Kia Sorento 2003 Manual Download Page 710

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REMOVAL AND INSTALLATION (DIESEL)

INSTALLATION

ALTERNATIOR ASSEMBLY

For belt tension, refer to Group EM Engine-Service adjustment procedures.

a. Install the oil hose to the alternator in advance.

When the alternator is installed, connect the oil hose to the nipple on the oil pan side. Clamp the
hose clip at the straight portion of the nipple.

b. When the oil tube is installed, do not take a sharp bend nor bring the tube in contact with the

cylinder block.

DISASSEMBLY

FRONT BRACKET

1. With a screwdriver blade inserted between the front bracket and stator core, pry it to separate the

stator and the front bracket.

2. If they are hard to separate, lightly strike the bracket with a plastic hammer while prying with the

screwdriver.

Do not insert the screriver too deep as the stator core could be damaged.

Summary of Contents for Sorento 2003

Page 1: ...nt of the oil pressure use with 09452 21000 09452 21600 09452 32300 09452 21600 Oil pressure gauge adapter Measurement of the oil pressure use with 09452 21000 09452 21500 09452 32300 09452 32100 Oil...

Page 2: ...ompressor Removal of the overdrive return spring Removal of the forward clutch spring Removal of the direct clutch spring 09454 38000 Second brake spring compressor Removal of second brake spring 0945...

Page 3: ...09454 38300 Reaction sleeve remover Removal of reaction sleeve...

Page 4: ...o stator shaft Valve body Oil strainer Oil pan Speed sensor Speedometer driven gear lock plate Union Transaxle range switch bolt Transaxle range switch nut Control shaft lever Shift knob screw Shift l...

Page 5: ...COMPONENTS AUTOMATIC TRANSAXLE CONTROL SYSTEM SHIFT LEVER...

Page 6: ...Disconnect the inhibitor switch indicator connector 5 Remove the control lever assembly 6 Remove the control lever bracket SHIFT LOCK DEVICE INSTALLATION INSTRUCTIONS INSPECTION a Check the detent pla...

Page 7: ...xing pin of P lock cam fix shift lock cable to A T lever 3 Checking that procedure for installing the shift lock is correct 1 When the brake pedal is not depressed push button of the shift lever at P...

Page 8: ...6 Adjust nut A and bolt B if necessary...

Page 9: ...ifted to the R range with the ignition switch in the ON position 3 Check the transaxle range switch if it is not working properly 1 Adjustment 1 Shift the selector lever to the N range 2 Loosen the tr...

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Page 11: ...COMPONENTS 1 AUTOMATIC TRANSAXLE SYSTEM...

Page 12: ...COMPONENTS 2...

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Page 14: ...Components...

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Page 16: ...rminal 2 Drain the automatic transmission fluid 3 Remove the control cable 4 Remove the under cover 5 Remove the front propeller shaft 4WD 6 Remove the front muffler and the heater protector 7 Remove...

Page 17: ...ve the rear propeller shaft 9 Remove the oil cooler pipe 10 Remove the speed sensor connector 11 Remove the back up lamp switch connector 12 Remove the starter motor 13 Remove the transmission mountin...

Page 18: ...sack 15 Remove the transmission assembly INSTALLATION 1 Installation is the reverse of the removal DISASSEMBLY 1 Remove the torque converter 2 Remove the oil filler gauge 3 Remove the wire harness cla...

Page 19: ...5 Remove the transaxle range switch 6 Remove the union 7 Remove the output speed sensor 8 Remove the input speed sensor...

Page 20: ...housing 10 Remove the extension housing 11 Using a dial indicator measure the inside diameter of the extension housing bushing Max 40 09mm 1 5783in If the inside diameter is greater than maximum repl...

Page 21: ...12 Remove the speedometer drive gear 13 Remove the sensor rotor and key 14 Remove the oil pan 15 Remove the magnets and use them to collect steel particles 16 Remove the oil strainer and gasket...

Page 22: ...te 18 Remove the valve body mounting bolts 19 Remove the check ball body springs 4EA and pins 2EA 20 REMOVE ACCUMULATOR SPRINGS AND PISTONS 1 Applying compressed air to the ATF hole remove the Bo accu...

Page 23: ...plying compressed air to the ATF hole remove the Co accumulator piston and spring 21 Remove the oil pump 22 Remove the overdrive planetary and the overdrive direct clutch 23 Remove the overdrive ring...

Page 24: ...24 Remove the snap ring 25 Remove the flanges the plates and the discs 26 Using the micrometer measure the thickness of the disc Minimum thickness 1 84mm 0 0724in 27 Remove the snap ring...

Page 25: ...r to the ATF hole remove the second coast brake piston 29 REMOVE OVERDRIVE SUPPORT 1 Remove the thrust bearing and race 2 Remove the overdrive support mounting bolts 3 After removing the snap ring rem...

Page 26: ...30 Remove the direct clutch and the forward clutch 31 SECOND COAST BRAKE BAND 1 Remove the E ring and pin 2 Remove the second coast brake band 32 FRONT PLANETARY RING GEAR 1 Remove the race...

Page 27: ...2 Remove the front planetary ring gear 33 FRONT PLANETARY GEAR 1 Remove the race 2 Remove the front planetary gear 34 Remove the sun gear input drum and the oneway clutch...

Page 28: ...ickness gauge measure the clearance between the second brake snap ring and the flange Standard value 0 62 1 98 mm 0 024 0 078 in 36 FLANGE PLATE DISC 1 Remove the snap ring 2 Remove the flange 1 discs...

Page 29: ...ng the micrometer measure the thickness of disc 38 PARKING LOCK ROD 1 Remove the parking lock pawl bracket 2 Remove the parking lock rod from the manual valve lever 39 Remove the parking lock pawl and...

Page 30: ...sure the clearance between the plate and the second brake drum Standard value 0 60 0 90 mm 0 024 0 035 in 41 Remove the second brake piston sleeve 42 REAR PLANETARY SECOND BRAKE DRUM 1 Remove the snap...

Page 31: ...ake drum and the output shaft 43 Using the screw driver remove the gasket REASSEMBLY 1 Install the rear planetary gear the second brake drum and the output shaft 1 Install the bearing and race 2 Insta...

Page 32: ...planetary gear second brake drum and output shaft 4 Install the snap ring 2 Measure the clearance between the plate and the second brake drum Clearance 0 6 0 9 mm 0 024 0 035 in 3 Install the second b...

Page 33: ...4 Install the brake drum gasket 5 Install the parking lock pawl and shaft 6 INSTALL PARKING LOCK ROD 1 Connect the parking lock rod to the manual valve lever 2 Install the parking lock pawl bracket...

Page 34: ...r is correctly fixed 7 Install the one way clutch 8 INSTALL FLANGE DISC PLATE 1 Install the plate with the rounded edge side of the plate facing the disc 2 Alternately install discs and plates Disc fi...

Page 35: ...hickness gauge measure the clearance between snap ring and flange Clearance 0 62 1 98 mm 0 024 0 078 in 10 Install the sun gear input drum 11 FRONT PLANETARY GEAR 1 Install the front planetary gear on...

Page 36: ...p ring 3 Install the bearing race on the front planetary gear 12 INSTALL SECOND COAST BRAKE BAND 1 Insert the second coast brake band to the case 2 Install the pin through the brake band 3 Install the...

Page 37: ...g and race onto the forward clutch 14 Install the race onto the front planetary gear 15 Install the forward clutch onto the front planetary ring gear 16 INSTALL DIRECT CLUTCH FORWARD CLUTCH 1 Install...

Page 38: ...utch the forward clutch and the front ring gear to the case 3 Using the vernier caliper measure the distance between the sun gear Standard value 5 3 7 3 mm 0 21 0 29 in 4 Install the bearing and race...

Page 39: ...oast brake piston 18 After installing the piston cover install the snap ring 19 Measure the stroke applying the compressed air Stroke 2 0 3 0 mm 0 079 0 12 in 20 OVERDRIVE SUPPORT 1 Install the race o...

Page 40: ...l holes of the overdrive support toward the valve hole side and align then with the bolt hole of the transmission case and insert 3 Install the snap ring 4 Install the bolts 2EA 21 Measure the end pla...

Page 41: ...rounded edge side of the flange facing the disc 23 Install the snap ring 24 PISTON STROKE OF OVERDRIVE BRAKE 1 Place the dial indicator onto the overdrive brake piston 2 Measure the stroke applying a...

Page 42: ...E PLATE DISC 1 Remove the snap ring 2 Remove the flanges 2EA plates 3EA and discs 4EA 26 OVERDRIVE RING GEAR 1 Install the bearing and the race onto the overdrive support 2 Install the overdrive plane...

Page 43: ...GEAR 1 Install the bearing and the race onto the planetary ring gear 2 Install the race onto the planetary gear 3 Install the overdrive planetary gear and the direct clutch 4 Install the bearing and t...

Page 44: ...C PLATE 1 Install the flange with the rounded edge side of the flange facing the disc 2 Alternately install discs and plates 3 Install the flange and the snap ring 29 INSTALL OIL PUMP 1 Install the ra...

Page 45: ...ompressed air into the oil hole indicated in the figure 1 Overdrive direct clutch 2 Direct clutch 3 Forward clutch 4 Overdrive brake 5 Second coast brake 6 Second brake 7 First and reverse brake When...

Page 46: ...Overdrive brake B2 Second brake 2 Install the spring Spring Free length Outer diameter Color 1 B2 Upper 70 50 2 776 19 70 0 776 Yellow 2 B2 Lower 22 0 0 866 14 00 0 551 Pink 3 C2 Upper inner 42 06 1...

Page 47: ...C0 Inner 46 00 1 811 14 02 0 552 Yellow 9 C0 Outer 74 60 2 937 20 90 0 823 Orange 33 Install the check ball body and the spring 34 INSTALL VALVE BODY 1 Align the groove of the manual valve to the pin...

Page 48: ...3 Install the valve body 35 INSTALL SOLENOID CONNECTOR 1 Install the stopper plate 2 Connect the solenoid connect 3 Install the clamp bolt 36 Install the oil strainer...

Page 49: ...he oil pan 38 INSTALL ROTOR SENSOR 1 Install the key 2 Install the snap ring 3 Install the spacer and the sensor rotor 4 Install the snap ring 39 Install the extension housing 40 Install the transmiss...

Page 50: ...stall the input speed sensor 42 Install the output speed sensor 43 INSTALL TRANSAXLE RANGE SWITCH 1 Install the transaxle range switch onto the manual valve shaft and temporarily tighten the adjusting...

Page 51: ...stall the washer and the nut 44 Tighten the adjusting bolt Disassembly 1 Remove the torque converter 2 Remove the converter housing transmission case installation bolts 8 then remove the converter hou...

Page 52: ...ger cut by the sharp edge in the converter housing engine section Do not reuse bolts of the seal bolt section 3 Remove the O ring of the input shaft Do not reuse O ring 4 Remove the oil pump transmiss...

Page 53: ...l the way Make sure the Bearing race comes out simultaneously Remove the outer O ring Do not reuse the O ring Puller installation position is as in figure below Where the screws grinded 6 Remove the t...

Page 54: ...the input clutch assembly as a unit Make sure that thrust bearing come out together 8 Remove the brake band Keep the brake band to be in sphere shape after having been removed by using the fixture of...

Page 55: ...ssembly and the rear carrier assembly as a unit 10 Remove the middle sun gear the rear sun gear assembly and the high low reverse clutch hub as a unit Be careful that the bearing race and bearing will...

Page 56: ...assembly Make sure that the bearing race is attached to the section 12 Remove the direct clutch assembly Also remove the bearings 2 on the section that support the drum 13 Remove oil pan bolts 22 then...

Page 57: ...of the connector from the terminal assembly with a hand driver to pull out the connector 15 Remove the connector of the temperature sensor Not necessary when not having to pull out the temperature se...

Page 58: ...16 Remove connector in front by hitting general tool 1 to fit intervals between the bracket and the connector 17 Remove the control valve T M case installation bolts 12...

Page 59: ...olts along with the clip with bolts attached to it at the same time Remove the clip that fixes the harness of the revolution sensor in advance 19 Remove the connector of the revolution sensor Pull out...

Page 60: ...of the terminal assembly and the revolution sensor in a row outward not to interfere with the one that is on hold during the control valve assembly installation 21 Pull out the control valve 22 Pull o...

Page 61: ...Tap the extension part lightly with a plastic hammer This does not easily come off since the sealant has been applied 24 Remove the output shaft Turn it right and left and pull it to the rear side 25...

Page 62: ...ut the snap ring that stops the plate of the reverse brake part Press and pull out the snap ring through the slit of the oil pan side of the case then pull out it once again with the first driver 27 R...

Page 63: ...iver to pull out the snap ring that stops the spring retainer of the reverse brake 29 Remove the spring retainer and spring plate screw 30 Remove the piston Pull out the pump seal the D ring and then...

Page 64: ...e general tool 1 said above Place the tool between the bracket and the connector and lift up the connector projection part to pull out the connector 32 Remove the terminal assembly 33 Tap the spring p...

Page 65: ...Discard the spring pin 34 Press the spring pin of the manual shaft with a nipper to pull out Discard the spring pin 35 Remove the manual shaft 36 Remove the oil seal 2 Discard the oil seal...

Page 66: ...37 Pull out the detent spring 38 Use the snap ring pliers to pull out the snap ring from the servo part 39 Remove the servo retainer stem piston return spring...

Page 67: ...40 Pull out the actuator support part 41 Remove the parking pole shaft and return spring REASSEMBLY 1 Use drift to punch the oil seal 2...

Page 68: ...ches the manual plate to the manual shaft Use the punch or something similar to fit with the holes Make sure that the spring pin can be pulled out Leave 2 0 5 mm 0 0787 0 0197in of the tip 4 Use the p...

Page 69: ...ase 5 Attach the manual shaft to the case Punch the spring pin Leave 5 1 mm 0 1969 0 0394in 6 Apply vaseline to the terminal assembly installation hole 7 Insert the terminal assembly to the installati...

Page 70: ...he terminal connector to the bracket The position for each connector is as in figure below 9 Attach the servo piston servo retainer and servo stem return spring to the case 10 Attach the snap ring of...

Page 71: ...etent spring Tightening torque 6 9 8 8 Nm 69 88kg cm 5 1 6 5lbf ft 12 Apply Vaseline to the outer O ring of the reverse brake piston 13 Assembly the reverse brake piston Apply the drum support bearing...

Page 72: ...the spring retainer Use the clutch compressor to install the snap ring that installs the spring retainer Use the driver to make sure since the tension of the snap ring is somewhat weak 15 Assembly the...

Page 73: ...imension is not within the aforesaid values check the thickness of the retainer plate and select the proper part of the following table and replace it Part number Dimension mm in 45627 4C000 4 2 0 165...

Page 74: ...e that is in contact with the extension with an oil whetstone lightly and remove the sealant completely Tap the seal bolt slit lightly Apply the washer fluid to wipe with the whetstone so that the rem...

Page 75: ...ightly and remove the sealant completely Tap the seal bolt slit lightly Apply the washer fluid to wipe with the whetstone so that the case not to become sticking after cleaning 23 Install the return s...

Page 76: ...turn spring shaft 25 Install the actuator support 26 Assemble the output shat Note that the shapes of the front and back are similar Front side is where the tip outer diameter is narrower Torque conve...

Page 77: ...made by Locktite Inc in Japan Remove the fluid gasket from the case contact surface EXT contact surface and wipe the contact surface with washer not to have any harmful oil or dusts 29 Assembly the ou...

Page 78: ...using the torque meter The seal bolt part is tightened at 58 63Nm 1 32 Apply vaseline to the seal ring of the drum support and then assemble the direct clutch 33 Make sure that both the drum support...

Page 79: ...34 Mount the bearing with vaseline applied to the drum support surface 35 Assemble the high low reverse clutch Use the one with the same part number when replacing the high low reverse clutch...

Page 80: ...lutch hub to the middle sun gear and then fix it with the snap ring Mount the bearing race and bearing called Middle gear sun sub assembly Use the one with the same part number when replacing the midd...

Page 81: ...everse clutch drum surface If there is no about 2mm 0 0787in of step height it wont fit to the position Remove it and try again 40 Apply Vaseline to the bearing race mount the rear carrier and then as...

Page 82: ...42 Assemble the input clutch front carrier and rear internal gear 43 Assemble the input clutch to the rear internal gear 44 Assemble the front carrier...

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Page 84: ...45 Insert the snap ring to the slit in the front carrier...

Page 85: ...liers and then combine the front carrier to the rear internal gear Loosen the snap ring and fix the front carrier and the rear internal gear at the same time 47 Assemble the input clutch pack 48 Apply...

Page 86: ...rovisionally Assemble the brake band provisionally For band assembly check Brake band assembly adjustment tips 50 Assemble the front sun gear Apply ATF to the bush section of the front sun gear and th...

Page 87: ...kes tighten lock nut with 40 51Nm 400 510 kg cm 29 5 37 6lb ft of torque 53 Check total end play For check tips see Total end play adjustment tips Total end play adjustment tips Adjust with BRG RACE s...

Page 88: ...oil pump Total end play adjustment tips a Adjust with the bearing race so that clearance L1 becomes 0 25 0 55mm 0 0098 0 0217in Bearing race part number Dimension mm in 45833 4C000 0 8 0 0315 45833 4C...

Page 89: ...he housing converter tightening bolts After provisional tightening use the torque meter and tighten them all with torque of 50 54 9Nm 500 549kg cm 36 9 40 5lbf ft 7 The seal bolts are tightened with t...

Page 90: ...terminal assembly and the harness of the revolution sensor to the outer side of the case 62 Mount the control valve assembly Adhere the turbine sensor to the case installation surface so that the slit...

Page 91: ...se installation bolts provisionally and the use the torque meter to tighten Tightening torque 6 9 8 8 Nm 69 88 kg cm 5 1 6 5lb ft Make sure that the harness does not get stuck in the case 64 Mount the...

Page 92: ...n bolts 1 2 3 of the figure above to prevent dislocation provisionally After that tighten them in order of 1 2 3 and then tighten the other bolts Code Size mm in Bolt head Count A 42 0 1654 B 5 B 55 0...

Page 93: ...1 Match the manual valve section part and the manual plate as shown in figure 2 Be careful when inserting the harness since the slit between the case and the control valve is small in the figure...

Page 94: ...65 Connect the terminal assembly and the control valve assembly connector 66 Connect the temperature sensor connector 67 Connect the revolution sensor connector...

Page 95: ...olution sensor harness to the control valve assembly with a clip 69 Fix the terminal assembly harness to the control valve assembly with a clip 70 Mount the oil pan gasket Match the mounting orientati...

Page 96: ...olt comes to the position of the figure on the left Make sure the harness does not get stuck 72 Tighten the oil pan installation bolts provisionally and then use the torque meter to tighten them with...

Page 97: ...SS section and the converter housing section is A2 5 31 55 mm 1 242 in 3 5 27 1 mm 1 063 in Disassembly and assembly of oil pan drain bolts a Disassembly Loosen the oil pan drain bolts and remove ATF...

Page 98: ...RING LIPSEAL location and part number O RING SEALING CUSHION SPRING location product numbers COMPONENTS AND COMPONENT LOCATION...

Page 99: ...SNAP RING location and part numbers...

Page 100: ...1 VALVE BODY type...

Page 101: ...2 VALVE BODY valve type...

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Page 103: ...3 VALVE BODY valve description 4 Fluid pressure measurement PORT location...

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Page 105: ...SYSTEM DIAGRAM HYDRAULIC CONTROL SYSTEM...

Page 106: ...with full range electronic control and sports mode that provides smooth driving with lesser transmission shock as well as pleasant driving from manual transmission A t electronic control system is th...

Page 107: ...HEIR FUNCTIONS Part name Acronyms Function Front brake F B Fastens the front sun gear Input clutch I C Engages the input shaft with the middle annulus gear and the front annulus gear Direct clutch D C...

Page 108: ...OPERATION...

Page 109: ...N range Since the forward and reverse brakes are released driving force of input shaft is not transmitted to output shaft 2 P range a Since the forward and reverse brakes are released as those in the...

Page 110: ...e 1st one way clutch regulates reverse rotation of the rear sun gear d The 3rd one way clutch regulates reverse rotation of the front sun gear POWER FLOW Input shaft Front internal gear Front carrier...

Page 111: ...5 range 3rd speed a Fastens the front brake b The 3rd one way clutch regulates reverse rotation of the front sun gear c The high low reverse clutch is coupled and the middle and rear sun gears are con...

Page 112: ...shaft Front internal gear Front carrier Rear internal gear Rear carrier Middle internal carrier Middle carrier Output shaft 7 D M5 range 5th speed a The front brake fastens the front sun gear b The di...

Page 113: ...verse clutch is coupled and the middle and rear sun gears are connected c The reverse brake fastens the rear carrier POWER FLOW Input shaft Front internal Front carrier Rear internal Rear sun gear Mid...

Page 114: ...T driving mode SW Self diagnosis indicator Engine torque signal Output revolution signal Sports mode SW Range signal P R N D Engine revolution signal Turbine sensor signal Up SW Range signal Torque r...

Page 115: ...AGRAM Line pressure control based on line pressure characteristic pattern of A T control unit TCM a A T control unit TCM has stored in memory a number of patterns for the optimum line pressure charact...

Page 116: ...n of each friction element the line pressure is set higher than the normal line pressure characteristic Shift control a The clutch pressure control solenoid is controlled by the signals from the switc...

Page 117: ...a signal from A T control unit TCM and lock up control valve behavior control engages or releases the lock up piston of the torque converter LOCK UP OPERATING CONDITION TABLE Lock up control valve con...

Page 118: ...tput to the lock up solenoid from A T control unit TCM to gradually increase lock up solenoid pressure In this way the lock up apply pressure gradually rises and while the lock up piston is put into h...

Page 119: ...re line pressure in response to the driving conditions Front brake control valve Regulates line pressure to the optimum pressure front brake pressure to be applied to the front brake during the front...

Page 120: ...witch torque converter cooling and oil path of lubrication system during lock up Cool bypass valve Allows excess oil to by pass cooler circuit without being fed into it Line pressure relief valve Disc...

Page 121: ...utomatically reads SUB ROM DATA during I G ON At this time shift range valve is off for about 2 5 second 2 When replacing A T regardless of new or old ones in the vehicle a Must erase SUB ROM DATA sto...

Page 122: ...TCM WIRING DIAGRAM 1 TCM WIRING DIAGRAM 2...

Page 123: ...CIRCUIT DIAGRAM...

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Page 125: ...e T C and A T When installing T C to drive plate make sure to use specified bolts Do not use longer bolts Using longer bolts will result in deformation of T C cover and damage to Lock up clutch lining...

Page 126: ...il temperature and blowing oil from breather b Return of T C clutch L up off pressure shall be closed and engine will stop at idle condition because of keeping L up operation LACK OF ATF MIXING OF WAT...

Page 127: ...contamination NG Replace A T or T C Inside A T failure Especially white colored contamination is caused by mixing of water Therefore inspect damage or brake of oil cooler system 1 ATF level a Lack of...

Page 128: ...INPUT SPEED SENSOR C0 OUTPUT SPEED SENSOR SP...

Page 129: ...diagnosis failure symptom accurately and check the failure symptom after procedure 1 D 2 L range test 1 Check for up shift down shift kick down and L up operation at the shift point 2 Check for engin...

Page 130: ...ance differ from standards except 20 C 68 F b It might become infinity ohm when inspect resistance at higher temperature OIL TEMPERATURE SENSOR OT 1 Inspect resistance between terminals of oil tempera...

Page 131: ...noid a Make sure to inspect resistance again at 20 C 68 F when resistance differ from standards except 20 C 68 F b It might become infinity ohm when inspect resistance at higher temperature 2 Inspect...

Page 132: ...shifted smoothly and accurately when shifting shift lever from N to other range 2 Inspect that indicating lamp can be turned on correctly NG Adjust shift cable no looseness cable to correct position a...

Page 133: ...out and clean oil leaked part sufficiently perform simulation test after spraying die check liquid Time duration is for 10 120 min due to oil leak condition Misunderstanding oil leak failure Because o...

Page 134: ...t or manual shift lever Replace oil seal install it correctly FIPG GASKET O RING 1 Simulation test Wipe out and clean oil leaked part sufficiently perform simulation test after spraying die check liqu...

Page 135: ...ne pressures at engine idle and stall speed for R range in the procedure described above Shift position Engine speed Pressure psi kg cm D Idle 57 65 4 0 4 6 Stall 166 188 11 7 13 2 R Idle 88 102 6 2 7...

Page 136: ...With the selector lever in the D position depress the accelerator pedal fully to read maximum engine rpm Do not holdthe throttle wide open any longer than 5 seconds is necessary to obtain maximum eng...

Page 137: ...nd low reverse brake PRECAUTION Engage the parking brake and apply wheel chocks to the front and rear wheels 1 Shift the selector lever from N to D range 2 Using stop watch measure the time it takes f...

Page 138: ...INPUT AND OUTPUT TERMINAL VOLTAGE TABLE No PIN NAME CONDITION INPUT OUTPUT SIGNAL REMARK TYPE LEVEL A7 SCSV 1 1st 2nd speed on DRIVING P N 1st 2nd 3rd 4th speed Frequency Vbatt 0V Io 1 9A MAX SCSV1 S...

Page 139: ...C Vbatt A2 LOCK UP SOL OPERATION OF LOCK UP SOL DRIVING OVER 45km h Frequency Vbatt 0V Io 1 9A MAX TORQUE CONVERTER SOLENOID VALVE A3 PCSV CORRENT CONTROL OF SOL V V IDLE OPERATING SOL V V BY CONTROLL...

Page 140: ...FF DC 0V IGN ON DC 9V 16V A6 EARTH FOR POWER B22 BRAKE SW SW OFF DC V GND 0 3 2V SW ON DC Vbatt 2 0 Vbatt A18 EARTH FOR POWER A12 EARTH FOR OTS OTS OIL TEM SENSOR B21 K LINE CONTINUITY 10 4Kbps PULSE...

Page 141: ...1 5V A24 CAN HIGH CONTINUITY 500kbit s A16 CAN LOW CONTINUITY 500kbit s HOW TO PROCEED WITH TROUBLESHOOTING...

Page 142: ...alfunction is completely presented like faulty parts of sensor or short open wiring detection will be easy But when intermittent abnormality or short wiring occurs self diagnosis can t detect the erro...

Page 143: ...ture signal malfunction from ECU to TCU B B O B 18 P1121 Throttle sensor signal invalid B O B O B O 19 P1630 CAN communication BUS OFF B O B O B O 20 P0631 No ID from ECU B O B O B O 21 P1795 Transfer...

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Page 145: ...Ground short P0740 L up solenoid circuit SL Failure stick OFF P0743 Open a No L up TCM judge normal B short Ground short P0748 Line pressure solenoid circuit SLT Open OFF a Emergency 1 b No L up c No...

Page 146: ...After TCM judge normal 0km h is detected P1631 CAN signal TCU detects no ID ON a No L up b No line pressure cont c No torque reduction cont After TCM judge normal 0km h is detected P1121 Throttle posi...

Page 147: ...ly b It is rare case wire harness is broken at the middle of it and most cases occur at the connector 4 Inspect short circuit of wire harness a Disconnect connectors of wire harness at both ends measu...

Page 148: ...nder the special conditions even when electronic circuit is normal In sucha case turn key switch OFF and ON again after 5 seconds so that you can return to normal shift pattern Therefore the vehicle c...

Page 149: ...Vehicle speed sensor 1 The output shaft rotation sensor a Signals are input from two systems from vehicle speed sensor1 revolution sensor installed on the...

