 21 3. Remove the clutch pedal mounting nuts. 4. Disconnect the push rod from the master cylinder by removing the snap pin (A) and washer (B). 5. Remove the pedal bracket nuts. Inspection 1. Check the pedal shaft and bushing for wear. 2.
Page 562 Page 18 of 21 3. Install the pedal bracket nuts. 4. Install the clutch pedal mounting nuts (A-2ea). Tightening torque : 17 ~ 26Nm (1.7 ~ 2.6kgf.m, 12.3 ~ 18.8Ib-ft) 5. Connect the push rod to the clutch pedal by installing the snap pin (A) and washer (B). 6.
Page 563 Page 19 of 21 1. Union bolt 7. Bleeder 2. Gasket screw 3. Tube joint 8. Release 4. Clutch tube cylinder 5. Valve plate 9. Return spring 6. Valve spring 10. Piston 11. Boot 12. Push rod Clutch System > Clutch System > Clutch Release Cylinder > Repair procedures Removal...
Page 564 Page 20 of 21 1. Drain the brake fluid through the bleed plug (A). 2. Disconnect the clutch tube (A). 3. Remove the two clutch release cylinder mounting bolts (B-2ea). Inspection 1. Check the release cylinder bore for rust and damage. 2.
Page 565 Page 21 of 21 3. Install the clutch tube (A). 4. Bleed the air in the clutch system. (Refer to Bleeding in Service Adjustment Procedure)
Page 566 Page 1 of 20 SOUL(AM) > 2010 > G 1.6 DOHC > Driveshaft and axle Driveshaft and axle > General Information > Specifications Specification Joint type Max. permissible angle Engine Outer Inner Outer Inner Diesel 1.6 M/T 43° 21° 43° 21°...
Page 567: Troubleshooting
Page 2 of 20 Tool(Number and Name) Illustration 09495-33000Puller Removal of spider assembly from a drive shaft. 09495-3K000Band installer Installation of ear type boot band 09568-34000Ball joint remover Removal of the rear upper arm ball joint 09568-4A000Ball joint Removal of the tie rod end ball joint remover 09568-2J100 Remover of ball joint...
Page 568 Page 3 of 20 Wear, rattle or scoring of wheel bearing Replace Loose hub nut Adjustment or Replace Defective front suspension and steering Adjustment or Replace Driveshaft and axle > Front Axle Assembly > Front Hub / Knuckle > Components and Components Location Components 1.
Page 569: Tightening Torque
Page 4 of 20 2. Remove the front wheel and tire(A) from front hub . Tightening torque: 90 ~ 110 N.m (9 ~ 11 Kgf.m, 65 ~ 80 lb.ft) Be careful not to damage to the hub bolts when removing the front wheel and tire (A). 3.
Page 570 Page 5 of 20 5. Loosen the front brake disc mount screw and then remove the front brake disc(A). 6. Remove the tie rod end ball joint from the knuckle. (1) Remove the split pin(A). (2) Remove the castle nut(B). (3) Disconnect the ball joint(C) from knuckle using the special tool (09568-4A000 or 09568-2J100).
Page 571 Page 6 of 20 7. Remove the driveshaft nut (A) from the front hub. Tightening torque: 240.2 ~ 269.6 N.m (24.5 ~ 27.5 Kgf.m, 177.2 ~ 197.9 lb.ft) - The driveshaft lock nut should be replaced with new ones. - After installation driveshaft lock nut, stake the lock nut using a chisel and hammer as shown in the illustration below.
Page 572 Page 7 of 20 9. Loosen the mount bolt and then remove the wheel speed sensor(B) from knuckle(A). 10. Disconnect the driveshaft (A) from the front hub assembly.. 11. Loosen the strut mount bolts and then remove the knuckle assembly(A). Tightening torque: 100 ~ 120 N.m (10 ~ 12 Kgf.m, 72 ~ 87 lb.ft) 12.
Page 573 Page 8 of 20 Driveshaft and axle > Driveshaft Assembly > Front Driveshaft > Components and Components Location Component location 1. Driveshaft(LH) 4. Circlip 2. Circlip 3. Transaxle Driveshaft(RH) Components...
Page 574 Page 9 of 20 1. BJ assembly 5. Dynamic 9. TJ boot 13. TJ circlip 2. BJ circlip damper band 10. Spider 3. BJ boot band 6. Dynamic assembly 4. BJ boot damper 11. Snap ring 7. Shaft 12. TJ Housing 8.
Page 575 Page 10 of 20 2. Remove the front wheel and tire(A) from front hub . Tightening torque: 90 ~ 110 N.m (9 ~ 11 Kgf.m, 65 ~ 80 lb.ft) Be careful not to damage to the hub bolts when removing the front wheel and tire (A). 3.
Page 576 Page 11 of 20 5. Loosen the front brake disc mount screw and then remove the front brake disc(A). 6. Remove the tie rod end ball joint from the knuckle. (1) Remove the split pin(A). (2) Remove the castle nut(B). (3) Disconnect the ball joint(C) from knuckle using the special tool (09568-4A000 or 09568-2J100).
Page 577 Page 12 of 20 7. Remove driveshaft nut(A) from the front hub under applying the break. Tightening torque: 240.2 ~ 269.6 N.m (24.5 ~ 27.5 Kgf.m, 177.2 ~ 197.9 lb.ft) - The driveshaft lock nut should be replaced with new ones. - After installation driveshaft lock nut, stake the lock nut using a chisel and hammer as shown in the illustration below.
Page 578 Page 13 of 20 9. Loosen the mount bolt and then remove the wheel speed sensor(B) from knuckle(A). 10. Disconnect the driveshaft (A) from the front hub assembly.. 11. Insert a pry bar(A) between the transaxle case and joint case, and separate the drive shaft(B) from the transaxle case.
Page 579 Page 14 of 20 • Do not disassemble the BJ assembly. • Special grease must be applied to the driveshaft joint. Do not substitute with another type of grease. • The boot band should be replaced with a new one. 1.
Page 580 Page 15 of 20 5. Remove the snap ring (A) and spider roller assembly from the shaft. 6. Remove the spider assembly (B) from the driveshaft (A) using the special tool (09495-33000). 7. Clean the spider assembly. 8. Remove the boot (A) of the transaxle side joint(TJ). For reusing the boot (A), wrap tape (B) around the driveshaft splines (C) to protect the boot (A).
Page 581 Page 16 of 20 10. Hold the driveshaft (A) with a vice (B) as illustrated. 11. Apply soap powder on the shaft to prevent being damaged between the shaft spline and the dynamic damper when the dynamic damper is removed. 12.
Page 582 Page 17 of 20 6. Using the alignment marks (D) made during disassembly as a guide, install the spider assembly (A) and snap ring (B) on the driveshaft splines (C). 7. Add specified grease to the joint boot as much as it was wiped away at inspection. 8.
Page 583 Page 18 of 20 1. Rear torsion beam 3. Rear wheel hub assembly assembly 4. Rear brake disc 2. Rear drum brake assembly Driveshaft and axle > Rear Axle Assembly > Rear Hub - Carrier > Repair procedures Replacement 1. Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.
Page 584 Page 19 of 20 2. Remove the rear wheel and tire(A) from rear hub . Tightening torque: 90 ~ 110 N.m (9 ~ 11 Kgf.m, 65 ~ 80 lb.ft) Be careful not to damage to the hub bolts (C) when removing the rear wheel and tire (A). 3.
Page 585 Page 20 of 20 5. Disconnect the wheel speed sensor connector(A) and then remove the hub bearing(B). Tightening torque: 70 ~ 90 N.m (7 ~ 9 Kgf.m, 51 ~ 65 lb.ft) 6. Install in the reverse order of removal. Inspection 1.
Page 586 Page 1 of 19 SOUL(AM) > 2010 > G 1.6 DOHC > Emission Control System Emission Control System > General Information > Description and Operation Description Emissions Control System consists of three major systems. • The Crankcase Emission Control System prevents blow-by gas from releasing into the atmosphere. This system recycles gas back into the intake manifold (Closed Crankcase Ventilation Type).
Page 587 Page 2 of 19 Symptom Suspect area Engine will not start or stuggle to Vapor hose damaged or disconnected start Engine stuggles to start Malfunction of the Purge Control Solenoid Valve Vapor hose damaged or disconnected Rough idle or engine stalls Malfunction of the PCV valve Rough idle Malfunction of the Evaporative Emission Control System...
Page 588 Page 3 of 19 Emission Control System > General Information > Components and Components Location Components Location [1.6 DOHC] 1. PCV Valve 5. Canister Close Valve (CCV) 2. Canister 6. Fuel Level Sensor (FLS) 3. Purge Control Solenoid Valve 7. Fuel Tank Air Filter (PCSV) 8.
Page 589 Page 4 of 19 1. PCV Valve 2. Canister 5. Canister Close Valve (CCV) 3. Purge Control Solenoid Valve (PCSV) 4. Fuel Tank Pressure Sensor (FTPS) 6. Fuel Level Sensor (FLS) 7. Fuel Tank Air Filter 8. Catalytic Converter (MCC) [2.0 DOHC]...
Page 590 Page 5 of 19 1. PCV Valve 5. Canister Close Valve (CCV) 2. Canister 6. Fuel Level Sensor (FLS) 3. Purge Control Solenoid Valve 7. Fuel Tank Air Filter (PCSV) 8. Catalytic Converter (MCC) 4. Fuel Tank Pressure Sensor (FTPS) tomsn048@gmail.com...
Page 591 Page 6 of 19 1. PCV Valve 2. Canister 5. Canister Close Valve (CCV) 3. Purge Control Solenoid Valve (PCSV) 4. Fuel Tank Pressure Sensor (FTPS) 6. Fuel Level Sensor (FLS) 7. Fuel Tank Air Filter 8. Catalytic Converter (MCC) Emission Control System >...
Page 592 Page 7 of 19 [2.0 DOHC] tomsn048@gmail.com...
Page 593 Page 8 of 19 Emission Control System > Crankcase Emission Control System > Repair procedures Inspection 1. After disconnecting the vapor hose from the PCV valve, remove the PCV valve. 2. Reconnect the PCV valve to the vapor hose.
Page 594 Page 9 of 19 3. Run the engine at idle, then put a finger over the open end of the PCV valve and make sure that intake manifold vacuum can be felt. The plunger inside the PCV valve will move back and forth at vacuum. 4.
Page 595 Page 10 of 19 1. Disconnect the vapor hose (A). [1.6 DOHC] [2.0 DOHC] 2. Remove the PCV valve (B). Inspection 1. Insert a thin stick (A) into the PCV valve (B) from the threaded side to check that the plunger movement. If the plunger does not move (PCV valve is clogged), clean or replace the valve.
Page 596 Page 11 of 19 Description The Evaporative Emission Control System prevents fuel vapor stored in fuel tank from vaporizing into the atmosphere. When the fuel evaporates in the fuel tank, the vapor passes through vent hoses or tubes to a canister filled with charcoal.
Page 597 Page 12 of 19 Evaporative System Monitoring The Evaporative Emission Control Monitoring System monitors fuel vapor generation, evacuation, and a leakage check step. At first, the OBD-II system checks if vapor generation due to fuel temperature is small enough to start monitoring.
Page 598 Page 13 of 19 1. Fuel Filler Cap 8. Evaporative Hose 2. Fuel Filler Pipe 9. Canister 3. Fuel Shut-OFF Valve 10. Canister Close Valve (CCV) 4. Fuel Tank 11. Fuel Feed Line 5. ORVR Valve 12. Fuel Tank Pressure Sensor 6.
Page 599 Page 14 of 19 [PCSV Inspection] 1. Turn ignition switch OFF and disconnect the negative (-) battery cable. 2. Disconnect the PCSV connector (A). [1.6 DOHC] [2.0 DOHC] 3. Disconnect the vapor hose (B) which is connected to the intake manifold from the PCSV. 4.
Page 600 Page 15 of 19 2. Proceed with the test according to the screen introductions. Emission Control System > Evaporative Emission Control System > Canister > Repair procedures Removal 1. Remove the fuel tank. (Refer to "Fuel tank" in this group.) 2.
Page 601 Page 16 of 19 loud clicking noise indicating the seal has been set. Emission Control System > Evaporative Emission Control System > Fuel Tank Air Filter > Repair procedures Replacement 1. Lift the vehicle. 2. Disconnect the vapor hoses (A,B) from the fuel tank air filter. 3.
Page 602 Page 17 of 19 Modifications to the combustion chamber, intake manifold, camshaft and ignition system form the basic control system. These items have been integrated into a highly effective system which controls exhaust emissions while maintaining good drivability and fuel economy. Air/Fuel Mixture Control System [Multiport Fuel Injection (MFI) System] The MFI system uses signals from the heated oxygen sensor to activate and control the injector installed in the manifold for each cylinder, thus precisely regulating the air/fuel mixture ratio and reducing emissions.
Page 603 Page 18 of 19 The CVVT (Continuously Variable Valve Timing) which is installed on the exhaust camshaft controls intake valve open and close timing in order to improve engine performance. The intake valve timing is optimized by the CVVT system depending on engine rpm. This CVVT system improves fuel efficiency and reduces NOx emissions at all levels of engine speed, vehicle speed, and engine load by EGR effect because of valve over-lap optimization.
Page 604 Page 19 of 19 1. The above figure shows the relative operation structures of the housing vane to the rotor vane. 2. When the CVVT is held in a certain control angle, its oil is replenished as it leaks by the oil pump. The OCV (CVVT Oil Control Valve) spool location at this time is as follows.
Page 605 Page 1 of 39 SOUL(AM) > 2010 > G 1.6 DOHC > Engine Electrical System Engine Electrical System > General Information > Specifications Specifications Ignition System Items Specification Primary resistance 0.7 ± 15 % (Ω) Ignition coil Secondary resistance Type RER8MC Spark plugs 1.0 ~ 1.1 mm (0.0394 ~...
Page 606: Troubleshooting
Page 2 of 39 Specific gravity [at 1.280 ± 0.01 20°C(68°F)] • COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminal voltage of 7.2V or greater at a specified temperature. • RESERVE CAPACITY RATING is amount of time a battery can deliver 25A and maintain a minimum terminal voltage of 10.5V at 26.7°C(80.1°F).
Page 607 Page 3 of 39 Symptom Suspect area Remedy Charging warning indicator does Fuse blown Check fuses not light with ignition switch "ON" Light burned out Replace light and engine off. Wiring connection loose Tighten loose connection Electronic voltage regulator Replace voltage regulator Charging warning indicator does Drive belt loose or worn Adjust belt tension or replace belt...
Page 608 Page 4 of 39 crank Pinion gear teeth broken or starter Replace motor Ring gear teeth broken Replace fly wheel or torque converter Engine Electrical System > General Information > Special Service Tools Special Service Tools Tool (Number and name) Illustration Micro-570 - Check the battery condition...
Page 609 Page 5 of 39 Battery Test Procedure 1. Connect the tester to the battery. A. Red clamp to battery positive (+) terminal. B. Black clamp to battery negative (-) terminal. Connect clamps securely. If "CHECK CONNECTION" message is displayed on the screen, reconnect clamps securely.
Page 610 Page 6 of 39 3. Choose either CCA or CCP and press the ENTER button. • CCA : Cold cranking amps, is an SAE specification for cranking batteried at -0.4°F (-18°C). • CCP : Cold cranking amps, is an SAE specification for korean manufacturer's for cranking batteried at -0.4°F (-18°C).
Page 611 Page 7 of 39 6. To conduct starter test, continuously, press ENTER. Battery Test Results Result On Printer Remedy Good battery No action is required Battery is in a good state Good recharge Recharge the battery and use Battery is not charged properly Charge &...
Page 612 Page 8 of 39 3. Cranking voltage and starter test results will be displayed on the screen. Take a relevant action according to the test results by referring to the starter test results as given below. 4. To continue charging system test, press ENTER. Starter Test Results Result On Printer Remedy...
Page 613 Page 9 of 39 2. If ENTER button is pressed, the tester displays the actual voltage of alternator. Press ENTER to test the charging system. 3. Turn off all electrical load and rev engine for 5 seconds with pressing the accelerator pedal. 4.
