STAVIC - Chassis Fal

SECTION INDEX
SERVICE VOLUME 2 OF 2
MANUAL (vol. 2 of 2) ELECTRICAL SYSTEM 02
STAVIC AIRCONDITIONING SYSTEM 03
CHASSIS SYSTEM 04
BODY SYSTEM 05
FOREWORD
This manual includes procedure for maintenance,

adjustment, service operation and removal and
installation of components.
All information, illustrations and specifications
contained in this manual are based on the latest
product information available at the time of manual
approval.
The right is reserved to make changes at any time
without notice.
PYUNGTAEK, KOREA
CHASSIS
CONTENTS
ELECTRICAL SYSTEM................... SECTION 02
AIRCONDITIONING SYSTEM......... SECTION 03

CHASSIS SYSTEM ......................... SECTION 04
BODY SYSTEM ............................... SECTION 05
SECTION 02
ELECTRICAL SYSTEM
CONTENTS
ELECTRICAL SYSTEM................................................. 2A
CLUSTER/WARNING & INDICATOR PANEL .............. 2B
RK STICS ....................................................................... 2C
RAIN SENSING WIPER ................................................ 2D
SWITCH ......................................................................... 2E
MULTIMETER ................................................................ 2F
AV SYSTEM ................................................................... 2G
PARKING ASSISTANCE SYSTEM ............................... 2H
LAMP............................................................................... 2I
2A 1
2A - Electrical System
Table of Contents
ELECTRIC SYSTEM LAYOUT .......................... 2A-2
1. Locations of units and sensors in passenger compartment
....................................................................................... 2A-2
2. Switches, units and sensors in engine compartment
(except engine related sensors and units) ................... 2A-4
3. Switches in passenger compartment ........................... 2A-6
4. System layout (based on DVD system equipped vehicle)
....................................................................................... 2A-8
ELECTRIC COMPONENTS AND LAYOUT .... 2A-10

1. Wiring harness arrangement ..................................... 2A-10
2. Components locator ................................................... 2A-11
FUSES AND RELAYS ..................................... 2A-12

1. Engine cmpartment fuse and relay box ..................... 2A-12
2. Interior fuse and ICM box .......................................... 2A-14
ELECTRICAL SYSTEM CHANGED BY

STAVIC - 2004.09 EFFECTIVE DATE
AFFECTED VIN
2 2A
ELECTRIC SYSTEM LAYOUT

1. LOCATIONS OF UNITS AND SENSORS IN PASSENGER COMPARTMENT
TV antenna Windshield
amplifier heated glass unit Sensor cluster (ESP) Air bag unit (SDM)
STICS
ICM
module
Sun sensor
Amplifier/Tuner/Navigation unit and PAS unit
PAS unit
DSP integrated amplifier
Tuner
Navigation unit
CHANGED BY ELECTRICAL SYSTEM

EFFECTIVE DATE STAVIC - 2004.09
AFFECTED VIN
2A 3
TV antenna Steering wheel angular

AM/FM radio amplifier amplifier sensor Rain sensing unit and ECM
Sun roof unit and motor
Interior temperature and

humidity sensor
Auto light sensor
Engine ECU
TCU and TCCU
TCU
TCCU

AFFECTED VIN
4 2A
2. SWITCHES, UNITS AND SENSORS IN ENGINE COMPARTMENT

(EXCEPT ENGINE RELATED SENSORS AND UNITS)
FFH (Fuel Fired Heater)
Horn
Ambient temperature sensor (FFH)
AQS/Ambient temperature sensor

(Integrated type) – Air conditioner Receiver drier
AQS sensor
Ambient tempera-
ture sensor

AFFECTED VIN
2A 5
Fuse and relay box in engine

Brake pressure sensor
compartment
ABS (ESP) HECU (under the battery)
PTC power supply relay (PTC system

equipped vehicle)
beside battery positive

(+) terminal
Theft deterrent horn (under the

Sub condenser washer fluid reservoir)

AFFECTED VIN
6 2A
3. SWITCHES IN PASSENGER COMPARTMENT
Audio remote control switch on the steering wheel
Power button
Mute button
Mode button
Volume button – Up
SEEK button – Up
Volume button – Down

SEEK button – Down
4WD switch and rear washer/

wiper switch
Outside rearview mirror

adjusting and folding
switch
Window switches

AFFECTED VIN
2A 7
Room lamp and sun roof switch

(multi meter integrated type) Driver seat warmer Front defogger switch Front fog lamp
switch
Sun roof switch
Room lamp switch

(coupled operation Hazard switch
with door)
Multi meter
Outside rearview mirror and ESPOFF
rear glass heated switch
Front room lamp switch
Passenger seat
warmer switch
Front room lamp switch
Multifunction switch and

steering wheel angular sensor
Passenger’s window
switch

AFFECTED VIN
8 2A
4. SYSTEM LAYOUT (BASED ON DVD SYSTEM EQUIPPED VEHICLE)
Tweeter speaker
Tweeter speaker
Center speaker
Center speaker
AV head unit
Audio remote
control switches
Front speaker (RH)

Sub woofer (amplifier
integrated type)
Front tweeter GPS antenna
speaker (RH)
Center speaker
(RH)
AV head unit
Center
DVD changer s p e a k e r
Center speaker
(LH)
Front tweeter
speaker (LH)
Front speaker (LH)
Amplifier integrated sub woofer

AFFECTED VIN
2A 9
DVD changer
Rear tweeter speaker (RH)

TV antenna amplifier (RH)
Rear speaker (RH)

Radio antenna
amplifier
Rearview camera
Rear monitor
Tuner/Amplifier/Navigation unit
Rear speaker (LH)
TV antenna amplifier (LH)

Rear tweeter speaker (LH) Tuner
DSP integrated
amplifier
Navigation unit

AFFECTED VIN
10 2A
ELECTRIC COMPONENTS AND LAYOUT

1. WIRING HARNESS ARRANGEMENT

AFFECTED VIN
2A 11
2. COMPONENTS LOCATOR

AFFECTED VIN
12 2A
FUSES AND RELAYS

Fuse and relay box is located in the engine compartment, and the interior fuse box is located under the driver side
instrument panel. Especially, ICM box, an integrated circuit of relays, is mounted along with STICS behind the driver
side instrument panel.
1. ENGINE COMPARTMENT FUSE AND RELAY BOX
Connector arrangement
Back of the fuse and relay box (after removal)
Fuses and relays

AFFECTED VIN
2A 13
Arrangement of Fuses and Relays
Descriptions of Fuses and Relays

Fuse NO. Capacity Usage Fuse NO. Capacity Usage
SB1 120A/140A Generator (FFH, PTC) Ef9 20A AV System
SB2 60A ABS, ABS/ESP Ef10 30A Glass HTD
SB3 30A IGN KEY “2”, Start RLY Ef11 15A
SB4 30A Condenser Fan (High) Ef12 15A Seat Warmer
SB5 30A Condenser Fan (Low),
Condenser Fan Ef13 20A Sun Roof
SB6 50A ENG MAIN RLY
SB7 30A Fuse Box “BATT-2”
Ef14 20A 4WD (TOD)
SB8 30A Blower (FRT)
SB9 30A PWR Window (FRT) Ef15 20A Driver PWR Seat
SB10 30A PWR Window (RR) Ef16 10A Tail Lamp (LH)
SB11 30A Fuse Box “BATT-1” Ef17 10A Tail Lamp (RH)
Ef1 10A A/C Compressor, A/C RLY Ef18 7.5A Illumination
Ef2 15A Fog Lamp (FRT) Ef19 15A ENG ECU
Ef3 15A DRL Ef20 15A Fuel Pump (GSL)
Ef4 10A Horn Ef21 15A Head Lamp (High)
Ef5 15A ENG SNR 1 Ef22 15A RR Blower
Ef6 20A FFH, Window Shield Glass Ef23 20A PWR Outlet (RR)
Ef7 30A ABS, ABS/ESP Ef24 20A AV Head Unit, Tuner Unit
Ef25 15A Buzzer
Ef8 15A Head Lamp (Low)
Ef26 15A Out Side Mirror

AFFECTED VIN
14 2A
2. INTERIOR FUSE AND ICM BOX

Interior Fuse Box
• The interior fuse box is located in the lower area of driver side instrument panel.
• To check the fuses, open the driver side door and remove the fuse box cover.

AFFECTED VIN
2A 15
ICM(Integrated Control Module) Box

The ICM box is installed along with RK STICS on the bracket behind the Instrument panel undercover.
It contains an integrated module with around 14 relays according to the vehicle model. Relays in the module are installed
on the integrated circuit with a safety circuit. This system operates with small current (by using transistor) and mini-
mizes the sparks that occur during operations (connection/disconnection) of relays; therefore its durability and wear
resistance has been greatly increased compared to the conventional relays.
Relays in the ICM box cannot be replaced respectively; so when the internal components (including relay) are defective,
ICM box should be replaced as an assembly.
RK STICS
ICM box

AFFECTED VIN
16 2A
Printed Circuit Board Arrangement of ICM Box

The figure shows the internal arrangement of ICM box when the cover is removed and then disassembled.
The relays cannot be disassembled and replaced respectively; so the ICM box should be replaced as an
assembly when any internal components are defective.
Front view
Relay 15
(rear fog lamp)
Relay 3
Relay 1 (spare 2) (seat warmer, LH)
Relay 4
Relay 2 (seat warmer, RH)
(O 2 sensor: gasoline)
Relay 9
Relay 5 (horn relay)
(wiper INT-LOW)
Relay 6 Relay 8
(wiper HIGH) (door lock relay)
Relay 7 Relay 14
(power socket) (flasher unit)
Relay 10
(front cigarette lighter
and power socket)
Relay 13
(theft deterrent relay) Relay 11
(door unlock)
Relay 12
(driver’s door unlock)
Buzzer 1
(Back sonar)
Chime bell circuit
Buzzer 2

AFFECTED VIN
2A 17
Rear view
Relay 3
Relay 4 Relay 1
(spare 2)
Relay 2
Relay 9
Relay 5
Relay 8
Relay 15
Relay 6
Relay 7
Relay 12
Relay 11 Relay 13
Buzzer 2 Relay 10 Relay 14 Buzzer 1

AFFECTED VIN
18 2A
ICM Connector Arrangement (Based on Wiring Connectors)

Never apply battery power from the rear of ICM printed circuit board directly to inspect internal circuit of the ICM box.
Otherwise, the precise internal circuits and safety circuit can be destroyed. When inspecting the power supply and
others, the connectors should be removed before starting the inspection.
The pin arrangements shown in the figure are also based on the connectors.
! " # $ % & '

! " # $ % & '
! " # $ % &
' ! ! ! !! !" !# !$ !% !& !' "

AFFECTED VIN
2A 19
ICM Box Power Supply Circuit
The figure shows ICM box power supply circuit. For details, refer to the appropriate wiring diagrams.
1) Door lock relay / Cigarette lighter relay / Power outlet relay
This circuit is supplied the power through the relevant fuse and STICS. The supplied power magnetize the switch to
supply the power to the appropriate system.
To inspect this circuit, turn the switch on and check if the voltage from ICM box is within specified range. After then,
check the output through the ICM box.
Checking the condition of the relevant component in the system should be done before doing this inspection.

AFFECTED VIN
20 2A
2) Wiper HI and LO relay / Horn relay
The rain sensing system in this vehicle has a different control logic compared to conventional rain sensing system. In the
conventional rain sensing system, the rain sensor unit controls the wipers directly. However, in this vehicle, the rain
sensor communicates the data with STICS, and the STICS controls the wiper motor.
Signals from STICS to rain sensor unit contain the information that there is no rain under the current mode based on
following conditions;
- Washer switch is operating,
- Operating under MIST mode, or
- The multifunction wiper switch is in AUTO mode.
For more details, refer to the “Rain Sensing Wiper” section in this manual.

AFFECTED VIN
2A 21
3) Flasher unit relay / Burglar relay / Chime bell
The relay and unit that controls the hazard warning flasher and turn
signal lamp is also installed in the ICM box as illustrated. Also, the
theft deterrent relay that operates the hazard warning flasher and the
theft deterrent horn is installed.
This vehicle has two separate horns in the engine compartment; a

horn (see figure) located in front of the battery is used for theft deter-
rent warning and beep sound during the operation of doors by remote
control key.

AFFECTED VIN
22 2A
4) Seat warmer relay (front seats) / Back sonar

Each seat warmer installed in the front seats has its own relay in ICM box.
When pressing the seat warmer switch prepared for each front seat, the seat cushion and seatback get warm. The
thermistor in the seat maintains the warming temperature at around 45¡ÆC by cutting off or connecting the power to the
heated wire.
The heated glass (defogger) system contains the windshield heated glass, outside rearview mirror heated glass, and
tailgate heated glass.
When the seat warmer switch is operated, the seat warmer relay in engine compartment fuse box supplies the power to
tailgate glass and outside rearview mirrors. This is controlled by STICS. However, the windshield heated glass (deicer)
is controlled by the separate control unit installed behind the driver side instrument panel undercover.
The fuse (30A) for tailgate heated glass and outside rearview mirror heated glass and the fuse (15A) for windshield
heated glass are in the engine compartment fuse box.