Page 150: ...ge indicator OFF and N P pelay OFF Starter start disabled and the position is fixed to the D range to make driving possible N P relay a Turn N P relay OFF Starter start disabled A T Inter lock determi...

Page 151: ...id a If an error occurs in solenoid ON or OFF electrical functional errors fix to 4th gear so that driving is enabled Direct clutch solenoid a If an error occurs in solenoid ON or OFF electrical funct...

Page 152: ...lem with valve and solenoid valve for A T system to normally operate b It is more difficult to diagnose troubles that occur intermittently rather than continuously Many intermittent troublescan be cau...

Page 153: ...Questionnaire sheet example...

Page 154: ...2nd 3rd 3rd O D No down shift O D 3rd 3rd 2nd 2nd 1st Lock up malfunction Shift point too high or too low Shift shock or slip N D Lock up Any drive position Noise or vibration No quick down No patter...

Page 155: ...ake Starter relay Throttle sensor Engine revolution signal CAN communication A T C U power Battery Others 4 2 Idle inspection P range lamp A T check indicator does not blink P range lamp A T check ind...

Page 156: ...4 D2 quick down Does not 1 2 shift up does not 4 2 quick down in D range Does not D2 D3 shift Does not 2 3 shift up in D range Does not D3 D4 shift Does not 3 4 shift up in D range Does not D4 D5 shif...

Page 157: ...ystem for self diagnosis NG items to repair or replace the malfunction parts 6 Perform complete road test and check for any required item once again 7 For any remaining NG items perform the diagnostic...

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Page 167: ...ter the engine is warmed up When ambient temperature is 20 C 68 F fluid temperature reaches 70 80 C 158 176 F after approximately 10 minutes of driving 2 Park the vehicle on level ground 3 Apply the p...

Page 168: ...ily viscous Damage to or wear of clutch band Change fluid and check if there is a problem with A T body or vehicle harness wiring cooler pipe etc Milky white or cloudy Water contained Change fluid and...

Page 169: ...ely engage the parking brake so that the tires do not turn 4 Start the engine Depress the foot brake Move the select lever to D range 5 Gradually depress the accelerator pedal while depressing the foo...

Page 170: ...at least 1 minute During A2 5 Idle N range 750rpm A CON OFF Others 800rpm A CON ON During STALL D range 2500rpm A CON OFF During 3 5 Idle N range 800rpm A CON OFF Others 900rpm A CON ON D range 750rpm...

Page 171: ...es not 1 2 shift up in D M ranges Slips in 2 3 4 Direct clutch slippage Does not 2 3 shift up in D M ranges Slips in 3 4 5 High low reverse clutch slippage Does not 3 4 shift up in D M ranges Slips in...

Page 172: ...ug 4 Securely engage the parking brake so that the tires do not turn 5 Start the engine and measure line pressure during idle rotation and stall speed a Shall be depressing the brake pedal all the way...

Page 173: ...e from oil strainer oil pump pressure regulator valve passage d Engine idling is too low Low in a specific range The probable cause is fluid pressure leakage of range related device or passage after t...

Page 174: ...ing of the pilot valve and clogging of pilot filter Low in a specific range The probable cause is fluid pressure leakage of range related device or passage after the pressure is distributed by the man...

Page 175: ...Check at idle...

Page 176: ...Drive test part 1...

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Page 179: ...Drive test part 2...

Page 180: ...Drive test part 3...

Page 181: ...Shift pattern...

Page 182: ...Trouble symptom chart...

Page 183: ...le speed sensor 1 2 5 Engine speed signal The parking does not operate in P range The parking does not release in other ranges either On vehicle only 1 Control cable adjustment 2 Inhibitor SW The vehi...

Page 184: ...Line pressure test 5 Line pressure solenoid valve 6 Control valve assembly 7 Accumulator N D Extremely large creep On vehicle only Engine idle speed No creep On vehicle only 1 Fluid level state 2 Line...

Page 185: ...re solenoid valve Driving disabled in D range Clutch slips Extremely poor acceleration On vehicle only 1 Fluid level state 2 Line pressure test 3 Line pressure solenoid valve 4 Inhibitor SW Clutch or...

Page 186: ...Fluid pressure SW3 Input clutch solenoid 4 5 shift failure On vehicle only 1 Inhibitor SW 2 Control cable adjustment 3 Vehicle speed sensor 1 2 4 Fluid pressure SW5 Front brake solenoid Shift point i...

Page 187: ...ing On vehicle only 1 Fluid level state 2 Accelerator sensor adjustment 3 Line pressure test 4 Engine revolution 5 Turbine sensor Shift down shock is high when releasing On vehicle only 1 Fluid level...

Page 188: ...ft or clutch slips On vehicle only 1 Fluid level state 2 Vehicle speed sensor 1 2 3 Fluid pressure SW1 Front brake solenoid Acceleration is low On vehicle only 1 Fluid level state 2 Line pressure chec...

Page 189: ...sure SW3 Input clutch solenoid 6 Fluid pressure SW1 Front brake solenoid The engine idles when changing from 5 4 3 2 by depressing the accelerator pedal Or clutch slips On vehicle only 1 Fluid level s...

Page 190: ...adjustment 4 Sports mode range SW 5 Fluid pressure SW3 Input clutch solenoid 6 Fluid pressure SW1 Front brake solenoid The engine brake does not operate in 5 4 3 2 On vehicle only 1 Inhibitor SW 2 Fl...

Page 191: ...uid temperature sensor 1 Approx 3 3V Approx 2 7V Approx 0 9V Approx 0 C 32 F Approx 20 C 68 F Approx 80 C 176 F Fluid temperature sensor 2 Approx 3 3V Approx 2 5V Approx 0 7V TCM TERMINAL DESCRIPTION...

Page 192: ...2 T CON out temperature 18 PVIGNRLY Solenoid power relay control step 19 B2 SOL Fr B Front brake solenoid output signal 20 L U SOL L U Lock up solenoid output signal 21 C3 SOL D C Direct clutch soleno...

Page 193: ...range lamp output signal 50 Selected gear Display Shift range display lamp output signal 51 N range LAMP N range lamp output signal 52 3 range LAMP 3 range lamp output signal 53 STOP Lamp SW Stop lam...

Page 194: ...dition Standard values 1 Line pressure solenoid valve Key SW ON Release accelerator pedal after the engine is warmed up Approx 2V Release accelerator pedal after the engine is warmed up Approx 0 7V 2...

Page 195: ...st brake solenoid valve When driving When solenoid valve operating Driving in M1 1 or M2 2 Power voltage When solenoid valve operating Driving in M1 1 or M2 2 Approx 0V 14 Ground P 15 Ground A 16 SEL1...

Page 196: ...se frequency measurement function of the diagnosis device when driving at 20km h Make sure to connect normal diagnosis data link cable to the vehicle side diagnosis connector Approx 149 Hz 28 29 30 In...

Page 197: ...position Power voltage Other than reverse position Below 2V 42 Power supply Key SW ON Power voltage Key SW OFF Approx 0V 43 44 45 Turbine sensor 2 When driving Use pulse frequency measurement function...

Page 198: ...prox 0V 54 Sports mode Up SW Sports mode UP Select sports mode SW to UP Power voltage Others Approx 0V 55 Sports mode Down SW Sports mode DOWN Select sports mode SW to DOWN Power voltage Others Approx...

Page 199: ...troubled part input the self diagnosis execution signal to output failure data memory to display the trouble part SELF DIAGNOSIS PROCEDURE 1 Warm up the engine 2 Turn key SW ON OFF over twice finally...

Page 200: ...tch to transmission range performance Sports mode SW 7 P0711 Transmission fluid temperature sensor A circuit range performance Fluid temperature sensor 8 P0705 Transmission range sensor circuit malfun...

Page 201: ...gear and sports mode Fix to 4th gear when both sensor 1 2 fail Reset at key off or confirm normal if 5km h Vsp 20kmh when comparing vehicle speed 1 2 P0741 TCC Lock up Inhibit L U Reset at key off Sli...

Page 202: ...off ON error fix to 5th gear PL Max L U Reset at key off P0756 Fr B solenoid function ON error fix to 5th gear OFF error fix to 4th gear Reset at key off P0763 D C solenoid open short Fix to 4th gear...

Page 203: ...s OFF the rest follows normal control ON error fix to 2nd gear Reset at key off P0870 Fluid pressure SW3 I C ON OFF error fix to 4th Reset at key off P0875 Fluid pressure SW5 D C ON OFF error fix to 4...

Page 204: ...VALVE BODY fluid pressure circuit diagram D Range Refer to body valves for L number valve name 1st gear...

Page 205: ...2nd gear...

Page 206: ...3rd gear...

Page 207: ...4th gear...

Page 208: ...5th gear lock up...

Page 209: ...5th gear...

Page 210: ...P N range...

Page 211: ...R range...

Page 212: ......

Page 213: ...COMPONENTS CLUTCH AND BRAKES CLUTCH DIRECT...

Page 214: ...DISASSEMBLY 1 Remove the direct clutch drum from the forward clutch 2 Remove the thrust washer from the direct clutch...

Page 215: ...COMPONENTS FORWARD CLUTCH...

Page 216: ...move the direct clutch and the forward clutch 2 Remove the bearing and the race 3 Remove the snap ring the flange the disc and the plate 4 Remove the cushion plate 5 Remove the pistion return spring a...

Page 217: ...6 Remove the forward clutch piston 7 Remove the O ring from the forward clutch 8 Remove the oil seal ring 9 Remove the bearing and the race...

Page 218: ...INSPECTION 1 Using a micrometer measure the thickness of the disc Minimum 1 84 mm 0 072 in 2 Measure the free length of the return spring 3 Check that check ball is free by shaking the piston...

Page 219: ...D 24 08 mm 0 948 in REASSEMBLY 1 Reassemble the bearing and the race 2 Install the oil seal onto the forward clutch 3 Install the O ring on the forward clutch drum and the piston 4 Being careful not t...

Page 220: ...5 Install the piston return spring and the snap ring 6 Install the piston return spring and the snap ring 7 Install the cushion plate 8 Install the disc the flange and the plate...

Page 221: ...9 Install the snap ring 10 Install the race and the bearing 11 Install the direct clutch onto the forward clutch assembly...

Page 222: ...COMPONENTS LOW AND REVERSE BRAKE...

Page 223: ...e 2 Remove the snap ring and the piston return spring 3 Apply the compressed air to the transmission case to remove the NO 2 first reverse brake piston 4 Remove the second brake from the output shaft...

Page 224: ...of the discs If the thickness is less than the minimun replace the disc Minimun thickness 1 51 mm 0 059 in REASSEMBLY 1 Make sure the first and reverse brake piston moves smoothly when applying and re...

Page 225: ...COMPONENTS ONE WAY CLUTCH...

Page 226: ...sun gear and turn the brake hub The brake hub should turn freely clockwise and should lock counterclockwise 2 Separate the one way clutch from the brake hub 3 Remove the thrust washer 4 Remove the oil...

Page 227: ...emove the sun gear input drum 7 Remove the snap ring of the planetary sun gear INSPECTION 1 Using a dial indicator measure the inner diameter of the planetary sun gear Maximum diameter 27 08 mm 1 066...

Page 228: ...REASSEMBLY 1 Install the one way clutch and the brake hub 2 Hold the planetary sun gear and turn the hub The brake hub should turn freely clockwise and should lock counterclockwise...

Page 229: ...COMPONENTS OVERDRIVE BRAKE...

Page 230: ...aring and the race 2 Remove the clutch drum washer 3 Hold the OD brake piston so it is not slanted and apply compressed air into the passage to remove the OD brake piston 4 Remove the OD brake piston...

Page 231: ...REASSEMBLY 1 Install the oil seal ring 2 Install the overdrive brake piston 3 Install the return spring 4 Install the clutch drum washer onto the OD support...

Page 232: ...5 Install the race...

Page 233: ...from the overdrive planetary gear 3 CHECK PISTON STROKE OF OVERDRIVE DIRECT CLUTCH Co 1 Place the oil pump onto the torque converter and then place the O D direct clutch assembly onto the oil pump 2 U...

Page 234: ...4 Remove the snap ring and the piston return spring 5 Remove the overdrive direct clutch piston 6 Remove the bearing and the race from the planetary ring gear 7 Remove the snap ring...

Page 235: ...8 Remove the ring gear flange 9 Remove the race from the overdrive planetary gear 10 Remove the snap ring 11 Remove the retaining plate...

Page 236: ...ve the overdrive one way clutch with the outer race 13 Remove the thrust washer 14 Remove the one way clutch INSPECTION 1 Using a micrometer measure the thickness of the disc Standard value 1 84 mm 0...

Page 237: ...k that check ball is free by shaking the piston b Check that the valve does not leak by applying low pressure compressed air 4 CHECK OVERDRIVE DIRECT CLUTCH DRUM BUSHINGS Using a dial indicator measur...

Page 238: ...aximum inside diameter 11 27 mm 0 444 in If the inside diameter is greater than the maximum replace the planetary gear REASSEMBLY 1 Install the thrust washer to the overdrive planetary gear facing the...

Page 239: ...3 Install overdrive one way clutch with outer race to overdrive planetary gear 4 Install retaining plate 5 Install snap ring 6 Coat the race with petroleum jelly and install it to the planetary gear...

Page 240: ...Race diameter Inside diameter 27 1mm 1 067in Outside diameter 41 8mm 1 646in 7 Install ring gear flange to overdrive planetary ring gear 8 Install snap ring 9 Install race and bearing...

Page 241: ...10 Install the race on the planetary gear 11 Install the piston return spring 12 Install the plate and the disc 13 Install the flange...

Page 242: ...TON 1 Place the oil pump onto the torque converter and then place the O D direct clutch assembly onto the oil pump 2 Using a dial indicator measure the overdrive direct clutch piston stroke applying a...

Page 243: ...ng and the race 17 Install the direct clutch assembly onto the O D planetary gear 18 Hold the O D direct clutch drum and turn the input shaft The input shaft should turn freely clockwise and should lo...

Page 244: ...COMPONENTS...

Page 245: ...COMPONENTS SECOND BRAKE...

Page 246: ...ISASSEMBLY 1 Remove the second brake assembly from the output shaft 2 Remove the thrust washer 3 Remove the snap ring the spring and the piston return spring 4 Remove the second brake piston INSPECTIO...

Page 247: ...Being careful not to damage the O ring press in the second brake piston into the second brake drum 2 Install the return spring the spring retainer and the snap ring 3 Make sure the second brake piston...

Page 248: ...4 Install the thrust washer 5 Install the second brake assembly to the output shaft...

Page 249: ...COMPONENTS GEAR SYSTEM FRONT PLANETARY GEAR...

Page 250: ...e front planetary ring gear 2 Remove the race from the front planetary gear 3 Turn over the planetary gear and remove the bearing and the race INSPECTION 1 Measure the inner diameter of the front plan...

Page 251: ...tall the race onto the planetary gear 2 Turn over the planetary gear and install the race 3 Install the race and the bearing onto the front planetary ring gear 4 Turn over the planetary ring gear and...

Page 252: ......

Page 253: ...COMPONENTS OUTPUT SHAFT...

Page 254: ...mbly from the output shaft 2 Remove the output shaft from the rear planetary gear 3 Remove the oil seal from the output shaft 4 Remove first and reverse brake discs plates and flange 5 Remove rear pla...

Page 255: ...one way clutch inner race should turn freely counterclockwise and should lockclockwise 7 Remove the one way clutch inner race from the rear planetary gear 8 Remove the snap ring with a screwdriver 9 R...

Page 256: ...10 Remove NO 2 and NO 1 thrust washers 11 Remove races and bearing from rear planetary ring gear 12 Remove the snap ring 13 Remove the ring gear flange...

Page 257: ...REASSEMBLY 1 Install the race and the bearing 2 Install the NO 2 one way clutch...

Page 258: ...COMPONENTS OIL PUMP...

Page 259: ...DISASSEMBLY 1 Remove the oil seal ring 2 Remove the stator shaft 3 Remove the driven and the drive gear INSPECTION 1 Measure the inner diameter of the oil pump bushing Standard value 38 19 mm 1 504 in...

Page 260: ...t bushing Front 21 58 mm 0 850 in Rear 27 08 mm 1 066 in 3 Using a filler gauge measure the clearance of the driven gear Standard value 0 07 0 15 mm 0 003 0 006 in REASSEMBLY 1 Install the driven gear...

Page 261: ...2 Install the stator shaft to the oil pump 3 Install the oil seal ring 4 Make sure the drive gear rotates smoothly when installed to the torque converter...

Page 262: ...1 and 3 terminal of remote control connector 2 Check the resistance between 1 and 3 terminal when each switch is operated Function Resistance Power 55 3 k 5 Mode 22 3 k 5 Seek 11 3 k 5 Vol up 5 7 k 5...

Page 263: ...COMPONENTS...

Page 264: ......

Page 265: ......

Page 266: ...uency of use and tape cleanness 2 To clean the tape head and capstan use a cotton swab dipped in ordinary rubbing an alcohol Wipe the head and capstan REMOVAL AND INSTALLATION 1 Disconnect the negativ...

Page 267: ...5 Remove the screws holding the audio unit then remove the audio assembly 6 Installation is the reverse of removal...

Page 268: ...nstallation is the reverse of removal INSPECTION SPEAKER 1 Check the speaker with an ohmmeter If an ohmmeter indicates the correct impedance of the speaker when checking between the speaker and speake...

Page 269: ...Specification impedance 4...

Page 270: ...CIRCUIT DIAGRAM DAYTIME RUNING LAMP...

Page 271: ...INSPECTION OPERATION CHECK REMOVAL AND INSTALLATION 1 Remove the driver side lower crash pad panel and disconnect the wire connector to DRL module...

Page 272: ...CIRCUIT DIAGRAM ETACS PIN NO AND DESCRIPTION ETACS ETACS MODULE...

Page 273: ...h B4 Main door switch LOCK C4 A5 Tail gate switch B5 Front door key switch LOCK C5 A6 Rear defroster switch B6 Horn relay C6 Door lock relay LOCK A7 B B7 Rear defroster relay C7 Front windshield heati...

Page 274: ...lock relay A14 Tail gate glass switch B14 Main door switch UNLOCK C14 Door lock relay UNLOCK A15 120 km h over speed Middle east B15 Front door key switch UNLOCK B16 Door warning lamp B17 B18 B19 Haza...

Page 275: ...e the 2 nuts holding the ETACS module and disconnect the connectors 4 Installation is the reverse of removal INSPECTION ETACS FUCTION 1 Intermittent wiper Time specification T1 Max 0 3 sec T2 0 7 0 1...

Page 276: ...7 1 0 sec This function should be operated preferentially even though the variable intermittent wiper is operating 3 Rear window defroster and front windshield defroster Time specification T1 20 1min...

Page 277: ...0 1 sec 2 Seat belt warning Europe Time specification T1 5 0 1 sec T2 6 0 5 sec T3 10 0 5 sec T4 15 0 1 sec T5 60 0 5 sec 5 Ignition key hole illumination Time specification T1 10 1sec T2 0 10 sec 6 D...

Page 278: ...Time specification T1 5 6 sec T2 30 3 sec T3 20 2 min 7 Ignition key reminder 8 Battery saver 9 Power window timer...

Page 279: ...Time specification T1 30 3 sec 10 Crash door unlock Time specification T1 200msec T2 0 5 0 1 sec T3 60 2 msec 11 Rear fog lamp control 12 Over speed warning Middle east area...

Page 280: ...sec 13 Door ajar Alarm occurs while the door or rear hatch opened when the vehicle speed is 5km h over 14 Rear hatch glass open Time specification T1 3 0 5 sec T2 0 5 0 1 sec 15 Central door lock unl...

Page 281: ...Time specification T1 3 0 5 sec T2 0 5 0 1 sec 17 Remote keyless Entry system 1 Door lock Time specification T1 1 0 sec 2 Door unlock...

Page 282: ...Time specification T1 1 0 sec 3 Rear hatch glass open Time specification T1 0 5 sec 4 Panic Time specification...

Page 283: ...switch to ON position 3 While coding one transmitter Press the lock button of transmitter for 3 seconds over until the turn signal lamp turns off 4 While coding two transmitters Press the lock button...

Page 284: ...6 Check the operation of the keyless entry system...

Page 285: ...30 C 80 C 100M or more DC 12V 200mA Relay load DC 12V 200mA Relay load DC 12V 200mA Relay load DC 12V 200mA Relay load DC 12V 1 4W Lamp load DC 12V 1 4W Lamp load DC 12V 10W x 2 Lamp load DC 12V 200m...

Page 286: ...first and completely eliminate the problem before installing a new fuse Never use a fuse of higher capacity than specified INSPECTION OF FUSES 1 Prior to replacing the fuse with a new one check the c...

Page 287: ...y A blade type fuse is identified by the numbered value in amperes If the fuse is blown be sure to replace a fuse with the same ampere rating If a fuse of higher capacity than specified is used parts...

Page 288: ...SPECIFICATION...

Page 289: ...COMPONENTS RELAY BOX...

Page 290: ...RELAY COMPONENTS...

Page 291: ...cause and correct it before replacing the fuse The fuse will burn out within 15 seconds if a higher than specified current flows through the circuit INSPECTION 1 Check for a burnt relay with an ohmme...

Page 292: ...r High 1A Relay load Low 1A Relay load Passing 1A Relay load Lighting 1A Relay load 6 6 0 5A Lamp load Low Int 6 0A Motor load High 6 5A Motor load Lock Max 25A Motor load 4 A Motor load 1 0A Relay lo...

Page 293: ...e 1 4 Red Parking brake 1 4 Red Battery charge 1 4 Red Snow 1 4 Amber Glow 1 4 Amber ABS 1 4 Amber 4WD 1 4 Green Seat belt 1 4 Red 4WD Low 1 4 Green Washer Low 1 4 Amber Immobilizer 1 4 Amber Low fuel...

Page 294: ......

Page 295: ...t position lamp 5W Front fog lamp 27W Rear combination lamps Tail stop lamp Back up lamp Turn signal lamp 5W 21W 21W 21W Rear fog lamp 21W Side repeater lamp 5W License plate lamp 5W Sun visor illumi...

Page 296: ...cation Rated output Max 41W x 4 Speaker impedance 4 X4 Band AM FM Tuning type PLL Synthesized type Dark current Max 2mA Items General Europe Frequency range Channel AM 531 1602KHZ 9KHZ AM 522 1620KHZ...

Page 297: ...sary Oil pressure warning lamp does not light Fuse blown Bulb burned out Oil pressure sender faulty Wiring or ground faulty Check for short and replace fuse Replace bulb Check sender Repair if necessa...

Page 298: ...lamps light Rheostat faulty Wiring or ground faulty Check rheostat Repair if necessary Turn signal lamp does not flash on one side Bulb burned out Turn signal switch faulty Wiring or ground faulty Re...

Page 299: ...CHART 1...

Page 300: ......

Page 301: ...CHART 2 CHART 3...

Page 302: ......

Page 303: ...CHART 4...

Page 304: ...CHART 5...

Page 305: ......

Page 306: ......

Page 307: ...CHART 6...

Page 308: ...CHART 7 CHART 8...

Page 309: ...CHART 9 CHART 10...

Page 310: ...off position Wiper fuse blown Wiper motor faulty Wiper switch faulty Wiring or ground faulty Check for short and replace fuse Check motor Check switch Repair if necessary Wipers do not operate in INT...

Page 311: ...or driver s window switch Replace the motor Check the harness and the connector Passenger s side window does not operate Defective power window subswitch Defective motor or circuit breaker Wiring faul...

Page 312: ...HEAD LAMP LEVELLING SWITCH CIRCUIT DIAGRAM HEAD LAMP LEVELLING DEVICE...

Page 313: ...r panel 2 Measure the voltage between terminals 1 and 4 V Position No Rotation Ratio 5 Voltage V 0 0 99 52 11 94 0 5V 1 20 82 67 9 92 0 5V 2 40 68 58 8 23 0 5V 3 60 58 33 7 00 0 5V 3 If the voltage is...

Page 314: ...he reverse of removal INSPECTION 1 Test the horn by connecting battery voltage to the 1 terminal and ground the 2 terminal 2 The horn should make a sound If the horn fails to make a sound replace it A...

Page 315: ...valid tester request c EEPROM faulty non plausible VSP data d Transponder fault e Smartra fault f Authentication not successful g EEPROM fault for KEY ID block IMMO data block P1633 Immobilizer status...

Page 316: ...e mode function is accepted by EMS The teaching of keys follows the procedure described for virgin EMS The vehicle specific data has to be unchanged due to the unique programming of transponder If dat...

Page 317: ...tic trouble codes displayed by Hi Scan Pro Tool Smartra immobilizer 2 5D E G Limp home override procedure by ignition key This procedure allows the unlocking of the EMS by entering the user password v...

Page 318: ...on off the EMS is locked For next start the input of user password is requested again Smartra immobilizer 2 5D E G Status of ems and user password The status of EMS defines the possibility of vehicle...

Page 319: ...the time approximately 1 5 seconds After elapsing this time new authentication is done or in case of limp home the input of user password is requested again Key teaching procedure refer to hi scan pro...

Page 320: ...ter sends for authorization of access either the old user password or the vehicle specific data After correct authorization the EMS requests new user password The status remains in learnt and the new...

Page 321: ...ecord the ID code Keys registration and correction 1 Initial registration method 2 Registration correction for master keys In cases when the master key is lost or where a new set of master keys need t...

Page 322: ...2 Using password When the customers lost the ID key new master keys can be registered by using Hi scan pro only ID key can not be corrected and reproduced...

Page 323: ...re by ignition key This procedure allows the unlocking of the EMS by entering the user password via the IG SW in case the transponder codecannot be read or is unknown after ignition ON a valid transpo...

Page 324: ...ord is the correct one the EMS is unlocked for approximately 10 seconds The engine can be started during this time After elapsing of timer noengine start is possible After new input of user password t...

Page 325: ...Smartra immobilizer 2 5D E G Schematic diagram Pin Description Pin Description 1 Antenna 4 Ground 2 EMS ECU 5 Antenna 3 IG 1...

Page 326: ...System block diagram Shinchang Immobilizer 2 4G 3 5G E G...

Page 327: ...Pin connection...

Page 328: ...Shinchang Immobilizer 2 4G 3 5 G E G0...

Page 329: ...e unique code is checked If it is equal to one of the transponder known to EMS the authentication procedure starts The authenticator the code and a random number are converted into the encrypted lock...

Page 330: ...in the condenser Once the energy supplied from the coil has stopped using the stored energy in the condenser the transponder transmits the ID code COIL ANTENNA Supplies energy to the transponder Recei...

Page 331: ...DATA LINK CONNECTOR By connecting the Hi scan pro the control module diagnostic code can be read DIAGNOSTIC TESTER Has the function of ICM ECM and keys diagnosis and change...

Page 332: ...artra immobilizer 2 5D E G Specification Type Encrypt type Manufacture Bosch Limp home function switch Ignition Key SW IMMO indicator IMMO indicator illuminates for approximately 30 seconds and goes o...

Page 333: ...CIRCUIT DIAGRAM SPECIFICATION INDICATORS AND GAUGES INSTRUMENT CLUSTER...

Page 334: ...r open 1 4 Red 6 Door ajar 1 4 Red 7 O D OFF 1 4 Amber 8 Air bag 1 4 Red 9 Engine check 1 4 Amber 10 Auto cruise 1 4 Green 11 Oil pressure 1 4 Red 12 Parking brake 1 4 Red 13 Battery charge 1 4 Red 14...

Page 335: ...22 Immobilizer 1 4 Amber 23 24 Low fuel 1 4 Amber 25 A T R 1 4 Red P N D 2 L 1 4 Green 26 Turn signal LH RH 1 4 Green...