Page 614: Spark Test
Page 10 of 39 6. Take a relevant action according to the test results by referring to the table below after shutting off the engine and disconnect the tester clamps from the battery. Charging System Test Results Result On Printer Remedy Charging system normal / Charging system is normal...
Page 615: Tightening Torque
Page 11 of 39 1. Remove the ignition coils(A). 2. Remove the fuel pump relay(A) from the fuse box for fuel not to be injected while checking. 3. Using a spark plug socket, remove the spark plug. 4. Install the spark plug to the ignition coil. 5.
Page 616 Page 12 of 39 10. Install a engine center cover and a engine cover. Tightening torque : 7.8 ~11.8 Nm (0.8~1.2 kgf.m, 5.8~8.7 Ib-ft) Inspect Spark Plug 1. Remove the ignition coil(A). When removing the ignition coil connector, pull the lock pin(A) and push the clip(B).
Page 617 Page 13 of 39 3. Inspect the electrodes (A) and ceramic insulator (B). Inspection Of Electrodes Condition Dark deposits White deposits - Fuel mixture too lean - Fuel mixture too rich Description - Advanced ignition timing - Low air intake - Insufficient plug tightening torque 4.
Page 618 Page 14 of 39 Engine Electrical System > Charging System > Description and Operation Description The charging system includes a battery, an alternator with a built-in regulator, and the charging indicator light and wire. The Alternator has eight built-in diodes, each rectifying AC current to DC current. Therefore, DC current appears at alternator "B"...
Page 619 Page 15 of 39 1. Visually check the belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt. Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced.
Page 620: Input Data
Page 16 of 39 2. After releasing the handle (A), read a value on the dial pointed by the indicator (B). Using a sonic tension meter (U-505/507 type) 1. Input the belt specifications into the tension meter. Input data Location of Belt type measurement M (Mass, g/m.rib)
Page 621 Page 17 of 39 2. Locate the micro phone (B) close to the center of belt span (A) and bounce the belt by finger 2~3 times. Read a value on the display. [With A/C] [Without A/C] If adjustment is necessary: 1.
Page 622 Page 18 of 39 2. Check that there is no abnormal noise from the alternator while the engine is running. Check Discharge Warning Light Circuit 1. Warm up the engine and then turn it off. 2. Turn off all accessories. 3.
Page 623 Page 19 of 39 1. Nut 11. Rear cover 2. Pulley 12. Bolts 3. Spacer 13. Seal 4. Front cover assembly 14. Rectifier assembly 5. Front bearing 15. Stud bolts 6. Bearing cover 16. Brush holder 7. Bearing cover bolt assembly 8.
Page 624 Page 20 of 39 4. Disconnect the air compressor connector(A) and the alternator connector (B), and remove the cable (C) from alternator "B" terminal. 5. Pull out the through bolt (A) and then remove the alternator. Tightening torque : 19.6~26.5 Nm (2.0~2.7 kgf.m, 14.5~19.5 Ib-ft)-12mm bolt 29.4~41.2 Nm (3.0~4.2 kgf.m, 21.7~30.4 Ib-ft)-14mm bolt 6.
Page 625 Page 21 of 39 2. Loosen the mounting bolts(A) and disconnect the brush holder assembly(B). 3. Remove the slip ring guide(A). 4. Remove the nut, pulley(A) and spacer. 5. Loosen the 4 through bolts(A).
Page 626 Page 22 of 39 6. Disconnect the rotor(A) and cover(B). 7. Reassembly is the reverse of disassembly. Inspection Rotor 1. Check that there is continuity between the slip rings (C). 2. Check that there is no continuity between the slip rings and the rotor (B) or rotor shaft (A). 3.
Page 627 Page 23 of 39 3. The battery is completely sealed, except for small vent holes in the cover. Engine Electrical System > Charging System > Battery > Components and Components Location Components...
Page 628 Page 24 of 39 1. Battery 3. Battery tray insulation pad 2. Battery Engine Electrical System > Charging System > Battery > Repair procedures Inspection Battery Diagnostic Flow Vehicle parasitic current inspection 1. Turn the all electric devices OFF, and then turn the ignition switch OFF. tomsn048@gmail.com...
Page 629 Page 25 of 39 2. Close all doors except the engine hood, and then lock all doors. (1) Disconnect the hood switch connector. (2) Close the trunk lid. (3) Close the doors or remove the door switches. 3. Wait a few minutes until the vehicle’s electrical systems go to sleep mode. For an accurate measurement of a vehicle parasitic current, all electriacl systems should go to sleep mode.
Page 630 Page 26 of 39 3. Remove the battery from the vehicle. Care should be taken in the event the battery case is cracked or leaking, to protect your skin from the electrolyte. Heavy rubber gloves (not the household type) should be wore when removing the battery. 4.
Page 631: Starter Circuit
Page 27 of 39 After disconnecting then reconnecthing the battery negative cable, reset some parts that require the reset procedures. (Refer to BE group - General Information) Engine Electrical System > Starting System > Description and Operation Description The starting system includes the battery, starter, solenoid switch, ignition switch, inhibitor switch (A/T), ignition lock switch, connection wires and the battery cable.
Page 632 Page 28 of 39 2. With the shift lever in N or P (A/T) or clutch pedal pressed (M/T), turn the ignition switch to "START" If the starter normally cranks the engine, starting system is OK. If the starter will not crank the engine at all, go to next step.
Page 633 Page 29 of 39 6. If the pinion doesn't have moved, the hold-in coil of the solenoid is working properly. This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. 7. If the pinion goes back in its original position when you disconnecting the (-) line from the body, the system must be in good condition.
Page 634 Page 30 of 39 7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely. Current : 60A MAX Speed : 5500 rpm. MIN Engine Electrical System > Starting System > Starter > Components and Components Location Components tomsn048@gmail.com...
Page 635 Page 31 of 39 1. Screw (for solenoid) 10. Armature 2. Front bracket 11. Yoke assembly 3. Stop ring 12. Brush (-) 4. Stopper 13. Brush holder 5. Overrun clutch assembly 6. Lever 14. Brush (+) 7. Lever plate 15. Rear bracket 8.
Page 636 Page 32 of 39 1. Disconnect the M-terminal (A) on the magnet switch assembly (B). 2. After loosening the 2 screws (A), detach the magnet switch assembly (B). 3. Loosen the brush holder mounting screw (A) and through bolts (B). 4.
Page 637 Page 33 of 39 5. Remove the yoke (A). 6. Remove the, lever plate (A) and packing (B). 7. Remove the overrunning clutch (A), armature (B) and lever (C). 8. Press the stopper (A) using a socket (B).
Page 638: Armature Inspection And Test
Page 34 of 39 9. After preparing to remove the stop ring (A) using stopper pliers (B). 10. Remove the stop ring (A), stopper (B), overrunning clutch (C). 11. Reassembly is the reverse of disassembly. Using a suitable pulling tool (A), pull the stop ring (B) over the stopper (C).
Page 639 Page 35 of 39 3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature. 4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with #500 or #600 sandpaper (B).
Page 640 Page 36 of 39 6. Measure the commutator (A) runout. A. If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments. B. If the commutator run out is not within the service limit, replace the armature. Commutator runout Standard (New): 0.05mm (0.0020in.) max Service limit: 0.1mm (0.0039in.)
Page 641 Page 37 of 39 9. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If continuity exists, replace the armature. Inspect Starter Brush Brushes that are worm out, or oil-soaked, should be replaced. Bruch length Standard : 12.3 mm (0.4843 in) Service linit : 5.5 mm (0.2165 in)
Page 642 Page 38 of 39 2. Rotate the overrunning clutch both ways. Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction of it locks in both directions, replace it. 3. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly. (the gear is not available separately).
Page 643 Page 39 of 39 4. Apply 12V to terminal 85 and ground to terminal 86. Check for continuity between terminals 30 and 87. 5. If there is no continuity, replace the starter relay. 6. Install the starter relay. 7. Install the fuse box cover.
Page 644 Page 1 of 109 SOUL(AM) > 2010 > G 1.6 DOHC > Engine Mechanical System Engine Mechanical System > General Information > Specifications Specifications Description Specifications Limit General Type In-line, DOHC Number of cylinders Bore 77mm (3.0315in) Stroke 85.44mm (3.3638in) Total displacement 1,591 cc (97.09 cu.in) Compression ratio...
Page 645: Valve Guide
Page 2 of 109 Thickness of valve Intake 1.1mm (0.0433in) 0.8mm (0.0315in) head (margin) Exhaust 1.26mm (0.0496in) 1.0mm (0.0394in) Valve stem to Intake 0.020 ~ 0.047mm (0.0008 0.10mm (0.0039in) valve guide ~ 0.0019in) clearance Exhaust 0.030 ~ 0.054mm (0.0012 0.15mm (0.0059in) ~ 0.0021in) Valve guide Length...
Page 646: Connecting Rod
Page 3 of 109 0.0110in) No. 2 ring 0.30 ~ 0.45mm (0.0118 ~ 0.50mm (0.0197in) 0.0177in) Oil ring 0.20 ~ 0.70mm (0.0079 ~ 0.80mm (0.0315in) 0.0276in) Piston pin Piston pin outer diameter 18.001 ~ 18.006mm (0.7087 ~ 0.7089in) Piston pin hole inner diameter 18.016 ~ 18.021mm (0.7093 ~ 0.7095in) Piston pin hole clearance...
Page 647: Cooling System
Page 4 of 109 Recommended SAE Refer to the "Lubrication System" SAE viscosity grade viscosity number 100kPa (1.0kg/cm², Oil temperature in oil pan : 110±2°C Oil pressure (at 1000rpm) 14.5psi) or above (230± 36°F) Cooling system Cooling method Forced circulation with water pump Coolant quantity 6.5L (6.86US qt., 5.71lmp...
Page 648: Cylinder Head
Page 5 of 109 Timing chain and oil pump assembly cover 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4 bolt(M8×22) Idler pulley assemlby bolt 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8 Timing chain tensioner arm bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Timing chain guide bolt...
Page 649 Page 6 of 109 Exhaust manifold and cylinder block, ladder 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2 frame mounting bolts Air cleaner lower cover mounting 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2 Exhaust manifold and catalytic convertor 43.1 ~ 45.1 4.4 ~ 4.6 31.8 ~ 33.3...
Page 650 Page 7 of 109 5. Check the cylinder compression pressure. (1) Insert a compression gauge into the spark plug hole. (2) Set the throttle plate in the wide-open position. (3) While cranking the engine, measure the compression pressure. Always use a fully charged battery to obtain engine speed of 250rpm or more. (4) Repeat step 1) through 3) for each cylinder.
Page 651: Tightening Torque
Page 8 of 109 8. Install the engine center cover. Tightening torque : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft) Valve Clearance Inspection And Adjustment Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C) and cylinder head is installed on the cylinder block.
Page 652 Page 9 of 109 (3) Loosen the cylinder head cover bolts and then remove the cover(A). Do not reuse the disassembled gasket. 3. Set No.1 cylinder to TDC/compression. (1) Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover. (2) Check that the marks of the camshaft timing sprockets are in straight line on the cylinder head surface as shown in the illustration.
Page 653 Page 10 of 109 4. Inspect the valve clearance. (1) Check only the intake valves of the 1st and 2nd cylinders and exhaust valves of the 1st and 3rd cylinders for their clearance. A. Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft. B.
Page 654 Page 11 of 109 (6) Remove the exhaust camshaft sprocket. (7) Remove the camshaft bearing caps(A) with the order below. (8) Remove the exhaust camshaft. (9) Remove the intake camshaft and CVVT module. When disconnecting the timing chain from the camshaft timing sprocket, hold the timing chain. (10) Tie a timing chain with a string.
Page 655 Page 12 of 109 (13) Select a new tappet with a thickness as close as possible to the caculated value. Shims are available in 41size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to 3.600mm (0.1417in.) (14) Place a new tappet on the cylinder head. (15) Hold the timing chain, and place the intake camshaft and CVVT module assembly.
Page 656: Troubleshooting
Page 13 of 109 Engine Mechanical System > General Information > Troubleshooting Troubleshooting Symptom Suspect area Remedy Engine misfire with Repair or replace the flywheel as Loose or improperly installed engine flywheel. abnormal internal required. lower engine noises. Worn piston rings. Inspect the cylinder for a loss of (Oil consumption may or may not cause the compression .
Page 657 Page 14 of 109 Inspect the valves and valve guides, then Worn valve guides or valve stems. repair as required. Stuck valves. (Carbon on the valve stem or Inspect the valves and valve guides, then valve seat may cause the valve to stay open.) repair as required.
Page 658 Page 15 of 109 Hydraulically locked cylinder. (crankshaft will not Inspect for broken head gasket. • Coolant/antifreeze in cylinder. rotate) Inspect for cracked engine block or • Oil in cylinder. cylinder head. Inspect for a sticking fuel injector and/or • Fuel in cylinder. leaking fuel regulator.
Page 659 Page 16 of 109 Crankshaft rear oil seal Installation of the crankshaft rear oil seal installer A : (09231-H1100) B : (09231-2B200) Ring gear stoppper Removal and installation of crankshaft pulley (09231-2B100) bolt. Ring gear stopper Removal and installation of crankshaft pulley (09231-3D100) bolt.
Page 660 Page 17 of 109 1. Engine mounting 3. Rear roll stopper bracket 2. Transaxle mounting bracket Engine Mechanical System > Engine And Transaxle Assembly > Engine And Transaxle Assembly > Repair procedures Removal • Use fender covers to avoid damaging painted surfaces. •...
Page 661 Page 18 of 109 1. Disconnect the battery terminal (A) and ECM connector (B). 2. Disconnect the breather hose (A) and then, remove the air cleaner assembly (B). 3. Remove the ECM (Engine Control Module) (A) and the battery (B). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Page 662 Page 19 of 109 4. Disconnect the throttle cable (A) and then, remove the battery tray (B). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 5. Loosen the drain plug (A), and drain the coolant. Remove the radiator cap to speed draining. 6.
Page 663 Page 20 of 109 8. Disconnect the wiring connectors, harness clamps and hoses from the engine. (1) Disconnect the brake booster vacuum hose (A). (2) Disconnect the oxygen sensor connectors (B). (3) Disconnect the condenser connector (C). (4) Disconnect the ignition coil connector (D). (5) Disconnect the ECT (Engine Coolant Temperature) sensor connector.
Page 664 Page 21 of 109 (10) Disconnect the fuel hose (A) and the PCV hose (B). (11) Disconnect the injector connectors (A). (12) Disconnect the compressor connector (A), the alternator connector (B) and the 'B' terminal cable (C). (13) Disconnect the OCV connector (A), the knock sensor connector (B) and the MAP sensor connector (C). tomsn048@gmail.com...
Page 665 Page 22 of 109 (14) Disconnect the starter connector (A) and the 'B' terminal cable (B). 9. Remove the transaxle wire harness connectors and control cable from the transaxle. (Refer to AT or MT group). 10. Remove the drive shafts. (Refer to Drive shaft In DS group) 11.
Page 666 Page 23 of 109 13. Remove the front muffler (A). Tightening torque : 39.2 ~ 49.0N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lb-ft) 14. Using a floor jack, support the engine and transaxle assembly. • After removing the mounting bolt (engine and transaxle), the engine and transaxle assembly may fall downward, and so support them securely with floor jack.
Page 667 Page 24 of 109 16. Disconnect the ground cable (A) and then, remove the transaxle mounting bracket (B). Tightening torque : Bolts (C) : 88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft) 17. Remove the engine and transaxle assembly by lifting vehicle. When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.
Page 668 Page 25 of 109 - After assembling fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump could run for approximately two seconds and fuel line could be pressurized. - Repeat this operation two or three times and check for fuel leakage at any point in the fuel line. Engine Mechanical System >...
Page 669 Page 26 of 109 Engine removal is not required for this procedure. 1. Loosen the water pump pulley bolt and the drive idler mounting bolt. 2. Loosen the alternator tension adjusting bolt(A) to loosen tension. 3. Remove the alternator drive belt(A). 4.
Page 670 Page 27 of 109 6. Remove the engine mounting bracket(A). Support the engine with a jack not to be tilted. 7. Remove the alternator bracket(B). 8. Remove the engine support bracket(A). 9. Remove the water pump pulley(A). tomsn048@gmail.com...