AFFECTED VIN
2A 23
Tailgate Heated Glass, Outside Rearview Mirror Heated Glass (controlled by STICS)
1. The outside rearview mirror heated glass operates for 12 minutes when turning on the defogger switch while the
engine is running.
2. If the defogger switch is pressed again during the operation, the operation stops.
3. If the defogger switch is pressed again within 10 minutes after completion of the first operation, the defogger
system operates for 6 minutes just for once.
4. The defogger is not available when the ignition switch is in “OFF” position or the alternator is not running.
Windshield Heated Glass (controlled by separate unit)

The windshield heated glass control unit is installed behind the driver side Instrument panel undercover. Whenever
pressing the switch, the windshield heated glass operates for 12 minutes and turns off if pressed again during its
operation. If the switch is pressed again, it operates another 12-minute operation.
Windshield heated glass unit
Defogger switch
Parking Aid Sensors on Rear Bumper

In the parking aid system equipped vehicle, its control unit is installed inside of the rear quarter trim behind the driver’s
seat. The buzzer for the back sonar is installed in ICM box. For more details, refer to “Parking Aid System” section in
this manual.
Back sonar
buzzer

AFFECTED VIN
24 2A
Removal and Installation of ICM Box

1. Disconnect the negative battery cable.
2. Unscrew the screws from driver side instrument panel
undercover and remove the undercover.
3. Unscrew the nuts and remove the ICM box.
4. Unscrew the connector mounting nuts from the back of the ICM box and disconnect the connector A and B.
5. Install in the reverse order of removal.

AFFECTED VIN
2A 25
Wiring Harness, Connector & Ground Location

1) W/H Engine room

AFFECTED VIN
26 2A
2) W/H Main

AFFECTED VIN
2A 27
3) W/H Floor (LH)

AFFECTED VIN
28 2A
4) W/H Floor (RH)

AFFECTED VIN
2A 29
5) W/H Air-con
Front air-con

AFFECTED VIN
30 2A
Rear air-con

AFFECTED VIN
2A 31
6) W/H Door
Front door
Rear door Tailgate door

AFFECTED VIN
32 2A
7) W/H Roof

AFFECTED VIN
2A 33
8) W/H Seat
Driver’s
Passenger’s

AFFECTED VIN
MEMO
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2B 1
2B - Cluster / Warning
& Indicator Panel
Table of Contents
METER CLUSTER / INDICATOR DISPLAY ...... 2B-3
1. Appearance ................................................................. 2B-3
2. Connectors and circuit diagram ................................... 2B-4
3. Descriptions of indicator display .................................. 2B-6
4. Function description and inspection of meter cluster ... 2B-7
5. Warning & indicator panel ......................................... 2B-12
6. Removal and installation of meter cluster and indicator
display ...................................................................... 2B-14
CLUSTER / WARNING & INDICATOR PANEL CHANGED BY

AFFECTED VIN
2B 3
METER CLUSTER / INDICATOR DISPLAY
1. APPEARANCE
The instrument panel in this vehicle is different from conventional type of instrument panel. The meter cluster and
indicator display are separated. The meter cluster is located at the center of the dash panel, and the indicator display is
located in front of driver’s seat.
Meter cluster
Coolant Fuel level

RPM gage
temperature Speedometer gauge
gauge
Warning lamps and indicators

AFFECTED VIN
4 2B
2. CONNECTORS AND CIRCUIT DIAGRAM
Gauge Panel
A B
Indicator Display D C
CHANGED BY CLUSTER / WARNING & INDICATOR PANEL

AFFECTED VIN
2B 5
Circuit Diagram of Indicator Display

AFFECTED VIN
6 2B
3. DESCRIPTIONS OF INDICATOR DISPLAY
Illumination lamp (bulb)
Connector B Connector A
1. Immobilizer indicator 12. Seat belt reminder

2. Glow indicator 13. Low fuel level warning light
3. Winter mode indicator 14. Defogger indicator
4. Left turn signal indicator and hazard flasher 15. Door open warning light
5. Auto shift indicator (for automatic transmission) 16. High beam indicator
6. Right turn signal indicator and hazard flasher 17. Engine oil pressure warning light
7. 4WD CHECK warning light 18. Air bag warning light
8. 4WD LOW indicator 19. Water separator warning light
9. Engine check warning light 20. ABS warning light
10. Brake warning light 21. EBD warning light
11. Battery charge warning light 22. ESP warning light

AFFECTED VIN
2B 7
4. FUNCTION DESCRIPTION AND INSPECTION OF METER CLUSTER

Meter Cluster
Tachometer – Engine RPM Display
Danger range (red zone)
The tachometer indicates engine speed in revolutions per minute. Multiply 1,000 to the current number, then it will be the
current number of engine revolutions.
Under the normal engine operating temperature, the proper idling speed is 700~800 rpm. The red zone (danger rpm
range) starts from 4,500 rpm.
1. Connect the tachometer for tune-up test and start the engine.
2. Eliminate the hysteresis by tapping the tachometer.
3. Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive.
Description Specification (VIN=13 ± 0.1V, Temperature: 25°C)

Engine speed (rpm) 700 1000 2000 3000 4000 5000 6000
Tolerance (rpm) +50 +100 +125 +150 +150 - -
-100 -100 -125 -150 -150
If the tachometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in
tachometer. If there is a difference between actual engine speed (rpm) and reading from tachometer, connect a scanner
and then compare the value on tachometer with the reading from scanner.

AFFECTED VIN
8 2B
Speedometer
The speedometer indicates the vehicle speed by calculating the signals from the rear right wheel speed sensor through
ABS or ESP unit.
If the speedometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in
speedometer. However, these symptoms also could be appeared when the tire has uneven wear, different tire inflation
pressures or different tire specifications.
Perform the speedometer test regarding the tolerance as described. However, it is not similar simple work in field due to
lack of measuring conditions such as test equipment and preciseness.
1. Check the allowable tolerance of the speedometer and operations of the trip odometer by using a tester.
2. Check if the speedometer pointer is shaking and the abnormal noise sounds.
3. Eliminate the hysteresis by tapping the speedometer.
[Notice]
The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range.
(VIN=13 ± 0.1V, Temperature: 25°C)

Standard speed (Km/h) 20 40 (60) 80 100 120 140 (160) (180)
Tolerance (Km/h) +4 +5.5 +7 +9 +10.5 +12.5 +14.5 +16 +18
0 +2 +2.5 +3.5 +4 +6 +7.5 +8.5 +10

AFFECTED VIN
2B 9
Fuel Level Gauge
The fuel level gauge displays the resistance value of the float on the fuel sender in the fuel tank through a pointer. Note
that this vehicle doesn’t have a service hole for checking the fuel sender connector in the fuel tank.
The fuel sender and its connector can be checked and replaced only when the fuel tank is removed. The power supply
and resistance value should be measured at the connector in front of the fuel sender (refer to wiring diagram).
When the power supply and output resistance are normal, the float operation by fuel level may be defective; if so, replace
the fuel sender.
Tolerance and resistance value by indicating angle

Scale Full (3/4) 1/2 (1/4) Full (LFW)
Indicating angle (°) 40 20 0 - 20 - 40
Tolerance (°) +4~0 ± 2.5 ±3 ± 2.5 + 1.5
Resistance(Ω) 38 ± 1 67 ± 1 99.5 ± 1 247 ± 1 260 ± 1
This table shows the tolerance and resistance value changes by fuel level in normal conditions. Therefore, the differ-
ences that can be occurred by the road conditions and fuel fluctuations are ignored.

AFFECTED VIN
10 2B
Coolant Temperature Gauge
40o
0o
-40o
The coolant temperature gauge displays the coolant temperature with a pointer. The angle of pointer that changes by
coolant temperature is as shown below.

Indicating angle - 40 (H) 0°C (1/2) +40(°C)
Tolerance ± 2.5 +0°C +5°C
- 5°C +1°C
Coolant temperature 40°C 70°C ~ 110°C Over 125°C
Measurement of coolant temperature sensor resistance

Measure the resistance between the terminal and the ground with an ohmmeter and replace if the resistance is out
of specified range.
Resistance value by coolant temperature: 20°C : 2449 Ω ±5 %

50°C : 826 Ω ±5 %
80°C : 321 Ω ±5 %
100°C : 112 Ω ±5 %
When the resistance value by coolant temperature is within the specified range, check thermostat, water pump, radiator
related coolant circuit for normal operation. Also, check the wiring harnesses and connectors for proper connection.

AFFECTED VIN
2B 11
TRIP ODOmeter (TRIP A, TRIP B) and ODOmeter
Reset button
* Press and hold (over 1 sec.)
Trip odometer “TRIP A” and “TRIP B” will be reset to 0. (However, only the corresponding driving
range will be set to 0.)
* Press shortly (between 0.1 ~ 1 sec.)

The mode changes in order as shown in the figure.
ODO TRIP A TRIP B

Displaying range: 0 ~ 999999 km Displaying range: 0.0 ~ 999.9 km Displaying range: 0.0 ~ 999.9 km
(The odometer stops at 999999 km.) Increment: 0.1 km Increment: 0.1 km
Increment: 1 km

AFFECTED VIN
12 2B
5. WARNING & INDICATOR PANEL
This indicator comes on when the ignition

switch is turned on and stays on for a short
time or may go off right away. When the glow Parking Reverse Neutral Driving Driving gears
plugs are sufficiently heated for cold starting,
the light will go out. Then, start the engine. This indicator shows the automatic
The indicator comes on when the Win- transmission selector lever position.
In the vehicle equipped with direct injection
type engine, this indicator may come on very ter mode (W) switch near the gear se- When the selector lever is at "D" posi-
shortly or may not come on. lector lever is pressed. Use this mode tion while driving, "D" indicator and cur-
to drive off smoothly under icy and slip- rently selected gear indicator are com-
pery road. In this mode, the vehicle ing on. If you move the selector lever to
Glow Indicator (For Diesel Engine)
drives off with second gear in forward left or right direction, only the selected
and reverse driving. gear indicator comes on.
This indicator indicates the operating condi- Winter Mode Indicator Auto Shift Indicator
tions of immobilizer system. This indicator
(For Automatic Transmission) (for automatic transmission)
comes on when the ignition key is communi-
cating with the engine control unit (during
engine starting) and goes out after starting
the engine. If this indicator blinks, it may indi-
cate that there is something wrong in the im-
mobilizer system.
Immobilizer Indicator
4WD CHECK Warning Light /

4WD LOW indicator
4WD CHECK Warning Light
This warning light comes on when the igni-
tion switch is turned to “ON” and should go
out if the system is normal. If “4WD CHECK”
warning light stays on or “4WD LOW” indica-
tor blinks continuously, it may indicate that
there is something wrong in the immobilizer
system.
Engine Check Warning Light Battery Charge Warning Light
4WD LOW indicator*
This warning light comes on when the
When shifting the driving mode between “4WD
ignition switch is turned to ON and goes This warning light comes on when the
LOW” and “4WD HIGH”, this indicator blinks
out if the engine is in normal condition. If ignition switch is turned on and go off
until the shifting operation is completed. After
the light stays on or comes on while when the engine is started. If this light
completion of mode change, the indicator goes
driving, some of engine control compo- doesn’t go off after engine starting or
out.
nents including sensors and devices are comes on while driving, it means there
defective. When this warning light comes is a malfunction in the system. The bat-
on, the vehicle operates in safety mode tery voltage is also displayed on the multi
to maintain minimum driving conditions meter.
and to prevent the system from being
Brake Warning Light damaged. In this mode, the engine driv-
Seat Belt Reminder
ing force may be decreased or the en-
When the ignition is switched on, this warn-
gine may stall. For more details, refer to The seat belt warning light comes on
ing light comes on and should go out. This
“Engine” section in this manual. and the seat belt warning chime sound
warning light comes on when the parking
brake is applied and/or the brake fluid level is for 6 seconds when the ignition switch
lower than specified level. If the vehicle is is turned to “ON” position unless the
driven for over 2 seconds (over 10 km/h) while driver’s seat belt is securely fastened.
the parking brake is applied, the parking brake This reminding operation stops when
warning light comes on and warning buzzer the driver fastens the seat belt even
sounds. during its operation period.