Page 336: ...uster and remove the instrument cluster 4 Installation is the reverse of removal INSPECTION OF COMPONENTS SPEEDOMETER 1 Adjust the pressure of the tires to the specified level 2 Drive the vehicle onto...

Page 337: ...0 180 200 Tolerance 0 0 0 0 0 0 0 0 0 0 12 6 7 3 5 9 5 2 5 5 5 5 5 5 Velocity MPH 10 20 40 60 80 100 120 140 Tolerance 0 0 0 0 0 0 0 0 13 6 8 8 5 7 5 0 5 0 5 0 5 5 TACHOMETER 1 Connect the scan tool t...

Page 338: ...Gasoline 12 1 5 FUEL GAUGE 1 Remove the instrument cluster 2 Check the fuel gauge by changing the resistance between the terminals Apply battery voltage to the terminal 9 ground the terminal 1a and c...

Page 339: ...Apply battery voltage to the terminal 9 ground the terminal 1a and connect the resistance to the terminal 2c and then check that the pointer is moved as shown in below table Temperature F C Resistanc...

Page 340: ...e the lamp assembly 3 Disconnect the wire connector 4 Installation is the reverse of removal FRONT FOG LAMP 1 Disconnect the negative battery terminal 2 Remove the screw 3 Installation is the reverse...

Page 341: ...assembly 4 Installation is the reverse of removal CENTER HIGH MOUNTED STOP LAMP 1 Disconnect the negative battery terminal 2 Remove tailgate upper trim 3 Remove the two mounting bolts 4 Disconnect th...

Page 342: ...the negative battery terminal 2 Detach the lamp assembly and disconnect the lamp connector 3 Installation is the reverse of removal OVERHEAD CONSOLE LAMP 1 Disconnect the negative battery terminal 2...

Page 343: ...ments 1 Inflate the tires to the specified pressure and remove any loads from the vehicle except the driver spare tire and tools 2 The vehicle should be placed on a flat floor 3 Draw vertical lines Ve...

Page 344: ...a Turn the low beam on without the driver aboard The cut off line should be projected in the allowable range shaded region...

Page 345: ...b Turn the high beam on without the driver aboard The cut off line should be projected in the allowable range shaded region...

Page 346: ...c Turn the front fog lamp on without the driver aboard The cut off line should be projected in the allowable range shaded region...

Page 347: ...COMPONENTS MULTIFUNCTION SWITCH...

Page 348: ...be disposed of in accordance with the procedures mentioned in the restraints section h When you disconnect the air bag module clock spring connector take care not to apply excessive force i The remove...

Page 349: ...and then remove the steering column upper shroud and steering column lower shroud 4 After removing the screws in the illustration remove the clock spring 5 Remove the 3 screws holding the multi functi...

Page 350: ...6 Installation is the reverse of removal INSPECTION LIGHTING SWITCH Connector 1 LIGHTING SWITCH With Auto light Connector 1 DIMMER AND PASSING SWITCH Connector 1...

Page 351: ...TURN SIGNAL AND LANE CHANGE SWITCH Connector 1 WIPER AND INTERMITTENT SPEED SWITCH Connector 2 WASHER SWITCH Connector 2 MIST SWITCH Connector 2...

Page 352: ...FRONT FOG SWITCH Connector 1 REAR WIPER WASHER SWITCH Connector 2...

Page 353: ...COMPONENTS POWER DOOR LOCK...

Page 354: ...INSPECTION 1 Disconnect the actuator connector from the wiring harness 2 Apply battery voltage 12V to each terminal as shown in the table and verify that the actuator operates correctly...

Page 355: ...CIRCUIT DIAGRAM POWER DOOR MIRRORS CONTROL UNIT...

Page 356: ...Check that the folding mirror operate according to the following timing chart 2 If operation is not normal inspect the wire connector on the mirror folding control unit It is installed in the driver...

Page 357: ...t the power door mirror connector from the harness 2 Apply battery voltage to each terminal as shown in the table and verify that the mirror operates properly MIRROR FOLDING INSPECTION POWER DOOR MIRR...

Page 358: ......

Page 359: ...irror switch from the door trim panel 2 Check for continuity between the terminals in each switch position according to the table If continuity is not as specified replace the power door mirror switch...

Page 360: ...COMPONENTS...

Page 361: ...COMPONENTS POWER WINDOW POWER WINDOW MOTOR...

Page 362: ...r terminals directly to battery voltage 12V and check that the motor operates smoothly Next reverse the polarity and check that the motor operates smoothly in the reverse direction If the operation is...

Page 363: ...CIRCUIT DIAGRAM POWER WINDOW SWITCH...

Page 364: ...SPECTION 1 Remove the switch from the door trim panel 2 Check for continuity between the terminals If continuity is not as specified in the table replace the power window switch Power window sub switc...

Page 365: ......

Page 366: ...reservoir tank fill the reservoir tank with water 2 Apply the battery voltage to the terminal a and ground the terminal b or c to see that the washer motor runs and water sprays from the front or rea...

Page 367: ...e 19 28Nm 190 280kg cm 14 20 6lb ft 2 Remove the weather strip and the cowl top cover then remove the 5 bolts holding the linkage Tightening torque 4 6Nm 40 60kg cm 2 9 4 4lb ft 3 Disconnect the winds...

Page 368: ...2 Set the washer nozzle on the specified spray position INSPECTION...

Page 369: ...terminal 2 and the negative lead to terminal 3 5 Check that the motor operates at high speed Automatic stop operation check 1 Operate the motor at low speed using the stalk control 2 Stop the motor o...

Page 370: ...COMPONENTS...

Page 371: ...nd 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...

Page 372: ...ve a resistance twice as that in other sections In the affected section move the test lead to a position where the resistance sharply changes REPAIR OF BROKEN HEATER LINE 1 Conductive paint 2 Paint th...

Page 373: ...After repairing clean the glass with a soft dry cloth or wipe along the grid line with a slightly moistened cloth...

Page 374: ...UAL MEASURED DIMENSIONS UNDER BODY PROJECTED DIMENSIONS Measurement point Description Hole size A Body mounting bracket No 1 36 mm B Body mounting bracket No 2 LH 32 mm RH 34 mm C Body mounting bracke...

Page 375: ...E Body mounting bracket No 5 LH 34x38 mm RH 32x36 mm...

Page 376: ......

Page 377: ...urement point Description Hole size A Body mounting bracket No 1 36 mm B Body mounting bracket No 2 LH 32 mm RH 34 mm C Body mounting bracket No 3 30 mm D Body mounting bracket No 4 30 mm E Body mount...

Page 378: ......

Page 379: ......

Page 380: ...COMPONENTS BUMPERS rear bumper...

Page 381: ...AND INSTALLATION 1 Remove rear combination light 1 Remove rear combination light screws 2 2 Remove bulb and socket 2 Remove rear bumper face 1 Remove bumper fasteners 9 and screws 2 from top of bumpe...

Page 382: ...2 Remove rear mud guard screws 3 3 Remove bumper face fasteners 8 from left and right side of bumper face...

Page 383: ...4 Remove bumper face screws 2 from left and right side of bumper face...

Page 384: ...5 Remove bumper face nuts 4 from inside of vehicle 6 Remove bumper face 3 Remove rear step member assembly 1 Remove rear step member nuts 10 4 Install in reverse order of removal...

Page 385: ...COMPONENTS front bumper...

Page 386: ...light 1 Remove headlight combination light bolts 3 2 Remove headlight combination light bulb and socket 2 Remove bumper guard 1 Remove bumper guard nuts 2 and bolts 4 2 Remove bumper guard 3 Remove bu...

Page 387: ...1 Remove headlight washer nozzle cover 2 Remove bumper upper cover fasteners 8 5 Remove bumper face 1 Remove bumper face fasteners 10 and nuts 2 from top of bumper face 2 Remove bumper face fasteners...

Page 388: ...ve bumper face screws 2 from side of bumper face 4 Remove bumper mounting bolt 2 from front of bumper face 5 Disconnect electrical connector and then remove bumper face 6 Install in reverse order of r...

Page 389: ...COMPONENTS EXTERIOR body side molding...

Page 390: ...REMOVAL AND INSTALLATION 1 Remove flange nut 12 2 Remove roof rack assembly 3 Install in reverse order of removal...

Page 391: ...COMPONENTS front door...

Page 392: ......

Page 393: ...e 2 Remove door inner handle cover 1 Remove door inner handle cover screw 1 2 Remove inner handle cover 3 Remove outside rearview mirror garnish 1 Remove garnish from door frame 2 Disconnect electrica...

Page 394: ...emove assist grip cover 2 Remove screws 2 5 Remove door trim 1 Remove door pull handle screw 1 2 Remove door trim fasteners 4 3 Disconnect electrical connector 6 Door inner handle and pull handle brac...

Page 395: ...racket screws 2 7 Remove outside rearview mirror folding control unit 1 Remove screw 1 2 Disconnect electrical connector 8 Remove door speaker 1 Remove door speaker screws 3 2 Disconnect electrical co...

Page 396: ...ch connector 2 Connect negative battery cable 3 Turn ignition switch ON and position window glass bolt access hole 4 Turn ignition switch OFF 5 Remove glass run channel 6 Remove widow glass grip bolts...

Page 397: ...7 Disconnect negative battery cable 11 Remove window glass guide 1 Remove window glass guide front bolt 1 and nut 1 Tightening torque 8 12 N m 0 8 1 2 kg m 6 9 lb ft...

Page 398: ...window glass guide rear bolt 1 Tightening torque 8 12 N m 0 8 1 2 kg m 6 9 lb ft 12 Remove power window regulator assembly 1 Remove power window regulator nuts 6 Tightening torque 4 6 N m 0 4 0 6 kg m...

Page 399: ...2 Disconnect electrical connector 13 Remove door outer handle and key set 1 Remove remote control rod 2 Remove door outer handle nuts 2 and bolt 1 Tightening torque 7 11 N m 0 7 1 1 kg m 5 8 lb ft...

Page 400: ...ect electrical connector 14 Remove door latch assembly 1 Remove door latch screws 3 Tightening torque Door latch 4 6 N m 0 4 0 6 kg m 3 5 lb ft Tightening torque Door striker 18 26 N m 1 8 2 6 kg m 13...

Page 401: ...2 Disconnect electrical connector 15 Remove outside rearview mirror 1 Remove bolts 3 and clip Tightening torque 5 7 N m 0 5 0 7 kg m 4 5 lb ft...

Page 402: ...tor 16 Remove door outside belt weatherstrip 1 Remove door outside belt weatherstrip nut 1 Tightening torque 2 5 3 6 N m 0 25 0 36 kg m 2 3 lb ft 2 Remove door outside belt weatherstrip from door fram...

Page 403: ...ody frame Tightening torque Body side 35 42 N m 3 5 4 2 kg m 25 30 lb ft Tightening torque Door side 18 30 N m 1 8 3 0 kg m 13 22 lb ft 20 Install in reverse order of removal ADJUSTMENT DOOR HINGE 1 C...

Page 404: ......

Page 405: ......

Page 406: ...an be closed easily If there is a problem loosen the striker install bolts and adjust the door by moving the striker verticallyand horizontally 2 Adjust the rear offset of the door to the body by movi...

Page 407: ...kg m 16 20 lb ft 2 Turn the hood rubber cushion either clockwise or counter clockwise to adjust the height of the hood HOOD LATCH 1 Loosen the hood latch bolts Tightening torque 7 11 N m 0 7 1 1 kg m...

Page 408: ......

Page 409: ...COMPONENTS...

Page 410: ...COMPONENTS mirror...

Page 411: ...tive battery cable 2 Remove outside rearview mirror garnish 1 Remove garnish from door frame 2 Disconnect electrical connector 3 Remove outside rearview mirror 1 Remove bolts 3 and clip 1 Tightening t...

Page 412: ...rt flat bladed screwdriver between the outside rearview mirror holder and the mirror assembly 5 Remove outside rearview mirror actuator When prying with a flat bladed screwdriver wrap it with a shop t...

Page 413: ...6 Install in reverse order of removal...

Page 414: ...COMPONENTS rear door...

Page 415: ......

Page 416: ...Disconnect negative battery cable 2 Remove door inner handle cover 1 Remove door inner handle screw 1 2 Remove door inner handle cover 3 Remove assist grip cover 1 Remove assist grip cover 2 Remove s...

Page 417: ...asteners 4 3 Disconnect electrical connector 5 Remove door inner handle and door pull handle bracket 1 Remove door lock rod 2 Remove door inner handle screws 2 3 Remove door pull handle bracket screws...

Page 418: ...2 Disconnect electrical connector 7 Remove door screen Peel door screen off carefully so that it can be reused 8 Remove window glass run channel...

Page 419: ...9 Remove window glass guide 1 Remove window glass guide front bolts 2 and screw 1 Tightening torque 8 12 N m 0 8 1 2 kg m 6 9 lb ft...

Page 420: ...10 Remove fixed glass 11 Remove window glass 1 Reconnect power window switch connector...

Page 421: ...rip bolt access hole 4 Turn ignition switch OFF 5 Remove window glass grip bolts 2 Tightening torque 8 12 N m 0 8 1 2 kg m 6 9 lb ft 6 Disconnect negative battery cable 12 Remove window regulator asse...

Page 422: ...2 Disconnect electrical connector 13 Remove door outer handle 1 Remove door outer handle nuts 2 Tightening torque 7 11 N m 0 7 1 1 kg m 5 8 lb ft...

Page 423: ...14 Remove door latch assembly 1 Remove door latch screws 3 Tightening torque Door latch 4 6 N m 0 4 0 6 kg m 3 5 lb ft Tightening torque Door latch striker 19 26 N m 1 8 2 6 kg m 13 20 lb ft...

Page 424: ...2 Disconnect electrical connector 15 Remove door outside belt weatherstrip 1 Remove door outside belt weatherstrip nut 1 Tightening torque 2 5 3 6 N m 0 25 0 36 kg m 2 3 lb ft...

Page 425: ...13 N m 0 9 1 3 kg m 7 9 lb ft 18 Remove door lower hinge bolts 2 and upper hinge bolts 2 from body frame Tightening torque Body side 35 42 N m 3 5 4 2 kg m 25 30 lb ft Tightening torque Door side 18 3...

Page 426: ...2 To adjust the door to body offset loosen the door hinge install bolts and make the adjustment...

Page 427: ......

Page 428: ...can be closed easily If there is a problem loosen the striker install bolts and adjust the door by moving the strikerve rtically and horizontally 2 Adjust the rear offset of the door to the body by mo...

Page 429: ...COMPONENTS tail gate...

Page 430: ...tailgate upper trim 1 Disconnect rear window defroster connector 2 Remove upper trim fastener 3 Remove high mounted brake light 1 Disconnect electrical connector 2 Remove high mounted brake light scre...

Page 431: ...ate light assembly 1 Remove license light nuts 2 and bolts 2 Tightening torque 7 11 N m 0 7 1 1 kg m 5 8 lb ft 2 Disconnect electrical connector 7 Remove rear wiper arm and wiper blade 1 Remove head c...

Page 432: ...nnector 2 Remove wiper control unit bolts 2 9 Remove rear wiper motor 1 Remove wiper motor cover 2 Remove wiper motor nut 3 Remove wiper motor bolts 3 Tightening torque nut 3 6 N m 0 3 0 6 kg m 2 4 lb...

Page 433: ...emove tailgate lifter 1 After pulling out lifter clip with screwdriver extract lifter 11 Remove tailgate glass 1 Remove tailgate glass hinge bolt 1 Tightening torque bolts 7 10 N m 0 7 1 0 kg m 5 7 lb...

Page 434: ...Remove tailgate latch controller rod 3 Remove tailgate latch controller bolts 3 Tightening torque bolts 7 11 N m 0 7 1 1 kg m 5 8 lb ft 13 Remove tailgate glass latch assembly 1 Remove tailgate glass...

Page 435: ...ove tailgate key cylinder nuts 2 Tightening torque 12 N m 1 2 kg m 9 lb ft 3 Disconnect electrical connector 15 Remove tailgate outside handle 1 Remove remote control rod 2 Remove tailgate outside han...

Page 436: ...ng torque tailgate latch 7 11 N m 0 7 1 1 kg m 5 8 lb ft Tightening torque tailgate lock striker 9 14 N m 0 9 1 4 kg m 7 10 lb ft 3 Disconnect electrical connector 17 Remove wiring harness and rear wa...

Page 437: ...19 Remove tailgate hinge 1 Remove tailgate hinge bolts 2 Tightening torque bolts 7 10 N m 0 7 1 0 kg m 5 7 lb ft...

Page 438: ...E 1 Check that the tailgate can be closed easily and that there is no play If there is a problem open the tailgate and tighten the tailgate hingeinstall bolts 2 To adjust the tailgate to body offset l...

Page 439: ......

Page 440: ...an be closed easily If there is a problem loosen the striker install bolts and adjust the tailgate by moving the strikervertically and horizontally 2 Adjust the rear offset of the tailgate to the body...

Page 441: ...m Rear door Construction Locking system Slide type Pin fork system Tailgate Type Inner hinged gas lifter type Glass thickness Windshield glass Front door glass Slide door glass Quarter window glass Ta...

Page 442: ...r 9 14 0 9 1 4 7 10 Latch 7 11 0 7 1 1 5 8 Latch remote controller 7 11 0 7 1 1 5 8 Front door Checker Body side 22 27 2 2 2 7 16 20 Checker Door side 9 13 0 9 1 3 7 9 Hinge Body side 35 42 3 5 4 2 25...

Page 443: ...le 7 11 0 7 1 1 5 8 Striker 18 26 1 8 2 6 13 19 Crash pad Cross bar mounting bolts 17 26 1 7 2 6 12 19 Seat Seat mounting bolt nut 39 3 9 28 Seat belt Front upper anchor 40 55 4 0 5 5 29 40 Front lowe...

Page 444: ...er adjustment Adjust Heavy tailgate opening lock Incorrect latch or striker adjustment Adjust Incorrect tailgate latch link assembly adjustment Adjust Uneven gap between body Incorrect tailgate instal...

Page 445: ...riker adjustment Adjust position Defective door check Correct or replace Door check hinge requires grease Apply grease Uneven gap between body Incorrect door installation Adjust position Sunroof Probl...

Page 446: ...Adjust Increased sunroof sliding resistance or interference of sunroof with drive cables weatherstrip etc due to maladjustment of sunroof Adjust or replace Noise in motor clutch slipping noise from mo...

Page 447: ...trip Replace Defective tailgate window flange Correct Water leak through front door window Incorrect window glass installation Adjust position Gap at upper window glass Adjust position Water leak thro...

Page 448: ...ce Missing attached hardware Accident or vibration Replace Seat belts Problem Possible cause Action Buckle release does not release reliably Faulty spring or dirt in the mechanism Replace buckle assem...

Page 449: ...ent Tighten to specified torque Retractor assembly is loose Vibration or accident Tighten to specified torque Anchor assembly is loose Vibration or accident Tighten to specified torque Driver s seat b...

Page 450: ...COMPONENTS INTERIOR crash pad...

Page 451: ...REMOVAL AND INSTALLATION 1 Disconnect negative battery cable 2 Remove A pillar trim 3 Remove cowl side trim 1 Remove front door scuff trim 2 Remove cowl side trim screw and fastener...

Page 452: ...rument panel 1 Remove side cover 2 Remove hood release cable 3 Remove lower instrument panel screws 4 4 Disconnect electrical connector 6 To remove the instrument panel first remove the following part...

Page 453: ...cluster hood 1 Remove instrument cluster hood screws 2 8 Remove instrument cluster assembly 1 Remove instrument cluster screws 4 2 Disconnect electrical connector 9 Remove upper tray 1 Remove screw 4...

Page 454: ...a 11 Remove audio panel 1 Remove audio panel screws 4 2 Disconnect electrical connector 12 Remove audio 1 Remove audio screws 4...

Page 455: ...Disconnect electrical connector and antenna cable 13 Remove heater controller 1 Remove heater controller screws 4 2 Disconnect electrical connector 14 Remove center panel 1 Remove center panel screws...

Page 456: ...2 Disconnect electrical connector 15 Remove center lower panel LH 1 Remove center lower panel screws 4 16 Remove glove box 17 Remove instrument lower panel RH 1 Remove side cover RH...

Page 457: ...ower panel screws 10 3 Disconnect electrical connector 18 Remove main instrument panel assembly 1 Disconnect electrical connector 2 Remove crossbar side mounting bolts 4 Tightening torque 17 26 N m 1...

Page 458: ...3 Remove crossbar lower mounting bolts 4 Tightening torque 17 26 N m 1 7 2 6 kg m 12 19 lb ft...

Page 459: ...4 Remove cross bar bracket bolts 2 5 Remove main instrument panel assembly 19 Install in reverse order of removal...

Page 460: ...COMPONENTS interior trim...

Page 461: ...LATION FRONT PILLAR TRIM 1 Remove front pillar trim 1 Remove screw 1 and cover 2 Remove front pillar trim COWL SIDE TRIM 1 Remove cowl side trim 1 Remove front door scuff trim 2 Remove cowl side trim...

Page 462: ...TER PILLAR TRIM 1 Remove center pillar lower trim 1 Remove front door scuff trim 2 Remove rear door scuff trim 3 Remove seat belt lower anchor bolt 1 Tightening torque 40 55 N m 4 0 5 5 kg m 29 40 lb...

Page 463: ...4 Remove center pillar lower trim screws 2 2 Remove center pillar upper trim 1 Remove seat belt upper anchor bolt 1 Tightening torque 40 55 N m 4 0 5 5 kg m 29 40 lb ft...

Page 464: ...2 Remove B pillar upper trim screws 2 and cover REAR SIDE TRIM 1 Remove rear door scuff trim 2 Remove transverse trim 3 Remove D pillar trim...

Page 465: ...Remove rear side trim screws 5 2 Remove rear package side garnish screws 2 3 Remove rear package side garnish 4 Disconnect electrical connector C PILLAR TRIM 1 Remove seat belt lower anchor bolt 1 2...

Page 466: ...1 Remove seat belt anchor bolt 1 2 Remove C pillar trim screws 3 and cover 3 Remove seat belt cover...

Page 467: ...COMPONENTS roof trim...

Page 468: ...two mounting screws from sunvisors 2 Remove sunvisors and sunvisors retainers 3 Remove assist handle covers unscrew mounting screws 4 Remove three assist handles 5 Gently remove lens assembly on inter...

Page 469: ...7 Remove two mounting screws 8 Disconnect power connector and remove interior and map light 9 Remove front center C and D pillar trims 10 Remove seven fasteners 11 Remove headling 12 Install in rever...

Page 470: ...COMPONENTS tailgate glass...

Page 471: ...m 1 Disconnect rear window defroster connector 2 Remove upper trim fastener 2 Remove high mounted brake light 1 Disconnect electrical connector 2 Remove high mounted brake light screw 2 3 Remove tailg...

Page 472: ...ws 2 4 Remove tailgate screen 5 Remove tailgate glass lifter 1 After pulling out lifter clip with screwdriver extract lifter 6 Remove tailgate glass 1 Remove tailgate glass hinge bolt 1 Tightening tor...

Page 473: ...7 Remove tailgate glass latch assembly 1 Remove tailgate glass latch bolt 2 Tightening torque 7 11 N m 0 7 1 1 kg m 5 8 lb ft 8 Install in reverse order of removal...

Page 474: ...COMPONENTS windshield glass...

Page 475: ...ve the following parts 1 Front pillar trims 2 Inside rear view mirror 3 Wiper arms 4 Cowl top cover 5 Windshield glass molding 2 Use the knife to cut through the sealant 3 Make mating marks on the gla...

Page 476: ...alant smoothly to a thickness of about 2 mm 0 08 in on the bonding surface around the entire windshieldflange Be careful not to remove more adhesive than necessary and also not to damage the paintwork...

Page 477: ...ned in alcohol or wax and grease remover 3 Center a new windshield glass in the opening Mark the location by marking lines across the glass and body with a grease pencil at the fourpoints as shown 4 I...

Page 478: ...primer with your hand If you do the adhesive may not bond to the glass properly causing a leak after the windshield glass is installed b Do not apply body primer to the glass c Keep water dust and abr...

Page 479: ...ply the adhesive within 5 minutes after applying the primer to the glass 8 Apply a light coat of body primer to the original sealant remaining around the window opening flange The glass should be inst...

Page 480: ...excess adhesive off with a putty knife or gauze Fill all cavities around the windshield glass 11 Perform a water leak test for the windshield Use a cold water spray being careful not to direct a powe...

Page 481: ...st four hours after windshield installation If the car has to be used within the first 8 hours it must be driven slowly c Take care not to slam the doors with all the windows rolled up d Take care not...

Page 482: ...COMPONENTS SEAT BELT front seat belt...

Page 483: ...e seat belt lower anchor bolt Tightening torque 40 55 N m 4 0 5 5 kg m 29 40 lb ft 2 Remove seat belt upper anchor bolt Tightening torque 40 55 N m 4 0 5 5 kg m 29 40 lb ft 3 Remove B pillar lower tri...

Page 484: ...2 Remove rear door scuff trim 3 Remove B pillar lower trim screws 2 4 Remove retractor 1 Turn ignition switch OFF 2 Disconnect negative battery cable 3 Wait for about 1 minute...

Page 485: ...unctions replace it with a new pretensioner seat belt c Be cautions in handling a pretensioner seat belt and do not expose itto water or oil If crushed damaged or deformed replace it with a newone d C...

Page 486: ...COMPONENTS rear seat belt...

Page 487: ...Remove seat belt lower anchor bolt Tightening torque 40 55 N m 4 0 5 5 kg m 29 40 lb ft 2 Remove rear side trim 1 Remove rear door scuff trim 2 Remove rear transverse trim 3 Remove hanger net 4 Remov...

Page 488: ...C pillar trim 4 Remove seat belt upper anchor bolt Tightening torque 40 55 N m 4 0 5 5 kg m 29 40 lb ft 5 Remove retractor 1 Remove retractor anchor bolt Tightening torque 40 55 N m 4 0 5 5 kg m 29 4...

Page 489: ...2 Remove retractor screw Tightening torque 18 27 N m 1 8 2 7 kg m 13 20 lb ft 6 Install in reverse order of removal...

Page 490: ...INSPECTION seat heater...

Page 491: ...COMPONENTS...

Page 492: ...COMPONENTS seat and power seat front seat...

Page 493: ...REMOVAL AND INSTALLATION 1 Remove seat mounting bolt 3 and nut 1 Tightening torque 39 N m 3 9 kg m 28 lb ft 2 Disconnect electrical connector 3 Install in reverse order of removal...

Page 494: ...COMPONENTS rear seat...

Page 495: ...REMOVAL AND INSTALLATION 1 Remove seat mounting bolt 8 Tightening torque 39 N m 3 9 kg m 28 lb ft 2 Install in reverse order of removal...

Page 496: ...COMPONENTS SUN ROOF...

Page 497: ...ove the sunroof first remove the following parts 1 Overhead console lamp 2 Sunvisor and assist grip handle 3 Pillar trims 2 Remove sunroof glass 1 Remove screw 6 3 Disconnect drain hose 4 Remove sunro...

Page 498: ...3 Make sure that when the glass panel opens the rear of the panel does not jam against the roof panel If there is interference fully openthe glass panel and move the stopper forward If the stopper is...

Page 499: ...5 After adjustment be sure to lock the nut with the pawl washer DISASSEMBLY 1 Remove motor When removing the motor the guide assembly should always be in the fully closed position...

Page 500: ...2 Remove drip rail 3 Remove stopper 4 Remove drip shoe and guide...

Page 501: ...5 Remove slider...