Page 671 Page 28 of 109 10. Remove the water pump(A). 11. Remove the drive belt idler(A). 12. Disconnect the ignition coil connector(A) and the breather hose(B).
Page 672 Page 29 of 109 13. Disconnect the positive crankcase ventilation(PCV) hose(A) and PCSV hose(B). 14. Remove the ignition coils(A). 15. Remove the cylinder head cover(A) with its gasket(B). 16. Remove side cover. tomsn048@gmail.com...
Page 673 Page 30 of 109 17. Turn the crankshaft pulley clockwise, and align its groove with the timing mark of the timing chain cover. 18. Remove the crankshaft bolt(B) and crankshaft pulley(A). There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley. •...
Page 674 Page 31 of 109 1. Remove the bracket (A). 2. Remove the dust cover (A) on the bottom of the ladder frame and unfasten the transaxle mounting bolt (B). 3. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
Page 675 Page 32 of 109 19. Remove the timing chain cover(A). 20. Align the timing marks of the camshaft sprocket with the upper surface of the cylinder head to make No.1 cylinder be positioned at TDC. (1) Check the dowel pin of the crankshaft for facing upside of the engine at this monent. Put paint marks on the timing chain links(3 places) that meet with the timing marks of the camshaft sprockets(In, Ex : 2) and the crankshaft sprocket.
Page 676 Page 33 of 109 22. Remove the timing chain tensioner arm(A) and guide(B). 23. Remove the timing chain(A). Inspection Sprockets, Hydraulic Tensioner, Chain Guide, Tensioner Arm 1. Check the camshaft sprocket, crankshaft sprocket teeth for abnormal wear, cracks or damage. Replace if necessary.
Page 677: Tightening Torque
Page 34 of 109 1. Align the timing marks of the camshaft sprocket with the upper sureface of the cylinder head to make No.1 cylinder be positioned at TDC. (1) Check the dowel pin of the crankshaft for facing upside of the engine at this monent. (2) Install the timing chain guide(A).
Page 678 Page 35 of 109 3. Install the hydraulic tensioner(A) and remove the pin(B). Tightening torque : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) Recheck the top dead center(TDC) marks on the crankshaft and camshaft. 4. Install the timing chain cover(A). (1) Before installing, remove the hardened sealant from the cylinder block and ladder frame surface.
Page 679 Page 36 of 109 (4) Align the dowel pin of the cylinder block and the holes of the oil pump. Tightening torque : 12mm bolts : 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft) 10mm bolts : 9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) After the installation, do not crank engine or apply pressure on the cover for half an hour.
Page 680 Page 37 of 109 There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley. • Install the SST (09231-2B100) to hold the ring gear after removing the starter. • Install the SST (09231-3D100) to hold the ring gear after removing the dust cover. 1.
Page 681 Page 38 of 109 2. Remove the dust cover (A) on the bottom of the ladder frame and unfasten the transaxle mounting bolt (B). 3. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
Page 682 Page 39 of 109 7. Install side cover. Tightening torque : 8.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~ 8.0 lb-ft) 8. Install the front right wheel and tire. 9. Before installing the cylinder head cover, remove oil, dust or hardened sealant from the timing chain cover and the cylinder head upper surface.
Page 683 Page 40 of 109 12. Tighten the cylinder head cover bolts(A) with the order and steps. Tightening torque : 1st step - 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft) 2nd step - 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft) 13.
Page 684 Page 41 of 109 15. Connect the ignition coil connector(A) and the breather hose(B). 16. Install the drive belt idler(A). Tightening torque : 42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft) 17. Install the water pump(A) with a gasket. Tighten bolts with the order below.
Page 685 Page 42 of 109 18. Install the water pump pulley(A). Tightening torque : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) Tighten the bolts diagonally. 19. Install the engine support bracket(A). Tightening torque : 29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft) 20.
Page 686 Page 43 of 109 21. Install the engine mounting bracket(A). Tightening torque : Nut(C): 78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft) Bolt(D) and Nuts(E) : 58.8 ~ 73.5 N.m (6.0 ~ 7.5 kgf.m, 43.4 ~ 54.2 lb-ft) 22.
Page 687 Page 44 of 109 24. Adjust tension by tightening the alternator tension adjust bolt(A). (Refer to Charging system in EE Group) Tension New belt: 882.6 ~ 980.7N (90 ~ 100kg, 198.4 ~ 220.5lb) Used belt: 637.4 ~ 735.5N (65 ~ 75kg, 143.3 ~ 165.3lb) 25.
Page 688 Page 45 of 109 1. Cylinder head cover 5. Camshaft front bearing cap 2. Cylinder head cover 6. Camshaft bearing cap gasket 7. Camshaft position sensor 3. Cylinder head assembly 4. Cylinder head gasket tomsn048@gmail.com...
Page 689 Page 46 of 109 1. Exhaust camshaft 8. Valve stem seal 2. Intake camshaft 9. Valve spring 3. Exhaust camshaft sproket 10. Valve spring seat 4. CVVT assembly 11. Intake valve 5. Mechanical Lash 12. Exhaust valve Adjuster(MLA) 13. Oil Control Valve(OCV) 6.
Page 690 Page 47 of 109 • Use Fender cover to avoid damaging painted surfaces. • To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it. • When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket. •...
Page 691 Page 48 of 109 7. Disconnect the camshaft position sensor(CMP) connector(A) and remove the purge control solenoid valve(PCSV) bracket(B) and the module hanger bracket(C). 8. Remove the water temperature control assembly and the oil control valve(OCV). 9. Remove the cylinder head bolts, then remove the cylinder head. (1) Uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown.
Page 692 Page 49 of 109 1. Remove the MLAs(A). When removing MLAs, mark all the MLAs for their rearrangement. 2. Remove the valves. (1) Using the SST (09222 - 3K000, 09222 - 3K100), compress the valve spring and remove the retainer lock. (2) Remove the spring retainer.
Page 693 Page 50 of 109 1. Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the manifolds for warpage. Flatness of cylinder head gasket surface Standard : Less than 0.05mm (0.0020in) 2.
Page 694 Page 51 of 109 (2) Using a micrometer, measure the outer diameter of valve stem. Valve stem outer diameter Intake : 5.465 ~ 5.480mm (0.2152 ~ 0.2157in) Exhaust : 5.458 ~ 5.470mm (0.2149 ~ 0.2154in) (3) Subtract the valve stem outer diameter measurement from the valve guide inner diameter measurement. Valve stem- to-guide clearance Intake : 0.020 ~ 0.047mm (0.0008 ~ 0.0019in) Exhaust : 0.030 ~ 0.054mm (0.0012 ~ 0.0021in)
Page 695 Page 52 of 109 (4) Check the length of valve. Valve length Standard Intake : 93.15mm (3.6673 in) Exhaust : 92.60mm (3.6457 in) (5) Check the surface of valve stem tip for wear. If the valve stem tip is worn, replace the valve. 3.
Page 696 Page 53 of 109 1. Inspect the cam height. Using a micrometer, measure the cam height. Cam height Intake : 43.85mm (1.7264in) Exhaust : 42.85mm (1.6870in) If the cam lobe height is less than specified, replace the camshaft. 2. Inspect the camshaft journal clearance. (1) Clean the bearing caps and camshaft journals.
Page 697 Page 54 of 109 (6) Measure the plastigage at its widest point. Bearing oil clearance Standard : 0.027 ~ 0.058mm (0.0011 ~ 0.0023in) Limit : 0.1mm ( 0.0039in) If the oil clearance is greater than specified, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
Page 698 Page 55 of 109 1. Inspect the Continuous variable valve timing(CVVT) assembly. (1) Fix the Continuous variable valve timing(CVVT ) with its camshaft in a vice. (2) Check that the CVVT assembly will not turn. If it is not turned, it is in normal condition. (3) Apply vinyl tape to all the parts except the one hole.
Page 699 Page 56 of 109 2. Using the SST(09222 - 3K000, 09222 - 3K100), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor. When installing the SST, use the torque, 1.2kgf.m or less.
Page 700 Page 57 of 109 1. Install the cylinder head assembly. (1) Before installing, remove the hardened sealant from the cylinder block and cylinder head surface. (2) Before installing the cylinder head gasket, apply sealant on the upper surface of the cylinder block and reassemble the gasket within five minutes.
Page 701: Tightening Torque
Page 58 of 109 3. Install the cylinder head bolts with washers. (1) Tighten the 10 cylinder head bolts, in several passes, in the sequence shown. Tightening torque : 1st step - 17.7~21.6 N.m (1.8 ~ 2.2 kgf.m, 13.0~15.9 lb-ft) 2nd step - 90°~95°...
Page 702 Page 59 of 109 5. Install the water temperature control assembly(A). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 6. Connect the camshaft position sensor(CMP) connector(A) and install the purge control solenoid valve(PCSV) bracket(B) and the module hanger bracket(C). 7.
Page 703 Page 60 of 109 10. Install the injector connector(A) and harness bracket(B). 11. Install the camshafts. (1) Before installing, apply engine oil on journals. Do not make oil flow down to the front side of the cylinder head. (2) After installing, check the valve clearance. 12.
Page 704 Page 61 of 109 1. Cylinder block 5. Crankshaft lower bearing 9. Drive plate 2. Ladder freme 6. Thrust bearing 10. Fly wheel & ring gear 3. Crankshaft 7. Main bearing cap 11. Crankshaft sproket 4. Crankshaft upper bearing 8. Adapter plate 12.
Page 705 Page 62 of 109 1. Piston ring 5. Connecting rod upper 2. Piston bearing 3. Piston pin 6. Connecting rod lower 4. Connecting rod bearing 7. Connecting rod bearing cap Engine Mechanical System > Cylinder Block > Cylinder Block > Repair procedures Disassembly Engine removal is required for this procedure.
Page 706 Page 63 of 109 7. Remove the knock sensor(A) and the oil filter(B). 8. Remove the oil pressure switch(A). 9. Using the SST (09215-3C000), remove the oil pan (A). • Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow.
Page 707 Page 64 of 109 10. Remove the oil screen(A). 11. Remove the rear oil seal(A). 12. Remove the ladder frame(A). 13. Check the connecting rod end play. 14. Remove the connecting rod caps and check oil clearance. 15. Remove the piston and connecting rod assemblies. (1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
Page 708: Connecting Rod And Crankshaft
Page 65 of 109 17. Check the crankshaft end play. 18. Lift the crankshaft(A) out of the engine, being careful not to damage journals. Arrange the main bearings and thrust bearings in the correct order. 19. Check fit between piston and piston pin. Try to move the piston back and forth on the piston pin.
Page 709 Page 66 of 109 1. Check the connecting rod end play. Using feeler gauge, measure the end play while moving the connecting rod back and forth. End play Standard : 0.1 ~ 0.25mm (0.0039 ~ 0.0098in) Maximum : 0.35mm (0.0138in) A.
Page 710 Page 67 of 109 (8) Measure the plastigage at its widest point. Standard oil clearance 0.032 ~ 0.052mm (0.0013 ~ 0.0020in) (9) If the measurement from the plastigage is too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark.
Page 711 Page 68 of 109 Connecting rod big-end Mark inner diameter A, 0 45.000 ~ 45.006mm (1.7717 ~ 1.7719in) B, 00 45.006 ~ 45.012mm (1.7719 ~ 1.7721in) C, 000 45.012 ~ 45.018mm (1.7721 ~ 1.7724in) Crankshaft Pin Diameter Mark Location Discrimination Of Crankshaft Pin Diameter Mark Crankshaft pin outer diameter 41.972 ~ 41.966mm (1.6524 ~ 1.6522in)
Page 712 Page 69 of 109 (11) Select the bearing by using selection table. Connecting Rod Bearing Selection Table Connecting rod mark A, 0 B, 00 C, 000 (Red) (Green) (None) Crank shaft pin journal mark (Green) (None) (Black) (None) (Black) (Blue) 3.
Page 713 Page 70 of 109 (5) Remove the cap and lower bearing again, and measure the widest part of the plastigage. Standard oil clearance : No.1, 2, 3, 4, 5 : 0.021 ~ 0.042mm (0.0008 ~ 0.0017in) (6) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark.
Page 714 Page 71 of 109 Discrimination Of Cylinder Block Crankshaft Journal Bore Cylinder block crankshaft journal bore Mark inner diameter 52.000 ~ 52.006mm (2.0472 ~ 2.0475in) 52.006 ~ 52.012mm (2.0475 ~ 2.0477in) 52.012 ~ 52.018mm (2.0477 ~ 2.0479in) Crankshaft Main Journal Mark Location Discrimination Of Crankshaft Main Journal Crankshaft main journal Mark...
Page 715 Page 72 of 109 Crankshaft main bearing thickness Mark Color No.1, 2, 3, 4, 5 Blue 2.026 ~ 2.029mm (0.0798 ~ 0.0799in) Black 2.023 ~ 2.026mm (0.0796 ~ 0.0798in) None 2.020 ~ 2.023mm (0.0795 ~ 0.0796in) Green 2.017 ~ 2.020mm (0.0794 ~ 0.0795in) 2.014 ~ 2.017mm (0.0793 ~ 0.0794in) (8) Select the bearing by using selection table.
Page 716 Page 73 of 109 3. Inspect the top surface of cylinder block for flatness. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Flatness of cylinder block gasket surface Standard : Less than 0.05mm (0.0020in) Less than 0.02mm (0.0008in) - 100mm ×...
Page 717 Page 74 of 109 6. Check the cylinder bore size code on the cylinder block side surface. Discrimination Of Cylinder Bore Size Mark Cylinder bore inner diameter 77.00 ~ 77.01mm (3.0315 ~ 3.0319in) 77.01 ~ 77.02mm (3.0319 ~ 3.0323in) 77.02 ~ 77.03mm (3.0323 ~ 3.0327in) 7.
Page 718: Piston-To-Cylinder Clearance
Page 75 of 109 1. Clean the piston. (1) Using a gasket scraper, remove the carbon from the piston top. (2) Using a groove cleaning tool or broken ring, clean the piston ring grooves. (3) Using solvent and a brush, thoroughly clean the piston. Do not use a wire brush.
Page 719 Page 76 of 109 If the clearance is greater than maximum, replace the piston. 5. Inspect the piston ring end gap. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston.
Page 720 Page 77 of 109 1. Measure the outer diameter of piston pin Piston pin diameter : 18.001 ~ 18.006mm (0.7087 ~ 0.7089in) 2. Measure the piston pin-to-piston clearance. Piston pin-to-piston clearance : 0.010 ~ 0.020mm (0.0004 ~ 0.0008in) 3. Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter. Piston pin-to-connecting rod interference : -0.032 ~ -0.016mm (-0.0013 ~ -0.0006in) Oil Pressure Switch...
Page 721 Page 78 of 109 2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even when the fine wire is pushed, replace the switch. 3. If there is no continuity when a 49.0kpa (0.5kg/cm², 7.1psi) is applied through the oil hole, the switch is operating properly.
Page 722 Page 79 of 109 2. Install the piston rings. (1) Install the oil ring expander and 2 side rails by hand. (2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward. (3) Position the piston rings so that the ring ends are as shown. 3.
Page 723 Page 80 of 109 5. Install the thrust bearing. Install the thrust bearing(A) on the No.3 journal position of the cylinder block with the oil grooves facing outward. 6. Place the crankshaft on the cylinder block. 7. Place the main bearing caps on the cylinder block. 8.
Page 724 Page 81 of 109 10. Install the piston and connecting rod assemblies. Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores. (1) Install the ring compressor, check that the rings are securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.
Page 725 Page 82 of 109 12. Install the ladder frame(A). Tightening torque : 18.6 ~ 24.2N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft) 13. Install the rear oil seal. (1) Apply engine oil to a new oil seal lip. (2) Using the SST(09231-H1100, 09231-2B200) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
Page 726: Tightening Torque
Page 83 of 109 15. Install the oil pan. (1) Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces. Check that the mating surfaces are clean and dry before applying liquid gasket. (2) Apply liquid gasket with the width of Ø3mm, starting 1mm-away position from the inner rounding of the oil pan rail.