AFFECTED VIN
2B 13
Windshield Heated Glass (controlled by separate unit)

The windshield heated glass control unit is installed on the
bottom of driver side Instrument panel. Whenever pressing the
switch, the windshield heated glass operates for 12 minutes
and turns off if pressed again during its operation. If the switch
is pressed again, it operates another 12-minute operation.
When the water level inside water separator
Tailgate Heated Glass, Outside Rearview Mirror in fuel filter exceeds a certain level, this warn-
Heated Glass (controlled by STICS) ing light comes on and buzzer sounds. Also,
The outside rearview mirror heated glass operates for 12 min- the driving force of the vehicle decreases. If
utes when turning on the seat warmer switch while the engine these conditions occur, immediately drain the
is running. If the seat warmer switch is pressed again within water from fuel filter and water separator.
10 minutes after completion of the first operation, the seat For the draining procedures, refer to “Engine”
warmer operates for 6 minutes just for once. section in this manual.
Defogger Indicator Water separator warning light
ABS / EBD ESP Warning Light

ESP Warning Light
This warning light comes on when pressing
the “ESP OFF” switch or the ESP system is
defective. If the ESP function operates while
Engine Oil Pressure Warning driving, this warning light flickers and the
alarm sounds.
Light
EBD Warning Light
This warning light comes on when the This warning light comes on when the igni-
ignition is switched on and should go tion switch is turned to ON and should go out
Door Open Warning Light out when the engine is started. If the if the system is normal. If the EBD system is
light comes on while driving, it indicates abnormal, both EBD warning light and ABS
This light comes on when a door or tail- that the oil pressure is dangerously low. warning light come on simultaneously.
gate is either opened or not closed Check the oil lines and lubricating sys-
ABS Warning Light
completely. If you drive over 10 km/h of tem for leak.
vehicle speed without closing the door, This warning light comes on when the igni-
the warning light blinks. tion switch is turned to ON and should go out
if the system is normal.
Air Bag Warning Light [NOTE]
When the ignition is switched on, this The vehicle equipped with ABS
Low Fuel Level Warning Light warning light illuminates and then performs self-diagnosis on the system
should go out, to confirm that the air when the engine is started and drives
This warning light indicates that the fuel bag is operational. If it does not come off. During the diagnosis, brake pedal
will soon be exhausted. The time it takes on, or if it does not go out, or if it flashes vibration and noise may be apparent
to turn on, however, varies according to or illuminates continuously while when the driving motors discharges
the vehicle operating conditions or gradi- driving, it means that there is malfunc-
ent of the road.
the hydraulic pressure from the
tion in the system.
internal hydraulic device. This means
the ABS is properly functioning.

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14 2B
6.REMOVAL AND INSTALLATION OF METER CLUSTER AND INDICATOR

DISPLAY
Meter Cluster
1. Remove the screws from the front cup holder.
2. Pull out the front cup holder, disconnect the cigarette connector and the power socket connector, and remove the
front cup holder.
3. Carefully pry off the chrome coated cover from the selector lever cover, unscrew the screws and remove the
selector lever cover.

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2B 15
4. Carefully pull out the center speakers and disconnect the connectors.
5. Remove the screws and take out the front cover from the instrument panel.
6. Disconnect all switch connectors including TRIP switch connector (2) during removal of the front cover.

AFFECTED VIN
16 2B
7. Unscrew four screws and pull out the meter cluster housing.
8. Disconnect the connector and remove the meter cluster housing.

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Indicator Display
1. Remove the indicator display cover.
2. Unscrew the screws and pull out the indicator display

housing.
3. Disconnect the connector and remove the indicator

display housing.

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MEMO
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2C 1
2C - RK Stics
Table of Contents
REKES + STICS (RK STICS) ............................ 2C-3
1. Components locator .................................................... 2C-3
2. Transmitter coding ...................................................... 2C-4
3. Descriptions ................................................................ 2C-5
4. Connector arrangement (unit) ...................................... 2C-6
5. Specifications ............................................................. 2C-7
6. Functions of RK STICS ............................................... 2C-9
7. Diagnosis trouble code and help tips ......................... 2C-40
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REKES + STICS (RK STICS)

The STICS in this vehicle has similar functions with the one used in other vehicle models. Additional function of diagnos-
ing through SCAN-I has been added into new STICS.
The major difference in hardware-wise is that receives automatic door unlock signal from airbag module through G-
sensor in RK STICS unit when the vehicle has collided over 15 km/h of vehicle speed.
1. COMPONENTS LOCATOR
Air bag ECU
Sends the vehicle collision signals

to STICS.
Theft deterrent horn
STICS / ICM module
RK STICS
Installed under the battery. This
horn works only for the theft deter-
rent function, panic function, and
remote starting.
ICM module Diagnosis connector
REKES
This module contains

This diagnosis connector is used for
various relays, chime and Added the escort and
STICS key coding and trouble
buzzer controlled by STICS panic function
diagnosis.
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2. TRANSMITTER CODING
Coding process:
1. Remove the ignition key from key hole.

2. Connect the No. 3 terminal (REKES coding) and No. 16 terminal (battery+) on the diagnosis connector with a
jumper cable.
3. Press any button on the remote control key shortly. (approx. 0.5 sec.)
4. When the coding is successful, turn signal lamps blink once and warning horn sounds once.
5. If the coding has failed, repeat 1 to 4 steps.
Connector pin descriptions
1 - 2 IG1
3 REKES (for coding) 4 Ground
5 Signal ground 6 CAN_High
7 ECU 8 ABS
9 Air bag 10 TGS
11 TCU 12 FFH (for diagnosis)
13 TCCU 14 CAN_Low
15 REKES (for diagnosis) 16 Battery+
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3. DESCRIPTIONS
Below table shows the major differences compared to the previous vehicle model before year 2004. For whole functions
and details, refer to corresponding section.
Item RK STICS
Door lock The door unlock output is sent to all doors once for 0.5 seconds when the “LOCK”
signal is inputted into unit within 0.5 seconds after closing the driver’s or
passenger’s door. This is regardless of key in or key out. It is to prevent the
doors from locking due to impact when the door is closed.
Auto door unlock Previously, G-sensor in STICS outputs auto door unlock signal if the vehicle
collides over 15 km/h of vehicle speed. However, the air bag system is installed
in this vehicle as a basic equipment. When a collision, the “Auto Door Unlock”
function is activated by using a collision signal from the air bag module.
Front room lamp 1. When receiving the unlock signal from remote control key with the door
closed, the front room lamp comes on for 30 seconds.
2. When receiving the unlock signal again during the time lagging operation,
another 30 seconds will be extended from unlock point.
Time lag power window control The power window can be operated for 30 seconds after removing the ignition
key from key switch. This lagging operation stops when closing the door.
Parking brake warning When the vehicle speed signal is inputted with the parking brake applied, the
warning light blinks and the chime buzzer in ICM box continuously sounds for 0.
6 seconds with 0.3 seconds of pausing time (when driving over 10 km/h of vehicle
speed for more than 2 seconds).
Tail lamp auto cut (battery saver) 1. Turns on or off the tail lamp relay according to the tail lamp switch
operations.
2. The tail lamp relay is turned off (auto-cut) when removing the ignition key
and opening and closing the door while the tail lamp switch is turned on.
Theft deterrent alarm The hazard warning relay in ICM box outputs when the remote control key is
operated or the theft deterrent alarm is activated. At this time, separate warning
horn sounds.
Panic alarm operating only 1. The theft deterrent horn sounds for 27 seconds when receiving the panic
(ON: IGN S/W in) signal from the remote control key.
2. The panic alarm is turned off when receiving any signal from the remote
control key during the panic alarm operation.
3. This function works under armed mode.
Headlamp control (escort) 1. The headlamp control supplies the power to headlamp relay for 20 seconds and
turns off when receiving the escort signal from the remote control key with the
ignition key off (if the escort signal is inputted again, it will be extended once for
20 seconds). However, the power supply and output is activated only when the
vehicle is in armed mode activated by remote control key.
2. The headlamp relay output is turned off immediately after receiving the
remote control lock signal during its operation (however, signals other than
lock signal from remote control key will be ignored).
3. The headlamp relay output is immediately turned off when the key is turned
to “ON” position during its operation (this function is also activated under
remote starting).
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4. CONNECTOR ARRANGEMENT (UNIT)
NO. Description Status NO. Description Status

1 Wiper relay (HI) Output 38 Hood switch Input
2 Tailgate heated glass/outside rearview mirror relay Output 39 Rear LH/RH door switch Input
3 Driver’s door unlock Output 40 Seat belt warning light Output
4 Coding 41 Wiper motor relay (parking) Input
5 Door lock Output 42 Vehicle speed signal Input
6 ALT_D Input 43 Tailgate switch Input
7 Power window relay Output 44 Tail lamp switch Input
8 Ground 45 Passenger’s door lock switch Input
9 Headlamp relay Output 46 Passenger’s door unlock switch Input
10 Door unlock Output 47 Diagnosis (KWP 2000) Input/Output
11 Passenger’s door lock switch Input 48 Rear door lock switch Input
12 Chime buzzer (in ICM box) Output 49 Washer switch Input
13 Front room lamp Output 50 Intermittent auto switch Input
14 Wiper relay (LO) Output 51 Door opening indication Output
15 Tail lamp relay Output 52 Intermittent volume Input
16 V+ 53 Key hole illumination Output
17 Engine start relay Output 54 Headlamp relay Output
18 Ground 55
19 Theft deterrent horn Output 56
20 Rear room lamp Output 57
21 IGN 2 Input 58
22 IGN 1 Input 59
23 Parking brake warning light Output 60
24 Tailgate glass and outside rearview mirror heated glass Input 61
25 Seat belt switch Input 62
26 Rain sensor input Input 63
27 Key reminder switch Input 64
28 Tailgate lock switch Input 65
29 Driver’s door lock switch Input 66
30 Input/Output 67
31 Hazard flasher relay (in ICM box) Output 68
32 Input 69
33 Theft deterrent alarm selection switch Input 70
34 Rain sensor output Output 71
35 Parking brake switch Input 72
36 Driver’s door switch Input 73
37 Passenger’s door switch Input 74
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5. SPECIFICATIONS
1) Electrical Performance
Item Requirement Remark
Rated voltage DC 12 V
Operating voltage DC 9~16 V Should operate normally within this range.
Operating temperature -30°C ~ +80°C
Reserved temperature -40°C ~ +85°C
Max. operating humidity 95%
Resistible voltage 24 V
Insulating resistance No heat and fire due to the Confined with PCB, waterproof and coating that requires
current leaks. the insulation.
Parasitic current below 4.0 mA IGN = OFF, Full output load = OFF, 90 seconds (after
(below 6.0 mA) received the signals), No input changes for 2 seconds
Voltage drop below 1.2 V Pin no. 8 and 2, 3, 5, 7, 10, 12, 13, 15, 19, 20, 23, 40, 47,
below 2.0 V 51, 53, 54
Pin no. 8 and 9, 13, 15, 23, 40, 51, 53
2) Chattering of Input Signals

1. Vehicle speed input:
The vehicle speed calculating time is 1.0 seconds. The elapsed time of 1.5 seconds after IGN 1 switch :ON” is not
included.
2. 20 ms target input:
Wiper motor A/S (parking) terminal
3. 100 ms target input switch

All switches except wiper motor A/S (parking) terminal
3) Time Tolerance
1. If not indicated, time tolerance will be ± 10%.
However, if less than 500 ms, time tolerance will be ± 50 ms.
2. The time indicated in each function does not include chattering processing time from switch input changing point.
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RK Stics
1 IGN 1 ON = BAT (IGN “ON” or “START”) BAT = Battery

2 IGN 2 ON = BAT (IGN “ON”)
3 ALT_D ON = BAT equivalent (engine running)
4 Key reminder (door ajar warning switch) IGN = BAT (Key in)
5 Driver’s door switch OPEN = GND
6 Passenger’s door switch OPEN = GND
7 Rear door switch OPEN (one of rear seat) = GND
CLOSE (one of rear seat) = OPEN
8 Tailgate switch OPEN = GND
9 Central door lock switch ON = GND
10 Central door unlock switch ON = GND
11 Driver’s door lock/unlock switch LOCK = OPEN, UNLOCK = GND
Passenger’s door lock/unlock switch LOCK = OPEN, UNLOCK = GND
12 Rear door lock/unlock switch UNLOCK (one of rear seat) = GND
LOCK (one of rear seat) = OPEN
13 Tailgate lock/unlock switch LOCK = OPEN, UNLOCK = GND
- - -
- - -
16 Hood switch OPEN = GND
17 Tailgate switch ON = GND
18 Defogger switch ON = GND
19 Seat belt switch Fastened = OPEN, Unfastened = GND
20 Parking brake switch ON = GND (applied)
21 Washer switch ON = GND
22 Intermittent switch ON = GND
23 Intermittent volume 0 Ω ~ 50 kΩ (for intermittent wiper)
24 Wiper motor (parking) ON = GND
25 Rain sensor unit input ON = GND (during sending from rain sensor)
26 Rain sensor unit output ON = GND (during sending from RK STICS)
27 Hazard warning flasher selection switch ON = GND
28 Collision sensor ON = 200 ms output (LOW)
29 Speed sensor Vehicle speed signal (OPEN COLLECTOR)
30 Coding ON = BAT
31 Diagnosis (K-Line) ON = BAT (during Installation or
communication)
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6. FUNCTIONS OF RK STICS
1) Wiper Control
Wiper MIST and Washer Coupled Wiper
1. The wiper relay is turned on 0.3 seconds (T1) after turning “ON” the washer switch for 0.2 ~ 0.59 seconds (T2) with
the ignition key “ON”, and it is turned off when the parking terminal is turned off.
2. The wiper relay is turned on 0.3 seconds (T1) after turning “ON” the washer switch over 0.6 seconds (T2) with the
ignition key “ON”, and it is turned on three times immediately after turning off the washer switch.
T1: within 0.5s T2: over 0.6s T3: one wipter cycle
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3. If the washer operating signal is inputted while the wipers are operating in intermittent or AUTO mode, the system
stores the previous intermittent interval and operates the washer coupled wiper. After then, the wiper operation
returns back to intermittent or AUTO mode with the stored operating interval.
T1: within 0.3s T2: 0.2 ~ 0.59s T3: over 0.6s T4: 3 cycles T5: operationg interval
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Rain Sensor Coupled Wiper
If equipped with RE-STICS rain sensor, has following operation system.
1. System layout
This vehicle has a different wiper control logic compared to other models. As shown in the system diagram, the rain
sensor unit does not control wiper directly. The rain sensor unit sends infrared rays signal through LED and then
receives it with photo diode and then sends the returned signal to STICS and the STICS controls the wipers directly.
For more details, refer to rain sensing wiper section in this manual.
Multi-function (wiper)
switch
Rain
RESTICS sensor
Wiper LO
Wiper HI
Wiper motor
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2. Rain sensing operation point