Page 502: ...6 Remove culisse and slider 7 Remove sunshade...

Page 503: ...8 Remove deflector REASSEMBLY 1 Install in reverse order of removal 2 Align the position of slider when installing the motor Be sure to align the center A and B...

Page 504: ...installing it 3 Method of motor initialization 1 Confirm the installation of glass The state of finishing gap control 2 Press the UP switch The state of pressing switch After pressing UP switch for 3...

Page 505: ...time to save initialization 1 When operate the sunroof is operated for the first time 2 When initial data is deleted or damaged by discharge or discontinuance of supply power 3 Driver s need 4 When th...

Page 506: ...e position of slide as shown in the figure 4 Initialize motor according to the way of initialization ADJUSTMENT Front side 0 0 1 0 mm Rear side 0 1 0 mm 1 Loosen the front screw and rear screw Adjust...

Page 507: ...and roof panel 2 Loosen the nuts holding the glass panel and adjust the gap between the glass panel and roof panel...

Page 508: ...Check the continuity between the terminals while operating the switch...

Page 509: ...CIRCUIT DIAGRAM...

Page 510: ...arged or you use the emergency handle to operate the sunroof you have to reset your sunroof system as follows 1 Turn the ignition key to the ON position 2 In tilt up position press the tilt up switch...

Page 511: ...COMPONENTS BRAKE SYSTEM ABS ABS control module...

Page 512: ...must be transported and stored in the upright position and with sealed ports The HECU must not be drained INSTALLATION 1 Follow the reverse order for removal 2 Tighten the modulator mounting nuts mod...

Page 513: ...ideal brake force distribution tothe rear wheels as well as to carry out the flexible brake force distribution proportioning to the vehicle load or weight increasing And in the event of malfunctionin...

Page 514: ...ing the wheel speed sensor connector INSPECTION 1 Connect an ohmmeter between the wheel speed sensor terminals and measure the resistance Service standard Front 1600 10 Rear 1600 10 2 Connect a voltme...

Page 515: ...re to remove the connector double lock and insert the probe into the harness side Inserting it into the terminal side will result in a bad connection 3 Rotate the wheel to be measured at approximately...

Page 516: ...REMOVAL rear wheel speed sensor...

Page 517: ...ne is normal but no signal is input to the motor monitor line it is abnormal a Malfunction of wiring harness or connector b Malfunction of hydraulic unit c Malfunction of HECU Because powering of the...

Page 518: ...compares the signals sent to the valve relay with the voltage in the valve power monitor line That is how to check if the valve relay is operating normally The HECU always checks if current flows in t...

Page 519: ...bable cause a Check relevant connector b Check malfunction of wiring harness c Check malfunction of brake lamp switch when applying brake pedal BV when releasing brake pedal 0V a Malfunction of wiring...

Page 520: ...el speed sensor frequency error Probable cause A wheel speed sensor outputs no signal a Malfunction of wheel speed sensor b Improper installation of wheel speed sensor c Malfunction of rotor excitor d...

Page 521: ...ble cause The HECU always monitors the solenoid valve drive circuit It determines that there is an open or short circuit in the solenoid coil or in a harness even if no current flows in the solenoid o...

Page 522: ...ied value If the voltage returns to the specified value this code is no longer output a Malfunction of wiring harness or connector b Malfunction of HECU If battery voltage drops or rises during inspec...

Page 523: ...gnal Only 4WD Probable cause This code is output at the following times The output from G sensor is between 0 5V and 5 0V An open or short circuit is present in the G sensor system a Malfunction of G...

Page 524: ...etermines that an open or short circuit has occured in more than one wire of the wheel speed sensors A wheel speed sensor outputs an abnormal signal other than an open short circuit a Malfunction of w...

Page 525: ...IAGNOSTIC TROUBLE CODES DTC No C0060 C0065 C0070 C0075 C0080 C0085 C0090 C0095 HECU hardware error Probable cause Replace HECU a Malfunction of wiring harness or connector b Malfunction of hydraulic u...

Page 526: ...ABS WIRING DIAGRAM...

Page 527: ......

Page 528: ...ight rear Resistance R 1 6k 50 Min detectable voltage 130mV peak to peak voltage at 50Hz 8 6 4 1 Wheel speed sensor Left rear Wheel speed sensor Left front Wheel speed sensor Right front Wheel speed s...

Page 529: ...TT2 Battery power source 2 terminal Motor power source Max current I 100A Rated current I 40A Rush current 15 IGN Power source via IG2 SW terminal Rated voltage 13 5V Over voltage detection 16 5V V 20...

Page 530: ...ge threshold Receiving sending signal 1 R 50k Sending signal 0 R 110k VB Ignition voltage Should be no use the unsettled unsettled voltage area 0 2 IGN voltage 0 8 GN voltage 10 GS Longitudinal Input...

Page 531: ......

Page 532: ...ABS operates sound is generated from the vehicle chassis due to repeated brake application and release Thump suspension squeak tires ABS operation Long braking distance For road surfaces such as snow...

Page 533: ...SHEET HI SCAN PRO CHECK 1 Turn the ignition OFF 2 Connect the Hi scan to the data link connector located underneath low crash pad panel 3 Turn the ignition ON 4 Use the Hi scan to check the self diagn...

Page 534: ...valve C0065 LF ABS solenoid or motor 2 circuit malfunction Inlet valve C0040 RF wheel speed sensor circuit malfunction C0070 RF ABS solenoid or motor 1 circuit malfunction Outlet valve C0075 RF ABS so...

Page 535: ...solenoid valve operation Click sounds 04 Rear left valve In Rear left solenoid valve operation Click sounds 05 Rear right valve In Rear right solenoid valve operation Click sounds 06 Front left valve...

Page 536: ...right valve Out 17 RL valve Out Rear left valve Out 18 RR valve Out Rear right valve Out INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble system Inspection procedure No Communication with Hi Scan is not...

Page 537: ...ystems is not possible Probable cause The reason is probably a defect in the power supply system including ground for the diagnosis line a Malfunction of connector b Malfunction of wiring harness INSP...

Page 538: ...CU the ABS relay turns from on to off as the initial check The ABS warning lamp will illuminate when the ABS relay is Off even if there is a problem with the circuit between the ABS warning lamp and t...

Page 539: ...ROCEDURE 4 Even after the engine is started the ABS warning lamp remains illuminated Probable cause The cause is probably a short circuit in the ABS warning lamp illuminationcircuit a Malfunction of c...

Page 540: ...ficult However if a normal diagnosis code is displayed carry out the following inspection a Improper installation of wheel speed sensor b Incorrect sensor harness contact c Foreign material adhering t...

Page 541: ...ould be used to insure adequate bleeding and filling of ABS unit brake lines master cylinder 1 Remove the reservoir cap and fill the brake reservoir with brake fluid Do not allow brake fluid remain on...

Page 542: ...eder plug and insert the other end of tube in a half filled clear plastic bottle 3 Connect Hi Scan to Data Link Connector located underneath the dash panel 4 Select and operate according to the instru...

Page 543: ...k brake system 3 Select air bleeding mode 4 Press YES to operate motor pump and solenoid valve 5 ON and OFF controls are automatically perfomed to prevent the motor pump from being burnt If not you ma...

Page 544: ...uid starts to run out without bubbles Then close the bleeder screw 6 Repeat the step 5 until there are no more bubbles in the fluid for each wheel in the sequence shown in the illustration 7 Tighten t...

Page 545: ...ables steering around obstacles with a greater degree of certainty even during emergency braking b Enables stopping during emergency braking while keeping stability and steerability even on curves War...

Page 546: ...vehicle five persons boarded and high speed At time of failure When it is transferred to ordinary brake but please drive slowly because generationof spin is worried because there is no P valve Abstai...

Page 547: ...the braking force tester a The roller of the braking force tester and the tire should be dry during testing b When testing the front brakes apply the parking brake and when testing the rear brakes st...

Page 548: ......

Page 549: ...ABS OPERATING MODES 1 Normal brake ABS is not operated 2 ABS operating Maintaining pressure mode...

Page 550: ...3 ABS operation Decreasing pressure mode...

Page 551: ...4 ABS operation Increasing pressure mode...

Page 552: ......

Page 553: ...A T and then remove joint pin and snap pin 4 Remove the lock nut and then remove brake booster INSTALLATION 1 When installing the booster assembly replace the packing of each end of booster installati...

Page 554: ...A T When installing the snap pin A new one must be used 4 Adjust push rod length 1 Insert the gasket onto the master cylinder 2 Put theSSTonto the gasket and tighten the adjusting bolt until the bolt...

Page 555: ...ake booster 7 After filling the brake reservoir with brake fluid bleed the system 8 Check for fluid leakage 9 Check and adjust the brake pedal for proper operation 10 After installing apply grease to...

Page 556: ...g tests 1 Remove the vacuum hose 2 When IG ON check whether parking brake warning lamp turns on 3 If the parking brake warning lamp turns on it is in good condition 4 Apply the 400mmHg vacuum with a v...

Page 557: ...COMPONENTS brake line...

Page 558: ...welding or moving parts 2 Tighten to the specified torque as follows Items Torque N m kg m lb ft Brake flare nut and brake hose 13 22 1 3 2 2 9 15 Brake hose and caliper 17 20 1 7 2 0 12 14 Air bleed...

Page 559: ...COMPONENTS brake pedal...

Page 560: ...emoval Nut tightening torque 20 35 N m 2 0 3 5 kg m 14 25 lb ft Coat the inner surface of the bushings with the specified grease Specified grease Chassis grease LiG 2 2 Before inserting the joint pin...

Page 561: ...4 Check all parts for crack and wear...

Page 562: ...left and right pads must be replaced as a complete set b When the thickness difference between the left pad and right pad is large check the sliding condition of the piston the lock pin and the guide...

Page 563: ...d clip a All four pads must be replaced as a complete set b When replacing the brake pads check for deformation When replacing the guide spring use a new one or thoroughly clean the used one 3 Press f...

Page 564: ...be disassembled separately into the left and right as a set 1 Remove the piston boot piston Blow compressed air into the brake hose seating hole so as to remove the piston and the piston boot When re...

Page 565: ...l because it may damage the cylinder 2 Clean the piston surface and inner cylinder using alcohol or the specified brake fluid Brake fluid DOT 3 or DOT 4 INSPECTION 1 Check the cylinder for wear damage...

Page 566: ...from the disc surface and then measure the disc thickness at 4 positions at least Front brake disc thickness Standard value 28mm 1 10 in Limit 26mm 1 02 in 2 Thickness variation should not exceed 0 0...

Page 567: ...ub by tightening the nut FRONT BRAKE DISC RUN OUT CORRECTION 1 If the runout of the brake disc is equivalent to or exceeds the limit specification replace the disc and hub and then measure the runout...

Page 568: ...1 Clean all components with isopropyl alcohol except for the pad and shim 2 Install the piston seal 3 After applying the specified brake fluid to the piston outer surface install the piston into the...

Page 569: ......

Page 570: ...T and then remove joint pin and snap pin 4 Remove the lock nut and then remove brake booster INSTALLATION 1 When installing the booster assembly replace the packing of each end of booster installatio...

Page 571: ...A T When installing the snap pin A new one must be used 4 Adjust push rod length 1 Insert the gasket onto the master cylinder 2 Put theSSTonto the gasket and tighten the adjusting bolt until the bolt...

Page 572: ...ake booster 7 After filling the brake reservoir with brake fluid bleed the system 8 Check for fluid leakage 9 Check and adjust the brake pedal for proper operation 10 After installing apply grease to...

Page 573: ...g tests 1 Remove the vacuum hose 2 When IG ON check whether parking brake warning lamp turns on 3 If the parking brake warning lamp turns on it is in good condition 4 Apply the 400mmHg vacuum with a v...

Page 574: ...brake pedal again and apply additional pressure until the pressure equal to B then record pressure B SPECIFICATIONS DYNAMIC CONDITION Slope tan Split point 11 3 35 bar Master cylinder output pressure...

Page 575: ...air into the brake hose and remove the piston and the piston boot Blow air slowly 2 Remove the piston seal 1 Remove the piston seal with your finger Do not use a screwdriver or another tool in order...

Page 576: ...ter cylinder reservoir until it remains half full 2 Remove the brake pad by turning the piston in the housing assembly Using the special tool 09581 11000 remove the piston 3 Install two caliper guide...

Page 577: ...rom the piston push the piston into the cylinder 3 5mm Put a lever or steel plate 1mm x 0 3m between the piston and disc being careful not to damage the contact surface of the disc or the piston end b...

Page 578: ...s not to damage the cylinder wall 5 Clean all removed parts with the specified fluid Item Specified fluid Metal section Trichloroethylene alcohol or brake fluid Piston seal If the oil level is low add...

Page 579: ...nd replace if necessary The pads for the right and left wheels should be replaced at the same time Pad thickness wear limit 2 0mm 0 08 in 6 Check for worn or damaged dust boots If dust or mud had ente...

Page 580: ...of piston cylinder Brake fluid DOT3 DOT4 As required Piston boot Brake fluid DOT3 DOT4 As required Locating pin insulator White silicone grease As required 3 Install the piston boot to the piston Con...

Page 581: ...he brake pedal arm 2 Adjust the brake pedal height by turning the operating rod with pliers with the operating rod lock nut loosened until the correct brake pedal height is obtained 3 After turning th...

Page 582: ...uter case of stop light switch and brake pedal is within the standard value If free play exceeds the standard value it is probably due to excessive clearance between the clevis pin and brake pedal arm...

Page 583: ...defective 3 With the engine running step on the brake pedal and then stop the engine Hold the pedal depressed for 30 seconds If the pedal height does not change the booster is in good condition if the...

Page 584: ...ace Wash it off immediately b Use the specified brake fluid Avoid using a mixture of the specified brake fluid and other fluid 2 Connect a vinyl tube to the wheel cylinder bleeder screw and insert the...

Page 585: ...4 and 5 until there are no more bubbles in the fluid 7 Tighten the bleeder screw Tighten torque 7 9 N m 70 90 kg cm 5 6 6 lb ft 8 Repeat the above procedure for each wheel in the sequence shown in th...

Page 586: ...SPECIAL SERVICE TOOLS Tool Number and Name Illustration Use 09581 11000 Piston expander Pushing back of the front disc and rear disc brake piston 0K993 430 032 Adjustment gauge...

Page 587: ...2V 80mA W ABS EBD common BRAKE EBD Brake Parking Brake oil EBD fail Wheel Speed Sensor Internal resistance Insulation resistance Output Voltage Tone wheel Air gap 1600 10 X 1M 0 15 50V 47 T 0 012 0 04...

Page 588: ...lay Parking brake lever stroke 200 mm 7 87 in 0 5 1 0 mm 0 020 0 040 in 4 7 mm 0 157 0 275 in 4 6 clicks When lever assembly is pulled with 10kgf Service limit Front disc brake pad thickness Front dis...

Page 589: ...Quantity Brake fluid DOT 3 or equivalent As required Brake pedal bushing and brake pedal bolt Chassis grease SAE J310 NLGI No 0 As required Joint pin Wheel bearing grease SAE J310 NLGI No 2 As requir...

Page 590: ...t Retighten Replace Clean Replace Correct Correct Lubricate Retighten Correct the runout Replace disc Vehicle pulls to one side when brakes are applied Difference in left and right tire inflation pres...

Page 591: ...COMPONENT parking brake system...

Page 592: ...m the lever 4 Remove the cable clip which connect the cable to the body and install the axle housing 5 Remove the parking cable from the operating lever REMOVAL BRAKE SHOE 1 Remove rear disk caliper a...

Page 593: ...SSEMBLY BRAKE SHOE 1 Install the parking brake cable to the operating lever and then install the operating lever as shown in the figure 2 Tighten the parking brake cable mounting nuts Tightening torqu...

Page 594: ...tall Direction of adjuster turn Clockwise narrowing the shoe gap Counterclockwise widen the shoe gap 6 Install the lower return spring 7 Install the shoe hold spring with a plier 8 Install the disk br...

Page 595: ...s greater than the service limit replace the brake drum 2 Measure the brake lining thickness Standard value 4mm 0 157 in Service limit 1 5mm 0 059 in If the brake lining thickness is less than the ser...

Page 596: ...rotating use a screwdriver flat tip 3 Turn the adjuster 5 notches in the opposite direction of arrow 4 Turn the adjuster nut to adjust the parking brake stroke to the specification If the number of p...

Page 597: ...ng should be possible on a hill of 30 with gross vehicle weight a BED IN Procedure of operating the vehicle with parking brakes active for the purpose of setting the position of the brake pads b DIH D...

Page 598: ...SPECIAL SERVICE TOOLS Tool Number and name Illustration Use 09411 43000 Clutch disc guide Installation of the clutch disc CLUTCH SYSTEM GENERAL INFORMATION...

Page 599: ...3 mm 0 406 0 0118 in A2 5 8 7 0 3 mm 0 34 0 0118 in S2 4D 3 5 163 8 mm 6 45 in 7 3 13 9 mm 0 28 0 55 in 150 mm 5 90 in Limit Clutch disc rivet inset Diaphragm spring end height difference Clutch relea...

Page 600: ...OT3 As required Inner surface of clutch disc spline CASMOLY L 9508 As required Inner surface of clutch master cylinder and outer circumference of piston assembly Brake fluid DOT 3 As required Clutch m...

Page 601: ...l wear or corrosion of the clutch disc spring Replace Excessive vibration distortion of the clutch disc Replace Clutch noisy When the clutch is not used Insufficient play of the clutch pedal Adjust Ex...

Page 602: ...logged hydraulic system Repair or replace parts Clutch disc lining oily or worn out Inspect the clutch disc Faulty pressure plate Replace the clutch cover Binding release fork Inspect the release fork...

Page 603: ...COMPONENTS aclutch cover and dinode...

Page 604: ...ning solvent INSTALLATION 1 Apply multipurpose grease to the spline of the disc Grease CASMOLY L 9508 When installing the clutch apply grease to each part but be careful not to apply excessive grease...

Page 605: ...of the pressure plate must be uniform over the entire disc surface If any part shows excessive wear the pressure plate is installed badly 3 Check the friction surface of the flywheel for color change...

Page 606: ...heck the pressure plate surface of wear cracks and color change 8 Check that the three dowel on the flywheel is installed completely CLUTCH RELEASE BEARING The release bearing is packed with grease Do...

Page 607: ...COMPONENTS COMPONENTS clutch master cylinder...

Page 608: ......

Page 609: ...5 Install the master cylinder 6 Apply the specified grease to the clevis pin and washer Wheel bearing grease SAE J310a NLGI NO 2 7 Install the push rod to the clutch pedal 8 Pour clutch fluid into th...

Page 610: ...st pitting or scoring 2 Check the piston cup for wear or distortion 3 Check the piston for rust pitting or scoring 4 Check the clutch tube line for clogged 5 Measure the master cylinder inside diamete...

Page 611: ...imit 0 15 mm 0 006 in REASSEMBLY 1 Apply brake fluid to the inner surface of the master cylinder body and to the entire periphery of the piston assembly Specified fluid Brake fluid DOT 3 or DOT4 2 Dep...

Page 612: ...COMPONENTS clutch pedal...

Page 613: ...specified grease to the clevis pin and washer Wheel bearing grease SAE J310 NLGI No 2 4 Install the push rod to the clutch pedal 5 Adjust the clutch pedal clevis pin play INSPECTION 1 Check the pedal...

Page 614: ...COMPONENTS clutch release bearing components...

Page 615: ...COMPONENTS clutch release cylinder...

Page 616: ......

Page 617: ...COMPONENTS...

Page 618: ...ith the specified grease Align the hose at the end of the release cylinder push rod with that of the clutch release fork shaft and insert the clevis pin into the holes Specified grease CASMOLY L9508 2...

Page 619: ...e cylinder bore for rust and damage 4 Measure the release cylinder bore at three locations bottom middle and top with a cylinder gauge and replace the release cylinder assembly if the bore to piston c...

Page 620: ...ows a Turn and adjust the bolt then secure it by tightening the lock nut After the adjustment tighten the bolt until it reaches the pedal stopper and then tighten the lock nut b Turn the push rod to c...

Page 621: ...EEDING Use the specified fluid Avoid mixing different brands of fluid Specified fluid SAE J1703 DOT3 or DOT4 1 Loosen the bleeder screw on the clutch release cylinder 2 Pump the clutch pedal slowly un...

Page 622: ......

Page 623: ...Components Front differential components DRIVESHAFT AND AXLE differential carrier assembly front differential carrier...

Page 624: ......

Page 625: ...t be careful not to damage the differential carrier oil seal by interference of spline part 3 Remove the front propeller shaft Make match mark on the flange yoke and differential companion flange to a...

Page 626: ...racket 6 Remove the front member 7 Remove the differential mounting bolt 8 Remove the differential carrier Installation 1 Installation is the reverse of removal 2 Align the matchmark on the flange yok...

Page 627: ...cannot move and measure the final drive gearbacklash with a dial indicator Measure at four points or more on the circumference of the drive gear Standard value 0 09 0 11mm 0 0035 0 0043 in DRIVE GEAR...

Page 628: ...ive pinion as a set DIFFERENTIAL GEAR BACKLASH 1 Fix the side gear with a wedge so it cannot move and measure the differential gear backlash with a dial indicator on the pinion gear Take the measureme...

Page 629: ...the drive gear so that some torque approximately 25 30 kg cm is applied to the drive pinion If the drive gear is rotated too much the tooth contact pattern will become unclear and difficult to check 3...

Page 630: ...th contact pattern is a method for judging the result of the adjustment of drive pinion height and final drive gear backlash The adjustment of drive pinion height and final drive gear backlash should...

Page 631: ...the gauge pressure value after motor had started to revolve by shifting transfer lever to 4H And also check that the motor stops after several secondssince it started to run ACTUATOR CHECK 1 Detach a...

Page 632: ...7 Check the length of the distance piece Standard length 54 80 58 09 mm 2 16 2 21 in 8 Check the air pump motor 1 Attach air pressure gauge voltmeter and battery to air pump motor as in figure Air pr...

Page 633: ...in figure Loosen adjustment screw before attaching air hose to air pressure gauge 2 Check that actuator is operated when air pressure gauge adjustment screw has been tightened to set at specified pre...

Page 634: ...the right and left side bearings separate so that they are not mixed during reassembly 2 REMOVAL OF THE SIDE BEARING INNER RACES Fit the nut on top of the differential case and then use the special to...

Page 635: ...rks to the differential case and the drive gear b Loosen the drive gear attaching bolts in diagonal sequence to remove the drive gear 4 REMOVAL OF LOCK PIN FOR CONVENTIONAL DIFFERENTIAL 5 REMOVAL OF S...

Page 636: ...ion flange and the propeller shaft b Drive out the drive pinion together with the drive pinion spacer and drive pinion front shims 7 REMOVAL OF DRIVE PINION INNER BEARING INNER RACE 8 REMOVAL OF OIL S...

Page 637: ...ING OIL SEAL 2 DRIVE PINION OUTER BEARING OUTER RACE INSTALLATION When press fitting the outer race do not incline it 3 DRIVE PINION INNER BEARING OUTER RACE INSTALLATION When press fitting the outer...

Page 638: ...pinion height adjustment gauge body 0K993 270 A09 and gauge block ht 28 mm 1 102 in 2 Assemble spacer and inner bearing inner race to pinion model and fix it with O ring Use spacer disassembled 3 Inst...

Page 639: ...g gauge body at right angle and adjust it to 0 7 Put pinion height adjusting gauge body and gauge block to the upper side of pinion model 8 Dial gauge needle should be placed at the lowest part of sid...

Page 640: ...3 17 0 1248 3 20 0 1259 3 23 0 1271 3 26 0 1283 29 32 35 38 41 44 47 3 29 0 1259 3 32 0 1307 3 35 0 1318 3 38 0 1330 3 41 0 1342 3 44 0 1354 3 47 0 1366 5 Adjustment of drive pinion preload 1 Install...

Page 641: ...ce piece and measure again Preload 127 176 N m 13 18 kg m 94 130 lb ft 9 Remove the lock nut and then install the oil seal 10 Install the companion flange and tighten lock nut Tightening torque 127 28...

Page 642: ...hrust spacers 5 Measure the differential gear backlash once again and confirm that it is within the limit a After adjustment check that the backlash is within the limit and the differential gear rotat...

Page 643: ...nd then clean the threaded holes with compressed air 3 Apply the specified adhesive to the threaded holes of the drive gear Specified adhesive LOCTITE 262 or equivalent 4 Install the drive gear in the...

Page 644: ...1 Install side bearing spacers which are thinner than those removed to the side bearing outer races and then mount the differential case assembly into the gear carrier Select side bearing spacers with...

Page 645: ...the drive pinion side and the drive gear side 4 Install the side bearing spacers and differential case assembly as shown in the illustration to the gear carrier 5 Tap the side bearing spacers with a...

Page 646: ...nts or more on the circumference of the drive gear Standard value 0 09 0 11 mm 0 0035 0 0043 in 8 Change the side bearing spacers as illustrated and then adjust the final drive gear backlash between t...

Page 647: ...ct is evident adjust again 10 Measure the drive gear runout at the shoulder on the reverse side of the drive gear Limit 0 05 mm 0 002 in 11 If the drive gear runout exceeds the limit reinstall by chan...

Page 648: ...COMPONENTS limited slip differential...

Page 649: ...they have grooves or a mirror likes finishing replacing the entire disc pack Small scratches on a buff like finish are okay REASSEMBLY AND SHIM SELECTION 1 Apply axle lubricant to all sliding surface...

Page 650: ...irst side gear subassembly and shim in the flange end of the case 11 Install a pinion and thrust washer througheach window so that the gear teeth mesh and so that the pinions are in line with each oth...

Page 651: ...COMPONENTS REAR DIFFERENTIAL COMPONENTS rear differential carrier...

Page 652: ......

Page 653: ...arking the match mark on the flange yoke of the rear propeller shaft and the companion flange of the differential case remove the rear propeller shaft assembly Suspend the propeller shaft from the bod...

Page 654: ...16 19 lb ft 2 PROPELLER SHART Align the match marks on the flange yoke and companion flange and install the propeller shaft Tightening torque 50 60 Nm 500 600 kg cm 37 44 lb ft 3 AXLE SHAFT ASSEMBLY...

Page 655: ...de bearing outer races separate so that they are not mixed during reassembly 3 REMOVAL OF THE SIDE BEARING INNER RACES Fit the nut on top of the differential case and then uses the special tool to rem...

Page 656: ...MOVAL THE LOCK NUT 6 REMOVAL OF DIRVE PINION a Make the match marks on the drive pinion and companion flange Match marks should not be made on the contact surfaces of the companion flange and the prop...

Page 657: ...FRONT BEARING INNER RACE DRIVE PINION FRONT BEARING OUTER RACE 9 REMOVAL OF DRIVE PINION REAR BEARING OUTER RACE INSPECTION BEFORE DISASSEMBLY 1 FINAL DRIVE GEAR BACKLASH Check the final drive gear b...

Page 658: ...ar s tooth contact 2 DRIVE GEAR RUNOUT Check the back face lash as follows 1 Place a dial gauge on the back face of the drive gear and measure the runout Limit 0 05mm 0 0020in 1 2 If the run out is be...

Page 659: ...1 Apply the same amount of machine blue slightly to both surfaces of the drive gear teeth 2 Insert a brass rod between the differential carrier and the differential case and then rotate the companion...

Page 660: ...side receiving power during coast down Problem Solution Tooth contact pattern resulting from excessive pinion height The drive pinion is positioned too far from the center of the drive gear Also for...

Page 661: ...When you cannot obtain a correct pattern the drive gear and drive pinion have exceeded their limits Both gears should be replaced as a set INSPECTION 1 Check the companion flange for wear or damage 2...