Page 727 Page 84 of 109 16. Install the oil pressure switch. (1) Apply adhesive to 2 or 3 threads. (2) Install the oil pressure switch(A). Tightening torque : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft) 17. Install the knock sensor(A) and the oil filter(B). Tightening torque : 16.7 ~ 26.5N.m (1.7 ~ 2.7kgf.m, 12.3 ~ 19.5lb-ft) 18.
Page 728 Page 85 of 109 23. M/T :install the fly wheel. Tightening torque : 71.6 ~ 75.5N.m (7.3 ~ 7.7kgf.m, 52.8 ~ 55.7lb-ft) 24. Install the engine. (Refer to Engine and transaxle assembly in this group) Engine Mechanical System > Cooling System > Coolant > Repair procedures Engine Coolant Refilling And Bleeding Never remove the radiator cap when the engine is hot.
Page 729 Page 86 of 109 11. Repeat steps 6 to 11 until the coolant level stays constant and all air is bleed out of the cooling system. Recheck the coolant level in the reservoir tank for 2~3 days after replacing coolant. Coolant capacity : 6.5 L (6.86 US qt, 5.71 lmp qt) Engine Mechanical System >...
Page 730 Page 87 of 109 1. Water inlet fitting 4. Water temp control 2. Thermostat assembly 3. Heater pipe 5. Water temperature sensor 6. O-ring Engine Mechanical System > Cooling System > Thermostat > Repair procedures Removal Disassembly of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. 1.
Page 731: Troubleshooting
Page 88 of 109 3. Check the valve lift. Valve lift : 8mm(0.3in) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. Installation 1. Place the thermostat in the block. (1) Install the thermostat(B) with the jiggle valve upward. (2) Install the new O-ring (B).
Page 732 Page 89 of 109 Remove the • Check if there are • Clean the thermostat thermostat and dusts or chips in the valve and reuse the inspect thermostat valve. thermostat. • Check adherence of • Replace the thermostat, the thermostat. if it doesn't work properly.
Page 733 Page 90 of 109 2. Remove the drive belt(A). 3. Remove the water pump pulley(A). 4. Remove the water pump(A). Water Temperature Control Assembly 1. Drain engine coolant.
Page 734 Page 91 of 109 2. Remove the air cleaner assemlby. 3. Remove the water temperature control assemlby(A). Tightening torque : 9.8 ~ 11.7N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 4. To install, reverse the removal orders. Clean the surface of the water temperature control assembly before installing.
Page 735 Page 92 of 109 1. Install the water pump. (1) Install the water pump(A) and a new gasket with the bolts. Tighten the bolts with the order blow. (2) Install the water pump pulley(A) with the four bolts. Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) Tighten the bolts diagonally.
Page 736 Page 93 of 109 Symptoms Possible Causes Remedy Coolant Visually check • From the bleed • Check leaks after • If coolant still leaks, leakage hole of the water about ten-minute replace a water pump. pump warming up. • If leakage stops, reuse the water pump (Do not replace the pump with a new one).
Page 737 Page 94 of 109 1. Cooling fan 5. Radiator 2. Radiator lower hose 6. Radiator upper mounting 3. Radiator upper hose bracket 4. Reservoir tank 7. Mounting insulator Engine Mechanical System > Cooling System > Radiator > Repair procedures Removal Never remove the radiator cap when the engine is hot.
Page 738 Page 95 of 109 1. Loosen the drain plug (A), and then drain the coolant. Remove the radiator cap to speed draining. 2. Remove the radiator upper hose (A) and lower hose (B). 3. Remove the radiator upper hose (A) and reservoir hose (B). 4.
Page 739 Page 96 of 109 5. Remove the horn (A) and the bracket cover (B). 6. Remove the radiator mounting brackets (A). Tightening torque : 6.9 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 8.0lb-ft) 7. After pulling back the condenser fixing bracket and then, remove the radiator assembly. 8.
Page 740 Page 97 of 109 1. Remove the radiator cap, wet its seal with engine coolant, then install it on a pressure tester. 2. Apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi). 3. Check for a drop in pressure. 4.
Page 741 Page 98 of 109 1. Timing chain cover 5. Oil pan 2. Inner roter 6. Oil drain plug 3. Outer roter 7. Oil screen 4. Pump cover 8. Oil pressure gauge Engine Mechanical System > Lubrication System > Engine Oil > Repair procedures Oil And Filter Replacement...
Page 742: Tightening Torque
Page 99 of 109 • Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. •...
Page 743 Page 100 of 109 2. Check the engine oil level. After warning up the engine and then 5 minutes after the engine stop, oil level should be between the "L" and "F" marks in the dipstick. If low, check for leakage and add oil up to the "F" mark. Do not fill with engine oil above the "F"...
Page 744 Page 101 of 109 Engine Mechanical System > Lubrication System > Oil Pan > Repair procedures Removal 1. Drain engine oil. 2. Using the SST(09215-3C000) and remove the oil pan. • Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow.
Page 745 Page 102 of 109 (3) Install the oil pan(A) with the bolts. Uniformly tighten the bolts in several passes. Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 2. Refill engine oil. Engine Mechanical System > Intake And Exhaust System > Intake Manifold > Components and Components Location Components...
Page 746 Page 103 of 109 1. Delivery pipe 5. Throttle body 2. Injector 6. Water hose 3. Intake manifold 7. Throttle position 4. MAP semsor sensor(TPS) Engine Mechanical System > Intake And Exhaust System > Intake Manifold > Repair procedures Removal tomsn048@gmail.com...
Page 747 Page 104 of 109 1. Disconnect the battery terminal (A). 2. Disconnect the breather hose (A) and then, remove the air cleaner assembly (B). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 3. Disconnect the wiring connectors and harness clamps. (1) Disconnect the TPS (Throttle Position Sensor) connector (A).
Page 748 Page 105 of 109 (8) Remove the knock sensor bracket (E) and disconnect MAP sensor connector (F). 4. Remove the oil level gauge (A). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 5. Remove the intake manifold assembly (A). Tightening torque : 18.6 ~ 23.5N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft) 6.
Page 749 Page 106 of 109 1. Heat protector 4. Gasket 2. Exhaust manifold 5. Catalytic convertor stay 3. Exhaust manifold Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold > Repair procedures Removal...
Page 750 Page 107 of 109 1. Disconnect the oxygen sensor connectors and then, remove the heat protector (A). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 2. Remove the catalytic converter (A). Tightening torque : Bolts : 43.1 ~ 45.1N.m (4.4 ~ 4.6kgf.m, 31.8 ~ 33.3lb-ft) Nuts : 39.2 ~ 58.8N.m (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lb-ft) 3.
Page 751 Page 108 of 109 Engine Mechanical System > Intake And Exhaust System > Muffler > Components and Components Location Components 1. Catalytic 3. Main Muffler convertor 2. Center muffler Engine Mechanical System > Intake And Exhaust System > Muffler > Repair procedures Removal...
Page 752 Page 109 of 109 1. Remove the catalytic converter (A). Tightening torque : Bolts : 43.1 ~ 45.1N.m (4.4 ~ 4.6kgf.m, 31.8 ~33.3lb-ft) Nuts : 39.2 ~ 49.0N.m (4.0 ~ 5.0kgf.m, 28.9 ~36.2lb-ft) 2. Remove the center muffler (A). Tightening torque : 39.2 ~ 49.0N.m (4.0 ~ 5.0kgf.m, 28.9 ~36.2lb-ft) 3.
Page 753 Page 1 of 97 SOUL(AM) > 2010 > G 1.6 DOHC > Fuel System Fuel System > General Information > Specifications Specifications Fuel Delivery System Items Specification 48 lit. (12.7 U.S gal., 50.7 U.S.qt., 42.2 Fuel Tank Capacity Imp.qt.) Fuel Filter Type Paper type Regulated...
Page 754 Page 2 of 97 60(140) 0.54 ~ 0.62 80(176) 0.29 ~ 0.34 Engine Coolant Temperature Sensor (ECTS) Type: Thermistor type Specification Temperature Resistance (kΩ) [°C(°F)] -40(-40) 48.14 -20(-4) 14.13 ~ 16.83 0(32) 5.79 20(68) 2.31 ~ 2.59 40(104) 1.15 60(140) 0.59 80(176) 0.32...
Page 755 Page 3 of 97 Crankshaft Position Sensor (CKPS) Type: Magnetic field sensitive Type Item Specification 774 ~ 946 [20°C Coil Resistance (Ω) (68°F)] Knock Sensor (KS) Type: Piezo-electricity type Specification Item Specification Capacitance 950 ~ 1,350 (pF) Resistance(MΩ) 4.87 Fuel Tank Pressure Sensor (FTPS) Type: Piezo-Resistive Pressure Sensor Specification Output Voltage...
Page 756 Page 4 of 97 Air Flow Rate Duty (%) ( /h) 0.5 ~ 1.4 4.6 ~ 8.0 25.0 ~ 32.0 33.0 ~ 40.0 Purge Control Solenoid Valve (PCSV) Specification Item Specification 16.0 [20°C Coil Resistance (Ω) (68°F)] CVVT Oil Control Valve (OCV) Specification Item Specification...
Page 757: Engine Control System
Page 5 of 97 Items Specification Ignition Timing BTDC 6° ± 10° Neutral,N,P- 660 ± 100 rpm range A/CON OFF D-range 660 ± 100 rpm Idle Speed Neutral,N,P- 660 ± 100 rpm range A/CON ON D-range 690 ± 100 rpm Tightening Torques Engine Control System Item...
Page 758 Page 6 of 97 Item kgf.m lb-ft Fuel tank installation bolt 4.0 ~ 5.5 39.2 ~ 53.9 28.9 ~ 39.8 Fuel tank installation nut 4.0 ~ 5.5 39.2 ~ 53.9 28.9 ~ 39.8 Fuel pump installation nut 0.2 ~ 0.3 2.0 ~ 2.9 1.4 ~ 2.2 Fuel tank air filter installation bolt 0.4 ~ 0.6 3.9 ~ 5.9...
Page 759 Page 7 of 97 Customer Problem Analysis Sheet...
Page 760 Page 8 of 97 Basic Inspection Procedure Measuring Condition of Electronic Parts' Resistance The measured resistance at high temperature after vehicle running may be high. So all resistance must be measured at ambient temperature (20°C, 68°F), unless stated otherwise. The measured resistance except at ambient temperature (20°C, 68°F) is a reference value. Intermittent Problem Inspection Procedure Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again...
Page 761 Page 9 of 97 during testing. An example would be if a problem appears only when the vehicle is cold but has not appeared when warm. In this case, the technician should thoroughly make out a "Customer Problem Analysis Sheet" and recreate (simulate) the environment and condition which occurred when the vehicle was having the issue.
Page 762 Page 10 of 97 Connector Inspection Procedure 1. Handling of Connector A. Never pull on the wiring harness when disconnecting connectors. B. When removing the connector with a lock, press or pull locking lever. C. Listen for a click when locking connectors. This sound indicates that they are securely locked. D.
Page 763 Page 11 of 97 E. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from harness side. • Use a fine wire to prevent damage to the terminal. • Do not damage the terminal when inserting the tester lead. 2.
Page 764 Page 12 of 97 6. If the covering of wire harness is damaged; secure, repair or replace the harness. Electrical Circuit Inspection Procedure ● Check Open Circuit 1. Procedures for Open Circuit A. Continuity Check B. Voltage Check If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity Check Method) or Step 3 (Voltage Check Method) as shown below.
Page 765 Page 13 of 97 B. Disconnect connector (B), and measure for resistance between connector (C) and (B1) and between (B2) and (A) as shown in [FIG. 3]. In this case the measured resistance between connector (C) and (B1) is higher than 1MΩ and the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Page 766 Page 14 of 97 2. Continuity Check Method (with Chassis Ground) Lightly shake the wire harness above and below, or side to side when measuring the resistance. Specification (Resistance) 1Ω or less → Short to Ground Circuit 1MΩ or Higher → Normal Circuit A.
Page 767: Diagnostic Procedure
Page 15 of 97 Symptom Troubleshooting Guide Chart Main symptom Diagnostic procedure Also check for Unable to start 1. Test the battery (Engine does not turn 2. Test the starter over) 3. Inhibitor switch (A/T) or clutch start switch (M/T) Unable to start 1.
Page 768 Page 16 of 97 • Low compression 3. Check the ignition circuit • Intake air leaks 4. Check the ECT Sensor and Circuit (Check DTC) • Contaminated fuel 5. Test the exhaust system for a possible restriction • Weak ignition spark 6.
Page 769 Page 17 of 97 load and warm status at the point the first fault is detected. Previously stored conditions will be replaced only if a fuel or misfire fault is detected. This data is accessible with the scan tool to assist in repairing the vehicle. The center of the OBD-II system is a microprocessor called the Engine Control Module (ECM) or Powertrain Control Module(PCM).
Page 770 Page 18 of 97 and battery supply (open collector amplifier). In most cars, the MIL will be installed in the instrument panel. The lamp amplifier can not be damaged by a short circuit. Lamps with a power dissipation much greater than total dissipation of the MIL and lamp in the tester may cause a fault indication.
Page 771 Page 19 of 97 The following is a list showing what numbers are assigned to each system. 1. Fuel and air metering 2. Fuel and air metering(injector circuit malfunction only) 3. Ignition system or misfire 4. Auxiliary emission controls 5. Vehicle speed controls and idle control system 6.
Page 772 Page 20 of 97 Catalytic Converter (WU-TWC) to determine the efficiency of the catalyst. Although the downstream H2OS is similar to the type used for fuel control, it functions differently. The downstream HO2S is monitored to determine if a voltage is generated. That voltage is compared to a calibrated acceptable range.
Page 773 Page 21 of 97 1. Engine Control Module (ECM) 2. Manifold Absolute Pressure Sensor (MAPS) 13. A/C Pressure Transducer (APT) 3. Intake Air Temperature Sensor (IATS) 14. Injector 4. Engine Coolant Temperature Sensor (ECTS) 15. Idle Speed Control Actuator (ISCA) 5.
Page 774 Page 22 of 97 2. Manifold Absolute Pressure Sensor (MAPS) 1. Engine Control Module (ECM) 3. Intake Air Temperature Sensor (IATS) 4. Engine Coolant Temperature Sensor (ECTS) 5. Throttle Position Sensor (TPS) 6. Crankshaft Position Sensor (CKPS) 7. Camshaft Position Sensor (CMPS) 8.
Page 775 Page 23 of 97 10. Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 11. Fuel Tank Pressure Sensor (FTPS) 12. Fuel Level Sensor (FLS) 13. A/C Pressure Transducer (APT) 14. Injector 15. Idle Speed Control Actuator (ISCA) 19. Ignition Coil 16. Purge Control Solenoid Valve (PCSV) 17.
Page 776 Page 24 of 97 20. Main Relay 18. Canister Close Valve (CCV) 21. Fuel Pump Relay 23. Multi-Purpose Check Connector Fuel System > Engine Control System > Engine Control Module (ECM) > Schematic Diagrams ECM Terminal And Input/Output signal ECM Harness Connector (A/T) ECM Terminal Function (A/T) Connector [EGGA-K] Description...
Page 777 Page 25 of 97 Heated Oxygen Sensor (Sensor 2) signal Heated Oxygen Sensor (Sensor 2) input 17 Alternator load signal input Alternator 20 Vehicle speed signal input ABS/ESP Control Module [With ABS/ESP] 22 Electric Load signal input Defrost 23 A/C Switch "ON" signal input A/C Switch 24 For Autotransaxle Control 25 For Autotransaxle Control...
Page 778 Page 26 of 97 46 A/C thermal switch signal input A/C Thermal Switch 47 For Autotransaxle Control 48 For Autotransaxle Control 49 For Autotransaxle Control 50 For Autotransaxle Control 51 Sensor ground Throttle Position Sensor (TPS) 53 Fuel Level Sensor signal input Fuel Level Sensor (FLS) 57 For Autotransaxle Control 60 For Autotransaxle Control...