1) The wiper relay is turned on and the wiper motor runs one cycle when the ignition key is turned to “ON” position
(while the wiper switch is in “AUTO” position).
2) The wiper relay (LO) is turned on and the wiper motor runs one cycle when changing the wiper switch to “AUTO”
position from any other positions (while the ignition key is in “ON” position). When the wiper switch is turned to
“AUTO” position again from other positions, the system drives the wiper relay (LO) to run the wiper motor one cycle
only when the rain sensor detects the “Rain Detected” signal.
T1: 1 cycle
3. Rain sensing sensitivity control

The wiper relay is turned on and the wiper motor runs one cycle when the volume sensitivity is increased (ex: from 0 to
1) (while the ignition key is in “ON” position, the wiper switch is in “AUTO” position, and the wiper motor is in “Parked”
position). However, the wiper motor can be operated only when the rain sensor detects the “Rain Detected” signal.
* If the volume sensitivity is changed more than 2 stages within 2 seconds, the wiper motor runs only one cycle.
SENSITIVITY
RAIN SENSOR Rain Detected

OFF
WIPER RELAY ON
LO OFF
T1: 1 cycle
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4. Wiper operation when the wiper parking terminal is grounded

1) The wiper system continuously outputs the parking signal of current sensitivity when the parking terminal is
grounded (while the ignition key is in “ON” position and the wiper switch is in “AUTO” position).
* The wiper motor runs only when the rain sensor requires.
IGN (Operation)
GND (Stop)
2) When the parking terminal is fixed to IGN (HIGH), the wiper system outputs the operating signal of current sensitivity
for 2 seconds, then continuously outputs the parking signal of current sensitivity
* The wiper motor runs only when the rain sensor requires.
IGN (Operation)
GND (Stop)
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5. Defective rain sensor

1) The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from
3 during receiving the malfunction signal (1) from the rain sensor (while the ignition key is in “ON” position and the
wiper switch is in “AUTO” position).
SENSITIVITY
RAIN SENSOR
Malfunction signal (1): Yes

Malfunction signal (1): No
WIPER RELAY ON
LO OFF
T1: 1 cycle
wiper switch is in “AUTO” position).
SENSITIVITY
RAIN SENSOR

WIPER RELAY ON
LO OFF
T1: 1 cycle
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wiper switch is in “AUTO” position). Also, the wiper relay (LO) is turned on and the wiper motor runs one cycle when
the wiper sensitivity is changed to 2 from 1 during receiving the ground fixed or IGN fixed signal from the rain
sensor.
SENSITIVITY
RAIN SENSOR

WIPER RELAY ON
LO OFF
T1: 1 cycle
Speed Sensitive INT (Intermittent) Wiper

For STICS without rain sensor, perform the following operation:
1. Controls the wiper intermittent operation by the values from vehicle speed and volume.
- Calculates and converts the Intermittent interval automatically by using the vehicle speed and INT VOLUME
when the ignition switch is in “ON” position and the INT switch is in “ON” position (the engine is running).
- The wipers are operated in vehicle speed sensitive mode when turning the INT switch to “ON” position with the
engine running or starting the engine with the INT switch positioned “ON”.
- Intermittent interval (at 0 km/h): 3 ± 0.5 ~ 19 ± 2 seconds
2. Vehicle speed calculation
[Input the vehicle speed]
It is calculated by the numbers of input pulses for one second.
1 [pulses/sec] = 60 [km/h] x 60 [sec] / 637 pulses = 1.41 [km/h]
3. VOLUME calculation
- Calculates the INT VOLUME with 5 grades as shown in the table in next page.
4. Pause time calculation
- Pause time: the duration that wipers are stopped at parking position
- Elapsed time: the duration after the wiper motor started to operate from parking position
- The pause time is calculated by the vehicle speed and VOLUME value as shown in the table in next page.
* If the pause time is below 1.0 second, the wipers operate without pause.
* If the pause time is over 1.5 seconds, the wipers operate intermittently.
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Pause time against vehicle speed
Pause time
(sec.)
Vehicle speed (km/h)
[Notice]
(1) Wiper MIST and washer coupled wiper
1) When turning on the washer switch while the wiper relay is operating.
- If the wiper relay “ON” request time is shorter than the remained “ON” time, it is disregarded.
(2) Speed sensitive INT (intermittent) wiper
1) The wiper relay continues to output for remaining “ON” time even when the INT switch is turned off.
2) IGN 2 switch “ON”, INT switch “OFF”: resume the intermittent time when turning “ON”
3) IGN 2 switch “OFF”, INT switch “ON”: resume the intermittent time when turning “ON”
(3) Controls when the wiper motor parking is defective
- The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while the wiper relay is
“ON” (INT switch = ON or Washer switch = ON) (The output stops immediately after turning off the switch)
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2) Ignition Key Reminder
Key Reminder Warning

1. The chime buzzer output in the ICM box continues when opening the driver’s door while the ignition key is inserted
into ignition switch.
2. When removing the ignition key or closing the driver’s door during chime buzzer output, the output turns off.
3. This function is not available when the ignition switch is “ON”.
CHIME BUZZER
Key Reminder
1. This function does not work if the vehicle speed is over 3 km/h.
2. The system outputs “UNLOCK” for 5 seconds (T2) from 0.5 seconds after the driver’s door is opened and the door
lock switch is changed to “LOCK” (while the ignition key is in ignition switch).
3. The system outputs “UNLOCK” for 5 seconds (T2) when the door lock switch is changed to “LOCK” from “UNLOCK”
and the driver’s door is closed within 0.5 seconds (T1) (while the ignition key is in ignition switch).
T1: 0.5s T2: 5s T3: within 0.5s
[Note]
Operating conditions for (*1) and (*2)
(*1): Driver’s door is opened and driver’s door lock switch is turned to LOCK
(*2): Passenger’s door is opened and passenger’s door lock switch is turned to LOCK
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All Door Lock Prevention Function when a Door is Opened

1. When a door is opened, all doors should be unlocked for 5 seconds if inputs LOCK signal.
- The LOCK signal means the central door locking (REKES, central door lock switch, knob switch) except LOCK
input by rear door knob.
- After unlocking and opening only the driver’s door with remote control key under armed mode (driver’s door is
unlocked but passenger’s and rear doors are locked), only the driver’s door generates unlock signal when trying to
lock the driver’s door with the driver’s door opened.
- Above operations is regardless of key positions and have priority over the ignition key reminder function.
2. When the door is closed during unlock output for 5 seconds under item 1 condition, the unlock output stops.
- All doors except tailgate and hood output “UNLOCK” for 5 seconds (T1) when the “LOCK” signal is inputted (while
the ignition key is removed and a of door is opened).
- When the door is closed during unlock output for 5 seconds, the unlock output stops.
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3) Mark Lamp Left on Warning

1. The chime buzzer in the ICM box sounds with the interval of 0.8 second when opening the driver’s door while the tail
lamp is turned on and the ignition key is removed.
2. The buzzer output stops when turning off the tail lamp and closing the driver’s door.
3. The system outputs “UNLOCK” for 5 seconds when the driver’s and passenger’s door lock switch is locked (while
the tail lamp is turned on and the driver’s door is opened).
4. This function is not available when the ignition key is in “ON” position.
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4) Door Ajar Warning

1. The warning light in indicator display comes on when opening any of driver’s door, passenger’s door, rear door or
tailgate while the vehicle speed is below 6 km/h (V1).
2. The warning light goes off when closing the door under step 1.
3. The warning light blinks when the vehicle speed is over 10 km/h (V1) for more than 2 seconds while the warning
light is turned on.
4. The warning light blinks when a door is opened while the vehicle speed is over 10 km/h (V1) (while the warning light
is turned off).
5. The warning light goes off when closing the door under step 3.
6. The warning light comes on when the vehicle speed is below 3 km/h (V2) under step 3.
VEHICLE SPEED OVER V1

BELOW V1
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5) Seat Belt Warning

1. The seat belt warning light comes on and the chime buzzer in the ICM box sounds for 6 seconds when turning the
ignition key to “ON” from “OFF”. If the seat belt is fastened before turning the ignition key to “ON” position, the
warning light in the indicator display blinks for 6 seconds, however, the chime buzzer does not sound.
2. The seat belt warning light goes off and the chime buzzer in the ICM box stops when turning the ignition switch to
“OFF” position.
3. The chime buzzer stops and the seat belt warning light stays on for the specified duration (6 seconds) when
fastening the seat belt during the warning operation.
4. The seat belt warning light comes on and the chime buzzer sounds for 6 seconds again when unfastening the seat
belt during fastening operation.
FASTEN
UNFASTEN
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6) Parking Brake Warning

1. The parking brake warning light comes on for approx. 4 seconds (T4) when turning the ignition key from “OFF” to
“ON” position regardless of the vehicle speed and parking brake switch position.
2. The warning light comes on when the parking brake switch is turned on while the vehicle speed is below 10 km/h
(V1).
3. The warning light goes off when turning off the parking brake switch under step 2.
4. The warning light blinks and the chime buzzer in the ICM box sounds for 2.85 seconds and stops for 1.5 seconds
when the vehicle speed is over 10 km/h (V1) for more than 2 seconds while the parking brake switch is turned on.
5. The warning light goes off and the chime buzzer stops when turning off the parking brake switch under step 4.
6. The warning light comes on and the chime buzzer stops when the vehicle speed goes down below 7 km/h (V2)
under step 4.
7. This function is not available when the ignition key is turned to “OFF” position.
VEHICLE SPEED OVER V1

BELOW V2
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7) Room Lamp Control
Front Room Lamp

1. The front room lamp comes on when opening the driver’s door or passenger’s
door while the front room lamp switch is at door coupled position and the
key reminder switch is turned off.
2. The room lamp stays on for 2 seconds (T1) and then decays through 3
seconds (T2) when closing the driver’s door or passenger’s door.
3. The room lamp output should stop immediately after turning on the ignition Door coupled front
key during decaying operation. room lamp switch
4. The front room lamp comes on for 30 seconds (T3) when receiving the
unlock signal from the remote control key while the door is closed.
5. The front room lamp output period is extended by 30 seconds (T3) when receiving the unlock signal from the remote
control key again during output.
6. When a door is opened during its extended period, the lamp stays on. If closed, operates as in step 2.
7. The room lamp output stops immediately after receiving the lock signal from driver’s door and passenger’s door
lock switch while the driver’s door and passenger’s door are closed.
RECEIVE
NO SIGNAL
OUTPUT
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Rear Room Lamp

1. The rear room lamp comes on when opening the rear door while the door
coupled rear room lamp switch is pressed (except for luggage room lamp).
2. The rear room lamp extends its lighting period by 5 seconds when closing
the rear door.
3. The room lamp output stops immediately after turning the ignition key to
“ON” position during the extended period. Door coupled rear
4. The room lamp output stops immediately after receiving the lock signal room lamp switch
from the rear door lock switch or the remote control key while the rear door
is closed.
CHANGED BY RK STICS
AFFECTED VIN
2C 25
8) Ignition Key Hole Illumination (Except For Immobilizer)

1. The ignition key hole illumination comes on when opening the driver’s door or passenger’s door while the ignition
key is removed.
2. The ignition key hole illumination stays on for 10 seconds when closing the door after step 1.
3. The output stops when the ignition key is turned to “ON” position.
4. The output stops when receiving the lock signal from the remote control key (under armed mode).
RK STICS CHANGED BY
AFFECTED VIN
26 2C
9) Battery Saver (Tail Lamp Auto Cut)