Page 662: ...nion height adjustment gauge body 0K993 270 A09 and gauge block ht 28 mm 1 102 in 2 Assemble spacer and inner bearing inner race to pinion model and fix it with O ring a Use spacer disassembled 3 Inst...

Page 663: ...g gauge body at right angle and adjust it to 0 7 Put pinion height adjusting gauge body and gauge block to the upper side of pinion model 8 Dial gauge needle should be placed at the lowest part of sid...

Page 664: ...3 17 0 1248 3 20 0 1259 3 23 0 1271 3 26 0 1283 29 32 35 38 41 44 47 3 29 0 1259 3 32 0 1307 3 35 0 1318 3 38 0 1330 3 41 0 1342 3 44 0 1354 3 47 0 1366 3 Adjustment of drive pinion preload 1 Install...

Page 665: ...not within specification use new distance piece and measure again Preload 127 176 N m 13 18 kg cm 94 130 lb ft 9 Remove the lock nut and then install the oil seal 10 Install the companion flange and...

Page 666: ...e gear thrust spacers 5 Measure the differential gear backlash once again and confirm that it is within the limit a After adjustment check that the backlash is within the limit and the differential ge...

Page 667: ...uivalent d Install the drive gear in the differential case with the matchmarks properly aligned Tighten the bolts to the specified torque 11 15 kg m in a diagonal sequence 7 Press fit the side bearing...

Page 668: ...the side bearing nut until it is in the state just before preloading of the side bearing 2 Measure the final drive gear backlash Standard value 0 13 0 18mm 0 0051 0 0071 in Measure at lease 4 points...

Page 669: ...ing nut on half the distance between centers of two neighboring holes 5 Choose and install the lock plates two kinds 6 Check the final drive gear tooth contact If poor contact is evident make adjustme...

Page 670: ......

Page 671: ...rential housing INSTALLATION 1 Install output shaft to differential case Tightening torque 80 120 N m 8 12 kg m 58 86 lb ft a Be carefully that oil seal does not damage by clip during install 2 Instal...

Page 672: ...N m 11 15 kg m 80 108 lb ft 3 Tighten diff mounting bracket bolt DISASSEMBLY 1 Remove axle clip using plier 2 Remove output shaft housing 3 Using a hydraulic press remove bearing housing from the outp...

Page 673: ...seal for damage d Bearing housing for cracks REASSEMBLY OUTPUT SHAFT 1 Install dust seal into bearing housing a Apply the grease on the lip of dust seal 2 Using a hydraulic press install bearing onto...

Page 674: ...Tightening torque 71 95 N m 7 1 9 5 kg m 51 68 lb ft 5 Using a plier install new clip onto output shaft...

Page 675: ...COMPONENTS T S J B J REPAIR KIT Kit name Illustration Components front driveshaft...

Page 676: ...kit a T S J boot band b T S J boot c Snap ring d Spider assembly e Snap ring f T S J assembly g Clip h Grease B J boot kit a B J assembly b B J inner race and ball c Snap ring d B J boot e B J boot ba...

Page 677: ...he spider ring for revolution and wear 4 Check the T S J case inside for wear and rust REMOVAL HALFSHAFTS 1 Remove the lock nut from front hub 2 Remove the upper control arm link lock bolt spring wash...

Page 678: ...shaft doing so will damage the boots Be sure to use the pry bar 6 Remove the drive shaft from the knuckle a Temporarily install the knuckle to the upper arm INSTALLATION 1 Coincide the joining mark be...

Page 679: ...n caulk the flange of lock nut on the end of drive shaft Tightening torque 245 275 N m 24 5 27 5 kg m 177 198 lb ft 4 Install wheel and tire DISASSEMBLY a Do not disassemble the B J assembly b The Dri...

Page 680: ...haft 5 Remove the B J boot band and pull out the T S J boot and the B J boot If the boot is reused wrap a tape around the drive shaft splines to protect the boot INSPECTION 1 Check the drive shaft spl...

Page 681: ...ply specified grease to the drive shaft and install the boots Items Quantity gr B J 170 T S J 140 3 Add specified grease as much as was wiped away at the time of inspection 4 Tighten the boot bands Ke...

Page 682: ......

Page 683: ...vehicle frame with wire 3 Remove two screws and remove brake rotor 4 Using a lock nut wrench or equivalent remove lock nut and plain washer 2WD 5 Remove the upper arm link lock bolt spring washer and...

Page 684: ...ALLATION 1 Put steering knuckle on the drive shaft end with upper and lower ball joints in mounting holes 2 Attach lower arm tighten lock nut and install cotter pin Tightening torque 160 180 N m 16 0...

Page 685: ...ft 5 Install the chamfer of plain washer toward the bearing 2WD 6 Screw lock nut up against wheel hub assembly and using a lock nut wrench tighten nut to tightening torque to set bearing preload Use s...

Page 686: ...plunger zeroed against brake rotor at 4 7 in 12 cm from rotor center 10 Turn rotor and read dial indicator for run out dimension Run out not to exceed 0 0012 inch 0 03 mm 11 Install brake caliper and...

Page 687: ...ct bearing for wear or damage 2 Inspect steering knuckle for wear or damage REASSEMBLY 1 Install the dust cover to the knuckle Tightening torque 16 23 N m 1 6 2 3 kg m 12 16 lb ft 2 Install new oil se...

Page 688: ...brake rotor Temporarily tie caliper to vehicle frame with wire 2 Mount dial indicator with plunger zeroed against brake rotor at 4 7 inch 12 cm from rotor center 3 Turn rotor and read dial indicator f...

Page 689: ...SPECFICATIONS GENERAL INFORMATION...

Page 690: ...e Repair kit grease 170 gr 6 0 oz 140 gr 4 9 oz Differential Front Rear Conventional differential With LSD Limited Slip Differential Hypoid gear oil SAE90 API GL 5 Mobil Mobil Lube HD Shell Shell Spir...

Page 691: ...g dust seal Bearing outer race installer 09432 33700 Installation of the front hub bearing Use with 09500 21000 Bar 09500 21000 Installation of the front hub bearing Use with 09432 33700 Draft 09517 2...

Page 692: ...ller 09517 43001 a Removal of the front lower arm ball joint b Removal of the differential side bearing Preload socket 09532 11600 Measurement of the drive pinion starting torque Use with torque wrenc...

Page 693: ...the differential drive pinion rear bearing outer race Use with 09500 11000 Working base 09517 43401 Supporting for the differential carrier End yoke holder 09517 21700 Removal and installation of the...

Page 694: ...Drive pinion model 0K993 270 A10 Adjusting nut wrench 0K993 270 014 For adjusting screw disassembly LSD test adapter 09530 FM000 For testing of LSD performance...

Page 695: ...Check or replace Noise due to excessive play of wheel in turning direction Inner shaft and side gear serration play Replace Drive shaft and side gear serration play Axle shaft axle housing Noise whil...

Page 696: ...noise while coasting Improper drive pinion preload adjustment Correct or replace Damaged gear Replace Bearing noise while driving or coasting Cracked or damaged drive pinion rear bearing Replace Noise...

Page 697: ...COMPONENTS propeller shaft assembly...

Page 698: ...ooth operation in all directions 5 Check the center bearing for smooth movement 2WD 6 Check the center bearing mounting rubber for damage or deterioration 4WD 7 Measure the propeller shaft run out wit...

Page 699: ...hen removing the propeller shaft be careful not to damage the dust cover or spline INSTALLATION 1 Connect propeller shaft flange to companion flange on front differential 4WD a Align index marks on th...

Page 700: ...43 lb ft 3 Connect rear propeller shaft flange to companion flange on transfer 4WD a Align index marks on the flange and connect the flanges with four bolts and nuts b Tighten the bolts Tightening to...

Page 701: ...r bolts and nuts b Tighten the bolts and nuts Tightening torque 50 60 N m 5 0 6 0 kg m 36 43 lb ft 6 After installing the propeller shaft fill the grease into the nipple until it comes out from the sl...

Page 702: ...g for smooth movement 2WD 6 Check the center bearing mounting rubber for damage or deterioration 4WD 7 Measure the propeller shaft run out with a dial indicator Limit Front 0 3 mm 0 012 in or less Rea...

Page 703: ...sensor cable 3 Remove the rear axle shaft mounting bolt 4 Remove the rear axle shaft 5 Using the special tool 09526 11100 remove the oil seal INSTALLATION 1 Installation is the reverse of removal 2 Ap...

Page 704: ...4 After installing the axle shaft tighten the nut Tightening torque 43 60 N m 4 4 6 2 kg m 32 44 lb ft 5 Adjust the parking brake lever stroke...

Page 705: ...eds the standard value replace the bearing with a new one GEAR OIL LEVEL CHECK 1 Remove the filler plug and check the quantity of oil in the differential carrier 2 It is enough if oil is applied until...

Page 706: ...DISASSEMBLY AND REASSEMBLY CHARGING SYSTEM alternator...

Page 707: ......

Page 708: ...of the battery condition and according to the external load change so that it sometimes causes battery under or overcharging or causes flickering of meters and lamps due to ripples of generated voltag...

Page 709: ......

Page 710: ...ip at the straight portion of the nipple b When the oil tube is installed do not take a sharp bend nor bring the tube in contact with the cylinder block DISASSEMBLY FRONT BRACKET 1 With a screwdriver...

Page 711: ...ress the diode leads 1 When removing the stator unsolder the three stator leads from the main diodes 2 When removing the rectifier from the brush holder unsolder two soldered points OIL SEAL Push out...

Page 712: ...f without continuity or shorted replace the rotor assembly Standard value 3 5 ohms 2 Check the rotor coil grounding Make sure that there is no continuity between the slip ring and core Replace the rot...

Page 713: ...ter check continuity between the heat sink and the stator coil lead connection terminals If there is continuity in both directions the diode is shorted Then replace the rectifier assembly 2 Inspection...

Page 714: ...ontinuity or no continuity in both directions the diode is damaged Then replace the rectifier assembly BRUSH 1 The brush must be replaced if worn to the wear limit line 2 Unsolder the brush lead wires...

Page 715: ...the steel wire 2 When installing the rotor on the alternator rear bracket wind vinyl tape round the splined shaft to prevent damage to the oil seal ROTOR AND VANES 1 Check well the housing rotor etc...

Page 716: ...f arrow so as to minimize the clearance at A and tighten the bolts uniformly After the assembly be sure to conduct the performance test to check to see that the ultimate vacuum is as specified below S...

Page 717: ...ip at the straight portion of the nipple b When the oil tube is installed do not take a sharp bend nor bring the tube in contact with the cylinder block DISASSEMBLY FRONT BRACKET 1 With a screwdriver...

Page 718: ...ress the diode leads 1 When removing the stator unsolder the three stator leads from the main diodes 2 When removing the rectifier from the brush holder unsolder two soldered points OIL SEAL Push out...

Page 719: ...f without continuity or shorted replace the rotor assembly Standard value 3 5 ohms 2 Check the rotor coil grounding Make sure that there is no continuity between the slip ring and core Replace the rot...

Page 720: ...ter check continuity between the heat sink and the stator coil lead connection terminals If there is continuity in both directions the diode is shorted Then replace the rectifier assembly 2 Inspection...

Page 721: ...ontinuity or no continuity in both directions the diode is damaged Then replace the rectifier assembly BRUSH 1 The brush must be replaced if worn to the wear limit line 2 Unsolder the brush lead wires...

Page 722: ...the steel wire 2 When installing the rotor on the alternator rear bracket wind vinyl tape round the splined shaft to prevent damage to the oil seal ROTOR AND VANES 1 Check well the housing rotor etc...

Page 723: ...f arrow so as to minimize the clearance at A and tighten the bolts uniformly After the assembly be sure to conduct the performance test to check to see that the ultimate vacuum is as specified below S...

Page 724: ...nspection Battery terminal damage Carelessness Over tightening the battery cable Replace O Cover Breakage Carelessness Replace O Electrolyte leakage Cover breakage Cover leakage Carelessness Bad cover...

Page 725: ...er to Load Test below O 4 11 0 V 2 Internal failure O 5 Battery voltage 11 0V or less 1 Charge condition failure Replace O 2 Battery discharged for a long period O 3 Internal circuit open O 3 LOAD TES...

Page 726: ...th moistened with baking soda and water 5 Clean the top of the battery with the same solution as described in Step 4 6 Inspect the battery case and cover for cracks If cracks are present the battery m...

Page 727: ......

Page 728: ...tifying AC current to DC current Therefore DC current appears at generator B terminal In addition the charging voltage of this generator is regulated by the battery voltage detection system The genera...

Page 729: ...which enables measurements to be taken without disconnecting the generator output wire is recommended Using this equipment will lessen the possibility of a voltage drop caused by a loose B terminal c...

Page 730: ...re that it is in good condition The battery checking method is de scribed in BATTERY The battery that is used to test the output current should be one that has been partially discharged With a fully c...

Page 731: ...ent value correctly RESULT 1 The ammeter reading must be higher than the limit value If it is lower but the generator output wire is in good condition remove the generator from the vehicle and test it...

Page 732: ...sion For belt tension check see COOLING section 2 Turn ignition switch to OFF 3 Disconnect the battery ground cable 4 Connect a digital voltmeter between the S L terminal of the generator and ground C...

Page 733: ...reading is other than the standard value the voltage regulator or the generator is faulty Regulating Voltage Table Voltage regulator ambient temperature C F Regulating voltage V 20 4 14 2 15 4 20 68 1...

Page 734: ...COMPONENTS LOCATION CRUISE CONTROL SYSTEM...

Page 735: ...sistion With SET COAST switch depressed and then releasely the cruise speed will be set at the speed the vehicle was going when SET COAST switch was released The coast position With SET COAST switch f...

Page 736: ...rouble symptom Probable cause Remedy The set vehicle speed varies greatly upward or downward Malfunction of the vehicle speed sensor circuit Repair the vehicle speed sensor system or replace the part...

Page 737: ...f inhibitor switch Malfunction of the ECM Replace the ECM TROUBLE SYMPTOM 5 Trouble symptom Probable cause Remedy Cannot decelerate coast by using the SET switch Temporary damaged or disconnected wiri...

Page 738: ...TOM 8 Trouble symptom Probable cause Remedy The cruise control lamp does not illuminate But CC system is normal Damaged or disconnected bulb of cruise control lamp Repair the harness or replace the pa...

Page 739: ...3 mV C BATTERY D4CB Type Ampere hours 5HR Cold cranking at 17 8 C 0 F Reverse capacity Specific gravity at 25 C 77 F MF 100 AH 80 AH or more 850 A or more 182 min 1 280 0 01 COLD CRANKING AMPERAGE is...

Page 740: ...Battery terminal 4 6 40 60 2 9 4 3...

Page 741: ...blown Check fuses Fusible link blown Replace fusible link Electronic voltage regulator or generator faulty Test generator Wiring faulty Repair wiring Engine hesitates poor acceleration Overcharge Dri...

Page 742: ...tch Starter spins but engine will not crank Short in wiring Repair wiring Pinion gear teeth broken or starter motor faulty Repair starter motor Ring gear teeth broken Replace flywheel ring gear or tor...

Page 743: ...essary Yellow glow lamp will not turn ON Open lamp Replace lamp Wiring connection loose or bad wiring Repair or replace wiring Shorted wiring Repair or replace wiring ECM failed Replace ECM if necessa...

Page 744: ...GLOW PLUG 1 Check the continuity between the terminal and body as illustrated Replace if discontinuity or with large resistance Standard value 1 0 1 8 Remove oil from plug before measuring as glow pl...

Page 745: ...2 Check for rust on glow plug plate 3 Check glow plug for damage...

Page 746: ...DISASSEMBLY AND REASSEMBLY starting system...

Page 747: ...ion key is turned to the start position current flows and energizes the starter motor s solenoid coil The solenoid plunger and clutch shift lever are activated and the clutch pinion engages the ring g...

Page 748: ...ion stroke the travel along which the pinion is pushed back This is the pinion gap 4 If the pinion gap is not up to specification adjust by adding or removing fiber washers between the magnetic switch...

Page 749: ...s in good condition if the pinion remains out when releasing it This test must be completed with 10 seconds RETURN TEST OF MAGNETIC SWITCH With a battery connected between the terminal M and body of t...

Page 750: ...ired Symptom Possible cause Large current with low rpm torque also being small Contaminated bearing Armature coil rubbing pole piece Armature and field coil grounding Armature coil shorting Large curr...

Page 751: ...COMPONENT ENGINE MECHANICAL SYSTEM cooling system radiator...

Page 752: ...lant 2 Remove the battery negative terminal 3 Loosen the drive belt tension by turn auto tensioner with spanner and then remove the drive belt 4 Remove the radiator upper hose and lower hose 5 Remove...

Page 753: ...3 Install the ATF oil hoses 4 Install the air con condenser and the ATF oil cooler to the radiator assembly 5 Install the radiator cowl lower cover 6 Install the cooling fan 7 Install the radiator cow...

Page 754: ...COMPONENTS radiator cap...

Page 755: ...adiator cap for damage cracks or weakening 2 Connect the tester to the radiator cap 3 Increase the pressure until the indicator stops moving 4 Replace the radiator cap if the reading does not hold ste...

Page 756: ...COMPONENTS thermostat...

Page 757: ...y 3 Verify the temperature at which the valve begins to open Valve opening temperature 82 C 180 F Valve closing temperature 77 C 171 F Full opening temperature 95 C 203 F INSTALLATION 1 Check that the...

Page 758: ...COMPONENTS water pump...

Page 759: ...5 Remove the water pump from cylinder block INSPECTION 1 Check the pump for cracks damage of wear Replace the water pump assembly if necessary 2 Check the bearing for damage abnormal noise and sluggis...

Page 760: ...45 2EA 19 6 26 5 N m 2 0 2 7 kg m 14 5 19 5 lb ft B bolts 8x45 2EA 19 6 26 5 N m 2 0 2 7 kg m 14 5 19 5 lb ft 2 Install the cooling fan 3 Install the drive belt 4 Install the radiator cowl upper cover...

Page 761: ...COMPONENTS cylinder block balance shaft...

Page 762: ...special tool 09231 4A000 3 When installing the bearing apply enough fluid to the bearing surface and cover 4 Press fit the bearing after aligning the bearing oil hole with the timing chain lower under...

Page 763: ...Check damage for balance shaft journal If defects are evident replace the balance shaft 3 Check the balance shaft for oil clearance If wear is excessive replace the balance shaft or cylinder block Ite...

Page 764: ...0 057 0 0009 0 0022 REASSEMBLY 1 Apply engine oil on the balance shaft journal and the balance shaft bearing bush 2 Insert the balance shafts into cylinder block 3 Install the balance shaft drive gea...

Page 765: ...ft A 6 x 14 4 EA 9 8 11 8 1 0 1 2 7 2 8 7 B 8 x 22 1 EA 19 6 26 5 2 0 2 7 14 5 19 5 C 8 x 30 3 EA 19 6 26 5 2 0 2 7 14 5 19 5 D 8 x 40 1 EA 19 6 26 5 2 0 2 7 14 5 19 5 Bolts size Diameter x Length 6 I...

Page 766: ...7 Install the LH balance shaft driven gear bolt 8 x 16 Tightening torque 33 3 39 2 N m 3 4 4 0 kg m 24 6 28 9 lb ft 8 Install the balance shaft sprocket Tightening torque...

Page 767: ...ft RH balance shaft sprocket bolt 8 x 16 33 3 39 2 N m 3 4 4 0 kg m 24 6 28 9 lb ft 9 Install plug on the cylinder block after remove screw driver Tightening torque plug 14 7 21 6 N m 1 5 2 2 kg m 10...

Page 768: ...COMPONENTS crankshaft...

Page 769: ...NDER BLOCK MAIN BEARING BORE DIAMETER Code Cylinder block main bearing bore diameter mm in A 71 000 71 006 2 7953 2 7955 B 71 006 71 012 2 7955 2 7957 C 71 012 71 018 2 7957 2 7960 2 Check the cranksh...

Page 770: ...C None Blue Red Main journal bearing oil clearance 0 024 0 042 mm 0 0009 0 0017 in MAIN JOURNAL BEARING THICKNESS Color Main journal bearing thickness mm in Red 1 997 2 000 0 0786 0 0787 Blue 1 994 1...

Page 771: ...NSPECTION 1 Before removing the main bearing cap measure crankshaft end play If end play exceeds specification replace the thrust bearing End play 0 05 0 25 mm 0 0020 0 0098 in 2 Remove the main beari...

Page 772: ...nder block Tightening torque 127 5 137 3 N m 13 14 kg m 94 0 101 3 lb ft 3 Install the connecting rod cap Tightening torque Tighten 58 8 N m 6 0 kg m 43 4 lb ft and fully loosen bolt Retighten 34 3 N...

Page 773: ...COMPONENTS cylinder block...

Page 774: ...the check If defects are evident correct or replace 2 Using a straightedge and thickness gauge check the cylinder block top surface for flatness Lay the straightedge longways and crossways as indicate...

Page 775: ...REASSEMBLY 1 Crankshaft 2 Flywheel 3 Piston 4 Cylinder head 5 Timing chain 6 Timing chain cover...

Page 776: ...COMPONENTS engine mount...

Page 777: ...COMPONENTS COMPONENTS pistons and connecting rod...

Page 778: ......

Page 779: ...60 000 60 006 2 3622 2 3624 B 60 006 60 012 2 3624 2 3627 C 60 012 60 018 2 3627 2 3629 2 Check the crankshaft pin journal size code Record the pin journal size code letters on the No 1 crankshaft ba...

Page 780: ...oil clearance 0 024 0 042 mm 0 0009 0 0017 in CONNECTING ROD BEARING THICKNESS Color Connecting rod bearing thicknessmm in Red 1 497 1 500 0 0589 0 0591 Blue 1 494 1 497 0 0588 0 0589 None 1 491 1 49...

Page 781: ...80 0 100 mm 0 0031 0 0039 in DISASSEMBLY 1 Remove the timing chain C Refer to Timing chain 2 Remove the camshaft Refer to Camshaft 3 Remove the cylinder head assembly Refer to Cylinder head 4 Remove t...

Page 782: ...d connecting rod assembly from the cylinder block 7 Remove the piston pin with snap ring 8 Remove the piston from connection rod 9 Remove the piston ring from piston INSPECTION CONNECTING ROD BEARING...

Page 783: ...n fits in the piston pin hole Replace any piston and pin assembly that is defective The piston pin must be smoothly pressed by hand into the pin hole at room temperature Piston pin outer diameter 32 9...

Page 784: ...25 0 40 mm 0 0098 0 0157 in No 2 ring 0 50 0 70 mm 0 0197 0 0276 in Oil ring 0 20 0 40 mm 0 0079 0 0157 in REASSEMBLY PISTON PIN 1 Check the front mark of the piston and connecting rod 2 Line up the f...

Page 785: ...rd into the piston as broken piston ring or damaged crankshaft pin journal could result 3 Install the connecting rod bearing on the connecting rod and cap 4 Install the connecting rod and cap to crank...

Page 786: ...connecting rod assembly from above the top of cylinder Ensure that the front mark on the piston crown and that front mark on the connecting rod face toward the front of engine to the crankshaft pulley...

Page 787: ...stall the cylinder head assembly Refer to Cylinder head 7 Install the camshaft Refer to Camshaft 8 Install the timing chain C Refer to Timing chain PISTON RING 1 Install the coil spring and oil ring t...

Page 788: ...COMPONENTS cylinder head assembly...

Page 789: ...s pay attention to safety precautions When remove the injectors set the special tool 09351 4A000 to where the injector holder removed install a slide hammer on the special tool using the hammer tap up...

Page 790: ...Remove the engine cover 3 Drain the engine coolant 4 Drain the transmission oil 5 Remove the battery and battery tray 6 Remove the inter cooler hose and pipe on the intake manifold side engine and tr...

Page 791: ...8 Disconnect the engine coolant reservoir tank hose and the heater hose 9 Remove the inter cooler hose on the turbo charger side 10 Loosen the drive belt tension by turning auto tensioner with spanne...

Page 792: ...r hose 12 Remove the radiator cowl upper cover 13 Remove the cooling fan 14 Remove the radiator cowl lower cover 15 Remove the fixing bolt of air con condenser and ATF oil cooler bracket from the radi...

Page 793: ...ect the engine oil pressure switch connector 23 Remove the air conditioner compressor within connected hose from the cylinder block and then fix it with a wire 24 Disconnect the injector TDC sensor wa...

Page 794: ...30 Remove the front propeller shaft 31 Remove the front exhaust pipe and muffler...

Page 795: ...32 Remove the shift cable from the transmission 33 Disconnect the connectors 8EA from the transmission...

Page 796: ...pulley to gain access to all bolts 36 Remove the starter 37 Remove the transmission housing fixing bolts 38 Remove the transmission mounting and the cross member after support the transmission by usi...

Page 797: ...g torque 68 6 88 3 N m 7 0 9 0 kg m 50 6 65 1 lb ft 3 Install the transmission to the vehicle by using a jack 4 Install the transmission mounting and the cross member Tightening torque Transmission to...

Page 798: ...the transmission oil pipe 10 Reconnect the connectors 8EA to the transmission 11 Install the shift cable to the transmission 12 Install the front exhaust pipe and muffler Tightening torque 42 2 60 8...

Page 799: ...TDC sensor water temperature sensor and starter connector 20 Install the air conditioner compressor to the cylinder block Tightening torque 19 6 24 5 N m 2 0 2 5 kg m 14 5 18 1 lb ft 21 To install all...

Page 800: ...es at least and then check the oil level 3 Check that the engine oil level is within the level range indicated on the oil dipstick If the oil level is found to have fallen to the lower limit the L mar...

Page 801: ...um protection of all types of operation select only those lubricants which a Satisfy the requirements of the API classification b Have the proper SAE grade number for expected ambient temperature reng...

Page 802: ...ller cap opening Capacity Drain and refill 7 4 liter Oil filter 0 8 liter Total 8 2 liter Do not overfill This will cause oil aeration and loss of oil pressure 6 Install the oil filler cap 7 Start and...

Page 803: ...the system because hot or scalding water could gush out causing personal injury Allow the vehicle to cool before servicing this system b When the tester is removed be careful not to spill any coolant...

Page 804: ...centration from the relation between the specific gravity and temperature using the following table for reference RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY Coolant temperature C F an...

Page 805: ...as CHECKING COMPRESSION PRESSURE 1 Before checking engine compression check the engine oil level Also check that the starter motor and battery are all in normal operating condition 2 Start the engine...

Page 806: ...asket are all possible causes ADJUSTING DRIVE BELT AND TENSIONER 1 Check that the belts are not damaged and are properly placed for the pulley grooves a When installing the V ribbed belt check that th...

Page 807: ...turning the auto tensioner clockwise about 39 and then install the belt on the idler between the alternator pulley and the water pump pulley Use torque wrench when rotating the auto tensioner because...

Page 808: ...an angular method Valve spring compressor 09222 22100 Removal and installation of intake and exhaust valves Compression gauge adapter 09351 27000 09351 4A100 Checking engine compression pressure Valve...

Page 809: ...oil seals Timing chain lower front cover oil seal installer 09214 4A000 Installation of timing chain lower front cover oil seal Balance shaft drive gear bearing bush installer remover 09231 4A000 Remo...

Page 810: ...rder 1 3 4 2 Valve timing Intake valve Opens BTDC 8 Closes ABDC 38 Exhaust valve Opens BBDC 52 Closes ATDC 8 Cylinder head Flatness of gasket surface 0 15 mm 0 0059 in Camshaft Cam height LH Intake 40...