Page 779 Page 27 of 97 81 For Autotransaxle Control 82 For Autotransaxle Control 83 For Autotransaxle Control 84 For Autotransaxle Control 86 For Autotransaxle Control 87 For Autotransaxle Control 88 For Autotransaxle Control 89 For Autotransaxle Control 90 For Autotransaxle Control 91 For Autotransaxle Control 92 For Autotransaxle Control 93 For Autotransaxle Control...
Page 780 Page 28 of 97 Cooling Fan Relay [Low] control output Cooling Fan Relay [Low] Idle Speed Control Actuator [CLOSE] control Idle Speed Control Actuator (ISCA) output Cooling Fan Relay [High] control output Cooling Fan Relay [High] Fuel consumption signal output Trip Computer Engine speed signal output Tachometer (Cluster)
Page 781: Test Result
Page 29 of 97 Injector (Cylinder #4) control output Injector (Cylinder #4) CVVT Oil Control Valve control output CVVT Oil Control Valve (OCV) Injector (Cylinder #1) control output Injector (Cylinder #1) Malfunction Indicator Lamp (MIL) control output Cluster (Malfunction Indicator Lamp) Injector (Cylinder #2) control output Injector (Cylinder #2) Crankshaft Position Sensor [B] signal input...
Page 782 Page 30 of 97 Hi: Battery Voltage 13.2V Alternator load signal input Idle Pulse Lo: Max. 1.5V 1.34V Hi: Min. 4.5V 12.2V Idle Lo: Max. 1.0V Freq: 72.2Hz Vehicle speed signal input Pulse Hi: Min. 4.5V 12.2V Vehicle Lo: Max. 1.0V (30km/h) Freq: 212Hz Electric Load signal input...
Page 783 Page 31 of 97 Hi: Battery Voltage 13.72V Camshaft Position Sensor signal input Idle Pulse Lo: Max. 0.5V 200mV Power Steering Switch signal input A/C S/W Max.1.0V 200mV A/C thermal switch signal input A/C S/W Battery Voltage 12.6V For Autotransaxle Control For Autotransaxle Control For Autotransaxle Control For Autotransaxle Control...
Page 784 Page 32 of 97 0.25 ~ 0.9V 0.34V Throttle Position Sensor signal input Analog W.O.T Min. 4.0V 4.43V Engine Coolant Temperature Sensor Idle Analog 0.5 ~ 4.5V 1.43V signal input A/C Pressure Transducer signal input A/C ON Analog Max. 4.8V 1.88V For Autotransaxle Control For Autotransaxle Control...
Page 785 Page 33 of 97 Hi: Battery Voltage 13.8V Idle Speed Control Actuator [OPEN] Idle Pulse control output Lo: Max. 1.0V 20mV Hi: Battery Voltage 14.2V Purge Control Solenoid Valve control Active Pulse output Inactive Lo: Max. 1.0V 120mV Relay Battery Voltage 12.78V 9 Main Relay control output Relay ON...
Page 786 Page 34 of 97 Hi: Battery Voltage 14.0V 25 Engine speed signal output Idle Pulse Lo: Max. 0.5V 20mV Freq.: 20 ~ 60Hz 22Hz RECESSIVE 2.0 ~ 3.0V 2.5V 27 CAN [LOW] Pulse DOMINANT 0.5 ~ 2.25V 1.5V 30 Sensor ground Idle Max.
Page 787 Page 35 of 97 IG OFF Max. 0.5V 3.6mV 43 Sensor power (+5V) IG ON 4.8 ~ 5.2V 5.02V When Hi: Min. 8.5V 12.51V communicating 44 Immobilizer communication line Pulse after Lo: Max. 3.5V 1.17V IG ON SINE 45 Wheel Speed Sensor [A] signal input Vehicle Run Vp_p: Min.
Page 788 Page 36 of 97 ECM Terminal Function (M/T) Connector [EGGM-K] Description Connectedto Ignition Coil (Cylinder #1) control output Ignition Coil (Cylinder #1) Power Ground Chassis Ground Ignition Coil (Cylinder #3) control output Ignition Coil (Cylinder #3) Battery voltage supply after main relay Main Relay Ignition Coil (Cylinder #4) control output Ignition Coil (Cylinder #4)
Page 789 Page 37 of 97 Cooling Fan Relay [Low] control output Cooling Fan Relay [Low] Ignition Coil (Cylinder #2) control output Ignition Coil (Cylinder #2) A/C Switch "ON" signal input A/C Switch Electric Load signal input Defrost Sensor ground Knock Sensor (KS) Sensor ground A/C Pressure Transducer (APT) Sensor ground...
Page 790 Page 38 of 97 Wheel Speed Sensor [A] signal input Wheel Speed Sensor (WSS) [Without ABS/ESP] Sensor power (+5V) A/C Pressure Transducer (APT) Sensor power (+5V) Throttle Position Sensor (TPS) Other control module, Data Link Connector (DLC), CAN [LOW] Multi-Purpose Check Connector Camshaft Position Sensor signal input Camshaft Position Sensor (CMPS) Vehicle speed signal input...
Page 791: Power Ground
Page 39 of 97 Injector (Cylinder #1) control output Injector (Cylinder #1) CVVT Oil Control Valve control output CVVT Oil Control Valve (OCV) ECM Terminal Input/Output Signal (M/T) Connector [EGGM-K] Description Condition Type Level Test Result 1st Voltage: 300 ~ 352V 400V Ignition Coil (Cylinder #1) control...
Page 792 Page 40 of 97 When Hi: Min. 8.5V 12.51V communicating 18 Immobilizer communication line Pulse after Lo: Max. 3.5V 1.17V IG ON Manifold Absolute Pressure Sensor IG ON 3.9 ~ 4.1V 4.09V signal input Idle 0.8 ~ 1.6V 1.44V Relay Battery Voltage 12.78V 22 Main Relay control output...
Page 793 Page 41 of 97 38 Sensor ground Idle Max. 50mV 6.8mV 0.2 ~ 0.7V 0.34V 39 Throttle Position Sensor signal input Analog W.O.T Min. 4.0V 4.43V A/C Pressure Transducer signal A/C ON Analog Max. 4.8V 1.88V input Intake Air Temperature Sensor signal Idle 0.2 ~ 4.8V...
Page 794 Page 42 of 97 IG OFF Max. 0.5V 3.6mV 59 Sensor power (+5V) IG ON 4.9 ~ 5.1V 5.02V IG OFF Max. 0.5V 3.6mV 60 Sensor power (+5V) IG ON 4.9 ~ 5.1V 5.02V RECESSIVE 2.0 ~ 3.0V 2.5V 62 CAN [LOW] Pulse DOMINANT 0.5 ~ 2.25V...
Page 795 Page 43 of 97 Engine Coolant Temperature Sensor Idle Analog 0.5 ~ 4.5V 1.43V signal input SINE 79 Wheel Speed Sensor [B] signal input Vehicle Run Vp_p: Min. 0.2V Wave IG OFF Max. 0.5V 3.6mV 80 Sensor power (+5V) IG ON 4.9 ~ 5.1V 5.02V IG OFF...
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Page 803 Page 51 of 97 Fuel System > Engine Control System > Engine Control Module (ECM) > Repair procedures Removal • In the case of the vehicle equipped with immobilizer, perform "Key Teaching" procedure together (Refer to "Immobilizer" in BE group). 1.
Page 804 Page 52 of 97 2. Disconnect the ECM connector (A). 3. Remove the bracket installation bolts (A) and the nut (B). 4. Remove the installation bolts (A), and then remove the ECM from the bracket. Installation • In the case of the vehicle equipped with immobilizer, perform "Key Teaching" procedure together (Refer to "Immobilizer"...
Page 805 Page 53 of 97 ECM Problem Inspection Procedure 1. TEST ECM GROUND CIRCUIT: Measure the voltage drop between ECM and chassis ground using the backside of ECM harness connector. The ECM harness should be connected to the ECM and the ECM must be powered up.
Page 806 Page 54 of 97 3. Input the VIN. Before inputing the VIN, confirm the VIN again because the programmed VIN cannot be changed. 4. Turn the ignition switch OFF, then back ON. Fuel System > Engine Control System > Manifold Absolute Pressure Sensor (MAPS) > Description and Operation Description Manifold Absolute Pressure Sensor (MAPS) is a speed-density type sensor and is installed on the surge tank.
Page 807 Page 55 of 97 Output Voltage Pressure (kPa) 20.0 0.79 46.66 1.84 101.32 Fuel System > Engine Control System > Manifold Absolute Pressure Sensor (MAPS) > Schematic Diagrams Circuit Diagram [A/T] [M/T]...
Page 808 Page 56 of 97 Fuel System > Engine Control System > Manifold Absolute Pressure Sensor (MAPS) > Repair procedures Inspection 1. Connect a scan tool on Data Link Connector (DLC). 2. Check MAPS output voltage at idle and IG ON. Condition Output Voltage (V) IG ON...
Page 809 Page 57 of 97 Fuel System > Engine Control System > Intake Air Temperature Sensor (IATS) > Specifications Specification Temperature Resistance(kΩ) [°C(°F)] -40 (-40) 40.93 ~ 48.35 -30 (-22) 23.43 ~ 27.34 -20 (-4) 13.89 ~ 16.03 -10 (14) 8.50 ~ 9.71 0 (32) 5.38 ~ 6.09 10 (50)
Page 810 Page 58 of 97 [M/T] Fuel System > Engine Control System > Intake Air Temperature Sensor (IATS) > Repair procedures...
Page 811 Page 59 of 97 Inspection 1. Turn ignition switch OFF. 2. Disconnect IATS connector. 3. Measure resistance between IATS terminals 3 and 4. 4. Check that the resistance is within the specification. Specification: Refer to “Specification” Fuel System > Engine Control System > Engine Coolant Temperature Sensor (ECTS) > Description and Operation Description Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the cylinder head for...
Page 812 Page 60 of 97 Fuel System > Engine Control System > Engine Coolant Temperature Sensor (ECTS) > Schematic Diagrams Circuit Diagram [A/T] [M/T]...
Page 813 Page 61 of 97 Fuel System > Engine Control System > Engine Coolant Temperature Sensor (ECTS) > Repair procedures Inspection 1. Turn ignition switch OFF. 2. Disconnect ECTS connector. 3. Remove the ECTS. 4. Measure resistance between ECTS terminals 1 and 3. 5.
Page 814 Page 62 of 97 Item Specification 1.6 ~ 2.4 Sensor Resistance(kΩ) [20°C(68°F)] Fuel System > Engine Control System > Throttle Position Sensor (TPS) > Schematic Diagrams Circuit Diagram [A/T] [M/T]...
Page 815 Page 63 of 97 Fuel System > Engine Control System > Throttle Position Sensor (TPS) > Repair procedures Inspection 1. Connect a scan tool on the Data Link Connector (DLC). 2. Start engine and check output voltages of TPS at C.T and W.O.T. Specification: Refer to “Specification”...
Page 816 Page 64 of 97 Fuel System > Engine Control System > Crankshaft Position Sensor (CKPS) > Specifications Specification Item Specification 774 ~ 946 [20°C Coil Resistance(Ω) (68°F)] Fuel System > Engine Control System > Crankshaft Position Sensor (CKPS) > Troubleshooting Waveform...
Page 817 Page 65 of 97 Fuel System > Engine Control System > Crankshaft Position Sensor (CKPS) > Schematic Diagrams Circuit Diagram [A/T]...
Page 818 Page 66 of 97 [M/T] Fuel System > Engine Control System > Crankshaft Position Sensor (CKPS) > Repair procedures Inspection 1. Check signal waveform of CKPS and CMPS using a scan tool. Specification: Refer to “Waveform”...
Page 819 Page 67 of 97 Fuel System > Engine Control System > Camshaft Position Sensor (CMPS) > Description and Operation Description Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft position by using a hall element. It is related with Crankshaft Position Sensor (CKPS) and detects the piston position of each cylinder which the CKPS can't detect.
Page 820 Page 68 of 97 Fuel System > Engine Control System > Camshaft Position Sensor (CMPS) > Schematic Diagrams Circuit Diagram [A/T]...
Page 821 Page 69 of 97 [M/T] Fuel System > Engine Control System > Camshaft Position Sensor (CMPS) > Repair procedures Inspection 1. Check signal waveform of CKPS and CMPS using a scan tool. Specification: Refer to “Waveform”...
Page 822 Page 70 of 97 Fuel System > Engine Control System > Knock Sensor (KS) > Description and Operation Description Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine damage. Knock Sensor (KS) is installed on the cylinder block and senses engine knocking. When knocking occurs, the vibration from the cylinder block is applied as pressure to the piezoelectric element.
Page 823 Page 71 of 97 [M/T] Fuel System > Engine Control System > Heated Oxygen Sensor (HO2S) > Description and Operation Description Heated Oxygen Sensors (HO2S) consists of zirconium and alumina and are installed both upstream and downstream of the Manifold Catalytic Converter (MCC). The sensor looks at the difference between the oxygen in the atmosphere with the oxygen in the exhaust gas.
Page 824 Page 72 of 97 The sensor must be hot in order to operate normally. To keep it hot, the sensor has a heater which is controlled by the ECM via a duty cycle signal. When the exhaust gas temperature is lower than the specified value, the heater warms the sensor tip.
Page 825 Page 73 of 97 Fuel System > Engine Control System > Heated Oxygen Sensor (HO2S) > Schematic Diagrams Circuit Diagram [A/T]...
Page 826 Page 74 of 97 [M/T]...
Page 827 Page 75 of 97 Fuel System > Engine Control System > Heated Oxygen Sensor (HO2S) > Repair procedures Inspection 1. Check signal waveform of HO2S using a scan tool. Specification: Refer to "Waveform" 2. Disconnect the HO2S connector. 3. Measure resistance between HO2S heater terminals 3 and 4. 4.
Page 828 Page 76 of 97 Fuel System > Engine Control System > Injector > Specifications Specification Item Specification 13.8 ~ 15.2 Coil Resistance (Ω) [20°C(68°F)] Fuel System > Engine Control System > Injector > Schematic Diagrams Circuit Diagram [A/T]...
Page 829 Page 77 of 97 [M/T]...
Page 830 Page 78 of 97 Fuel System > Engine Control System > Injector > Repair procedures Inspection 1. Turn ignition switch OFF. 2. Disconnect injector connector. 3. Measure resistance between injector terminals 1 and 2. 4. Check that the resistance is within the specification. Specification: Refer to “Specification”...
Page 831 Page 79 of 97 provide additional air during starting. The ISCA consists of an opening coil, a closing coil, and a permanent magnet. Based on information from various sensors, the ECM controls both coils by grounding their control circuits. According to the control signals from the ECM, the valve rotor rotates to control the by-pass airflow into the engine.
Page 832 Page 80 of 97 [M/T] Fuel System > Engine Control System > Idle Speed Control Actuator (ISCA) > Repair procedures Inspection 1. Turn ignition switch OFF. 2. Disconnect ISCA connector. 3. Measure resistance between ISCA terminals 2 and 1 [Opening Coil]. 4.
Page 833 Page 81 of 97 5. Check that the resistance is within the specification. Specification: Refer to “Specification” Fuel System > Engine Control System > Purge Control Solenoid Valve (PCSV) > Description and Operation Description Purge Control Solenoid Valve (PCSV) is a solenoid valve and is installed on the surge tank and controls the passage between the canister and the intake manifold.
Page 834 Page 82 of 97 [M/T] Fuel System > Engine Control System > Purge Control Solenoid Valve (PCSV) > Repair procedures Inspection 1. Turn ignition switch OFF. 2. Disconnect PCSV connector. 3. Measure resistance between PCSV terminals 1 and 2. 4. Check that the resistance is within the specification. Specification: Refer to “Specification”...
Page 835 Page 83 of 97 Fuel System > Engine Control System > CVVT Oil Control Valve (OCV) > Description and Operation Description The Continuously Variable Valve Timing (CVVT) system controls the amount of valve overlap by varying the amount of oil flow into a phaser assembly mounted on the intake camshaft through ECM control of an oil control valve.
Page 836 Page 84 of 97 [M/T] Fuel System > Engine Control System > CVVT Oil Control Valve (OCV) > Repair procedures Inspection 1. Turn ignition switch OFF. 2. Disconnect OCV connector. 3. Measure resistance between OCV terminals 1 and 2. 4. Check that the resistance is within the specification. Specification: Refer to “Specification”...