1. The tail lamp is turn on or off according to the operations of the multifunction tail lamp switch.
2. The tail lamp relay is turned off (auto cut) when opening and closing the driver’s door after removing the ignition key
without turning off the tail lamp.
3. Tail lamp relay is turned on when inserting the ignition key into ignition switch again after step 2 operation.
4. The tail lamp relay is turned off (auto cut) when opening and closing the driver’s door while the ignition key is
removed and the tail lamp is turned on.
AUTO CUT
AUTO CUT
CHANGED BY RK STICS
AFFECTED VIN
2C 27
10) Defogger Timer

1. The system outputs the tailgate, windshield and outside rearview mirror heated glass “ON” signal when turning on
the defogger switch (while the engine is running).
2. The output stops when turning on the defogger switch again during its operation.
3. The output is “ON” only for 6 minutes (T3) when turning “ON” the rear defogger switch within 10 minutes (T2) after
completion of output.
When turning on the defogger switch again within 10 minutes (T2) after completion of initial 12 minutes (T1) of
output, the output comes on for 6 minutes (T3) again once only.
4. The output stops when the IGN 2 switch is turned to “OFF” position or the ALT is “OFF”.
OVER 9V
BELOW 9V
REAR DEFOGGER
SWITCH
REAR DEFOGGER
RELAY
T1: 12 min. T2: 10 min. T3: 6 min.
This vehicle has the windshield heated glass and the tailgate and outside rearview mirror heated glass. The heater relay
in the ICM box controls the tailgate and outside rearview mirror heated glass and its fuse (15A) is located in the engine
compartment fuse box.
Defogger switch
RK STICS CHANGED BY
AFFECTED VIN
28 2C
11) Door LOCK/UNLOCK Control
Door Lock/Unlock by Door Lock Switch

1. The door lock system outputs “LOCK” for 0.5 seconds (T1) when positioning the driver’s or passenger’s door lock
switch to lock position (while the driver’s and passenger’s door lock switch is in “UNLOCK” position).
2. The door lock system outputs “UNLOCK” for 0.5 seconds (T2) when positioning the driver’s or passenger’s door
lock switch to unlock position.
3. “LOCK” or “UNLOCK” by the door lock switch is ignored when outputting the “LOCK” or “UNLOCK” by other
functions.
4. The door lock/unlock system is not working regardless of the door lock switch positions when connecting the
battery.
5. All door lock signals are “UNLOCK” for 0.5 seconds (T4) just for once when receiving the “LOCK” signal within 0.5
seconds (T3) after closing the driver’s or passenger’s door. However, this operation is regardless of the ignition key
positions.
[Notice]
This function prevents the door from locking by shock when slamming a door while the ignition key is inserted into the key
switch hole.
T3: within 0.5s
CHANGED BY RK STICS
AFFECTED VIN
2C 29
Door Lock/Unlock by Central Door Lock Switch

1. The door lock system outputs “LOCK” for 0.5 seconds (T1) when pressing “LOCK” button on the central door lock
switch.
2. The door lock system outputs “UNLOCK” for 0.5 seconds (T2) when pressing “UNLOCK” button on the central door
lock switch.
3. The “LOCK” or “UNLOCK” inputs from the central door lock switch in armed mode are ignored.
RK STICS CHANGED BY
AFFECTED VIN
30 2C
Door LOCK/UNLOCK by Remote Control Key

1. The door lock system outputs “LOCK” for 0.5 seconds (T2) when receiving “LOCK” signal from the remote control
key.
2. The door lock system outputs “UNLOCK” signal for driver’s door for 0.5 seconds (T3) when receiving “UNLOCK”
signal from the remote control key.
3. The door lock system outputs “UNLOCK” signal for all doors for 0.5 seconds (T3) when receiving “UNLOCK” signal
again within 30 seconds (T1) after receiving the first “UNLOCK” signal (second unlock step).
4. The “second unlock step” is canceled when receiving “LOCK” signal within 30 seconds (T1) after receiving the first
“UNLOCK” signal.
NO SIGNAL
T1: within 30s
CHANGED BY RK STICS
AFFECTED VIN
2C 31
Auto Door Lock

1. The door lock system outputs “LOCK” when the vehicle speed stays over 50 km/h. However, it doesn’t output
“LOCK” when all doors are locked or failed.
2. If any of doors is unlocked after outputting “LOCK” in step 1, outputs “LOCK” up to 5 times (except step 1) with
interval of one second.
3. If any of doors is unlocked after 5 times of “LOCK” outputs, the door is regarded as “FAIL”.
4. If the door that was regarded as fail changes (UNLOCKàLOCK) to unlock, only one “LOCK” output will be done.
5. If the door that was “LOCK” is changed to “UNLOCK”, only one “LOCK” output will be done.
However, if it maintains unlock after lock output, the corresponding door will not be regarded as fail.
6. The door lock system outputs “UNLOCK” automatically if the “LOCK” output conditions are established by this
function or the key is cycled (IGN1=ONàOFF) (even when there is no “Lock” output while the vehicle speed stays
over 50 km/h under lock condition).
However, when the ignition key is turned to “OFF” position, the lock output conditions will be cancelled.
7. The “FAIL” condition of the door will be erased when the ignition key is turned to “OFF” position.
VEHICLE OVER 50 KM/H

SPEED BELOW 50 KM/H
LOCK OUTPUT
5 times
RK STICS CHANGED BY
AFFECTED VIN
32 2C
Auto Door Unlock (Crash Unlock)

For conventional vehicles, G-sensor in RK STICS generates “UNLOCK” signal when collided over 15 km/h over vehicle
speed. In this vehicle, the factory installed air bag module transmits the collision signal to STICS to unlock the door.
1. The air bag collision signal cannot be accepted within 7 seconds after turning the ignition key to “ON” position.
2. After this period, the door lock system outputs “UNLOCK” for all doors for 5 seconds (T2) from 0.4 seconds (T2)
after receiving the air bag collision signal.
3. Even though the key is turned to “OFF” position during the output of “UNLOCK”, the output continues on for
remaining period.
4. After input of the air bag collision signal, the door lock system doesn’t output “UNLOCK” even when turning the
ignition key to “ON” position.
ING SW(*1) ON
OFF
AIR BAG SIG ON

OFF
UNLOCK ON
RELAY OFF
[Notice]
(1) The “Unlock” control by air bag signal prevails over any “LOCK” or “UNLOCK” control by other functions.
(2) The “LOCK/UNLOCK” request by other functions will be ignored after/during the output of “UNLOCK” by the air bag.
However, the door lock is controlled by other functions when IGN1 SW is “OFF” and IGN2 SW is “OFF”.
(3) If the door lock system outputs “LOCK” and “UNLOCK” simultaneously, only the “LOCK” output can be activated.
(4) Even though the “LOCK/UNLOCK” output is requested, the door lock system cannot output “LOCK/UNLOCK” when all
door lock switches are locked/unlocked.
Also, even though the “UNLOCK” output for the driver’s door is requested, the door lock system cannot output “UNLOCK”
when the driver’s door is unlocked.
CHANGED BY RK STICS
AFFECTED VIN
2C 33
12) Time Lag Power Window Control

1. The power window is turned off when turning the ignition key to “ON” position.
2. The power window relay is turned “ON” for 90 seconds (T1) when turning the ignition key to “OFF” position.
However, the power window relay stays on for 90 seconds (T2) when the ignition key is turned to “OFF” position
while the door is opened.
3. The power window relay is turned “ON” again for 90 seconds (T2) just for once when opening the door during its
extended operation period of 90 seconds (T1).
4. The power window relay is turned “OFF” when closing the door during its extended operation period of 90 seconds
(T2).
RK STICS CHANGED BY
AFFECTED VIN
34 2C
13) REKES (Remote Keyless Entry System)
Transmitter
PANIC function is added on the previous version of REKES.
Door lock button

1. Door locking and theft deterrent armed mode
2. Press door lock button to release.
Door unlock (2-step operation)

Step 1: Unlocking driver’s door
Step 2: Unlocking all doors and tailgate Panic button: Operates under the theft deterrent
armed mode
Theft deterrent horn: Sounds approx. 27 seconds
Specification: CR 2032
Quantity: 1 ea
CHANGED BY RK STICS
AFFECTED VIN
2C 35
Receiver
1. Operating requirements
- IGN key = OUT (removed)
2. Code registration requirement
- After connecting the B+ to external coding terminal (applying battery voltage)
Transmitter Code Registration

- Only one transmitter code can be registered.
- The received code cannot be output during the registration.
1. Coding terminal: OFF à ON (applying battery voltage)

2. Press LOCK, UNLOCK or PANIC switch on the transmitter.
3. Outputs hazard warning flasher for 0.5 seconds (once) and horn for 0.04 seconds (once) during registration.
4. Code output requirements
- The system outputs the function code when the CUSTOM and ID code are correct and the Rolling code is within
operating range while the ignition key is removed and the coding terminal is turned off (grounded).
- Available function code: LOCK / UNLOCK / PANIC
RK STICS CHANGED BY
AFFECTED VIN
36 2C
14) Theft Deterrent
Description of Burglar Alarm Function

1) Armed mode activation requirements
1. The “LOCK” output is “ON” when receiving the “LOCK” signal from transmitter while the ignition key is removed and
all doors are closed. The armed mode is activated when the door lock switch is locked (theft deterrent horn output:
once, hazard relay output: twice).
2. The theft deterrent horn and hazard relay outputs are “ON” when receiving the “LOCK” signal from the remote
control key again in armed mode (theft deterrent horn output: once, hazard relay output: twice).
3. When receiving “LOCK” signal from the remote control key while any of doors is not closed, only the “LOCK” output
can be done and then activates the armed ready mode (without theft deterrent horn and hazard warning flasher). At
this moment, if the ignition key is in the ignition switch, the door unlock switch is turned “ON” or the door lock
switch is unlocked (after 0.6 seconds), cancels the armed mode and activates the normal mode. However, in these
cases, if closing the door and locking the door lock switch, the theft deterrent horn outputs once and the hazard
warning flasher outputs twice and then activates armed mode.
4. When the door is not opened or the ignition key is not inserted into ignition switch for 30 seconds after receiving
“UNLOCK” signal, outputs “LOCK” and then activates armed mode (RELOCK operation). Also, at this moment, the
system outputs the theft deterrent horn and hazard warning flasher.
5. The armed mode will not be activated except above conditions.
Ex) The armed mode will not be activated when the door is locked by the ignition key.
Tx SIGNAL
NO SIGNAL
ENTRANCE
DOOR SW
ENTRANCE
DOOR
LOCK SW
OPERATION ARMED MODE

OTHERS
CHANGED BY RK STICS
AFFECTED VIN
2C 37
2) Armed mode cancellation requirements

1. Unlocking by remote control key or engine starting.
3) Warning operation requirements

1. When opening the door in armed mode
2. When unlocking the door lock switch in armed mode
3. When closing and then opening the door after completion of warning (27 seconds)
4) Warning operation
1. The theft deterrent horn and hazard warning flasher output is “ON” for T3 (27 seconds) with the interval of T2 (1
second).
5) Warning cancellation requirements

1. Cancels warning by using any signal from the remote control key (LOCK, UNLOCK, START, STOP, PANIC,
CHECK) during warning operation.
2. Cancels warning after 27 seconds (remaining period) while the ignition key is turned to “ON” position.
6) Operation when warning is cancelled

1. The theft deterrent horn and hazard warning flasher outputs are “OFF”.
WARNING ESTABLISHED
REQUIREMENTS NO ESTABLISHED
WARNING ESTABLISHED
CANCELLATION NO ESTABLISHED
THEFT WARNING
DETERRENT ARMED
STATE NORMAL
RK STICS CHANGED BY
AFFECTED VIN
38 2C
15) PANIC Warning

1. The PANIC warning output is “ON” (theft deterrent horn) when receiving the PANIC signal from the remote control
key (pressing PANIC button for less than 0.5 ~ 1.0 second).
2. The PANIC warning output is “OFF” when receiving any signal from the remote control key during PANIC warning.
3. Followings are theft deterrent warnings:

1) The theft deterrent warning is canceled when receiving PANIC signal from the remote control key during theft
deterrent.
2) The theft deterrent warning output is “ON” when the theft deterrent conditions are established during PANIC
warning (PANIC output is “OFF”).
3) The PANIC warning output is “ON” when receiving the PANIC signal from the remote control key in Armed Ready
/ Armed / Warning Completion / Relock Ready mode (maintaining the theft deterrent mode).
4. This function operates only in armed mode.