Page 811: ...m 0 071 0 079 in Valve stem to valve guide clearance Intake 0 020 0 050 mm 0 0008 0 0020 in 0 1mm 0 0039in Exhaust 0 050 0 080 mm 0 0020 0 0031 in 0 15mm 0 0059in Valve guide Length Intake 43 3 mm 1 7...

Page 812: ...0 0035 in Oil ring 0 04 0 08 mm 0 0016 0 0031 in End gap No 1 ring 0 25 0 40 mm 0 0098 0 0157 in No 2 ring 0 50 0 70 mm 0 0197 0 0276 in Oil ring 0 20 0 40 mm 0 0079 0 0157 in Piston pin Piston pin ou...

Page 813: ...0 0069 in Relief valve opening pressure 784 5 78 4 Kpa Balance shaft Front journal outer diameter 48 975 49 000 mm 1 9281 1 9291 in Rear journal outer diameter 47 965 47 990 mm 1 8884 1 8894 in Front...

Page 814: ...t 10 127 5 137 3 13 14 94 0 101 3 Connecting rod cap nut 8 58 8 0 34 3 60 64 6 0 0 3 5 60 64 43 4 0 25 3 60 64 Oil jet bolt 4 29 4 34 3 3 0 3 5 21 7 25 3 Crank shaft pulley bolt 1 274 6 294 2 28 30 20...

Page 815: ...1 6 1 5 2 2 10 8 15 9 Cylinder head cover bolt 1 6 9 8 11 8 1 0 1 2 7 2 8 7 Camshaft cap bolt 20 13 7 14 7 1 4 1 6 10 1 10 8 Cylinder head bolt 18 49 0 120 90 5 0 120 90 36 2 120 90 TDC sensor bolt 1...

Page 816: ...olt 1 33 3 39 2 3 4 4 0 24 6 28 9 Timing chain guide A bolt upper 1 9 8 11 8 1 0 1 2 7 2 8 7 Timing chain guide A bolt lower 1 19 6 26 5 2 0 2 7 14 5 19 5 Timing chain lever A bolt 1 19 6 26 5 2 0 2 7...

Page 817: ...amp bolt 4 27 5 33 3 2 8 3 4 20 3 24 6 High pressure pipe pump to rail 1 24 5 28 4 2 5 2 9 18 1 21 0 High pressure pipe injector to rail 4 24 5 28 4 2 5 2 9 18 1 21 0 Water pump pulley nut 4 9 8 11 8...

Page 818: ...Starter fixing bolt 2 26 5 33 3 2 7 3 4 14 5 24 6 Engine support bracket bolt 2 47 1 51 0 4 8 5 2 34 7 37 6...

Page 819: ...relief valve stuck open Repair Excessive bearing clearance Replace High oil pressure Oil relief valve stuck closed Repair Excessive engine vibration Loose engine mounting bolt Retighten Loose transmi...

Page 820: ...ir or replace Faulty electric fan Repair or replace Faulty thermo sensor on radiator Replace Insufficient coolant Refill coolant Abnormally low coolant temperature Faulty thermostat Replace Faulty tem...

Page 821: ...COMPONENT intake and exhaust system air cleaner...

Page 822: ...COMPONENTS exhaust manifold...

Page 823: ...COMPONENTS intake manifold...

Page 824: ...A 8 x 112 4 EA 14 7 19 6 1 5 2 0 10 8 14 5 B 8 x 32 4 EA 14 7 19 6 1 5 2 0 10 8 14 5 C Nut 2 EA 14 7 19 6 1 5 2 0 10 8 14 5 Bolts size Diameter x Length 2 Install the EGR valve and pipe Tightening tor...

Page 825: ...COMPONENT muffer...

Page 826: ...COMPONENTS turbocharger...

Page 827: ...COMPONENTS LUBRICATION SYSTEM oil cooler...

Page 828: ...ning torque Oil cooler by pass valve 49 0 58 8 N m 5 6 kg m 36 2 43 4 lb ft Relief valve plug 39 2 49 0 N m 4 5 kg m 28 9 36 2 lb ft 2 Install the oil cooler to oil cooler cover Tightening torque 17 7...

Page 829: ...heck that the valve operates properly 2 Verify the temperature at which the valve begins to open Item Temperature C F Lift mm in Valve opening temperature 91 5 94 5 196 7 202 1 0 05 0 002 Full opening...

Page 830: ......

Page 831: ...COMPONENT oil pan...

Page 832: ...tening torque N m kg m lb ft A 6 x 18 3 EA 7 8 11 8 0 8 1 2 5 8 8 7 B 6 x 30 13 EA 7 8 11 8 0 8 1 2 5 8 8 7 C 8 x 45 8 EA 19 6 26 5 2 0 2 7 14 5 19 5 Bolts size Diameter x Length 2 Install the oil pan...

Page 833: ...COMPONENTS oil pump...

Page 834: ...clearance and body clearance Side clearance Inner rotor 0 040 0 085 mm 0 0016 0 0033 in Outer rotor 0 050 0 100 mm 0 0020 0 0039 in Body clearance Between outer rotor and body 0 100 0 176 mm 0 0039 0...

Page 835: ...oil feed pipe to the oil pump and bed plate Tightening torque 19 6 26 5 N m 2 0 2 7 kg m 14 5 19 5 lb ft 4 Install the oil pan Refer to Oil pan 5 Install the timing chain B and C Refer to Timing chain...

Page 836: ...Components timing systm...

Page 837: ......

Page 838: ...Component...

Page 839: ......

Page 840: ...move the timing chain C with the camshaft sprocket 10 Remove the timing chain upper under cover TIMING CHAIN B 1 Remove the timing chain C 2 Remove the crankshaft pulley 3 Remove the oil pan 4 Remove...

Page 841: ...ling surface after remove the chain cover and oil pan If any impurities are left at the sealing face oil may leak after reassembly even with the sealant application REASSEMBLY TIMING CHAIN A 1 Check t...

Page 842: ...mark of LH balance sprocket with the timing mark of timing chain lower under cover 5 Check the LH balance shaft whether it is located at the right position To prevent the rotation of balance shaft rem...

Page 843: ...1 2 kg m 7 2 8 7 lb ft Lower bolt 19 6 26 5N m 2 0 2 7 kg m 14 5 19 5 lb ft 11 Install the timing chain lever A Tightening torque 19 6 26 5 N m 2 0 2 7 kg m 14 5 19 5 lb ft 12 Install the timing chai...

Page 844: ...arks of crankshaft sprocket and oil pump sprocket align with each other 6 Assemble the RH balance shaft sprocket to the balance shaft tentatively 7 Install the timing chain guide B 1 B 2 Tightening to...

Page 845: ...9 5 B 8 x 70 1 EA 19 6 26 5 2 0 2 7 14 5 19 5 C 8 x 50 3 EA 19 6 26 5 2 0 2 7 14 5 19 5 D 8 x 40 1 EA 19 6 26 5 2 0 2 7 14 5 19 5 E 8 x 22 1 EA 19 6 26 5 2 0 2 7 14 5 19 5 Bolt Size Diameter x Length...

Page 846: ...t the oil leak to the overlapping part T joint 2 points right and left of the engine where cylinder head timing chain cover plate and timing chain upper under cover overlap 4 Install the timing chain...

Page 847: ...as the timing marks of high pressure pump sprocket and LH camshaft sprocket align with each other 9 Assemble the RH camshaft sprocket to the RH camshaft tentatively 10 Install the timing chain guide...

Page 848: ...of the camshaft positions at the right place finally 15 Apply the sealant at the timing chain upper front cover Sealant type Lotite 5902 Bead width 2 4 mm 0 08 0 16 in 16 Install the timing chain upp...

Page 849: ......

Page 850: ...1 SMARTRA IMMOBILIZER System Anti Theft Protection SMARTRA IMMOBILIZER 12 13 SYSTEM POWER RELAY MAIN RELAY 14 AUTO CRUISE MAIN INDICATOR LAMP AUTO CRUISE MAIN INDICATOR LAMP 15 GLOW PLUG RELAY GLOW PL...

Page 851: ...IARY WATER HEATER RELAY AUXILIARY WATER HEATER RELAY 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 CRUISE CONTROL Supply CRUISE CONTROL ACTIVATOR 41 42 43 44 45 46 47 ENGINE SPEED Signal To TACHO...

Page 852: ...en AT Ground 57 58 Terminal 15 IG ON OFF Signal IGNITION S W 59 BRAKE S W Input BRAKE S W 60 A CON ON S W Input THERMO S W 61 CLUTCH S W Input CLUTCH S W 62 BLOWER S W Input BLOWER S W 63 64 65 66 67...

Page 853: ...E SENSOR WTS Ground WATER TEMPERATURE GLOW UNIT SENSOR 86 AIR TEMPERATURE SENSOR ATS Signal AIR FLOW SENSOR HFMS 87 SMARTRA IMMOBILIZER Ground 88 AIR FLOW SENSOR HFMS Ground AIR FLOW SENSOR HFMS 89 AI...

Page 854: ...0 MALFUCTION INDICATOR LAMP MIL LAMP MALFUNCTION INDICATOR LAMP MIL LAMP 111 GLOW TIME INDICATOR LAMP GLOW TIME INDICATOR LAMP 112 113 114 INJECTOR CYLINDER No 1 INJECTOR CYLINDER No 1 115 116 117 INJ...

Page 855: ...t the battery groud terminal 3 Lift the passenger side carpet for LHD vehicle and then remove the protection plate 4 Remove the ECU mounting nuts 5 Disconnect ECU harness connector To do this pull loc...

Page 856: ...AIR FLOW SENSOR AFS CIRCUIT DIAGRAM HOT FILM AFS OUTPUT FEATURES Mass air flow kg h Output voltage V 10 1 2226 1 2398 15 1 3552 1 3778 30 1 6783 1 7146 60 2 1619 2 2057...

Page 857: ...120 2 7215 2 7762 250 3 4388 3 5037 370 3 8796 3 9511 480 4 1945 4 2683 640 4 5667 4 6469 TEST PROCEDURE...

Page 858: ...nspect the following conditions 1 Chect the poor attachment of airflow cut air duct and air cleaner filter branched from AFS 2 Bad combustion in the cylinder or fault injector 3 Even it no AFS malfunc...

Page 859: ...ATS INTAKE AIR TEMPERATURE SENSOR HARNESS INSPECTION PROCEDURE...

Page 860: ...SENSOR INSPECTION 1 Inspect the resistance of sensor using a multi tester 2 Measure the resistance between ATS and terminal CONDITION TEMPERATURE C RESISTANCE k Ignition switch ON 40 39 260 30 22 960...

Page 861: ...609 70 0 452 80 0 340 90 0 261 100 0 202 110 0 159 120 0 127 130 0 102 3 If resistance value is out of standard replace the intake air temperature sensor assembly Intake air temperature sensor is inte...

Page 862: ...TROUBLESHOOTING HINTS When idling speed is not appropriate or blacksmoke arises it is likely to be a defect of water temperature sensor HARNESS INSPECTION PROCEDURES...

Page 863: ...20 C 40 C 40 C 80 C 80 C USING MULTITESTER 1 Remove the water temperature sensor from the engine coolant passage of the cylinder head 2 With the temperature sensing portion of the engine coolant temp...

Page 864: ...rom the standard value greatly replace the sensor INSTALLATION 1 Apply sealant LOCTITE 962T or equivalent to threaded portion 2 Install water temperature sensor and tighten it to specified torque Tigh...

Page 865: ...HARNESS INSPECTION PROCEDURES...

Page 866: ...CRANSHAFT POSITION SENSOR CKP CIRCUIT DIAGRAM...

Page 867: ...HARNESS INSPECTION PROCEDURES...

Page 868: ...INJECTOR CIRCUIT DIAGRAM...

Page 869: ...ns Measuring range 25A Bandwidth 100kHz 2 Attach the plug to the injector Fasten clip on ammeter around lead to pin 2 of corresponding injector Allow engine to be at idle Refer to the set value curren...

Page 870: ...all injectors have to be replaced AFTER RUN TEST 1 Measure the supply voltage at ECU pin 114 Clinder 1 Injector pin 119 Clinder 4 Injector to pin 117 and pin 120 Cylinder 3 Injector pin 121 Cylinder 2...

Page 871: ...ENSOR INSPECTION USING HI SCAN Check item Data display Check conditions Rail pressure Set value HI SCAN Rail pressure sensor Rail pressure Engine at idle 220 300bar 260bar HARNESS INSPECTION PROCEDURE...

Page 872: ...r is re used 2 When removing seal take care not to damage sealing surface 3 When installing RPS provide the sealing washer with grease if necessary 4 Tightening torque is 35 2 N m 25 8 1 5 Ib ft Repla...

Page 873: ...CIRCUIT DIAGRAM HARNESS INSPECTION PROCEDURES...

Page 874: ...ondition Engine condition Standard value EGR solenoid valve solenoid valve OFF ON Ignition switch ON Check the sound for proper operation USING VOLTMETER Check item Specified value EGR solenoid valve...

Page 875: ...ine rpm is not dropped below the lower set value error is detected The reasons are short circuit connecting resistance faulty rail pressure sensor continuity of fuel pump relay faulty rail pressure co...

Page 876: ...2 9 3 15 Replace the faulty fuel rail assembly in case of new model vehicle within a year or replace the faulty parts of vehicle of which model year is more than a year DON T DISASSEMBLE OR DISASSEMBL...

Page 877: ...HARNESS INSPECTION PROCEDURES...

Page 878: ......

Page 879: ...COMPONENTS LOCATION fuel delivery system common rail...

Page 880: ...ion to safety precaution d Ensure the absolute cleanliness e It is not recommanded to remove the injectors 1 Disconnect high pressure fuel tube rail to injector high pressure pump to rail 2 Disconnect...

Page 881: ...torque Rail fixing bolt 14 7 21 6N m 150 220 kg cm 10 8 15 9 lbf ft 2 Assemble intake manifold Refer to ENGINE MECHANICAL group 3 Assemble EGR valve 4 Connect rail pressure sensor connector 5 Connect...

Page 882: ...ermoswitch heater and water sensor connector 3 Unscrew fixing bolt and nut in bracket then remove fuel filter You must be careful of fuel spillage from fuel filter Tightening torque Fuel filter fixing...

Page 883: ...do not use any extreme force or any tools b The high pressure line must only be installed to the injector when the injector is tightly secured in its position c Tightening torque must never exceed th...

Page 884: ...eat 3 Remove carpet and then disassemble service cover plate 4 Disconnect the sender connector 5 Disconnect the main and return tube 6 Remove breather hose and joint hose in fuel filler pipe 7 Remove...

Page 885: ......

Page 886: ...COMPONENTS LOCATION high pressure pump...

Page 887: ...onnect fuel tube HP to rail and rail pressure regulator MPROP connector 3 Unscrew high pressure mounting bolts and then disassemble high pressure pump Tightening torque High pressure pump fixing bolt...

Page 888: ...ACCELERATOR PEDAL REMOVAL 1 Unscrew fixing bolts or nuts and disconnect APS sensor connector which senses position of accelerator pedal 2 Disassemble APM...

Page 889: ...extremely high pressure 1350 bar b Never perform any work on injection system with engine runnin or within 30 seconds after stopping the engine c Always pay attention to safety precaution d Ensure the...

Page 890: ...ck up type Accel position sensor APS Type Variable resistor type Potentiometer type Fuel pressure sensor Type Piezo electricity type Actuators Injectors Type Electromagnetic type Resistance 0 3 0 6 Fu...

Page 891: ...il pressure sensor 30 4 40 2 310 410 22 4 29 6 Clamp bolt for injector 30 4 2 9 310 30 22 4 2 17 Retaining bolt for high pressure pump 14 7 19 6 150 200 10 8 14 5 Flange bolt EGR solenoid valve 6 9 10...

Page 892: ...y injection Check and if necessary replace injectors Engine mechanical faults as described earlier under this heading Test compression and if necessary repair engine Faulty injection pump Try to start...

Page 893: ...replace pump permanently Poor power output slow acceleration speedometer accurate clutch not slipping Maximum rpm incorrect Check and if necessary replace injection pump Air cleaner filter dirty Clean...

Page 894: ...ction Short circuit in injector wiring Check injector wiring ENGINE STARTING SYSTEM Trouble symptom Probable cause Remedy Engine will not crank Battery charge low Charge or replace battery Battery cab...

Page 895: ...tank fuel filter Replace Water in fuel filter Replace the fuel filter or clean the fuel tank and fuel lines Dirty or rusted fuel tank interior Clean or replace Malfunctioning fuel pump Clogged filter...

Page 896: ......

Page 897: ......

Page 898: ......

Page 899: ...TROUBLESHOOTING PROCEDURES Communication with SCAN TOOL is not possible Communication with all system is not possible...

Page 900: ...s may be suspected a No power supply to ECU b Defective ground circuit of ECU c Defective ECU d Improper communication line between ECU and scan tool a Malfunction of ECU power supply circuit b Malfun...

Page 901: ...ROUGH IDLE OR ENGINE STALLS...

Page 902: ...ENGINE HESITATES OR ACCELERATES POORLY...

Page 903: ...WHEN GLOW PREHEATING LAMP IS ILLUMINATED AT ALL TIMES ECU AUTOMATIC RECOGNITION PROCEDURE...

Page 904: ...DTC code P1629 existing test the ECU by performing ECU Automatic Recognition routine using HI SCAN c When MT AT is properly selected press ESC key to stop the automatic recognition d If the ECU is at...

Page 905: ...CASE 2 When ECU is incorrectly adapted for transaxle...

Page 906: ......

Page 907: ...TION C001 Signal below lower limit C002 Signal above upper limit 0120 ACCEL POSITION SENSOR MALFUNCTION C001 Signal below lower limit C002 Signal above upper limit C003 General error C004 Plausibility...

Page 908: ...CTION C002 Signal above upper limit C003 General error C004 Plausibility error C001 Signal below lower limit 0403 EGR SOLENOID VALVE CIRCUIT MALFUNCTION C018 Line short circuit C019 Line open circuit...

Page 909: ...03 General error 1181 Fuel pressure monitoring MALFUNCTION C005 Maximum pressure exceeded C006 Minimum pressure at engine speed too low C008 DRV sticking C009 Leakage of Fuel C010 Governor deviation a...

Page 910: ...e short circuit C019 Line open circuit 1635 Water heater relay MALFUNCTION C018 Line short circuit 1638 Microcontroller MALFUNCTION C022 Microcontroller error C023 Fuel cut off monitoring error C024 M...

Page 911: ...act resistance c HFM5 defective d ECU defective Sensor supply voltage DTC P1526 C001 C002 Signal above upper limit a Short circuit to battery line or open circuit in wiring b HFM5 defective c ECU defe...

Page 912: ...hort circuit to ground line b Accel position sensor defective c ECU defective Sensor supply voltage DTC P1526 C001 C002 Signal above upper limit a Short circuit to battery line b Throttle position sen...

Page 913: ...OR CIRCUIT MALFUNCTION CYLINDER 4 C018 Line short circuit a Short circuit of high side line to battery b Short circuit of low side line to ground c Injectors d Injector voltage ECU C019 Line open circ...

Page 914: ...it a Short circuit to battery line open circuit in wiring C019 Line open circuit a Short circuit to ground line 0500 VEHICLE SPEED SENSOR MALFUNCTION C002 Signal above upper limit a Vehicle speed sens...

Page 915: ...ort circuit General error a Short circuit to battery line open circuit in wiring b Engine Coolant temperature sensor defective C019 Line open circuit a Short circuit to ground line open circuit C003 G...

Page 916: ...lamp C019 Line open circuit a Short circuit to ground line b Fuse defective c Contact resistance d Glow time control e Glow plug indicator lamp 1616 MAIN RELAY MALFUNCTION C004 Plausibility error a Op...

Page 917: ...circuit a Short circuit to battery line open circuit in wiring b Fuse defective c Open circuit Contact resistance d Additional water heater relay defective 1645 INJECTOR SUPPLY VOLTAGE MALFUNCTION C0...

Page 918: ...iring b ECU defective Sensor supply voltage Step Inspection 1 Check actual value for evaluation engine idling or engine warm at approximately 80 C a Specification 600 mg stroke EGR OFF 400 mg stroke E...

Page 919: ......

Page 920: ...tive Step Inspection 1 Check actual value for evaluation set value ambient temperature a Evaluation display temperature 40 C open circuit in the signal line temperature 130 C short to GND in the signa...

Page 921: ......

Page 922: ...or defective c ECU defective Step Inspection 1 Check actual value of evaluation set value approximately 80 C with warm engine a Evaluation display temperature 40 C open circuit in the signal line temp...

Page 923: ......

Page 924: ...a ECU defective Sensor supply voltage DTC P1526 C004 Plausibility error a Brake switch defective b Accel position sensor defective c ECU defective Sensor supply voltage DTC P1526 Step Inspection 1 Che...

Page 925: ...pin 1 and pin 6 a Specification 0 2475 0 5225 at IDLE Stroke 1 575 2 585 at FULL Stroke...

Page 926: ...C code from this error reports the error source Step Inspection 1 Check actual value for evaluation engine warm approximately 80 C engine idling a Specification 220 300 bar typically 260 bar Rail pres...

Page 927: ...N m a When removing seal take care not to damage sealing surface b When installing RPS bond on sealing washer with grease if necessary c Replace whole FUEL RAIL ASSEMBLY if vehicle was produced withi...

Page 928: ......

Page 929: ...GR valve and solenoid valve 4 Pull off the plug of solenoid valve measure the resistance of solenoid valve a Specification 15 4 0 7 5 Measure the frequency of control voltage a Specification 300Hz 6 C...

Page 930: ......

Page 931: ...ED SENSOR MALFUNCTION Related items according to CC code C002 Signal above upper limit a Vehicle speed sensor defective C004 Plausibility error a Clutch switch defective b Vehicle speed sensor defecti...

Page 932: ...attery connected b Alternator over charging Step Inspection 1 Check ECU plug and wiring plug contact condition 2 After IG ON check the supply voltage of ECU pin 4 to GND and of ECU pin 5 to GND a Spec...

Page 933: ......

Page 934: ...on 8 15 V Check fuse if set value is not attained 2 IG OFF Measure resistance of switch at detached plug a Specification more than 1M Press brake a Specification 0 1 3 Check wiring between switch pin...

Page 935: ......

Page 936: ...n wiring short circuit b Fuse defective c Poor connection d Switch defective Step Inspection 1 Measure voltage at switch pin ECU side to GND with IG ON a Specification 8 15V Check wiring if set value...

Page 937: ......

Page 938: ...Signal below lower limit a Defective atmospheric pressure sensor in ECU C002 Signal above upper limit Step Inspection 1 Check possible actual value a Specification 1 atm approximately 101 325 3 kPa 2...

Page 939: ...High pressure pump g ECU Step Inspection 1 Pull off PRV Pressure Regulator Valve Check wiring between ECU pin 108 109 and PRV 2 Measure resistance of PRV a Specification 2 9 3 15 at 20 C 3 Check RPS...

Page 940: ......

Page 941: ...ts if fault is again stored 3 Check pipes rail and connections for leakage visual inspection 4 Check low pressure circuit a Possible causes of trouble Leakage fuel filter clogged gear pump suction pum...

Page 942: ...leakage in the rail pull out all the fuel tubes injector return hose to pump and check whether the fuel flow out through the limiting valve on the rail if leakage detected and limiting valve failure r...

Page 943: ...time control e Glow plug indicator lamp Step Inspection 1 Activate lamp by way of actuator diagnosis If check lamp does not flash check fuse Check glow lamp wiring Glow plug indicator lamp lights bri...

Page 944: ......

Page 945: ...lity error a Open circuit in wiring short circuit b Contact resistance c Fuse defective d Main relay defective Step Inspection 1 After IG ON check supply voltage ECU pin 4 to GND and ECU pin 5 to GND...

Page 946: ......

Page 947: ...gnetic clutch Step Inspection 1 IG ON Measure voltage at compressor relay A C comp pin 86 to GND a Specification 8 15V If set value is not attained check fuse 2 Measure voltage at compressor relay A C...

Page 948: ......

Page 949: ...ry line Step Inspection 1 Perform the actuator diagnosis 2 If lamp does not flash measure supply voltage at engine check to GND with IG ON a Specification 8 15 V 3 Check fuse if set value is not attai...

Page 950: ......

Page 951: ...defective Step Inspection 1 Measure voltage at relay pin 85 to GND a Specification OFF 8 15V ON 0V Check additional water heater relay wiring 2 Measure the supply voltage at relay pin 86 to GND a Spec...

Page 952: ......

Page 953: ...tems according to CC code C002 Signal above upper limit C001 Signal below lower limit Step Inspection 1 Capacitor in the ECU charges for activating the injectors Check wiring of injectors to ECU Recti...

Page 954: ...defective c Incorrect installation position or sensor loose d Camshaft and crankshaft misarrangement e Interference on signal line from other component Alternator injector line C001 Signal below lowe...

Page 955: ......

Page 956: ...sion fluid ATF Only ATF Apply grease Appropriate grease Apply sealant Appropriate sealant Apply petroleum jelly Appropriate petroleum jelly Whenever special oil or grease is required it will be identi...

Page 957: ...ABOUT SAFETY 1 Block the wheels 2 Use only the specified jacking positions 3 Support the vehicle with safety stands PREPARATION OF TOOLS AND MEASURING EQUIPMENT SPECIAL SERVICE TOOLS SST S REMOVAL OF...

Page 958: ...DISASSEMBLY INSPECTION OF PARTS ARRANGEMENT OF PARTS CLEANING PARTS FOR REUSE...

Page 959: ...rs f Nylon nuts DEPENDING ON LOCATION 1 Sealant should be applied or new gaskets installed 2 Oil should be applied to the moving components of parts 3 Specified oil or grease should be applied at the...

Page 960: ...checks and in checking for short circuits When checking the engine control module ECM never use a bulb exceeding 3 4W ELECTRICAL TROUBLESHOOTING TOOLS JUMPER WIRE Do not connect a jumper wire from th...

Page 961: ...VOLTMETER OHMMETER Do not attempt to connect the ohmmeter to any circuit in which voltage is applied Such a connection may damage the ohmmeter ELECTRICAL PARTS...

Page 962: ...can be removed by pressing or pulling lock lever LOCKING A CONNECTOR Listen for a click when locking connectors This sound indicates that they are securely locked INSPECTION OF CONNECTORS 1 When a tes...

Page 963: ...they cannot be accessed from harness side a Use a fine wire to prevent damage to the terminal b Do not damage the terminal when inserting the tester lead Pull lightly on individual wires to ensure tha...

Page 964: ...strike them against other parts WIRING COLOR CODES CODE COLOR CODE COLOR B BLACK P PINK BR BROWN R RED G GREEN S SILVER LIGHT BLUE GY GRAY T TAWNY L BLUE V VIOLET LG LIGHT GREEN W WHITE O ORANGE Y TE...

Page 965: ...cessary to prevent damage to the vehicle It is recommended that your vehicle be towed with a wheel lift or flatbed eguipment Do not tow with a slingbelt Our company has not approved a slingbelt towing...

Page 966: ...ia SORENTO 6 7 Body Type 52 4 door wagon 8 Engine Type 1 2 5L Diesel 2 2 4L Gasoline 3 3 5L Gasoline 9 Transmission type 5 5 speed manual 4 8 4 speed automatic 4 4 10 Model Year 2 2002 3 2003 11 Plant...

Page 967: ...5 2 5 Diesel 2 5L TCI AT K N E J C 5 2 1 8 2 5 Gasoline 2 4L MT K N E J C 5 2 2 5 2 5 Gasoline 3 5L AT K N E J C 5 2 3 8 2 5 0 symbol according to No 3 1 2 sentence 4 of 76 114 EEC 1 3 World Manufact...