Page 837 Page 85 of 97 Fuel System > Engine Control System > Fuel Tank Pressure Sensor (FTPS) > Description and Operation Description Fuel Tank Pressure Sensor (FTPS) is a component of the evaporative emission control system and is installed on the fuel tank, the fuel pump, or the canister.
Page 838 Page 86 of 97 Fuel System > Engine Control System > Fuel Tank Pressure Sensor (FTPS) > Repair procedures Inspection 1. Connect a scantool on the Data Link Connector (DLC). 2. Measure the output voltage of the FTPS. Specification: Refer to "Specification" Fuel System >...
Page 839 Page 87 of 97 Item Specification 15.5 ~ 18.5 Coil Resistance (Ω) (20°C) Fuel System > Engine Control System > Canister Close Valve (CCV) > Schematic Diagrams Circuit Diagram Fuel System > Engine Control System > Canister Close Valve (CCV) > Repair procedures Inspection 1.
Page 840 Page 88 of 97 1. Fuel Tank 5. Canister 2. Fuel Pump (Including Fuel Filter) 6. Vapor Hose (Canister → Intake 3. Fuel Pressure Regulator Manifold) 4. Fuel Filler Pipe 7. Vapor Hose (Canister ↔ Fuel Tank) 8. Ventilation Hose (Canister ↔ Atmosphere) Fuel System >...
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Page 842 Page 90 of 97...
Page 843 Page 91 of 97 Fuel System > Fuel Delivery System > Fuel Tank > Repair procedures Removal 1. Preparation (1) Remove the rear seat cushion (Refer to "Seat" in BD group). (2) Open the service cover (A).
Page 844 Page 92 of 97 (3) Disconnect the fuel pump connector (A) and the fuel tank pressure sensor connector (B). (4) Start the engine and wait until the fuel engine has stalled. (5) After engine stalls, turn the ignition switch to OFF position. 2.
Page 845 Page 93 of 97 7. Remove the fuel tank air filter installation bolt (A). 8. Remove the brake line bracket mounting bolt (A). 9. Remove the fuel tank mounting bolts (A) and nuts (B), and then remove the fuel tank (C). Installation Installation is reverse of removal.
Page 846 Page 94 of 97 1. Preparation (1) Remove the rear seat cushion (Refer to "Seat" in BD group). (2) Open the service cover (A). (3) Disconnect the fuel pump connector (A) and the fuel tank pressure sensor connector (B). (4) Start the engine and wait until fuel in fuel line is exhausted. (5) After engine stalls, turn the ignition switch to OFF position.
Page 847 Page 95 of 97 Installation Installation is reverse of removal. Fuel pump installation nut: 2.0 ~ 2.9 N.m (0.2 ~ 0.3 kgf.m, 1.4 ~ 2.2 lb-ft) When installing the fuel pump module, be careful not to get the seal-ring entangled. Fuel System >...
Page 848 Page 96 of 97 7. Remove the plate assembly (B) after removing the cushion pipe fixing clip (A). 8. Remove the pump & pre-filter assembly (A) and the fuel pressure regulator (A) from the fuel filter. Fuel System > Fuel Delivery System > Filler-Neck Assembly > Repair procedures Removal...
Page 849 Page 97 of 97 1. Disconnect the fuel filler hose (A) and the ventilation hose (B) from the fuel tank air filter. 2. Open the fuel filler door and unfasten the filler-neck assembly mounting screws (A). 3. Remove the rear-LH wheel, tire, and the inner wheel house. 4.
Page 850 Page 1 of 46 SOUL(AM) > 2010 > G 1.6 DOHC > Heating,Ventilation, Air Conditioning Heating,Ventilation, Air Conditioning > General Information > Specifications Air conditioner Item Specification Type VS12 Oil type & Capacity FD46XG(PAG) 100 ± 10cc Compressor Pulley type 5PK-TYPE Displacement 126cc/rev...
Page 851 Page 2 of 46 Before replacing or repairing air conditioning components, first determine if the malfunction is due to the refrigerant charge, air flow or compressor. Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem.
Page 852 Page 3 of 46 No cooling fan 1.Cooling fan fuse operation 2.Fan motor 3.Engine ECM 4.Wire harness Heating,Ventilation, Air Conditioning > General Information > Special Service Tools Special tools Tool (Number and name) Illustration 09977-29000 Removal and installation of disc & hub Disc &...
Page 853 Page 4 of 46 7. If an accidental discharge of refrigerant occurs, ventilate the work area before resuming work. When replacing parts ON A/C system 1. Never open or loosen a connection before discharging the system. 2. Seal the open fittings of components with a cap or plug immediately to prevent intrusion of moisture or dust. 3.
Page 854 Page 5 of 46 Size Tightening torque [ N.m (kg.m, lbf.ft) ] General bolt, nut 5 - 6(0.5 - 0.6, 3.6 - 4.3) 9 - 11(0.9 - 1.1, 6.5 - 7.9) 12 - 14(1.2 - 1.4, 8.7 - 20 - 26(2.0 - 2.6, 14 - 18) M10 25 - 28(2.5 - 2.8, 18 - 20) 45 - 55(4.5 - 5.5, 32 - 39) Size Flange bolt, nut...
Page 855 Page 6 of 46 Heating,Ventilation, Air Conditioning > Air conditioning System > Repair procedures 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.
Page 856 Page 7 of 46 - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or oil vapor. If accidental system discharge occurs, ventilate work area before resume of service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
Page 857 Page 8 of 46 2. Connect an R-134a refrigerant Recovery/Recycling/Charging System (A) to the high-pressure service port (B) and the low-pressure service port (C) as shown, following the equipment manufacturer's instructions. 3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 10 minutes, there is probably a leak in the system.
Page 858 Page 9 of 46 2. If leakage continues even after the fitting has been tightened, discharge the refrigerant from the system, disconnect the fittings, and check their seating faces for damage. Always replace, even if the damage is slight. 3. Check the compressor oil and add oil if required. 4.
Page 859 Page 10 of 46 Interior...
Page 860 Page 11 of 46 Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor oil > Repair procedures Oil Specification 1. The HFC-134a system requires synthetic (PAG) compressor oil whereas the R-12 system requires mineral compressor oil. The two oils must never be mixed. 2.
Page 861 Page 12 of 46 Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the original amount of oil. Oil total volume in system : 100±10cc (3.52±0.34 fl.oz) Oil Return Operation There is close affinity between the oil and the refrigerant.
Page 862 Page 13 of 46 1. Bolt 6. Retainer ring (Field 2. Disc & hub assembly coil) 3. Shim 7. Field coil 4. Retainer ring (pulley) 8. Connector bracket 5. Pulley 9. Screw 10. Compressor assembly Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Repair procedures Removal 1.
Page 863 Page 14 of 46 5. Remove the bolts, then disconnect the suction line (A) and discharge line (B) from the compressor. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination. 6. Disconnect the compressor clutch connector (A), and then remove 4 mounting bolts and the compressor (B). Installation 1.
Page 864 Page 15 of 46 Inspection 1. Check the plated parts of the disc & hub assembly (A) for color changes, peeling or other damage. If there is damage, replace the clutch set. 2. Check the pulley (B) bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag.
Page 865 Page 16 of 46 Disassembly 1. Remove the center bolt (A) while holding the disc & hub assembly with a commercially available disc & hub assembly bolt remover; Special tool number 09977-29000. TORQUE : 10~15N.m (1.02~1.53kgf.m, 7.37~11lbf.ft) 2. Remove the disc & hub assembly (A) and shim (gap washer) (B), taking care not to lose the shims. If the clutch needs adjustment, increase or decrease the number and thickness of shims as necessary, then reinstall the disc &...
Page 866 Page 17 of 46 4. Reassemble the compressor clutch in the reverse order of disassembly, and note these items : A. Clean the pulley and compressor sliding surfaces with non-petroleum solvent. B. Install new retainer rings, and make sure they are fully seated in the groove. C.
Page 867 Page 18 of 46 Condenser Assembly 1. Recover the refrigerant with a recovery/ recycling/ charging station . 2. Disconnect the negative (-) battery terminal. 3. Remove the front bumper. (Refer to BD group-front bumper) 4. Disconnect the refrigerant line(A). 5. Remove the mount bumper(A). 6.
Page 868 Page 19 of 46 1. Remove the condenser, and then remove the bottom cap (B) with L wrench (A) from the condenser. TORQUE : 20~25N.m (2.0~2.5kgf•m, 14.5~18.2lb-ft) 2. Remove the desiccant (A) from condenser using a long nose plier. Check for crumbled desiccant and clogged bottom cap filter.
Page 869 Page 20 of 46 Heating,Ventilation, Air Conditioning > Air conditioning System > A/C pressure transducer > Description and Operation Description The A/C pressure transducer converts the pressure in the high pressure line into a voltage signal. The engine ECU uses this signal to control the compressor and the cooling fan. The Engine ECU will stop the operation of the compressor when the temperature of refrigerant line is too high or too low.
Page 870 Page 21 of 46 1. Measure the pressure of high pressure line by voltage output between NO.1 and NO.2 terminals 2. Determin if the voltage is within spec. Voltage = 0.00878835 * Pressure + 0.37081095 [PSIA] 3. If the measured voltage value is not within specification, replace the A/C pressure transducer. Replacement 1.
Page 871 Page 22 of 46 Heating,Ventilation, Air Conditioning > Air conditioning System > Evaporator temperature sensor > Repair procedures Inspection 1. Ignition "OFF" 2. Disconnect evaporator temperature sensor. 3. Using the multimeter, Measure resistance between terminal "1" and "2" of evaporator temperature sensor Specification Coolant temperature [°C(°F)] Resistance (kΩ)
Page 872 Page 23 of 46 3. Remove the evaporator temperature sensor (B), by pulling it after rorating 90° in a counter clock wise direction. 4. Installation is the reverse order of removal Heating,Ventilation, Air Conditioning > Air conditioning System > Refrigerant line > Components and Components Location Component location...
Page 873 Page 24 of 46 Heating,Ventilation, Air Conditioning > Air conditioning System > Refrigerant line > Repair procedures Replacement 1. Discharge refrigerant from refrigeration system . 2. Replace faulty tube or hose. • Cap the open fittings immediately to keep moisture or dirt out of the system.
Page 874 Page 25 of 46 Compoment...
Page 875 Page 26 of 46 1. Heater case (LH) 6. Drain hose 11. Shower duct (LH) 2. Evaporator core 7. Blower motor 12. Heter core cover 3. Evaporator lower insulator 8. Blower resistor 13. Temp control actuator 4. heater lower case 9.
Page 876 Page 27 of 46 1. Heater case (RH) 6. Temp door 11. Shower duct 16. Air filter cover 2. Duct seal 1 7. Vent arm (RH) 17. Inlet duct case 3. Duct seal 2 8. Vent door lever 12. Intake seal 18.
Page 877 Page 28 of 46 4. Remove the bolts (A) and the expansion valve (B) from the evaporator core. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination. 5. Disconnect the inlet (C) and outlet (D) heater hoses from the heater unit. •...
Page 878 Page 29 of 46 9. Remove the cover (A). 10. Be careful that the inlet and outlet pipe are not bent during heater core removal, and pull out the heater core(A). 11. Remove the intake assembly(A). 12. Remove the heater unit lower case(A).
Page 879 Page 30 of 46 13. Remove the evaporator core(A). 14. Installation is the reverse order of removal, and note these items : A. If you're installing a new evaporator, add refrigerant oil (ND-OIL8). B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing. Be sure to use the right O-rings for R-134a to avoid leakage.
Page 880 Page 31 of 46 Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Description and Operation Description 1. Heater unit includes mode control actuator and temperature control actuator. 2. The HVAC uses the temperature control actuator to control the vent temperature. The temperature control actuator is located on the heater unit..
Page 881 Page 32 of 46 3. Verify that the temperature control actuator operates to the hot position when connecting 12V to the terminal 3 and grounding terminal 4. Verify that the temperature control actuator operates to the cool position when connecting in the reverse. 4.
Page 882 Page 33 of 46 4. Disconnect the connector(A). 5. After loosening the mounting bolts, then the reinforcing panel (A). 6. Remove the shower duct(A). 7. Loosen the mounting screw and then remove the temperature control actuator (B). 8. Installation is the reverse order of removal.
Page 883 Page 34 of 46 Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Components and Components Location Component Location Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Description and Operation Description The mode control actuator is located at the heater unit. It adjusts position of mode door by operating mode control actuator based on signal of A/C control unit.
Page 884 Page 35 of 46 3. Verify that the mode control actuator operates to the defrost mode when connecting 12V to the terminal 3 and grounding terminal 4. 4. Verify that the mode control actuator operates to the vent mode when connecting in the reverse. 5.
Page 885 Page 36 of 46 4. Remove the shower duct(A). 5. Loosen the mounting screw and then remove the temperature control actuator (B). 6. Installation is the reverse order of removal. Heating,Ventilation, Air Conditioning > Heater > Positive Temperature Coefficient Heater > Description and Operation Description PTC (Positive Temperature Coefficient) heater (A) is an electric heater using a PTC element as an auxiliary heating...
Page 886 Page 37 of 46 Operation Principle ECM outputs a PTC on signal. Operate PTC from 1st setting to 3rd setting with an interval of 15 seconds. Heat up the air, which passes through a heater core. Operation Condition Judge the condition by ambient temperature is below 5°C, coolant temperature is below 70°C, and battery voltage is above 11V and engine RPM is above 700RPM.
Page 887 Page 38 of 46 2. Cancellation method (1) Select the A/C button or intake button. (2) IG "OFF" (3) Cancel the logic after 30 seconds automatically. 3. If the PTC operation is not operated, substitute with a known-good PTC and check for proper operation. If the problem is corrected, replace the PTC.
Page 888 Page 39 of 46 Replacement 1. Disconnect the negative (-) battery terminal. 2. Remove the crashpad(refer to BD group-crashpad) 3. Disconnect the connector (A) of the blower motor. 4. Remove the blower motor (B) after loosening the mounting screws. 5. Installation is the reverse order of removal. Heating,Ventilation, Air Conditioning >...
Page 889 Page 40 of 46 3. Disconnect the connector and then remove the blower resistor (A). 4. Installation is the reverse order of removal. Heating,Ventilation, Air Conditioning > Blower > Climate control air filtar > Description and Operation Description This vehicle may or may not be equipped with a particle filter which eliminates foreign materials and odor. Heating,Ventilation, Air Conditioning >...
Page 890 Page 41 of 46 3. Replace the air filter (B), install it after making sure of the direction of air filter. 4. Installation is the reverse order of removal. • In case of driving in an air-polluted area or rugged terrain, check and replace the air filter as frequently as possible.
Page 891 Page 42 of 46 Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Description and Operation Description 1. The intake actuator is located at the blower unit. 2. It regulates the intake door by signal from control unit. 3. Pressing the intake selection switch will shift between recirculation and fresh air modes. Heating,Ventilation, Air Conditioning >...
Page 892 Page 43 of 46 4. Verify that the intake actuator operates to the fresh position when connecting in the reverse. 5. If the measured resistance is not within specification, replace the evaporator temperature sensor. 6. If the evaporator temperature sensor resistance in within specs. check the voltage between pins 5 and 7 of the harness.
Page 893 Page 44 of 46 Connector Pin Function Connector Function Connector Function Connector(A) Tail (ILL+) Connector(B) Battery MID HIGH A/C Output MID LOW (Thermo) Mode actuator HIGH (Vent) Mode actuator (Def) Temp actuator(Cool) Temp actuator(Warm)
Page 894 Page 45 of 46 Intake actuator(Fre) Intake actuator(Rec) Sensor REF(+5V) Blower ON signal Rheostat (ILL-) IGN2 PTC relay2 PTC relay3 Temp actuator Mode actuator Intake actuator(Def) Evaporator sensor(+) Blower ON signal A/C Select signal Rear defog S/W Sensor GND PTC ON signal(Low) Heating,Ventilation, Air Conditioning >...
Page 895 Page 46 of 46 2. Use a panel/facia tool to pull the center facia panel(A). 3. Disconnect the connector(A) and then remove the center facia panel. 4. Remove the heater & A/C controller (A) from center facia panel. 5. Disconnect the connector(A) and then remove the controller (B). 6.