5. The system sends the current vehicle conditions (LOCK, engine running) when the PANIC warning is turned off by
the remote control key.
REMOTE
CONTROL KEY
PANIC SIGNAL
THEFT WARNING
DETERRENT OTHERS
MODE
HORN
CHANGED BY RK STICS
AFFECTED VIN
2C 39
16) Auto Light Function

1. The lights automatically come on and off according to the ambient brightness when the multifunction light switch is
in “AUTO” position while the ignition key is in “ON” position.
RK STICS CHANGED BY
AFFECTED VIN
40 2C
7. DIAGNOSIS TROUBLE CODE AND HELP TIPS

The RK STICS and related devices in this vehicle can be diagnosed by SCAN-100.
Diagnostic Procedures
1. Select the vehicle model.
2. Select RK STICS. 3. Select the DTC code.
Check the part number and version for Sensor data check screen
installed units
CHANGED BY RK STICS
AFFECTED VIN
2C 41
Code Descriptions Help

01 Defective auto door lock opera- This DTC is set when the unit didn’t receive the contact signal of door
tion lock actuator after the unit has sent the “LOCK” signal to the door lock
relay (while the auto door lock is activated and the vehicle speed is
over 50 km/h).
02 Defective door lock relay This DTC is set when the unit didn’t receive the contact signal of door
lock actuator after the unit has sent the “LOCK” signal to the door lock
relay by the remote control key or knob.
03 Defective door unlock relay This DTC is set when the unit didn’t receive the contact signal of door
unlock actuator after the unit has sent the “LOCK” signal to the door
unlock relay by the remote control key or knob.
04 Defective driver’s door unlock This DTC is set when the unit didn’t receive the contact signal of door
relay unlock actuator after the unit has sent the “LOCK” signal to the door
unlock relay by the remote control key. (When the function that opens
driver’s door only is not operating)
05 Defective wiper relay This DTC is set when the wiper stop signal cannot be detected during
the wiper relay operation.
06 Defective INT operation This DTC is set if the “OPEN” signal (4 V) is detected when changing
the INT VOLUME value (0 V: FAST, 4 V: SLOW) in vehicle speed
sensitive INT wiper equipped vehicle.
07 Abnormal speed signal This DTC is set when more than 3 km/h of vehicle speed is detected
from the vehicle speed signal input area while the ignition key is in
“ON” position and ALT D is “LOW”.
08 Abnormal air bag collision signal The air bag unit receives the collision signal.
This DTC is set when the door lock actuator is locked in unlock condi-
tions after the collision signal is entered into collision sensor input end
in air bag unit.
09 Abnormal door ajar warning light This DTC is set when the door ajar warning light comes on while the
signal vehicle speed is over 3 km/h.
10 Abnormal air bag collision This DTC is set whenever the collision signal is entered into the colli-
sensor’s input signal sion sensor while the ignition key is in “OFF” position
11 Abnormal air bag collision signal This DTC is set when the STICS sends the door unlock signal and its
feedback value is normal.
12 Abnormal speed signal This DTC is set when more than 200 km/h of vehicle speed is detected.
13 Defective parking brake warning This DTC is set when the brake warning light comes on while the
light vehicle speed is over 3 km/h.
14 Numbers of auto door lock fault Maximum numbers: 20 times
The number increases by 1 up to 20 when the fault is detected during
every IGN ON. It is reset to 0 when the DTC code is erased.
15 Numbers of door lock relay fault Maximum numbers: 20 times
The number increases by 1 up to 20 when the fault is detected during
16 Numbers of door unlock relay Maximum numbers: 20 times
fault The number increases by 1 up to 20 when the fault is detected during
17 Numbers of driver’s door unlock Maximum numbers: 20 times
relay fault The number increases by 1 up to 20 when the fault is detected during
RK STICS CHANGED BY
AFFECTED VIN
42 2C
Removal and Installation of STICS

Preceding Work: Removal of driver side instrument panel undercover
1. Unscrew four bolts and remove the STICS unit.
CHANGED BY RK STICS
AFFECTED VIN
2D 1
2D - Rain Sensing Wiper
Table of Contents
RAIN SENSING WIPER .................................... 2D-3
1. Components................................................................ 2D-3
2. Rain sensor operation ................................................. 2D-4
3. Rain sensor related circuit ........................................... 2D-5
4. Operation mode of rain sensing wiper system ............. 2D-6
5. Functions of rain sensor .............................................. 2D-7
6. Diagnosis procedures .................................................. 2D-9
7. Troubleshooting ......................................................... 2D-10
8. Removal and installation of rain sensor ...................... 2D-12
RAIN SENSING WIPER CHANGED BY

AFFECTED VIN
2D 3
RAIN SENSING WIPER

The rain sensing wiper unit in this vehicle doesn’t control the wiper directly. The rain sensing unit detects the amount of
rain drops and sends the operating signal to STICS, and STICS drives the wiper directly.
1. COMPONENTS
Multifunction wiper switch:
Rain sensing unit AUTO and sensitivity control
AUTO
A sensor that emits infrared rays through LED : Wiper operates automatically by rain sensor
and then detects the amount of rain drops by
FAST <-------> SLOW
receiving reflected rays against sensing section
(rain sensor mounting section on the windshield) : Auto delay/Auto speed control. A position that
with photodiode. can control sensitivity against rains on the
windshield and transmits wiping demand
signal accordingly.
STICS The rain sensing unit detects the amount of

rain drops and sends the operating signal to
STICS, and STICS drives the wiper directly.
At this moment, STICS determines the wiper ICM box
operation mode (washer, MIST, AUTO), then The wiper related relays are
sends the information to the rain sensor. installed in ICM box.

AFFECTED VIN
4 2D
2. RAIN SENSOR OPERATION

The rain sensor is installed on the specific heat treated windshield that has minimum 13% of transmittance rate with
specified intensity of radiation. It is installed on the glass with a adhesive of Sorepa. It communicates with STICS and
makes the wipers to operate automatically under the rain sensing mode (multifunction switch wiper: AUTO mode). The
emitting section of the rain sensor unit emits infrared rays against the windshield and then detects the amount of rain
drops by receiving reflected rays with photodiode.
The sensing section on the windshield is located just above the center point between LED and photodiode.
Components and functions of the rain sensor unit
Rain sensor unit (including cover)
Rear Front
PCB assembly and

emitter lens
Unit latch
Emitter lens
Rain sensor The LED emits the infrared
unit rays is located at bottom and
the lens guides the infrared
rays to target point.
Housing and
receiver lens
Receiver lens
The receiver lens guides the
reflected infrared rays from
windshield to photodiode.
Housing and PCB
CHANGED BY RAIN SENSING WIPER

AFFECTED VIN
2D 5
3. RAIN SENSOR RELATED CIRCUIT

The rain sensor has one connector with 4 pins and each pin has following function as shown in the circuit diagram.
However, in this vehicle, the terminal No. 1 and No. 2 are for communications between STICS and the rain sensor; the
No. 1 terminal sends the detected value from the rain sensor to STICS then the STICS drives wiper motor.
No.2 terminal sends the wiper and washer operation information such as
- washer operation mode,
- MIST mode, or
- AUTO wiper position
to the rain sensor to recognize whether it is actual rain or it is in rain sensing wiper operation mode.
Multifunction switch Rain sensor unit
Wiper
relay (LO)
STICS
Wiper
motor
Wiper relay
(HI)
Washer motor

AFFECTED VIN
6 2D
4. OPERATION MODE OF RAIN SENSING WIPER SYSTEM

Switch positions Operation mode
MIST (Transmits the manual operation As long as the switch is in MIST position, the wiper motor operates in
mode signal to sensor) low speed. The wiper blade returns to parking position if the switch
returns to the original position. The rain sensor ignores inputs during
parking signal periods.
OFF (Transmits the manual operation The wiper motor rotates in low speed until it returns to parking position.
mode signal to sensor) When the system is in manual mode, the sensitivity of sensor will be
set to 2 (AUTO 2) internally. By doing so, immediate wiping with proper
intervals is possible when a driver sets the system from OFF to AUTO.
AUTO 1 SLOW Auto delay/auto speed control. Low sensitivity against rains on
(Low sensitivity) windshield. When the switch is in AUTO position, the sensor trans-
mits the wiping request signal to STICS.
AUTO 2 Auto delay/auto speed control.
(Low/medium sensitivity) Low/medium sensitivity against rains on windshield.
(Medium sensitivity) Medium sensitivity against rains on windshield.
(Medium/High sensitivity) Medium/high sensitivity against rains on windshield.
FAST
(High sensitivity) High sensitivity against rains on windshield.
LOW SPEED (transmits the manual The wiper motor rotates continuously in low speed of approx. 45 rev./
operation mode signal to sensor) minute at B+=13.5V. The rain sensor operations are same as in MIST.
HI SPEED (transmits the manual operation The wiper motor rotates continuously in high speed of approx. 70 rev./
mode signal to sensor) minute at B+=13.5V. The rain sensor operations are same as in MIST.
Washer switch The washer can be operated as long as the washer switch is pressed.
And, the wiper operates several times as specified. When releasing
the washer switch, the wiper returns back to the parking position. The
STICS transmits the washer signal during its whole washing period
(including dry wiping operation). The rain sensor ignores the rain de-
tection during the washing period.

AFFECTED VIN
2D 7
5. FUNCTIONS OF RAIN SENSOR

1) Windshield Glass and Coupler Attachment
Check the outer windshield surface of sensing area for wear, damage and scratch. The sensor is able to compensate the
wear up to a specific level. Check the coupler attached surface of windshield for porosity. If the porosity exists, the
sensor cannot function properly.
[Notice]
If the installed wiper brushes are out of specification (size and length), the rain sensing area cannot be fully wiped.
In this case, the rain sensor’s sensitivity could be decreased and the wipers are not properly operated.
2) Recognition of AUTO Mode

1) When the engine is started with the wiper switch “AUTO” position, the wiper operates one cycle to remind a driver
that the wiper switch is in “AUTO” position.
2) When the wiper switch is turned to “AUTO” from OFF, the wiper operates one cycle. It always operates one cycle
for the initial operation, however, the wiper does not operate afterwards to prevent the wiper blade wear if not raining
when turning the wiper switch to “AUTO” from “OFF”. However, the wiper operates up to 5 minutes after rain stops.
3) If this function does not occur, check No. 2 terminal on the rain sensor. If any defective cannot be found, check the
wiper relay (LOW) for defective.
[Notice]
As described, the STICS recognizes the wiper switch “AUTO” position. If there are not any problem, go to diagnosis mode
in STICS and check the terminal that receives signal from wiper and communication lines between rain sensor unit and
STICS.
3) Instant Wipe Function

When the variable resistance knob on the multifunction wiper switch is turned by each 1 stage from low sensitivity (S
mark) to high sensitivity (F mark), the wiper operates one cycle.
And, the wiper also operates during raining up to 5 minutes after rain stops.

AFFECTED VIN
8 2D
4) Washer Coupled Wiper Function

Check the washer coupled wiper operation by pressing the washer switch.
5) Irregular Operations (Abrupt Operations)

- Check the sensor for coming off.
- Check the rain sensor cover installation.
- Check that the customer is familiar to how to control the wiper sensitivity.
Check that the customer can select the sensitivity by selecting the variable resistance value (stage 1 to stage 5),
that is, the wiper sensitivity control value. And, also check whether the sensitivity is selected to the highest value of
FAST (stage 5).
- Check the wiper blade for wear.
If the wiper blade cannot wipe the glass uniformly and clearly, the irregular operations could be occurred. And, the
wiper blade should be replaced with new one with same specifications.
6) Self Diagnosis
Poor sensing
Position the wiper switch to “AUTO” position and rotate the variable resistance knob from “FAST” toward “SLOW” by one
step. At this moment, check if the wiper operates one cycle.
The wiper operates when the windshield glass is excessively worn or scratched, the windshield glass is not cleared
wiped due to using worn wiper blade or different wiper blade, or the rain sensor is not improperly installed.
Poor sensor
Rotate the variable resistance knob toward “SLOW” by 2 more steps. At this moment, check if the wiper operates one
cycle.
The wiper operates when the sensor is defective.

AFFECTED VIN
2D 9
6. DIAGNOSIS PROCEDURES
1. Check the glass and coupler for proper installation.
2. Check the power up function.
3. Check the instant wipe function.
4. Check the washer coupled wiper function.
5. Check the high speed.
6. Find the causes for irregular operations (abrupt operations).
7. Check the system with self-diagnosis function.

AFFECTED VIN
10 2D
7. TROUBLESHOOTING
1. The wiper should not operate one cycle when turning the wiper switch to “AUTO” from “OFF” position
or Ig S/W (Ig2) while the wiper switch is in “AUTO” position.
1) When Ig2 with the wiper switch “AUTO” position, the wiper operates one cycle to remind a driver that the wiper
switch is in “AUTO” position.
2) When the wiper switch is turned to “AUTO” from OFF, the wiper operates one cycle. It always operates one cycle
for the initial operation, however, the wiper does not operate afterwards to prevent the wiper blade wear if not raining
when turning the wiper switch to “AUTO” from “OFF”. However, the wiper operates up to 5 minutes after rain stops.
If this function does not occur, check No. 1 pin. If the pin is normal, check the wiper relay related terminals in ICM
box.
2. It rains but the system does not work in “AUTO” position.
1) Check whether the wiper switch is in “AUTO” position.