Page 968: ...ENGLISH METRIC CONVERSION TABLE...

Page 969: ...UNITS...

Page 970: ...ABBREVIATIONS...

Page 971: ...MAINTENANCE SCHEDULE...

Page 972: ...MAINTENANCE UNDER SEVERE USAGE CONDITIONS...

Page 973: ......

Page 974: ...nged to fresh status 2 Dissolution Reinstatement of logic 1 Turn off the blower switch 2 Move to defrost mode 3 Press the recirculation button 5 times within 3 seconds On keeping A C button selected 4...

Page 975: ...SCHEMATIC DIAGRAM FULL AUTO BLOWER AND A C CONTROLS FULL AUTO FULL AUTOMATIC AIR CONDITIONER FATC CONTROL PANEL...

Page 976: ...Connector Pin Description...

Page 977: ...HOT B6 AQS SENSOR A7 SENSOR GND B7 AMB SENSOR A8 INTAKE FRE B8 BATT A9 3B JOINT BLWR COMM B9 BLOWER MOTOR FEEDBACK A10 ILL B10 P TR BASE A11 GND B11 N C A12 MODE VENT B12 N C A13 MODE HEAT B13 N C A1...

Page 978: ...C8 N C...

Page 979: ...l discharge air control 2 The switch will raise up or lower down the temperature by unit of 0 5 3 Setting at 17 C 62 F will provide max cooling and setting at 32 C 90 F will provide max heating 4 Swit...

Page 980: ...ually control recirculation g Defroster Manually control defroster when air conditioning system is on and recirculation selected AMB Indicate ambient air temperature a AMB lamp will be indicated b Amb...

Page 981: ...s at 0 15 second interval a AUTO Auto control b OFF System off c Fan speed control Manually control blower fan speed Output increment step by step Fan speed levels and voltages a Auto heating No level...

Page 982: ...AMB lamp ambient air temperature will come on for 5 seconds and then go out a AUTO Auto control b Blower speed Return to MANUAL LOW c Others Return to the previous condition before system off a A C Ai...

Page 983: ...control b Others Return to the previous condition before system off AUTO A CON OPERATION TABLE...

Page 984: ...with lower temperature and decrease with higher temperatures 2 The sensor output will be used for discharge temperature sensor sensor fail safe temperature regulation door control blower motor level c...

Page 985: ......

Page 986: ...COMPONENTS 2 5D ENGINE 2 4G ENGINE 3 5G ENGINE compressor...

Page 987: ......

Page 988: ...EM Group 2 5D Remove the drive belt after loosening the tension pulley 2 4G 3 5G 2 Discharge the refrigerant 3 Remove the discharge and suction hoses 4 Remove the compressor 5 Installation is the rev...

Page 989: ...GERANT LEAKS Always conduct a leak test with an electronic leak detector whenever leakage or refrigerant is suspected and when conducting service operations which are accompanied by disassembly or loo...

Page 990: ...ed air If bent gently bend them using a screwdriver or a pliers 2 Check the condenser connections for leakage and repair or replace it if required CONDENSER FAN 1 Check the condenser fan for proper op...

Page 991: ...sure switches The low pressure switch will be turned off to stop compressor operation if refrigerant pressure is low The high pressure switch will be turned off to stop compressor operation if refrige...

Page 992: ...temperature control sensor failsafe temperature door control blower motor level control A C auto control Check resistance of the sensor Temperature C F Resistance between 1 and 2 3 18 64 4 21 69 8 25...

Page 993: ......

Page 994: ...35 0 65mm 0 0138 0 0256 in 2 Check the gap around the pulley at 3 points 3 If the clutch air gap is outside the normal range correct it using a shim of proper size MAGNETIC CLUTCH OPERATION Connect t...

Page 995: ...sponse to photo intensity level in vehicle the sensor will send signal to control module to control the blower level and discharge temperature Emit intensive light toward driver side and passenger sid...

Page 996: ...check both the inlet and outlet temperatures If the difference in temperatures between the inlet and outlet is large replace the receiver drier a Plug the all open fittings immediately to keep moistu...

Page 997: ...mperature or in car humidity is outside certain range it will turn on A C to control incar humidity preventing incar fogging Air conditioner operation depending on ambient temperature and humidity SEN...

Page 998: ...85 0 98 90 0 94...

Page 999: ...y excessive cooling The thermistor is an NTC device Thermistor check 1 Remove the glove box 2 Start the engine 3 Turn on the air conditioner 4 Using the multi tester check the output voltage between t...

Page 1000: ...d off to stop compressor operation if refrigerant pressure is low The high pressure switch will be turned off to stop compressor operation if refrigerant pressure is too high The medium switch will be...

Page 1001: ......

Page 1002: ...oisture from the atmosphere at a rapid rate therefore the following precautions must be observed a When removing refrigerant components from a vehicle cap immediately the components to prevent from th...

Page 1003: ...specified torque Size Tightening torque N m kg m lb ft General bolt nut 4T 7T M6 4 6 0 4 0 6 2 9 4 3 7 11 0 7 1 1 5 0 7 9 M8 9 14 0 9 1 4 6 5 10 17 26 1 7 2 6 12 18 M10 19 28 1 9 2 8 14 20 35 55 3 5...

Page 1004: ...ED 1 When it is necessary to open the refrigeration system have everything you will need to service the system ready so the system will not be left open any longer than necessary 2 Cap or plug all lin...

Page 1005: ...t of new refrigerant oil back into the A C system before charging SYSTEM EVACUATION Use only service equipment that is U L listed and is certified to meet the requirements of SAE J2210 to remove HFC 1...

Page 1006: ...d lubricant manufacturers Connect a R 134a refrigerant Recovery Recycling Charging System to the high pressure service port and the low pressure service port as shown following the equipment manufactu...

Page 1007: ...3 Check the system for leaks using a R 134a refrigerant leak detector with an accuracy of 14g 0 5 oz per year or better 4 If you find leaks that require the system to be opened to repair or replace h...

Page 1008: ...If the intersection is within the block cooling performance is satisfactory PERFORMANCE TEST DIAGNOSIS USING MANIFOLD GAUGE STANDARD VALUE If cooling cycle is operating normally the manifold gauge rea...

Page 1009: ...ntain the proper level of refrigerant Clean the condenser b Adjust the belt a Low pressure and high pressure are high b Low pressure pipe is not cold a Air in the system a Clean or repair the receiver...

Page 1010: ...re is frozen at expansion valve hole a Repair and bleed receiver drier a Low pressure and high pressure are high b Much frost or dew on the low pressure side piping a Expansion valve failure Receiver...

Page 1011: ...REFRIGERATION CYCLE...

Page 1012: ......

Page 1013: ...REFRIGERATION LINE...

Page 1014: ...CHECK 1 Connect the battery voltage and check the blower motor rotation BLOWER...

Page 1015: ...CHECK MANUAL CONTROL 1 Check for continuity and resistance between terminals Terminal Resistance 10 3 1 3 2 3 4 0 33 0 85 2 07 blower speed control...

Page 1016: ...CONTROL PANEL Connector Pin Description...

Page 1017: ...edback 6 7 A C select high 7 Check coupler 8 Mode Floor defrost 8 9 Mode Face floor 9 10 IG 1 10 11 ILL 11 12 Intake Recirculation 12 13 Sensor voltage 5V 13 14 Thermistor 14 15 Mix Cool 15 16 A C the...

Page 1018: ...les to change the intake status at defrost and floor defrost mode The A C button enables to change the A C status at defrost and floor defrost mode Be impossible to enter defrost and floor defrost log...

Page 1019: ...SCHEMATIC DIAGRAM MANUAL BLOWER AND A C CONTROLS MANUAL...

Page 1020: ...intake selection switch is located on the control panel Pressing the switch will shift between recirculation and fresh air modes CHECK Input Output 5 7 Fresh recirculation shifting Recirculation fresh...

Page 1021: ...age of blower motor between pin 1 and 2 2 Select the control switch to raise voltage until high relay operates CHECK Fan Motor Voltage First speed 4 0V Second speed 5 6V Third speed 7 3V Fourth speed...

Page 1022: ......

Page 1023: ...TION METHOD SELF DIAGNOSIS The F A T C module self test feature will detect electrical malfunction and provide error codes for system components with suspected failures FAIL SAFE FUNCTION No Item Fail...

Page 1024: ...aximum heating position HOW TO READ SELF DIAGNOSTIC CODE 1 After the display panel flickers three times every 0 5 second the corresponding error code flickers on the setup temperature display panel ev...

Page 1025: ...assembly c A C control assembly E3 Open Shorted Thermistor sensor a Thermistor sensor b Harness or connector between evap sensor and A C control assembly c A C control assembly E5 Open Shorted photo...

Page 1026: ...OWER SUPPLY CHECK In turning off IGN battery supplies power for ordinary power FATC connector B 8 through Audio fuse FATC performs memory function by means of battery power supplied as described below...

Page 1027: ...or Measure voltage of tail light shown in the below figure after switching on light If 10V and more check FATC connector and if no problem measure signal voltage of rheostat shown in the below figure...

Page 1028: ...tch works Triple switch checks pressure of refrigerant flowing through pipe and turns on off switches in it according to standard So it controls that output signal of air conditioner outputted from FA...

Page 1029: ...FATC connector A 8 terminal If 8V and more check actuator or wiring state and if 9V and less check the inside of controller Indoor mode running error Power supply error in actuator Select indoor mode...

Page 1030: ...parating connector linked with actuator If 8V and more check the inside of controller Mode actuator running error If 1V and less at measuring in the above method check mode actuator and wiring state M...

Page 1031: ...location of temp actuator through FATC connector A 5 terminal Comparing original value with inputted value it works until they are same If 4 9V and more is inputted in A 5 terminal it is regarded as...

Page 1032: ...ts cause is internal failure of FATC Sensor 5 power supply error If automatic control isn t operated smoothly measure voltage of FATC connector A 18 terminal If under 4 8V or over 5 2V its cause is in...

Page 1033: ...Medium Kg cm G 15 5 1 3 Low Kg cm G 2 0 0 2 EXPANSION Valve TYPE BLOCK Refrigerant TYPE R 134a Capacity g 600 25 Blower and Evaporator Unit ITEM MANUAL AUTO Fresh and Recirculation Operating method A...

Page 1034: ...tion HEATING efficient area 325 4cm Operating method ACTUATOR TEMP selection Operating method ACTUATOR Control unit ITEM MANUAL AUTO INCAR SENSOR AMBIENT SENSOR PHOTO SENSOR HUMIDITY SENSOR X X X X O...

Page 1035: ...TROUBLESHOOTING MALFUNCTION CAUSES AND REMEDIES Numbers Indicate checking inspection order...

Page 1036: ......

Page 1037: ...ease of coolant temperature and ignition off During cleaning process supplied fuel in the heater will be burnt completely and any smoke will be expelled It is a necessary process for next operation an...

Page 1038: ...he glow plug and combustion air fan are operated first and after 30 seconds the dosing pump is operated with stopping the combustion fan for 3 seconds After that the operation of the fan increases con...

Page 1039: ...uring the heater operation The heater conducts cleaning operation at this time This is a process of burning the fuel completely supplied in the heater inner In this process the glow plug and combustio...

Page 1040: ...EXPLODED VIEW COMPONENT...

Page 1041: ...Back of front bumper Components characteristics The fuel fired heater consists of a fuel fired heater body a dosing pump and an ambient temperature switch The fuel fired heater body consists of a com...

Page 1042: ...is generated in the combustion chamber and it heats the coolant directly which passes through the outside the combustion chamber The ECU recognizes and controls the whole process of the combustion Fur...

Page 1043: ...type and the switch is turned on when the temperature is 0 C 5 C and turned off when the temperature is 5 C 10 C This switch is consisted of 2 terminals and one terminal receives signal from the alter...

Page 1044: ...e fuel line relating components has been done This means the fuel is in the fuel line If an excessive fuel is supplied it may cause smoke and abnormal Banging noise when the fuel is burned If the F2 K...

Page 1045: ...est perform self diagnosis test 3 It is recommended to conduct the fuel fired heater system test after completing the component test 4 Test values for glow plug Resistance 0 324 W 0 360 W Current 5mA...

Page 1046: ...ould be taken when removing hot coolant 6 Remove the fuel hose after loosening the fuel pump side fuel hose clamp connected to the fuel fired heater The amount of fuel in the fuel hose between the fue...

Page 1047: ...efully remove the gasket and do not make damage to the gasket when removing 3 Check the electrical terminal for corrosion and damage 4 Be sure to operate the components by force using the Hi Scan afte...

Page 1048: ...screw and burner assembly 6 Remove the gasket Assembly 1 Install the new gasket 2 Insert the burner assembly rubber grommet in the wire and then tighten the screw Tightening torque 3 2 3 8N m 0 32 0 3...

Page 1049: ...SCHEMATIC DIAGRAM FOR FUEL FIRED HEATER...

Page 1050: ...oad 37w Normal Half load 13w Normal Permissible ambient temperature At operation 40 C 80 C At storage 40 C 120 C Permissible operation pressure 0 4bar 2 5bar Minimum coolant flow volume 250 l h Permis...

Page 1051: ...l there is likelihood of fuel leaking from the heater inner Repair the heater after removing it Malfunction Error caused by heater malfunction 1 In case of No flame up fuel is cut for maximum 180 seco...

Page 1052: ......

Page 1053: ...emp actuator operates to the hot position when connecting 12V to the terminal 7 and grounding terminal 5 3 Verify that the temp actuator operates to the cool position when connecting in the reverse 4...

Page 1054: ...verse sleeve hub 09432 3E100 Sleeve hub remover 1st 2nd Removal of main shaft 1st 2nd sleeve hub 09432 3E200 Main shaft bearing remover Rear Removal of main shaft bearing Rear 09432 H1100 Lock nut wre...

Page 1055: ...0 3rd sleeve remover Removal of main shaft 3rd sleeve 09431 2C200 Taper roller bearing outer race remover Removal of adapter housing taper roller bearing outer race 09432 3A100 Double ball bearing ins...

Page 1056: ...haft taper roller bearing 0k9A1 190 004 3rd 4th sleeve hub installer Installation of main shaft 3rd 4th sleeve hub 09432 3E800 Snap ring guide 2nd Assister of installing main shaft 2nd snap ring 09432...

Page 1057: ......

Page 1058: ...g retainer 8X28 Back up lamp switch Main shaft lock nut Clutch release cylinder Fulcrum Reverse idle shaft bolt 10X40 Transmission case and adapter 10X50 Rear retainer bearing 2WD 8X60 4WD 43 55 43 55...

Page 1059: ...8L 0 0 0031 3rd gear end play 0 1 0 2L 0 0039 0 0079 Reverse gear end play 0 08 0 18L 0 0031 0 0071 5th R snap ring end play 0 0 08L 0 0 0031 5th gear end play 0 13 0 28L 0 0051 0 0110 Reverse retaine...

Page 1060: ...rectly Repair or replace Replace parts Replace Adjust or replace Jumps out of gear or has too much play Shift rod malfunction Worn bush Bent lever Clutch dose not release correctly Replace Replace Rep...

Page 1061: ...COMPONENTS MANUAL TRANSAXLE SHIFT CONTROL...

Page 1062: ...EMBLY 1 Remove cap sealing 2 Remove both of plunger rolling assembly in shift control housing 3 Remove pin detent and change shifter 4 Loosen the stopper bracket bolt 5 Loosen the shift control finger...

Page 1063: ...6 Remove the control shaft...

Page 1064: ...ASSEMBLY NOTICE 1 Using SST 09432 22000 install taper bearing onto both side of counter shaft manual transaxle gear system count shaft...

Page 1065: ...COMPONENTS...

Page 1066: ...COMPONENTS main shaft...

Page 1067: ......

Page 1068: ...SST 09432 3E000 remove 3rd 4th synchronizer hub sleeve 3rd speed gear and synchronizer ring 3rd 3 Remove 3rd speed gear needle bearing 4 Using SST 09432 3E600 remove 2nd gear and 3rd speed gear beari...

Page 1069: ...move main shaft rear ball bearing after removing snap ring 10 Using SST 09432 H1100 09432 3E300 remove lock nut after releasing calking of lock nut 11 Using SST 09432 3E400 remove space after removing...

Page 1070: ...every part before assembly 1 Install reverse needle bearing onto the main shaft Apply grease to reverse needle bearing 2 Install reverse gear and synchronizer ring Reverse Check and separate synchron...

Page 1071: ...sleeve hub assembly 4 Install snap ring 5 Measure the clearance between sleeve hub and snap ring with feeler gage after installing snap ring End play 0 0 0 08mm 0 0 0031 in 6 Install 5th needle bearin...

Page 1072: ...rt ball as shown below picture after installing 5th gear 8 Install space with suitable tool after applying transmission oil to space 9 Install the double bearing using SST 09432 3A100 after install do...

Page 1073: ...10 Tighten hub lock nut Tightening torque 170 190N m 1700 1900 kg cm 120 140 lb ft 11 Calk one part of lock nut using suitable tool 12 Install snap ring under the rear ball bearing of main shaft...

Page 1074: ...Rotate main shaft to reverse direction and install 1st needle bearing Apply transmission oil to 1st needle bearing 15 Install 1st gear and synchronizer ring 1st 16 Using SST 0K552 171 AA0 install 1st...

Page 1075: ...clearance between sleeve and snap ring using feeler gage after installing 1st 2nd sleeve and snap ring End play 0 0 0 08mm 0 0 0031 in 19 Install 2nd needle bearing and synchronizer ring 2nd Apply tra...

Page 1076: ...ap ring guide 09432 3E800 21 Install 2nd gear onto the main shaft 22 Using SST 09432 22000 install 3rd speed gear bearing sleeve 23 Measure the clearance between 2nd gear and main shaft sleeve using f...

Page 1077: ...24 Install 3rd needle bearing Apply transmission oil to 3rd needle bearing 25 Install 3rd gear onto the main shaft End play 0 1 0 2mm 0 0039 0 0079 in 26 Install 3rd synchronizer ring 3rd...

Page 1078: ...3rd 4th synchronizer sleeve and hub 28 Measure the clearance between sleeve and snap ring using feeler gage after installing snap ring End play 0 0 0 08mm 0 0 0031 in 29 Install 4th synchronizer ring...

Page 1079: ...nion gear onto the main shaft 32 Measure the clearance of 1st and reverse gear End play 1st 0 10 0 20mm 0 0039 0 0079 in R 0 08 0 18mm 0 0031 0 0071 in 33 Measure the clearance of 2nd and 3rd gear End...

Page 1080: ...34 Measure the clearance of 5th gear End play 0 13 0 28mm 0 0051 0 0110 in 35 Measure the length of main shaft Main shaft length 4X2 558 6 559 mm 21 99 22 00 in 4X4 490 490 4 mm 19 29 19 30 in...

Page 1081: ...COMPONENTS reverse idle gear assembly...

Page 1082: ...COMPONENTS 1 manual transaxle...

Page 1083: ......

Page 1084: ...COMPONENTS 2...

Page 1085: ......

Page 1086: ......

Page 1087: ...ansmission under cover 5 Remove the clutch release cylinder 6 Remove the front propeller shaft 4WD vehicle 7 Remove the front muffler and the heater protector 8 Remove the transfer case connector 4WD...

Page 1088: ...solvent before disassembly b Clean the removed parts except sealed bearings and all sealing surfaces with cleaning solvent and dry with compressed air c Clean out all holes and passages with compress...

Page 1089: ...4 Remove transmission shift control housing 5 Remove back up lamp switch 6 Using the pin punch remove shift rail roll pin Do not use old roll pin again...

Page 1090: ...ngs and ball after loosing interlock puppet plate bolts 8 Loose a reverse idle shaft bolt on the transmission case housing side 9 Remove retainer after loosing the front retainer bolt 10 Remove snap r...

Page 1091: ...after loosing case housing bolt 13 Remove bearing retainer bolt In case of 4WD remove bearing retainer bolt after loosing the transfer case bolt 14 Remove reverse idle shaft after loosing a reverse i...

Page 1092: ...apter with electrical heater Leister 4000 or SST 09432 3E000 as shown picture below a Secure main shaft assembly counter shaft assembly and shift rail with a strap or cord for ease of removal and then...

Page 1093: ...ter and the sealing surface of the adapter 2 Measure the thickness B of main shaft double bearing Measured value A B End play 0 0 1mm 0 0 0039 in 3 Select a shim that is equal to the measured value co...

Page 1094: ...face of the bearing race located on the counter shaft Measured value A B End play 0 02 0 12mm 0 0008 0 0047 in Select a shim that is equal to the measured value considering the end play 6 Install the...

Page 1095: ...holes 10 In order to secure two interlock balls temporarily install flexible hoses into the rail holes 11 Match up and secure the main shaft counter shaft and 1st 2nd and 5th R shift fork assembly wit...

Page 1096: ...eat the main shaft double bearing seat part in adapter with electrical heater Leister 4000 or SST 09432 3E000 13 Install the main shaft counter shaft and shift fork assembly into the adapter after rem...

Page 1097: ...to the rail hole Make sure to set each gear to the neutral position before inserting Be careful not to fall out interlock ball into the adapter when inserting 3rd 4th shift rail 15 Using the pin punch...

Page 1098: ...550 kg cm 31 40 lb ft 17 Tighten three rear bearing retainer bolts with washer Tightening torque 20 27 N m 200 270 kg cm 14 15 lb ft 18 Using SST 09432 3E700 install oil seal on the adapter housing A...

Page 1099: ...of shift control rails 21 Insert new roll pins into the control lugs and shift rails 22 Insert two dowel pins into the grooves on the sealing surface of shift control housing in adapter 23 Measure the...

Page 1100: ...urface of snap ring Measured value A B C End play 0 0 1 mm 0 0 0039 in Select a shim that is equal to the measured value considering the end play 26 Install outer race and spacer on the counter shaft...

Page 1101: ...ing 28 Install reverse idle shaft bolt on the case housing side Tightening torque 43 55 N m 430 550 kg cm 31 40 lb ft 29 Using SST 09432 3E900 install the front retainer oil seal Apply grease to the o...

Page 1102: ...se to spacer 32 Tighten the front retainer bolts Tightening torque Flange bolt 20 27 N m 200 270 kg cm 14 20 lb ft Fulcrum bolt 30 42 N m 300 420 kg cm 22 30 lb ft Apply grease to the contacting surfa...

Page 1103: ...Install back lamp switch and washer Tightening torque 30 35 N m 300 350 kg cm 22 25 lb ft 35 Install shift control case on the adapter housing Tightening torque 20 27 N m 200 270 kg cm 14 20 lb ft App...

Page 1104: ...200 270 kg cm 14 20 lb ft Apply sealant to the sealing surface of shift control case 37 Install release fork tube release bearing and release fork Apply grease to spread bearing sliding surface and h...

Page 1105: ...cle on hoist and remove the filler plug and check the oil level 2 In case of the oil replacement remove the drain plug and drain the oil and tighten the drain plug and new packing 3 Fill the specified...

Page 1106: ...CLOCK SPRING air bag amodule RESTRAINTS...

Page 1107: ...DRIVER AIR BAG DAB...

Page 1108: ...attery cable before doing any further work 2 Remove the ignition key from the vehicle 3 Remove the side protect cover of steering wheel and airbag module mounting bolts using a hexagonal wrench 4 Remo...

Page 1109: ...e the collapsible column mechanism 6 Remove the steering column the few and high cover 7 When disconnecting the connector of the clock spring from the airbag module pull the airbag s lock toward the o...

Page 1110: ...y 1 Check pad cover for dents cracks or deformities 2 Check the airbag module for denting cracking or deformation 3 Check hooks and connectors for damage terminals for deformities and harness for bind...

Page 1111: ...2 Check connectors and protective tube for damage and terminals for deformities...

Page 1112: ...t to measure the circuit resistance of the airbag module squib even if you are using the specified tester If the circuit resistance is measured with a tester accidental airbag deployment will result i...

Page 1113: ...6 The skin of the passenger airbag module is integrated with the crash pad therefore the crash pad must be replaced if the PAB deploys...

Page 1114: ...N CASE DISPOSAL PLAN Abnormal problems in airbag module Deploy and discard Car scrapping DAB PAB CAB P Deploy the airbag module with the SST Crash Deployed Discard UNDEPLOYED AIRBAG MODULE DISPOSAL a...

Page 1115: ...l before attempting to handle it Although not poisonous do not inhale gas from airbag deployment See the Deployed Airbag Module Disposal Procedures for post deployment handling instructions c If the a...

Page 1116: ...5 Be sure to always wash your hands after completing this operation...

Page 1117: ...rtant source of information when troubleshooting 4 When troubleshooting the airbag system always inspect the diagnostic codes before disconnecting the battery 5 Never use airbag parts from another veh...

Page 1118: ...case the twin lock type connector lock lever should be in the locked state and care should be taken to place it so the conector will not be damaged Do not store a steering wheel pad on top of another...

Page 1119: ...SWITCH connector before starting work...

Page 1120: ...ol Airbag deployment tool DAB 0957A 38100 PAB CAB 0957A 34600 PT 0957A 34200 0957A 38000 Diagnosis checker Wring harness checker for each module 0957A 38200 Dummy Simulator to check the resistance of...

Page 1121: ...SYSTEM COMPONENT AND LAYOUT...

Page 1122: ...bing guide 7 Remove the front seat belt assembly a Never attempt to disassemble or repair the BPT b Do not drop the BPT or allow contact with water grease oil Replace it if a dent crack deformation or...

Page 1123: ...SRSCM SRS CONTROL MODULE...

Page 1124: ...ses Voltage and current flow is increased to maintain the film s temperature and resistivity TROUBLESHOOTING GUIDE DTC detection condition Probable cause Background a While the engine is running the m...

Page 1125: ...TEST PROCEDURE...

Page 1126: ......

Page 1127: ......

Page 1128: ...op across the sensor increases Since the MAP sensor is used as an air flow sensor the sensor signal is an important input The ECU uses the information to determine fuel amount and ignition timing TROU...

Page 1129: ...TEST PROCEDURE...

Page 1130: ......

Page 1131: ......

Page 1132: ...sing injector pulse width as the air warms the injector pulse width time is shortened TROUBLESHOOTING GUIDE DTC detection condition Probable cause Background a The intake air temperature sensor conver...

Page 1133: ......

Page 1134: ......

Page 1135: ......

Page 1136: ...Probable cause Background a The Water temperature sensor converts the water temperature to a voltage and outputs it b ECU checks whether the voltage is within a specified range In addition it checks t...

Page 1137: ...CIRCUIT DIAGRAM TEST PROCEDURE...

Page 1138: ......

Page 1139: ......

Page 1140: ...The TPS signal along with the MAP sensor signal is used by the ECU to calculate the engine load TROUBLESHOOTING GUIDE DTC detection condition Probable cause Background a The Throttle Position sensor o...

Page 1141: ...TEST PROCEDURE...

Page 1142: ......

Page 1143: ......

Page 1144: ...s LEAN the oxygen concentration in the exhaust increases and the HO2S informs the ECU of the LEAN condition When the air fuel ratio is RICHER than the stoichiometric air fuel ratio the oxygen concentr...

Page 1145: ...pplied to HO2S output line via a resistor Proper Operation a WTS Normal b Water Temperature is 50 C 122 F or more c Engine speed is between 1 500 and 3 000 r min or 1 100 and 3 000 r min d Engine load...

Page 1146: ...TEST PROCEDURE...

Page 1147: ......

Page 1148: ......

Page 1149: ......

Page 1150: ...O2 Sensor Bank 1 Circuit Malfunction DTC Diagnostic item P0134 O2 Sensor Bank 1 Circuit Malfunction No Activity CIRCUIT DIAGRAM...