Page 896 Page 1 of 22 SOUL(AM) > 2010 > G 1.6 DOHC > Manual Transaxle System Manual Transaxle System > General Information > Specifications Specifications Transaxle M5CF1-1 type Engine type Gasoline 1.6 3.615 1.962 1.286 Gear ratio 0.971 0.839 Reverse 3.545 Final gear ratio 4.267 Tightening Torques...
Page 897 Page 2 of 22 Tool Illustration (Number and Name) 09200-38001 Removal and installation of the transaxle Engine support fixture 09624-38000 Supporting of crossmember Crossmember supporter 09452-21200 Installation of differential oil seal Oil seal installer Manual Transaxle System > General Information > Troubleshooting Troubleshooting Symptom Probable cause...
Page 898 Page 3 of 22 1. Remove oil filler plug(A). 2. Check level with finger. Oil level must be up to fill the hole, if not, add oil until it runs over. 3. Install filler plug. Tightening torque : 60~80 Nm (6.0~8.0 kgf.m, 43.4~57.8 lb-ft) Replacement 1.
Page 899 Page 4 of 22 2. Using a flat-tip screwdriver, remove the oil seal. 3. Using the special tool(09452-21200), tap the drive shaft oil seal into the transaxle. Manual Transaxle System > Manual Transaxle System > Manual Transaxle > Components and Components Location Components (1)
Page 900 Page 5 of 22 1. Control shaft complete 6. 3&4th shift rail 11. Output shaft assembly 2. Rear cover 7. 3&4th shift fork 12. Oil guide 3. Transaxle case 8. 1&2nd shift rail 13. Differential assembly 4. 5th shift rail 9.
Page 901 Page 6 of 22 1. Lock nut 6. Needle roller bearing 2. 5th synchronizer hub 7. 5th gear (output) 3. 5th synchronizer 8. Snap ring sleeve 9. 5th shift fork 4. 5th synchronizer ring 5. 5th gear (input) Manual Transaxle System > Manual Transaxle System > Manual Transaxle > Repair procedures Removal •...
Page 902 Page 7 of 22 1. Remove the air cleaner assembly and the intake hose by removing the bolts and the clamps. 2. Remove the ECU by removing the bolts(2ea) and a nut. 3. Remove the battery (A). 4. Remove the battery tray by removing the bolts(3ea).
Page 903 Page 8 of 22 5. Disconnect the vehicle speed sensor connector (A) and the back lamp switch connector (B). 6. Remove the ground wire by removing a bolt. 7. Remove the snap pins (A) and clips (B). 8. Remove the control cable bracket by removing bolts(3ea). 9.
Page 904 Page 9 of 22 10. Remove the transaxle upper mounting bolts (A-2ea) and the starter motor mounting bolts (B-2ea). 11. Remove the transaxle support bracket bolts (A-3ea,B-3ea). 12. Lifting up the vehicle. 13. Remove the front wheels and tires. 14. Remove the lower arm ball joint mounting nut and the stabilizer link mounting nut from the front knuckles. (refer to Front suspension system in SS group) 15.
Page 905 Page 10 of 22 16. Drain the transalxe fluid by removing the drain plug. 17. Disconnect the drive shafts from the transaxle. (refer to Front Driveshaft in DS group) 18. Remove the CKP sensor (A) by removing a bolt. 19. Remove the roll stopper bracket by removing bolts(A-1ea,B-2ea). 20.
Page 906 Page 11 of 22 21. Remove the bolt left in the engine side. 22. Supporting the transaxle with a jack, remove the transaxle lower mounting bolts(A-3ea, B-1ea). 23. Lowering the jack slowly, remove the transaxle. Installation 1. Install the transaxle lower mounting bolts (A-3ea,B-1ea) after fitting the transaxle assembly into the engine assembly.
Page 907 Page 12 of 22 2. Install the bolt left in the engine side. Tightening torque : 43~55 Nm (4.3~5.5 kgf.m, 31.1~39.8 lb-ft) 3. Install the clutch release cylinder assembly. Tightening torque : 15~22 Nm (1.5~2.2 kgf.m, 10.8~15.9 lb-ft) 4. Install the roll stopper bracket by installing bolts(A-1ea,B-2ea). Tightening torque : [A] 90~110 Nm (9~11 kgf.m, 65~79 lb-ft) [B] 50~65 Nm (5.0~6.5 kgf.m, 36.2~47.0 lb-ft)
Page 908 Page 13 of 22 5. Install the CKP sensor (A) by installing a bolt. 6. Connect the drive shafts to the transaxle. (refer to Front Driveshaft in DS group) 7. Refill the transaxle fluid through the filler hole. (refer to Service Adjustment Procedure) 8.
Page 909 Page 14 of 22 12. Install the transaxle upper mounting bolts (A-2ea) the starter motor mounting bolts (B-2ea). Tightening torque : [A] 60~80 Nm (6.0~8.0 kgf.m, 43.4~57.9 lb-ft) [B] 39~60 Nm (3.9~6.0 kgf.m, 28.2~43.4 lb-ft) 13. Put aside the engine support fixture (09200-38001). 14.
Page 910 Page 15 of 22 16. Install the ground wire by installing a bolt. 17. Connect the vehicle speed sensor connector (A) and the back lamp switch connector (B). 18. Install the battery tray by installing the bolts(3ea). 19. Install the battery (A).
Page 911 Page 16 of 22 20. Install the ECU by installing the bolts(2ea) and a nut. 21. Install the air cleaner assembly and the intake hose by installing the bolts and the clamps. Manual Transaxle System > Manual Transaxle Control System > Shift Lever > Components and Components Location Components...
Page 912 Page 17 of 22 1. Shift lever knob 4. Shift cable assembly 2. Shift lever assembly 5. Retainer 3. Select cable assembly 6. Manual transaxle assembly Manual Transaxle System > Manual Transaxle Control System > Shift Lever > Repair procedures Removal 1.
Page 913 Page 18 of 22 2. Remove the shift boot. 3. Remove the center console.(refer to Console in BD group) 4. Remove the snap pin (A) and remove the select cable assembly. 5. Remove the cable assembly by pulling the marking parts. 6.
Page 914 Page 19 of 22 7. Remove the shift cable assembly (A) by loosening the clip. 8. Remove the retainer (A) and nuts (B). 9. Remove the select and shift cable assembly from the transaxle. (refer to Manual Transaxle removal). Inspection 1.
Page 915 Page 20 of 22 3. Install the shift cable with the clip (A) to the shift lever. 4. Install the shift lever assembly by installing the bolts (4ea). Tightening torque : 10~14Nm (1.0~1.4kgf.m, 7.2~10.1lb-ft) 5. Install the cable with the clip to the shift lever. 6.
Page 916 Page 21 of 22 8. Install the shift boot. 9. Install the spring(B) and the shift lever knob (A) by turning the knob. Manual Transaxle System > Manual Transaxle Control System > Back-up Lamp Switch > Description and Operation Description Back up lamp switch is pushed by the reverse lug sliding when shifting reverse, and switches the back up lamp.
Page 917 Page 22 of 22 3. If necessary, repair or replace the backup lamp switch. Replacement 1. Disconnect the back up lamp switch connector. 2. Remove the back up lamp switch. 3. Install new back up lamp switch, then connect the connector. Tightening torque : 30~35 Nm (3.0~3.5 kgf.m, 21.7~25.3 lb-ft)
Page 918 Page 1 of 44 SOUL(AM) > 2010 > G 1.6 DOHC > Restraint Restraint > General Information > General Information General The supplemental restraint system (SRS) is designed to supplement the seat belt to help reduce the risk or severity of injury to the driver and passenger by activating and deploying the driver, passenger, side airbag and belt pretensioner in certain frontal or side collisions.
Page 919 Page 2 of 44 Item kgf.m lb-ft Driver Airbag (DAB) 7.8 ~ 10.8 0.8 ~ 1.1 5.8 ~ 8.0 Passenger Airbag (PAB) 7.8 ~ 8.8 0.8 ~ 0.9 5.8 ~ 6.5 Curtain Airbag (CAB) 10.8 ~ 14.7 1.1 ~ 1.5 8.0 ~ 10.8 Side Airbag (SAB) 5.9 ~ 7.8 0.6 ~ 0.8...
Page 920: General Precautions
Page 3 of 44 Dummy Simulator to check the resistanceof each wiring 0957A-38200 harness Dummy adapter Use with dummy 0957A-3F000 (SAB) Dummy adapter Use with dummy 0957A-2G000 (DAB, PAB, CAB, BPT) DAB : Driver Airbag PAB : Passenger Airbag SAB : Side Airbag CAB : Curtain Airbag BPT : Seat Belt Pretensioner Restraint >...
Page 921 Page 4 of 44 • Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. • Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector.
Page 922 Page 5 of 44 • Be sure the SRS unit, the front impact sensor and side impact sensors are installed securely with the mounting bolts. • Do not spill water or oil on the SRS unit, or the front impact sensor or the side impact sensors and keep them away from dust.
Page 923 Page 6 of 44 • Use specified service connectors for troubleshooting. Using improper tools could cause an error in inspection due to poor metal contact. Spring-laded Lock Connector Some SRS system connectors have a spring-loaded lock. Airbag Connector Disconnecting To release the lock, pull the spring-loaded sleeve (A) and he slider (B), while holding the opposite half of the connector.
Page 924 Page 7 of 44 1. Active fault or historical fault counter is greater or equal to 10 2. Normal or historical fault counter is less than 10. 3. SRSCM Variant Coding not performed. SRSCM Independent warning lamp activation There are certain fault conditions in which the SRSCM cannot function and thus cannot control the operation of the standard warning lamp.
Page 925 Page 8 of 44 Restraint > General Information > Repair procedures Component Replacement after Deployment Before doing any SRS repairs, use the GDS to check for DTCs. Refer to the Diagnostic Trouble Code list for repairing of the related DTCs. When the front airbag(s) deployed after a collision, replace the following items.
Page 926: Supplemental Restraint System Control Module (Srscm)
Page 9 of 44 1. Driver Airbag (DAB) 9. Curtain Airbag (CAB) 2. Steering Wheel 10. Supplemental Restraint System Control 3. Clock Spring Module(SRSCM) 4. Seat Belt Pretensioner (BPT) 11. Airbag Warning Lamp 5. Side Impact Sensor (SIS) 12. Telltale Lamp 6.
Page 927 Page 10 of 44 Front Impact Sensor (FIS) Driver Airbag (DAB) / Passenger Airbag (PAB)
Page 928 Page 11 of 44 Curtain Airbag (CAB) Side Airbag (SAB)
Page 929 Page 12 of 44 Seat Belt Pretensioner (BPT)/Side Impact Sensor (SIS) Restraint > SRSCM > SRS Control Module (SRSCM) > Description and Operation Description The primary purpose of the SRSCM (Supplemental Restraints System Control Module) is to discriminate between an event that warrants restraint system deployment and an event that does not. The SRSCM must decide whether to deploy the restraint system or not.
Page 930 Page 13 of 44 guaranteed to fully function after prove-out is completed. The SRSCM must perform a diagnostic routine and light a system readiness indicator at key-on. The system must perform a continuous diagnostic routine and provide fault annunciation through a warning lamp indicator in the event of fault detection.
Page 931 Page 14 of 44 7. Remove the SRSCM mounting bolts(3EA) from the SRSCM, then remove the SRSCM. Installation 1. Remove the ignition key from the vehicle. 2. Disconnect the battery negative cable and wait for at least three minutes before beginning work. 3.
Page 932 Page 15 of 44 1. On SRSCM variant coding mode, the airbag warning lamp is periodically blinking (ON: 0.5sec., OFF: 0.5sec.) until the coding is normally completed. 2. If the variant coding is failed, DTC B1762 (ACU Coding Error) will be displayed and the warning lamp will be turned on.
Page 933 Page 16 of 44 4) Variant coding's proceeding screen-2 5) Variant coding is completed...
Page 934 Page 17 of 44 1) Screen of Retrying the Variant coding after finishing variant coding 2) Screen of communication failure ■ Off-line type on GDS (This can be used when not connecting to internet) 1) Initial ACU Variant Coding screen 2) ACU CODING Code entering screen...
Page 935 Page 18 of 44 3) Screen of rechecking ACU CODING code's entering 4) Variant coding's proceeding screen-1 5) Variant coding's proceeding screen-2 6) Variant coding is completed...
Page 936 Page 19 of 44 1) Screen of Retrying the Variant coding after finishing variant coding Restraint > SRSCM > Front Impact Sensor (FIS) > Description and Operation Description The Front Impact Sensor (FIS) is installed in the Front End Module (FEM). They are remote sensors that detect acceleration due to a collision at its mounting location.
Page 937: Tightening Torque
Page 20 of 44 • Removal of the airbag must be performed according to the precautions/ procedures described previously. • Before disconnecting the front impact sensor connector, disconnect the front airbag connector(s). • Do not turn the ignition switch ON and do not connect the battery cable while replacing the front impact sensor. 1.
Page 938 Page 21 of 44 Restraint > SRSCM > Side Impact Sensor (SIS) > Repair procedures Removal 1. Disconnect the battery negative cable and wait for at least three minutes before beginning work. 2. Remove the door scuff trim. (Refer to the Body group- Intorior trim) 3.
Page 939 Page 22 of 44 4. Reconnect the battery negative cable. 5. After installing the side impact sensor, confirm proper system operation: A. Turn the ignition switch ON, the SRS indicator light should be turned on for about six seconds and then go off.
Page 940 Page 23 of 44 3. Loosen the two STPS screws, then remove the STPS after disconnecting the STPS connector. Installation Be sure to install the harness wires not to be pinched or interfered with other parts. 1. Remove the ignition key from the vehicle. 2.
Page 941 Page 24 of 44 Restraint > SRSCM > Seat Belt Buckle Switch (BS) > Repair procedures Removal 1. Disconnect the battery negative cable, and wait for at least three minutes before beginning work. 2. Remove the front seat assembly. (Refer to the Body group - Seat) 3.
Page 942 Page 25 of 44 Restraint > SRSCM > Occupant Classification Sensor (OCS) > Description and Operation Description In contrast to the initial one-stage airbag systems, newer restraint systems involve complex logic to select, or alternatively suppress, various levels of safety system deployment. Inherent to an Advanced Restraint System is the ability to discern information regarding passenger occupancy.
Page 943 Page 26 of 44 ODS(Occupant Detection System) is utilizing a robust weight measuring technology. Thus, if any of the following conditions occur, WCS reset and accuracy check should be performed. • The occupant classification ECU or any of the sensors is replaced. •...
Page 944 Page 27 of 44 (8) Confirm that the result of accuracy check is within the standard value. specification : 31kg ~ 43kg (68.34lb ~ 94.79lb) • When performing the accuracy check, use a solid metal weight and place it at the center of the seat. If the weight made from liquid is used or the weight slides, the check result may not accurate, and could result in unwanted fail •...
Page 945 Page 28 of 44 Circuit Diagram (2)
Page 946 Page 29 of 44 SRSCM Connector Terminal Harness Connector Function (Connector A) Function (Connector B) Ignition Passenger Seat Belt Pretensioner...
Page 947 Page 30 of 44 (2nd stage) Passenger Airbag (1st stage) Passenger Airbag Driver Seat Belt Pretensioner Driver Front Impact Sensor Low Driver Side Airbag Low Passenger Front Impact Sensor Passenger Side Airbag Low (1st stage) Driver Airbag Low Passenger Curtain Airbag Low (2nd stage) Dirver Airbag Low Driver Curtain Airbag Low (2nd stage) Passeng Airbag High...
Page 948 Page 31 of 44 Telltale Warning Lamp Driver Seat Track-Position Sensor Driver Side Impact Sensor Low Passenger Side Impact Sensor Driver Seat Belt Buckle Switch CAN-Low Restraint > Airbag Module > Driver Airbag (DAB) Module and Clock Spring > Description and Operation Description Driver Airbag (DAB) is installed in steering wheel and electrically connected to SRSCM via clock spring.