2) Check the power to sensor. Check the conditions of pin 3 (Ground) and pin 4 (IGN).
3) Check the wiper relay for defective.
3. The wiper operates 3 or 4 times with high speed abruptly.
Check whether the variable resistance knob on the wiper switch is set in “FAST”. The “FAST” is the highest stage
of sensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to low sensitivity.
4. The wiper operates continuously even on the dry glass.
1) Check the wiper blade for wear. If the wiper blade cannot wipe the glass uniformly and clearly, this problem could
be occurred. In this case, replace the wiper blade with new one.
2) Check whether the variable resistance knob on the wiper switch is set in “FAST”. The “FAST” is the highest stage
of sensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to low sensitivity.

AFFECTED VIN
2D 11
5. The wiper responses are too fast or slow.
Check whether the variable resistance knob on the wiper switch is set in “FAST” or “SLOW”.
Notify that the customer can select the sensitivity by selecting the variable resistance value. And, select a proper
stage.

AFFECTED VIN
12 2D
8. REMOVAL AND INSTALLATION OF RAIN SENSOR

1. Pry off the rain sensor cover by inserting a small flat-blade screwdriver into service holes at both sides.
[Notice]
Otherwise, the cover or rain sensor components could be damaged.
Service hole
2. Pull of the rain sensor unit from the windshield glass and disconnect the rain sensor connector.

AFFECTED VIN
2E 1
2E - Switch
Table of Contents
INTERIOR SWITCHES ...................................... 2E-2
SWITCHES ........................................................ 2E-4
1. Center switch .............................................................. 2E-4
4WD SWITCH, REAR WIPER/WASHER SWITCH

......................................................................... 2E-16
1. 4WD (4H ↔ 4L) switch: TOD (Full time 4 wheel drive)
..................................................................................... 2E-16
SWITCHES ON STEERING WHEEL .............. 2E-19

1. Audio remote control switch ...................................... 2E-19
2. Circuit diagram of audio remote control switch .......... 2E-20
3. Horn and theft deterrent horn ..................................... 2E-22
4. Switches on door trim ............................................... 2E-23
MULTIFUNCTION SWITCH ............................ 2E-29

1. Multifunction switch ................................................... 2E-29
2. Auto light sensor ....................................................... 2E-36
WIPER AND WASHER ASSEMBLY ............... 2E-39

1. General ..................................................................... 2E-39
2. Removal and Installation of wiper assembly ............... 2E-41
SWITCH CHANGED BY
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2 2E
INTERIOR SWITCHES
Audio remote control switch
Audio power button
Mute button
Mode button
Volume button - Up
SEEK button – Up
Volume button - Down

SEEK button - Down
4WD switch and rear

washer/wiper switch
Outside rearview mirror control

and folding switch
Window switch
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2E 3
Room lamp and sun roof switch

(multi-meter integrated type)
Driver’s seat warmer switch Rear fog lamp switch Front fog lamp switch
Hazard warning flasher switch

Sun roof switch
Multi-meter
Defogger switch ESP OFF switch Passenger’s seat
Front room lamp Front room lamp warmer switch
operation operation
Multifunction switch
Window switch
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4 2E
SWITCHES
1. CENTER SWITCH
Seat Warmer Switch
The seat warmer relay is installed in ICM box and the seat heated wire is installed in the driver’s and passenger’s seat.
When the seat warmer switch is operated, the seat cushion and seatback gets warm. If the temperature of seat surface
gets 40 ± 5°C, the thermistor cuts or connects the power to heated wire to maintain the temperature to the specified
level.
The is no control switch and unit to control the temperature of the seat surface temperature.
Driver’s seat warmer Passenger’s seat

switch warmer switch
Seat heated wire (driver’s and Seat heated wire (driver’s and passenger’s seat)
passenger’s seat) – in ICM box
Seat heated wire relay - LH
Seat heated wire relay - RH
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2E 5
Connector Terminals and Circuit

- Internal circuit diagram of seat warmer switch
Rated capacity: DC 12V, 1A
Seat warmer relay

(in ICM box)
[Notice]
The temperature of seat surface should be increased over 20°C within 3 minutes after turning on the switch while a person
(height: 175 ± 5 cm, weight: 75 ± 5 kg).
[Notice]
- Do not place anything sharp on the seat.

- When cleaning the seats, do not use organic solvents such as benzene or thinner.
- Do not use this function when the engine is not running. The battery could be discharged.
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6 2E
Fog Lamp Switch
Fog lamp
Fog lamp relay

Fog lamp switch Fog lamp connector
• The fog lamp with indicator comes on when pressing the fog lamp switch while the light switch is “ON”. It goes off
when pressing the switch again.
Rated capacity: DC 12V, 1A
Fog lamp relay

Engine compartment
fuse and relay box
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2E 7
Hazard Warning Flasher Switch

The hazard warning flasher switch is connected to the turn signal lamp circuit. The hazard warning flasher unit is
integrated into the ICM box. If the flasher unit is defective, should replace the ICM box assembly.
Indicator lamp
Flasher unit (in ICM box)
• The hazard warning indicators on the indicator display, both turn signal lamps, and both side repeaters blink when
pressing the hazard warning flasher switch.
ICM box
Flasher unit Turn signal lamp

switch
Left side Right side

lamps lamps
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8 2E
Defogger Switch
The windshield, tailgate glass, and outside rearview mirrors have heated wire. STICS controls the defogger relay in the
engine room fuse and relay box.
Defogger indicator STICS Defogger relay and fuses
Comes on during operation Controls the heated glass In the engine compartment
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2E 9
Circuit Diagram
The defogger switch is connected to STICS. The STICS controls the tailgate windshield and outside rearview mirror
heated glass according to the switch operations while the engine is running.
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10 2E
Tailgate Heated Glass, Windshield Galss and Outside Rearview Mirror Heated Glass (controlled
by STICS)
1. The outside rearview mirror heated glass operates for 12 minutes when turning on the defogger switch while the
engine is running.
2. If the defogger switch is pressed again during the operation, the operation stops.
3. If the defogger switch is pressed again within T2 (10 minutes) after completion of the first operation (T1), the
defogger system operates for 6 minutes just for once.
4. The defogger is not available when the ignition switch is in “OFF” position or the alternator is not running.
OVER 9 V
BELOW 9 V
T1: 12 min. T2: within 10 min. T3: 6 min.
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2E 11
ESPOFF Switch
If the driving wheels are slipping on the snowy or icy road, the engine rpm may not be increased even when depressing
the accelerator pedal, and accordingly, the vehicle may not be started off. In this case, stop the ESP function by
pressing the ESPOFF switch. When the ESPOFF switch is pressed, the ESP function stops and the vehicle is driven
independently from the sensor outputs. However, the ABS function is still activated.
ESP OFF switch ESPOFF switch and connector
ESP indicator and warning light ICM box
ESP operation alarm buzzer
• When the ESP warning light comes on

The lamp comes on when the vehicle posture control function is cancelled by pressing ESPOFF switch or ESP
related system is defective.
• When the ESP warning light blinks and the alarm sounds
It means the ESP function is operating while the vehicle is driving under extremely unstable conditions.
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12 2E
Resuming the ESP function by using ESPOFF switch
The ESP function will be resumed if pressing the ESPOFF switch on the center switch panel again shortly when the ESP
function is cancelled (when the ESP warning light comes on). At this moment, the ESP warning light in the indicator
display goes off and the ESP function is resumed.
[Notice]
- The ESP system deactivates when stopping the engine. It will be resumed when the engine is started again.
- If the vehicle is controlled by ESP during driving, the ESPOFF switch will not work.
- If the ESP warning light comes on, the ESP related system is defective. At this moment, the ABS works in a basic way.
- If the ESP warning light and the ABS warning light come on simultaneously, both ESP and ABS system are not working.
- If the ESP warning light blinks and the alarm sounds, it means that the vehicle stability is controlled by the ESP function
when the vehicle stability is extremely unstable.
- If the ESP function operates while driving, the indicator lamp blinks and the alarm sounds with the interval of 0.1
second.
Rated capacity: DC 12 V, 1 A
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2E 13
Removal and Installation of Center

Switches
1. Remove the screws from the front cup holder.
2. Pull out the front cup holder, disconnect the cigarette connector and the power socket connector, and remove the
front cup holder.
3. Carefully pry off the chrome coated cover from the selector lever cover, unscrew the screws and remove the
selector lever cover.
SWITCH CHANGED BY
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14 2E
4. Carefully pull out the center speakers and disconnect the connectors.
5. Remove the screws and take out the front cover from the instrument panel.
6. Disconnect all switch connectors including TRIP switch connector during removal of the front cover.
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2E 15
• Disconnect the air conditioner connector.
7. Remove the center switch cover and pull out the switches from it.
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16 2E
4WD SWITCH, REAR WIPER/WASHER SWITCH

1. 4WD (4H ↔ 4L) SWITCH: TOD (FULL TIME 4 WHEEL DRIVE)
Driving Mode Change

4WD CHECK Warning Light
Driving mode 4H ↔ 4L This warning light comes on when the
Changing requirement Vehicle is stationary. 4WD system is defective.
Selected gear Neutral
4WD LOW indicator

“4H” (4-Wheel Drive, High) : for driving on normal road
This indicator blinks during mode changes
“4L” (4-Wheel Drive, Low) : for maximum traction needed
(4H ↔ 4 L), then goes off after completion.
in slippery roads, steep hills
and rough roads.
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2E 17
Rear Wiper/Washer Switch
The rear wiper operates with a specific speed when The washer fluid is sprayed when pressing the switch.
pressing this switch. It stops when pressing the switch And, the wiper operates when pressing the switch
again. over 0.6 seconds.
Rated capacity : wiper - DC 12V, 3.0A

washer - DC 12V, 3.8A
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18 2E
Removal and Installation

1. Remove the driver side lower switch panel and remove
the switch bezels.
[Notice]
Be careful not to damage the surroundings during its removal

procedures.
2. Disconnect the connectors and remove the switches.
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2E 19
SWITCHES ON STEERING WHEEL

1. AUDIO REMOTE CONTROL SWITCH
POWER
Turns on and off the audio system.
MODE
Changes the audio mode in order as below:
MUTE
SEEK Stops audio output from audio system.
SEEK To resume the audio output, press the
button again.
• In radio mode
VOLUME
- Press briefly: Manual searching for a station.
VOLUME
- Press and hold: Automatic searching for a station.
• In CD (DVD) player/Cassette tape mode Increases or decreases the volume.
- Press briefly: Replay next/previous track.

- Press and hold: Move forward/backward in current tract.
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20 2E
2. CIRCUIT DIAGRAM OF AUDIO REMOTE CONTROL SWITCH
Audio
switches
Tail
lamp
relay
Pin number Descriptions

31 Audio signal
32 Audio ground
33 Tail lamp relay
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2E 21
Remote control switch on steering

wheel
1. Remove the screws at both sides.
2. Remove the air bag module (horn) from the steering
wheel.
3. Unscrew the bolts and disconnect the remote control switch connector.
4. Remove the remote control switch from the steering wheel.
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22 2E
3. HORN AND THEFT DETERRENT HORN

Horn
Theft Deterrent Horn
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2E 23
4. SWITCHES ON DOOR TRIM

System Components
Outside rearview mirror switch
Outside rearview mirror folding switch

The mirrors are folded/unfolded when pressing the
switch more than 1 second.
Mirror selection switch
[Note]
The mirrors can be folded/unfolded for 30 seconds
after turning the ignition key to “OFF” position.
Manual folding or unfolding the outside rearview
mirrors may cause a malfunction of the mirror
folding system.
Driver’s door trim panel
Outside rearview mirror folding unit
Switches on driver’s door trim

Driver’s door window switch
• When the front of the switch is lightly pressed (stage 1), the
window will be lowered while the switch is pressed. When
pressed to its end (stage 2), the window will open automati-
Window lock cally until it is fully opened. The window stops during its
switch operation when pressing the switch (stage 1) again or pulling
If this switch is pressed, up the switch.
all door windows are • The other window can be operated only while the appropriate
operated only by driver’s switch is activated.
door window switches.
Time lag of window operation

The operation of power window can be continued for
90 seconds after turning the ignition switch to “OFF”
position.
Central door locking switch
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24 2E
2) Switches on Driver’s Door
Driver’s door window switch
Door lock switch Window lock switch
Window lock switch
* Abbreviations
FLU: Front Left Up FLD: Front Left Down
FRU: Front Right Up FRD: Front Right Down
RLU: Rear Left Up RLD: Rear Left Down
RRU: Rear Right Up RRD: Rear Right Down
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2E 25
2) Circuit Diagram of Switches on Driver’s Door
Front Left Front Left Down (FLD) 4

Front Left Up (FLU) 2
Front Right Front Right Down (FRD) 5
Front Right Up (FRU) 7
Rear Left Rear Left Down (RLD) 8
Rear Left Up (RLU) 11
Rear Right Rear Right Down (RRD) 12
Rear Right Up (RRU) 14
Door Lock LOCK 10
UNLOCK 6
Illumination ILL 1
Power B+ 3
B+ (S) 13
E(-) 9
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26 2E
Removal of Outside Rearview Mirror Switch

Preceding Work: Disconnection of negative battery cable
1. Remove the screws (arrows) from the door trim.