Page 1151: ...TEST PROCEDURE...

Page 1152: ......

Page 1153: ......

Page 1154: ......

Page 1155: ...l ratio the oxygen concentration in the exhaust gas is reduced and the HO2S informs the ECU of the RICH condition The ECU determines by the electromotive force from the HO2S whether the air fuel ratio...

Page 1156: ...b Monitored only once per trip CIRCUIT DIAGRAM TEST PROCEDURE...

Page 1157: ......

Page 1158: ......

Page 1159: ...orms the ECU of the LEAN condition When the air fuel ratio is RICHER than the stoichiometric air fuel ratio the oxygen concentration in the exhaust gas is reduced and the HO2S informs the ECU of the R...

Page 1160: ...s 25 or more f Monitoring Time 7 10 sec Items to Check a Input voltage supplied to the ECU interface circuit is 4 5V or more when 5V is applied to the HO2S output line via a resistor b Making the air...

Page 1161: ...TEST PROCEDURE...

Page 1162: ......

Page 1163: ......

Page 1164: ......

Page 1165: ...tio the oxygen concentration in the exhaust gas is reduced and the HO2S informs the ECU of the RICH condition The ECU determines by the electromotive force from the HO2S whether the air fuel ratio is...

Page 1166: ...b Monitored only once per trip CIRCUIT DIAGRAM TEST PROCEDURE...

Page 1167: ......

Page 1168: ...Fuel System Too Lean DTC Diagnostic item P0171 P0172 Fuel System Too Lean Bank 1 Fuel Sysstem Too Rich Bank 1 TEST PROCEDURE...

Page 1169: ......

Page 1170: ......

Page 1171: ......

Page 1172: ...eter interface part of the ignition power transistor provides the ECU and Transaxle Control Module TCM with an RPM signal TROUBLESHOOTING GUIDE DTC detection condition Probable cause Background a If a...

Page 1173: ...than allowed during the last 200 revolutions when the catalyst temperature is higher than 950 C 1 742 F b A misfire has occurred more frequently than the allowed number of times 2 during 1 000 motor r...

Page 1174: ......

Page 1175: ......

Page 1176: ......

Page 1177: ...me the tachometer interface part of the ignition power transistor provides the ECU and Transaxle Control Module TCM with an RPM signal TROUBLESHOOTING GUIDE DTC detection condition Probable cause Back...

Page 1178: ...an allowed for during the last 200 revolutions when the catalyst temperature is higher than 950 C 1 742 F b A misfire has occurred more frequently than the allowed number of times 2 during 1 000 motor...

Page 1179: ......

Page 1180: ...with an RPM signal TROUBLESHOOTING GUIDE DTC detection condition Probable cause Background a If a misfire occurs while the engine is running the engine speed suddenly changes b ECU checks for changes...

Page 1181: ...TEST PROCEDURE...

Page 1182: ......

Page 1183: ......

Page 1184: ...Knock Sensor Circuit Malfunction DTC Diagnostic item P0325 Knock Sensor Circuit Malfunction CIRCUIT DIAGRAM TEST PROCEDURE...

Page 1185: ......

Page 1186: ...sition TROUBLESHOOTING GUIDE DTC detection condition Probable cause Background a When the engine is running the CKP a pulse signal b ECU checks whether the pulse signal is input while the engine is cr...

Page 1187: ...TEST PROCEDURE...

Page 1188: ......

Page 1189: ......

Page 1190: ...U to determine when to operate the fuel injectors TROUBLESHOOTING GUIDE DTC detection condition Probable cause Normal Operation a When the engine is running the Camshaft Position sensor outputs a puls...

Page 1191: ...TEST PROCEDURE...

Page 1192: ......

Page 1193: ......

Page 1194: ...Ignition Coil Circuit Malfunction DTC Diagnostic item P0350 Ignition Coil Circuit Malfunction Circuit Diagram TEST PROCEDURE...

Page 1195: ......

Page 1196: ...n the waveform of the front HO2S When both waveforms change at a similar rate catalyst performance has deteriorated TROUBLESHOOTING GUIDE DTC detection condition Probable cause Normal Operation a The...

Page 1197: ......

Page 1198: ...coal canister until it can be flushed into the intake manifold TROUBLESHOOTING GUIDE DTC detection condition Probable cause Normal Operation a ECU checks current flows in the evaporative emission purg...

Page 1199: ...TEST PROCEDURE...

Page 1200: ......

Page 1201: ......

Page 1202: ...ion Probable cause Normal Operation a The vehicle speed sensor outputs a pulse signal while the vehicle is driven b ECU checks whether the pulse signal is present Normal Operation a Closed throttle po...

Page 1203: ...TEST PROCEDURE...

Page 1204: ......

Page 1205: ......

Page 1206: ...nction of the ISC system the actual engine speed will not be identical to the target engine speed b ECU checks the difference between the actual engine speed and the target engine speed Check Area a U...

Page 1207: ...Check Area a During idle speed closed loop control b Power steering pressure switch is off c Engine load is 40 or less d Intake air temperature is 10 C 14 F or more Judgment Criteria a Actual idle sp...

Page 1208: ...TEST PROCEDURE...

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Page 1210: ......

Page 1211: ...ttery Supply Input 27 Airbag Warning Lamp Output 28 Ground Input 29 Driver Airbag DAB Stage 1 Output 30 Driver Airbag DAB Stage 1 Output 31 Passenger Airbag PAB Stage 1 Output 32 Passenger Airbag PAB...

Page 1212: ...river Curtain Airbag DCAB Output 39 Passenger Curtain Airbag PCAB Output 40 Passenger Curtain Airbag PCAB Output 41 42 43 44 45 46 47 48 49 50 51 52 53 54 Diagnostic Line Input and Output 55 56 57 58...

Page 1213: ...low Fault definitely detected 1 6 R 4 1 Resistance whithin tolerance Definitely no fault detected R 6 0 Resistance too high Fault definitely detected 0 9 R 1 6 4 1 R 6 0 Tolerance band Fault may or m...

Page 1214: ...0 9 R 1 8 3 1 R 4 7 Tolerance band Fault may or may not be detected...

Page 1215: ...AIRBAG SYSTEM...

Page 1216: ...function can be displayed in the form of diagnostic trouble code using Hi scan 5 MIL Malfunction Indication Lamp notification If any fault is detected the SRSCM sends a signal to the indicator lamp on...

Page 1217: ...SATELLITE SENSOR...

Page 1218: ...wise the airbag system could unexpectedly deploy DIAGNOSIS WITH SCAN TOOL CHECK PROCEDURES 1 Connect the Hi Scan Pro to the vehicle data link connector located underneath the dash panel 2 Turn the ign...

Page 1219: ...iate component Never attempt to repair the component 5 If the Hi Scan Pro finds that a component of the system is faulty there is a possibility that the fault is not in the components but in the SRS w...

Page 1220: ......

Page 1221: ...Front Impact Sensor FIS RH Wrong ID B1346 1st Stage Driver Airbag Resistance too high R 6 0 B1347 1st Stage Driver Airbag Resistance too low R 0 9 B1348 1st Stage Driver Airbag Short to GND B1349 1st...

Page 1222: ...able Curtain Driver Resistance too high R 4 2 B1474 Inflatable Curtain Driver Resistance too low R 1 0 B1475 Inflatable Curtain Driver Short to GND B1476 Inflatable Curtain Driver Short to Vbatt B1477...

Page 1223: ...B1651 Crash recorded Driver Side Side Airbag Replace ACU B1652 Crash recorded Passenger Side Side Airbag Replace ACU B1657 Crash recorded Belt Pretensioner B2500 Warning lamp failure...

Page 1224: ...with water grease and oil Replace it if a dent crack deformation or rust are detected c Do not place anything on the CAB d Do not expose the CAB to temperature over 93 C 200 F e CAB functions one time...

Page 1225: ...lizer bar 4 Remove the lower nut of shock absorber 5 Remove the bolts and nuts that joins lower arm and lower arm ball joint 6 Remove the cotter pin and castle nut from the lower arm ball joint 7 Remo...

Page 1226: ...s make note of the numerical setting and mark the location on the frame bracket and plate so it can be re installed to the same setting and location 10 Remove the lower arm BUSHING REPLACEMENT 1 For b...

Page 1227: ...ition the lower arm to the front frame crossmember brackets and then position the spindle during lift up the steering gear box by using suitable bar 4 Install the lower arm spindles Tightening torque...

Page 1228: ...t 7 Install the wheels and secure the lock nuts Tightening torque 90 120 N m 9 12 kg m 65 86 Ib ft 8 Remove the safety stands and lower the vehicle After installation measure the wheel alignment and a...

Page 1229: ...4 Replace if damaged deformed or cracked replace bushing if worn or deteriorated Refer to Bushing Replacement in the following procedure...

Page 1230: ...link 5 Remove the stabilizer bar bushing brackets and then remove the stabilizer bar 6 Remove the control link from the lower arm INSTALLATION 1 Position the control links to the lower arm 2 Loosely t...

Page 1231: ...ghten to the specified length 6 Tighten the lower nut of control link Tightening torque 95 117 N m 9 5 11 7 kg m 68 84 Ib ft INSPECTION 1 Inspect for bent cracked or damaged stabilizer bar 2 Inspect f...

Page 1232: ...lock nuts from the mounting block 3 Raise the front of the vehicle and support it with safety stands 4 Remove the front wheels 5 Remove the bolt on the steering knuckle side that secures the upper arm...

Page 1233: ...identification mark on the spring seat Position the spring and shock absorber assembly into the upper mounting block 2 Install the mounting block nuts by 3 4 threads only 3 Insure the front of the ve...

Page 1234: ...6 Install the upper arm ball joint into the top of the steering knuckle and tighten the side bolt and nut Tightening torque 45 55 N m 4 4 5 5 kg m 31 39 Ib ft 7 Tighten the upper arm bolts and nuts a...

Page 1235: ...attery mounting bracket and the battery 12 After installing the front shock absorber and coil spring assembly measure the wheel alignment and adjust if necessary DISASSEMBLY 1 Secure the shock absorbe...

Page 1236: ...3 While still secured in a vise compress the coil spring with SST 4 Remove the piston rod nut and each part as below...

Page 1237: ...INSPECTION REBUILD 1 Secure a handle to the shock absorber piston rod and compress and lift the rod three times with a constant speed Inspect for uniform working force and abnormal noise...

Page 1238: ...seat and rubber seat ASSEMBLY 1 Secure the bottom portion of the shock absorber in a vise and compress the coil spring with SST Use copperplate in the jaws of the vise to protect the shock absorber b...

Page 1239: ...arefully loosen the coil spring compressor and remove it 6 With the bottom bracket of the shock absorber still in the vice tighten the piston rod nut Tightening torque 76 95 N m 7 6 9 5 kg m 54 68 Ib...

Page 1240: ...ndard bearing press remove the old bushing 3 Install the new bushing and then press it into the upper arm with a standard bearing press Apply lubricant to the new bushings to facilitate insertion into...

Page 1241: ...bolt and nut Tightening torque 44 55 N m 4 4 5 5 kg m 31 39 Ib ft 4 Tighten the upper arm bolts and nuts and then install brake hose brackets Tightening torque 76 95 N m 7 6 9 5 kg m 54 68 Ib ft 5 Ins...

Page 1242: ...on INSPECTION 1 Inspect for bent cracked or otherwise damaged upper arm 2 Inspect for worn or deteriorated upper arm bushing 3 Inspect for worn or damaged ball link and replace if damaged deformed or...

Page 1243: ...EST COMPONENTS 1 TRANSFER SYSTEM transfer case...

Page 1244: ......

Page 1245: ...COMPONENTS 2 ATT ACTIVE TORQUE TRANSFER COMPONENTS...

Page 1246: ......

Page 1247: ......

Page 1248: ...blocks under front to keep assembly level 1 Remove nut and washer 2 Pull companion flange 3 Remove oil seal 4 If installed remove two plugs from cover EXTERNAL ELECTRIC SHIFT 1 Remove bolt 1 2 Remove...

Page 1249: ...lift cover assembly straight up to remove 3 On electric shift units remove oil seal 5 bearing three nuts and clutch coil assembly 4 Remove snap ring and pull ball bearing from cover This will free spe...

Page 1250: ...shaft 3 Together slide 2W 4W lockup assembly and lockup fork from output shaft and rail shaft Separate assemblies and remove rail shaft 4 To disassemble 2W 4W lockup assembly remove snap ring lockup h...

Page 1251: ...s and chain when out of assembly OIL PUMP 1 Remove four bolts 2 and retainer Slide rear pump cover off output shaft 2 Loosen hose clamp and separate hose coupling from pump housing Slide pump housing...

Page 1252: ...om transfer case 2 Remove two facings from shift fork assembly 3 Disassemble fork assembly only if parts replacement is required Cut plastic retainer to remove freeing pin and cam roller FRONT OUTPUT...

Page 1253: ...s an assembled group 4 Holding end of input shaft on workbench press down on adapter while expanding long ends of snap ring 5 Remove snap ring and pump oil seal from front adapter Remove pin only if r...

Page 1254: ...r case as an assembly 2 Slide electric shift cam off shift shaft 3 Clamp retainer end of shift shaft Keeping fingers away from spring ends pry torsion spring out of engagement with shaft drive tang us...

Page 1255: ...r and nut 3 Disconnect the shift motor clutch coil connector and the speed sensor connector 4 Remove the outer tube of the speed sensor connector wire 5 Remove the wire fixing cap in the rear of the s...

Page 1256: ...ff the flange seal Do not damage the bearing and the bearing case 14 Remove the speedometer drive gear and upper tone wheel 15 If the rear output shaft bearing requires replacing remove the internal s...

Page 1257: ...the output shaft 21 Remove the balls and the apply cam and the waver washer from the output shaft 22 Remove the snap ring from the output shaft 23 Remove the clutch pack and lower tone wheel from outp...

Page 1258: ...the large snap ring in the case using the Ring Plier or equivalent 34 With the input shaft against a bench push the case down and slide the main drive gear bearing retainer off the bearing 35 Lift th...

Page 1259: ...flange seal 44 If required remove the internal snap ring retaining the front output shaft ball bearing and remove the bearing REASSEMBLY CASE ASSEMBLY 1 If ring gear was removed for replacement align...

Page 1260: ...1 Insert spacer in torsion spring and install over free end of shift shaft 2 Slide torsion spring and spacer on shift shaft up to drive tang and position first spring end to left Viewed from free end...

Page 1261: ...drive tang on shift shaft and between spring ends and slide cam as far as it will go ADAPTER INPUT SHAFT AND CARRIER 1 Lay planet carrier assembly on work bench with end having groove for retaining r...

Page 1262: ...ress new pin into front adapter 8 Position oil seal and press into front adapter to dimension shown 9 Install snap ring in groove in front adapter with long ends of snap ring in adapter groove to comp...

Page 1263: ...Install assembled adapter input shaft and carrier group on transfer case and attach with six bolts Torque bolts to 20 34 lb ft 27 46 Nm 13 Install breather bard and torque to 6 14 lb ft 8 19 Nm FRONT...

Page 1264: ...that it will be at top of transfer case when installed in vehicle Install front pump cover over output shaft in this position 2 Install two pump pins with spring between them in output shaft Flat sur...

Page 1265: ...xt to transfer case assembly position driven sprocket with internal spline at front output shaft end of case and drive sprocket with smooth bore at output shaft end 2 Assemble drive chain around sproc...

Page 1266: ...only install electric shift cam group previously assembled and clutch housing as follow 1 Position electric shift cam group rotated so that end of torsion spring will contact side of reduction shift f...

Page 1267: ...CASE COVER...

Page 1268: ...ottom in cover and install snap ring 4 On electric shift units only install parts as follow 1 Verify that four O rings one on wire and one each on three studs are in place on clutch coil assembly Inst...

Page 1269: ...Loctite 598 all around transfer case mounting face for cover assembly Center sealant bead between edges of face Circle bolt holes Remove excess if sealant bead is larger than 1 16 in 1 6 mm 8 Install...

Page 1270: ...tput shaft into cover assembly 11 Press new oil seal into cover assembly EXTERNAL ELECTRIC SHIFT 1 Position motor assembly so that triangular slot in motor will align with shift shaft Move motor in to...

Page 1271: ...removed drive the bearing into the front output case bore 3 Install the internal snap ring that retains the bearing to the front case 4 If removed install the front yoke to flange seal in the front ca...

Page 1272: ...ss the bearing over the input shaft 11 Install the external snap ring to the input shaft 12 Install the front planet to the sun gear and input shaft 13 Install the internal snap ring to the planetary...

Page 1273: ...reely 18 Inspect the outside surfaces and bore of the oil pump 19 Install the output shaft and oil pump in the input shaft Make sure that the internal splines of the output shaft engage the internal s...

Page 1274: ...nt output shaft in the front case 22 Install the thrust washer on the rear output shaft 23 Install the chain drive sprocket and driven sprocket as an assembly over the output shaft The driven sprocket...

Page 1275: ...ft Start the snap ring over the spline and use the wave spring to seat the snap ring in the snap ring groove If the snap ring will not install the thrust washer inside the clutch pack may not be seate...

Page 1276: ...extend through the cover 33 Install the washers and nuts and tighten to 8 11Nm 34 Slide the spring spacer on the cam shaft and position it beneath the drive tang 35 Place the torsion spring on the cam...

Page 1277: ...tall the helical cam and slide the drive tang between the torsion spring tangs as far as it will go 39 Install the pin on the tang end of the helical cam into the hole in the front case Position the t...

Page 1278: ...el speedometer gear and rear output seal 43 Coat the mating surface of the front case with sealant 44 The following procedure must be followed prior to installing the rear case onto the front case hal...

Page 1279: ...s that attach the slotted support bracket to the end of the motor house 49 Apply the sealant to motor housing base and install on transfer case 50 Install the transfer case shift motor 51 Holding the...

Page 1280: ...ssary to stop the vehicle for transfer a M T vehicle Transfer the switch after pressing the clutch pedal b A T vehicle Transfer the switch after positioning the A T lever to N b All vehicles with 4L m...

Page 1281: ...b A T vehicle Transfer the switch after positioning the A T lever to N b All vehicles with 4L mode should stop the vehicle for transfer EST POWER FLOW 1 2H Mode Rear Wheel Drive...

Page 1282: ......

Page 1283: ...2 4H Mode Transfer Operation...

Page 1284: ......

Page 1285: ......

Page 1286: ...3 4L Mode...

Page 1287: ......

Page 1288: ......

Page 1289: ...ATT ACTIVE TORQUE TRANSFER POWER FLOW 1 AUTO Mode...

Page 1290: ......

Page 1291: ......

Page 1292: ...2 LOW Mode...

Page 1293: ......

Page 1294: ......

Page 1295: ......

Page 1296: ...ACTIVE TORQUE TRANSFER...

Page 1297: ......

Page 1298: ...ELECTRIC SHIFT TRANSFER...

Page 1299: ......

Page 1300: ......

Page 1301: ...ion sensor 3 Diagnosis memory is erased by grounding the TCCM NO 22 pin or DLC NO 12 pin 4 DTC Table Code Item 001 010 011 100 101 110 111 TCCM Shift motor Synchronizer clutch Speed sensor Hub solenoi...

Page 1302: ...EX TCCM Fault DTC 001 1 Indicator lamp check 0 6S 2 Lamp OFF 3S 3 Lamp ON 0 5S 4 Lamp OFF 0 5S 5 Lamp ON 0 5S 6 Lamp OFF 0 5S 7 Lamp ON 1S 8 Lamp OFF 3S 9 Repeat steps 3 8 READING METHOD Normal Fault...

Page 1303: ...DTC PATTERN Code Output pattern Item 001 TCCM 010 Shift motor 011 Magnetic synchronizer clutch 100 Speed sensor 101 Hub solenoid valve...

Page 1304: ...SPEED SENSOR LOW INPUT P1731 FRONT SPEED SENSOR HIGH INPUT P1732 REAR SPEED SPEED SENSOR LOW INPUT P1733 REAR SPEED SPEED SENSOR HIGH INPUT P1734 SPEED SENSOR REFERENCE LOW INPUT P1735 SPEED SENSOR RE...

Page 1305: ...DTC Memory Erase DTC memory in case of the Active Torque Transfer type is erased by the Hi Scan...

Page 1306: ...shortly after shutdown b Do not use an impact wrench to remove or install the fill or drain plugs since this will damage female threads in transfer case cover FLUID REPLACEMENT 1 Wipe fluid level and...

Page 1307: ......

Page 1308: ...AIR FLOW SENSOR AFS CIRCUIT DIAGRAM HOT FILM AFS OUTPUT FEATURES Mass air flow kg h Output voltage V 10 1 2226 1 2398 15 1 3552 1 3778 30 1 6783 1 7146 60 2 1619 2 2057...

Page 1309: ...120 2 7215 2 7762 250 3 4388 3 5037 370 3 8796 3 9511 480 4 1945 4 2683 640 4 5667 4 6469 TEST PROCEDURE...

Page 1310: ...nspect the following conditions 1 Chect the poor attachment of airflow cut air duct and air cleaner filter branched from AFS 2 Bad combustion in the cylinder or fault injector 3 Even it no AFS malfunc...

Page 1311: ...ATS INTAKE AIR TEMPERATURE SENSOR HARNESS INSPECTION PROCEDURE...

Page 1312: ...SENSOR INSPECTION 1 Inspect the resistance of sensor using a multi tester 2 Measure the resistance between ATS and terminal CONDITION TEMPERATURE C RESISTANCE k Ignition switch ON 40 39 260 30 22 960...

Page 1313: ...609 70 0 452 80 0 340 90 0 261 100 0 202 110 0 159 120 0 127 130 0 102 3 If resistance value is out of standard replace the intake air temperature sensor assembly Intake air temperature sensor is inte...

Page 1314: ...TROUBLESHOOTING HINTS When idling speed is not appropriate or blacksmoke arises it is likely to be a defect of water temperature sensor HARNESS INSPECTION PROCEDURES...

Page 1315: ...20 C 40 C 40 C 80 C 80 C USING MULTITESTER 1 Remove the water temperature sensor from the engine coolant passage of the cylinder head 2 With the temperature sensing portion of the engine coolant temp...

Page 1316: ...rom the standard value greatly replace the sensor INSTALLATION 1 Apply sealant LOCTITE 962T or equivalent to threaded portion 2 Install water temperature sensor and tighten it to specified torque Tigh...

Page 1317: ...HARNESS INSPECTION PROCEDURES...

Page 1318: ...CRANSHAFT POSITION SENSOR CKP CIRCUIT DIAGRAM...

Page 1319: ...HARNESS INSPECTION PROCEDURES...

Page 1320: ...INJECTOR CIRCUIT DIAGRAM...

Page 1321: ...HARNESS INSPECTION PROCEDURES INJECTOR OPERATION INSPECTION...

Page 1322: ...h the injector plug from each boxes and connect to replaced injector If change to enine running results injector is injecting If no change to engine running results injector is not injecting This test...

Page 1323: ...3 Connect the connector to the injector RAIL PRESSURE SENSOR RPS CIRCUIT DIAGRAM...

Page 1324: ...ENSOR INSPECTION USING HI SCAN Check item Data display Check conditions Rail pressure Set value HI SCAN Rail pressure sensor Rail pressure Engine at idle 220 300bar 260bar HARNESS INSPECTION PROCEDURE...

Page 1325: ...r is re used 2 When removing seal take care not to damage sealing surface 3 When installing RPS provide the sealing washer with grease if necessary 4 Tightening torque is 35 2 N m 25 8 1 5 Ib ft Repla...

Page 1326: ...CIRCUIT DIAGRAM HARNESS INSPECTION PROCEDURES...

Page 1327: ...ondition Engine condition Standard value EGR solenoid valve solenoid valve OFF ON Ignition switch ON Check the sound for proper operation USING VOLTMETER Check item Specified value EGR solenoid valve...

Page 1328: ...ine rpm is not dropped below the lower set value error is detected The reasons are short circuit connecting resistance faulty rail pressure sensor continuity of fuel pump relay faulty rail pressure co...

Page 1329: ...2 9 3 15 Replace the faulty fuel rail assembly in case of new model vehicle within a year or replace the faulty parts of vehicle of which model year is more than a year DON T DISASSEMBLE OR DISASSEMBL...

Page 1330: ...HARNESS INSPECTION PROCEDURES...

Page 1331: ......

Page 1332: ...sion fluid ATF Only ATF Apply grease Appropriate grease Apply sealant Appropriate sealant Apply petroleum jelly Appropriate petroleum jelly Whenever special oil or grease is required it will be identi...

Page 1333: ...ABOUT SAFETY 1 Block the wheels 2 Use only the specified jacking positions 3 Support the vehicle with safety stands PREPARATION OF TOOLS AND MEASURING EQUIPMENT SPECIAL SERVICE TOOLS SST S REMOVAL OF...

Page 1334: ...DISASSEMBLY INSPECTION OF PARTS ARRANGEMENT OF PARTS CLEANING PARTS FOR REUSE...

Page 1335: ...rs f Nylon nuts DEPENDING ON LOCATION 1 Sealant should be applied or new gaskets installed 2 Oil should be applied to the moving components of parts 3 Specified oil or grease should be applied at the...

Page 1336: ...checks and in checking for short circuits When checking the engine control module ECM never use a bulb exceeding 3 4W ELECTRICAL TROUBLESHOOTING TOOLS JUMPER WIRE Do not connect a jumper wire from th...

Page 1337: ...VOLTMETER OHMMETER Do not attempt to connect the ohmmeter to any circuit in which voltage is applied Such a connection may damage the ohmmeter ELECTRICAL PARTS...

Page 1338: ...can be removed by pressing or pulling lock lever LOCKING A CONNECTOR Listen for a click when locking connectors This sound indicates that they are securely locked INSPECTION OF CONNECTORS 1 When a tes...

Page 1339: ...they cannot be accessed from harness side a Use a fine wire to prevent damage to the terminal b Do not damage the terminal when inserting the tester lead Pull lightly on individual wires to ensure tha...

Page 1340: ...strike them against other parts WIRING COLOR CODES CODE COLOR CODE COLOR B BLACK P PINK BR BROWN R RED G GREEN S SILVER LIGHT BLUE GY GRAY T TAWNY L BLUE V VIOLET LG LIGHT GREEN W WHITE O ORANGE Y TE...

Page 1341: ...cessary to prevent damage to the vehicle It is recommended that your vehicle be towed with a wheel lift or flatbed eguipment Do not tow with a slingbelt Our company has not approved a slingbelt towing...

Page 1342: ...ia SORENTO 6 7 Body Type 52 4 door wagon 8 Engine Type 1 2 5L Diesel 2 2 4L Gasoline 3 3 5L Gasoline 9 Transmission type 5 5 speed manual 4 8 4 speed automatic 4 4 10 Model Year 2 2002 3 2003 11 Plant...

Page 1343: ...5 2 5 Diesel 2 5L TCI AT K N E J C 5 2 1 8 2 5 Gasoline 2 4L MT K N E J C 5 2 2 5 2 5 Gasoline 3 5L AT K N E J C 5 2 3 8 2 5 0 symbol according to No 3 1 2 sentence 4 of 76 114 EEC 1 3 World Manufact...

Page 1344: ...ENGLISH METRIC CONVERSION TABLE...

Page 1345: ...UNITS...

Page 1346: ...ABBREVIATIONS...

Page 1347: ...MAINTENANCE SCHEDULE...

Page 1348: ...MAINTENANCE UNDER SEVERE USAGE CONDITIONS...

Page 1349: ......

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Summary of Contents for Sorento 2003

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Kia Sorento 2003, Manual, Page: 710 / 1349

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Summary of Contents for Sorento 2003

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