Page 949 Page 32 of 44 1. Driver Airbag 3. Clock Spring (DAB) 2. Steering Wheel Restraint > Airbag Module > Driver Airbag (DAB) Module and Clock Spring > Repair procedures Removal 1. Disconnect the battery negative cable and wait for at least three minutes before beginning work. 2.
Page 950: Driver Airbag (Dab)
Page 33 of 44 4. Remove the wiring fixing clip(A) and disconnect airbag module connector (B). 5. Disconnect the horn connector. 6. Separate the airbag module from the steering wheel. The removed airbag module should be stored in aclean, dry place with the pad cover face 7.
Page 951 Page 34 of 44 4. Check airbag inflator case for dents, cracks or deformities. 5. Install the airbag module to the steering wheel to check for fit or alignment with the wheel. Clock Spring 1. If, as a result of the following checks, even one abnormal point is discovered, replace the clock spring with a new one.
Page 952 Page 35 of 44 7. Secure the Driver Airbag (DAB) with the new mounting bolts. Tightening torque : 7.8 ~ 10.8 Nm (0.8 ~ 1.1 kgf.m, 5.8 ~ 8.0 lb.ft) 8. Connect the battery negative cable. 9. After installing the airbag, confirm proper system operation: A.
Page 953 Page 36 of 44 Restraint > Airbag Module > Passenger Airbag (PAB) Module > Repair procedures Removal 1. Disconnect the battery negative cable and wait for at least three minutes before beginning work. 2. Remove the glove box and glove box housing. (Refer to the Body group- crash pad). 3.
Page 954 Page 37 of 44 6. Remove the mounting screws(10EA) from the Crash pad. Then remove the passenger airbag. The removed airbag module should be stored in a clean, dry place with the airbag cushion Installation 1. Remove the ignition key from the vehicle. 2.
Page 955 Page 38 of 44 Restraint > Airbag Module > Side Airbag (SAB) Module > Repair procedures Removal 1. Disconnect the battery negative cable and wait for at least 3 minutes before beginning work. 2. Remove the front seat assembly. (Refer to the Body group- Seat) 3.
Page 956 Page 39 of 44 • Do not open the lid of the side airbag cover. • Use a new mounting nuts when you replace a side airbag. • Make sure that the airbag assembly cover is installed properly. Improper installation may prevent the proper deployment.
Page 957 Page 40 of 44 Restraint > Airbag Module > Curtain Airbag (CAB) Module > Repair procedures Removal 1. Disconnect the battery negative cable and wait for at least 3 minutes before beginning work. 2. Remove the Interior trim. (Refer to the Body group - Interior trim) 3.
Page 958 Page 41 of 44 Installation 1. Remove the ignition key from the vehicle. 2. Disconnect the battery negative cable and wait for at least three minutes. 3. Tighten the Curtain Airbag (CAB) mounting bolts. Tightening torque : 10.8 ~ 14.7 Nm (1.1 ~ 1.5 kgf.m, 8.0 ~ 10.8 lb.ft) •...
Page 959 Page 42 of 44 3. Confirm that the special tool is functioning properly by following the check procedure. (1) Driver’s Airbag : A. Remove the driver’s airbag and install the SST (0957A-38500). B. Install the driver’s airbag on the steering wheel. (2) Front Passenger’s Airbag : A.
Page 960 Page 43 of 44 Restraint > Seat Belt Pretensioner > Seat Belt Pretensioner (BPT) > Repair procedures Removal 1. Disconnect the battery negative cable, and wait for at least three minutes before beginning work. 2. Remove the lower anchor bolt. (Except Anchor Pretensioner) 3.
Page 961: Tightening Torque
Page 44 of 44 4. Connect the Seat Belt Pretensioner (BPT) connector. Tightening torque : 39.2 ~ 53.9 Nm (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb.ft) 5. Install the upper anchor bolts. Tightening torque : 39.2 ~ 53.9 Nm (4.0 ~ 5.5 kgf.m, 28.9 ~39.8 lb.ft) 6.
Page 962 Page 1 of 19 SOUL(AM) > 2010 > G 1.6 DOHC > Steering System Steering System > General Information > Specifications Specifications Item Specification Motor driven Power Steering Type Hydraulic Power Steering System Type Rack & Pinion Steering gear Rack stroke 140 ±...
Page 963 Page 2 of 19 Tool (Number and Name) Illustration 09561-11001 Removal of steering wheel Steering wheel puller 09572-21000 Measurement of oil pressure Oil pressure gauge (Use with 09572-22100, 09572- 21200) 09572-22100 Measurement of oil pressure Oil pressure gauge adaptor (Use with 09572-21000, 09572- 21200) 09572-21200 Measurement of oil pressure...
Page 964 Page 3 of 19 2. Measure the distance the steering wheel can be turned without moving the front wheels. Standard value: 30mm (1.18in.) or less 3. If the play exceeds standard value, inspect the steering column, shaft, and linkages. Checking stationary steering effort 1.
Page 965 Page 4 of 19 1. Fill the reservoir with the power steering fluid up to the level of 'COLD MAX' marked on the reservoir. While conducting the following operations, keep replenishing the reservoir so that the fluid level can be always between the 'COLD MAX' and the 'COLD MIN' marked on the reservoir.
Page 966 Page 5 of 19 4. Close the shut-off valve of the special tools and measure the fluid pressure. Relief pressure: 88 ~ 93kgf/cm² (1325 ~ 1400psi, 9.1 ~ 9.6Mpa) Do not keep the shut-off valve on the pressure gauge closed for longer than 10 seconds. 5.
Page 967 Page 6 of 19 7. Remove the clock spring. 8. Loosen the screw and then remove the multifunction switches. 9. Remove the lower crash pad. (Refer to BD group) 10. Loosen the bolt and then disconnect the universal joint assembly from the pinion of the steering gear box. Tightening torque : 30 ~ 35 N.m (3.0 ~ 3.5 kgf.m, 22 ~ 25 lb-ft) Keep the neutral-range to prevent the damage of the clock spring inner cable when you handlethe steering...
Page 968 Page 7 of 19 12. Remove the steering column & EPS unit assembly by loosening the mounting bolts and nuts. Tightening torque : 13 ~ 18 N.m (1.3 ~ 1.8 kgf.m, 9 ~ 13 lb-ft) 13. Installation is the reverse of the removal. When installing the clock spring, refer the RT group to prevent the damage of clock spring inner cable.
Page 969 Page 8 of 19 1. Protector rubber 8. Needle bearing 15. Feed tube 22. Bellows band 2. Dust cap 9. Rack support yoke 16. Rack housing 23. Tie rod 3. Snap ring 10. Rack support 17. Mounting bracket 24. Bellows 4.
Page 970 Page 9 of 19 2. Disconnect the stabilizer link with the front strut assembly after loosening the nut. Tightening torque : 100 ~ 120N.m (10.0 ~ 12.0kgf.m, 72 ~ 87lb-ft) 3. Disconnect the tie-rod end with the knuckle using a SST (09568-2J100 or 09568-4A000). 4.
Page 971 Page 10 of 19 5. Remove the cross member from the body by loosening the mounting bolts and nuts. 6. Remove steering gearbox from the cross member by loosening the bracket mounting bolts. 7. Remove steering gearbox from the cross member by loosening the mounting bolts. 8.
Page 972 Page 11 of 19 2. After mounting the tie rod end(A) in a vise, remove the dust cover(B) from the ball joint. 3. Remove the bellows band(A). 4. Remove the bellows clip(A). 5. Pull the bellows out toward the tie rod. Check for rust on the rack when the bellows are replaced.
Page 973 Page 12 of 19 8. Remove the tie rod(B) from the rack(A). Remove the tie rod(B) from the rack(A), taking care not to twist the rack. 9. Remove the yoke plug locking nut(A). 10. Remove the yoke plug(B) with a 14mm socket(A). 11.
Page 974 Page 13 of 19 12. When the end of the circlip comes out of the notched hole of the housing rack cylinder, turn the rack stopper counterclockwise and remove the circlip. Be careful not to damage the rack. 13. Remove the rack bushing and rack from the rack housing. 14.
Page 975 Page 14 of 19 19. Using the special tool (09573-21200, 09555-21000), remove the oil seal (A) from the rack housing. Be careful not to damage the rack cylinder inside of the rack housing. 20. Reassembly is the reverse of the disassembly. Inspection 1.
Page 976 Page 15 of 19 1. Bearing (1) Check for seizure or abnormal noise during a bearing rotation. (2) Check for excessive play. (3) Check for missing needle bearing rollers. 2. Others (1) Check for damage of the rack housing cylinder bore. (2) Check for boot damage, cracking or aging.
Page 977 Page 16 of 19 1. Pulley & driveshaft assembly 9. Vane 17. Oil pump side plate 2. Oil seal 10. Rotor 18. O-ring (Outer) 3. Bush 11. Cam ring 19. O-ring (Inner) 4. Front housing 12. Oil pump cover assembly 20.
Page 978 Page 17 of 19 3. Remove the pressure hose from the oil pump and the suction hose from the suction pipe. 4. Loosen the mounting bolts and then remove the power steering pump. 5. Installation is the reverse of the removal. Disassembly 1.
Page 979 Page 18 of 19 6. Remove the inner O-ring(A) and outer O-ring(B). 7. Remove the snap ring and take out the pulley and the drive shaft assembly(A). 8. Remove the oil seal(A) from the oil pump body. 9. Remove the connector from the oil pump body, and take out the flow control valve and the flow control spring. Inspection 1.
Page 980 Page 19 of 19 7. Check the free length of the flow control spring. Free length of the flow control spring : 36.5 mm (1.4in)
Page 981 Page 1 of 43 SOUL(AM) > 2010 > G 1.6 DOHC > Suspension System Suspension System > General Information > Specifications Specifications Front Suspension Item Specification Suspension type Mac Pherson Strut Shock absorber Type 313.6mm (Yellow – Yellow) 298.8mm (White – Yellow) Free Height Coil spring [I.D.
Page 982 Page 2 of 43 Specification Item Front Rear Total -0.2°~0.2° 0.4°±0.2° Toe-in Individual -0.1°~0.1° 0.2°±0.1° Camber -0.5°±0.5° -1.5°±0.5° Caster 3.4°±0.5° King-pin 12.53°±0.5° Tightening Torques Front Suspension Tightening torque Item Kgf.m lb-ft Hub nuts 90 ~ 110 9 ~ 11 65 ~ 80 160 ~ 180 /100 ~ 115 ~ 130 /72 ~ Lower arm to sub frame...
Page 983 Page 3 of 43 Tool (Number and Illustration Name) 09546-26000 Compression of coli spring Strut spring compressor 09568-2J100 Remover of ball joint Ball joint puller 09568-4A000 Removal of the tie rod end ball joint Ball joint remover Suspension System > General Information > Troubleshooting Troubleshooting Symptom Possible cause...
Page 984 Page 4 of 43 Vehicle pulls to one side Improper front wheel alignment Correct Excessive turning resistance of lower arm ball joint Replace Broken or worn coil spring Replace Bent lower arm Repair Steering wheel shimmy Improper front wheel alignment Correct Poor turning resistance of lower arm ball joint Replace...
Page 985 Page 5 of 43 • Caused by irregular burrs on brake • Toe adjustment out of • Excessive toe on non-drive drums specification wheels • Damaged or worn tie rods • Lack of rotation • Damaged knuckle Suspension System > Front Suspension System > Components and Components Location Components 1.
Page 986 Page 6 of 43 Suspension System > Front Suspension System > Front Strut Assembly > Components and Components Location Components 1. Insulator cap 6. Coil spring 2. Insulator 7. Spring lower pad assembly 8. Dust cover 3. Strut bearing 9. Bumper rubber 4.
Page 987 Page 7 of 43 1. Remove the front wheel & tire. Tightening torque : 90 ~ 110 N.m (9.0 ~ 11.0 kgf.m, 65 ~ 80 lb-ft) 2. Remove the brake hose and the wheel speed sensor bracket from the front strut assembly by loosening the mounting bolts.
Page 988 Page 8 of 43 5. Disconnect the front strut assembly with the knuckle by loosening the bolt & nut. Tightening torque : 140 ~ 160 N.m (14.0 ~ 16.0 kgf.m, 101 ~ 115 lb-ft) 6. Installation is the reverse of removal. Disassembly 1.
Page 989 Page 9 of 43 Reassembly 1. Install the spring lower pad (D) so that the protrusions (A) fit in the holes (C) in the spring lower seat (B). 2. Compress coil spring using special tool (09546-26000). Install compressed coil spring into shock absorber. 1) Indicated two identification color marks on the coil spring one follows model option (see page SS-2) the other follows load classification according to the below.
Page 990 Page 10 of 43 2. Remove the lower arm ball joint mounting bolts. Tightening torque : 58.8 ~ 70.6 N.m (6.0 ~ 7.2 kgf.m, 43.4 ~ 52.1 lb-ft) 3. Remove the lower arm mounting bolts. Tightening torque : 160 ~ 180 N.m (16.0 ~ 18.0 kgf.m, 115 ~ 130 lb-ft) 100 ~ 120 N.m (10.0 ~ 12.0 kgf.m, 72 ~ 87 lb-ft) 4.
Page 991 Page 11 of 43 2. Disconnect the stabilizer link with the front strut assembly after loosening the nut. Tightening torque : 100 ~ 120 N.m (10.0 ~ 12.0 kgf.m, 72 ~ 87 lb-ft) 3. Disconnect the tie-rod end with the knuckle using a SST (09568-2J100 or 09568-4A000). 4.
Page 992 Page 12 of 43 5. Loosen the bolt and then disconnect the universal joint assembly from the pinion of the steering gear box. Keep the neutral-range to prevent the damage of the clock spring inner cable when you handlethe steering wheel.
Page 993 Page 13 of 43 7. Remove the stabilizer from the cross member by loosening the bracket mounting bolts. Tightening torque : 45 ~ 55 N.m (4.5 ~ 5.5 kgf.m, 32 ~ 40 lb-ft) 8. Disconnect the stabilizer link (A) with the stabilizer bar by loosening the nut. 9.
Page 994 Page 14 of 43 1. Remove the sub frame. (Refer to front stabilizer) 2. Remove the front lower arm. 3. Remove the front strut assembly. 4. Remove the front stabilizer. 5. Remove the steering gear box. 6. Installation is the reverse of removal. Suspension System >...
Page 995 Page 15 of 43 1. Torsion beam axle 2. Coil spring assembly Suspension System > Rear Suspension System > Rear Shock Absorber > Components and Components Location Components...
Page 996 Page 16 of 43 1. Dust cover 2. Shock absorber Suspension System > Rear Suspension System > Rear Shock Absorber > Repair procedures Replacement 1. Remove the rear wheel & tire. Tightening torque : 90 ~ 110 N.m (9.0 ~ 11.0 kgf.m, 65 ~ 80 lb-ft)
Page 997 Page 17 of 43 2. Remove the rear shock absorber from the frame by loosening the bolt. Tightening torque : 100 ~ 120 N.m (10.0 ~ 12.0 kgf.m, 72 ~ 87 lb-ft) 3. Remove the rear shock absorber from the torsion beam axle by loosening the nut. Tightening torque : 100 ~ 120 N.m (10.0 ~ 12.0 kgf.m, 72 ~ 87 lb-ft) 4.
Page 998 Page 18 of 43 1. Spring upper pad 2. Spring 3. Spring lower pad Suspension System > Rear Suspension System > Rear Coil Spring > Repair procedures Replacement 1. Remove the rear wheel & tire. Tightening torque : 90 ~ 110 N.m (9.0 ~ 11.0 kgf.m, 65 ~ 80 lb-ft)
Page 999 Page 19 of 43 2. Remove the rear shock absorber from the torsion beam axle by loosening the nut. Tightening torque : 100 ~ 120 N.m (10.0 ~ 12.0 kgf.m, 72 ~ 87 lb-ft) 3. Installation is the reverse of removal. Inspection 1.
Page 1000 Page 20 of 43 1. Rear torsion beam axle Suspension System > Rear Suspension System > Rear torsion beam axle > Repair procedures Replacement 1. Remove the rear wheel & tire. Tightening torque : 90 ~ 110 N.m (9.0 ~ 11.0 kgf.m, 65 ~ 80 lb-ft)