2. Remove the door armrest grip cover and unscrew the screw.
3. Pry off the door lever cover and remove the mounting screws.
4. Remove the door trim.
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2E 27
5. Unscrew the bolts and remove the door grip from the removed door trim.
6. Unscrew the bolts and remove the outside rearview mirror switch from the door grip.
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28 2E
Removal and Installation of Window Switch

Preceding works: Disconnection of negative battery cable, Removal of door trim
Unscrew the screws and remove the window switch from the removed door trim.
Driver side
Passenger side
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2E 29
MULTIFUNCTION SWITCH
1. MULTIFUNCTION SWITCH
Steering wheel
Steering wheel
angular sensor
Light switch Wiper/washer
switch
Specifications
Descriptions Specifications
Multifunction Rated voltage DC 12V
switch Operating temperature range -30°C ~ +80°C
Rated load Light switch Turn on: 1 A (relay load)
Dimmer and passing switch Hi/Low/Passing: 0.3 A (relay load)
Turn signal switch 6.6 ± 0.5 A (lamp load)
Wiper switch Low: 5 A, Hi: 7 A (motor load)
AUTO: 0.22 ± 0.05 A (relay load)
Fixed: max. 28 A (motor load)
Washer switch 4 A (motor load)
Intermittent wiper switch Max. 25 mmA
MIST switch 5 A (motor load)
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30 2E
Multifunction Switch Operating Range
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2E 31
Connector Pins and Designations of Multifunction Switch
Connector A Connector B
1. Connector A Pin number Descriptions

1 EB: Dimmer and passing ground
2 HL: Headlamp low beam
4 3 11 9 10 3 HU: Headlamp high beam

4 HS(2): Passing switch
5 TS: Tail lamp switch
2 1 56 7 8
6 HS(1): Headlamp switch
7 F/AUTO: Rear fog lamp
8 DEL: Light switch ground
9 TB: Flasher unit power
10 TL: Turn signal (LH) lamp switch
11 TR: Turn signal (RH) lamp switch
2. Connector A Pin number Descriptions

14 LO: Low wiper speed
15 HI: High wiper speed
16 S: Wiper stop
15 14 16 22 21 17 20
17 AUTO(W): Intermittent wiper
18 INT(T): Intermittent WIPER
18 19 19 BWT: Intermittent power
20 W: Front washer switch
21 BW: Wiper and washer switch
22 MS: Low wiper speed (MIST switch)
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32 2E
Multifunction switch connector
1) Light switch and auto light switch
2) Dimmer and passing switch
3) Turn signal lamp switch
4) Wiper and intermittent switch
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2E 33
Removal and Installation of Multifunction Switch Assembly

Preceding work: Disconnection of negative battery cable
Cautions
1. Be careful not to drop or shock the air bag module

during removal procedures.
A
2. Lift up the hook when disconnecting the air bag
contact coil connector.
1. Place the steering wheel to the straight forward direction.

Unscrew the screws at both sides and remove the horn
pad (air bag module).
2. Put an installation mark on the steering wheel and nut and remove the steering wheel.
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34 2E
3. Remove the driver side instrument lower panel .
4. Unscrew the screws from the steering column cover and

remove the upper and lower covers.
5. Disconnect the multifunction switch connector. Unscrew the screws from the air bag contact coil, and remove the
air bag contact coil assembly.
* For installation, align the steering wheel to the

installation mark and tighten the nut to the
specified tightening torque.
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2E 35
6. Disconnect the steering wheel angular sensor connector. Unscrew the screws and remove the multifunction switch
assembly.
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36 2E
2. AUTO LIGHT SENSOR

Overview
The auto light control is a system that turns on/off the tail
lamps and headlamps automatically. The auto light sensor is
installed on the instrument panel (passenger side). This sen-
sor detects the ambient brightness and automatically turns
on and off the tail lamps and headlamps while the light switch
is in AUTO position without light switch operations. The sys-
Auto light sensor
tem turns on and off the lamps when passing through the
tunnel during day driving and getting dark due to fog, rain or
snow.
Specifications
Description Specifications
Auto light sensor unit Operating voltage 9 ~ 16V
Load Max. 200 mA (relay load)
Operating temperature -30°C ~ +85°C
Storage temperature -40°C ~ +120°C
Location on instrument panel (passenger side)
Input / Output Circuit Diagram
Headlamp
relay
Tail lamp
relay
Ignition switch
Battery 12V Control

circuit
Auto light switch
Tail lamp
Headlamp switch
switch
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2E 37
Auto Light Sensor Unit Terminals
1. System power supply

2. Tail lamp relay
3. Headlamp relay
4. Brightness detecting sensor
5. Auto light switch
6. System ground
Auto light operating conditions

Switch functions
1. Turn the ignition switch to “ON” position and turn the multifunction switch in order of OFF → tail lamp → headlamp
→ AUTO.
2. Turn on and off the light switch.
3. Turn the light switch to “AUTO” position. At this moment, the tail lamps and headlamps come on and off automatically
when the brightness of light that reflected on the photodiode in the auto light sensor is the same as voltage that is
set by software in CPU.
4. When operating the tail lamp and headlamp switch manually again, the lamps comes on and off according to the
switch operations not by brightness of light that detected by sensor.
5. When the ignition key is removed, tail lamps and headlamps go off.
Turning on conditions
Lamp
Tail lamp ON condition Headlamp ON condition Operation delay time
Brightness
ON 30.5 ± 5(LUX) 8.9 ± 3(LUX) 0.5 ± 0.1 second
OFF 60.5 ± 5(LUX) 17.2 ± 3(LUX) 3 ± 1 second
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38 2E
Operational Characteristics
IGN SW
Within OFF range Within ON range
AUTO light SW
Tail lamp
Headlamp
However, the tail lamp and headlamp should be within ON and OFF ranges.
T1: 3 ± 1.0 sec T2: 500 ± 100 msec
Inspection
Position the multifunction switch to “AUTO” position and cover
the auto light sensor on the instrument panel (passenger side)
with a cloth to block the light coming from outside and then
check the auto light functions.
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2E 39
WIPER AND WASHER ASSEMBLY

1. GENERAL
System Layout of Wiper and Washer
Front wiper and washer assembly
Wiper blade
assembly
Washer nozzle and

washer hose
Wiper motor and

linkage assembly Washer motor and
washer fluid reservoir
Rear wiper and washer assembly
Washer nozzle and

washer hose
Wiper blade
assembly Wiper motor and
linkage assembly
Washer motor and

washer fluid reservoir
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40 2E
Specifications
Motor Rated voltage DC 12 V ± 0.3 V
Test voltage DC 13.5 V ± 0.3 V
Operating voltage range DC 10 ~ 15 V
Minimum operating voltage Below DC 8 V
Insulating voltage Over 1 mΩ
Restraint test Torque Over 1.1 Km
Voltage Below 14 A
Surrounding voltage range -40°C ~ +80°C
Control Rated voltage DC 12 V
Operating voltage range DC 9 ~ 16 V
Operating temperature range -30°C ~ +80°C
Reserving temperature range -40°C ~ +90°C
Insulating voltage Over 1 mΩ
Voltage drop Below 0.5 V
(terminals between 5-7, 6-8, 5-8, 6-7 @ 5 A)
Test voltage 14.0 ± 0.5 A
Acceptable load current Maximum 10 A
Circuit Diagram
Relay 1
Voltage
controller
Relay 2
Wiper motor
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2. REMOVAL AND INSTALLATION OF WIPER ASSEMBLY

1. Front Wiper Assembly
Components Locator
Wiper blade
Wiper linkage
Wiper motor
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42 2E
1. Detach the washer hose , unscrew the nut and remove the wiper blade assembly, and remove the hood cowl
grille.
A. Wiper blade assembly
B. Cowl grill
2. Unscrew the bolts and remove the wiper linkage assembly.
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2E 43
3. Disconnect B motor connector . Unscrew two mounting bolts and two nuts and remove the wiper motor.
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2. Rear Wiper Assembly

Preceding work: Disconnection of negative battery cable, removal of tailgate trim
Components Locator
Wiper blade assembly
Rear wiper motor
Rear wiper assembly
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2E 45
1. Release the wiper arm cap , remove the wiper nut and wiper blade , and unscrew the motor lock nut .
2. Disconnect the wiper motor connector , unscrew the bolts , and remove the wiper motor assembly from
tailgate.
1. Motor connector
2. Motor mounting bolts
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MEMO
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2F 1
2F - Multimeter
Table of Contents
MULTI-METER................................................... 2F-3
1. Location ...................................................................... 2F-3
2. Circuit diagram ............................................................ 2F-4
3. Display mode .............................................................. 2F-5
4. Functions in each mode .............................................. 2F-6
REMOVAL AND INSTALLATION .................... 2F-13
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MULTI-METER
1. LOCATION
1. MODE button - Mode change and reset

Selects a mode (altitude, direction, time, calendar, average speed, driving time, battery)
2. UP button - coupled operation with MODE button

Increases the value (altitude, direction, date, atmospheric pressure) in each mode.
3. DOWN button - coupled operation with MODE button

Decreases the value (altitude, direction, date, atmospheric pressure) in each mode.
4. Display
Displays a selected mode screen, parking aid signal, and battery voltage message.
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4 2F
2. CIRCUIT DIAGRAM
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2F 5
3. DISPLAY MODE
Mode changing sequence:
[Time and Calendar] [Altitude, Direction] [Driving time]
[Note]
The previously selected

mode screen appears
when starting the engine.
[Battery voltage] [Average speed]
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6 2F
4. FUNCTIONS IN EACH MODE

1) Time and Date
Displays and adjusts time, date, and day of the week.
Adjusting the Time and Date

1. Press and hold the MODE button for more than 1 second to start time and date mode. Move and select the
information to be adjusted while briefly pressing the MODE button (0.5 seconds). The selected information
is blinking.
Changing sequence:
AM (PM) Hour Minute Day Month Year
3. Adjust the information by using UP or DOWN button.

4. Press and hold the MODE button for more than 1 second to set the time and date.
[Note]
- A day of the week is automatically changed according to the adjusted date, month, and year.
- An intercalary is automatically calculated.
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2F 7
2) Direction, Atmospheric Pressure, Altitude Mode
Electronic Compass
It indicates 8-direction by interval of 45° according to the vehicle’s driving direction.
1. Screen display for direction
Display Direction
N 0°
NE 45°
E 90°
SE 135°
S 180°
SW 225°
W 270°
NW 315°
[Note]
This function is available only when the vehicle speed is over 2.8 km/h.
2. Turning Calibration
This operation is needed to calibrate the indication tolerance between the actual direction and the indicated direction
at current vehicle location.
Turning calibration conditions

- when the multi-meter is installed in the vehicle.
- when the battery is replaced.
Turning calibration procedure

1. When pressing the MODE and UP button simultaneously for more than 1 second, the current direction flashes.
2. Turn the vehicle over 1 complete circle within 128 seconds slowly, then the calibration will be accomplished.
3. When the calibration is finished, the vehicle’s new direction will be indicated.
[Note]
The turning calibration process is automatically canceled if the vehicle is not turned within 120 seconds after calibration
mode started.
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8 2F
Altimeter
1. Absolute Altimeter
0 m above the sea level is equivalent to 1013.25 hpa and the altimeter convert the difference between this pressure and
atmospheric pressure to absolute altitude. Its Indication range is -200 m to 2,800 m.
Current atmospheric pressure
Current altitude
How to calibrate the absolute altitude

1) UP button
Press briefly (below 0.5 seconds): increases by 20 m
Press and hold (over 0.5 seconds): continues to increase by 20 m with the interval of 0.2 seconds
2) DOWN button
Press briefly (below 0.5 seconds): decreases by 20 m
Press and hold (over 0.5 seconds): continues to decrease by 20 m with the interval of 0.2 seconds
How to erase the calibrated altitude value

Press the UP and DOWN buttons simultaneously for more than 1 second to cancel the altitude calibration.
Altitude calibration range

It can be calibrated by 300 m within the range of 0 to 2,800 m.
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2. Relative Altimeter
It indicates the specific area’s relative altitude based on the current altitude of the vehicle (current altitude is indicated
to 0 m).
Indication of relative altimeter
Indication of base altitude
Changing to relative altimeter mode

The mode is switched between the relative altimeter mode and absolute altimeter mode when pressing the MODE
button over 1 second in direction/atmospheric pressure/altitude mode.
Barometer
It indicates the current atmospheric pressure in range from 720 hpa to 1045 hpa by 1 hpa.
AFFECTED VIN
10 2F
3) Speed Sensing Indicator

The flashing interval of the road signs changes gradually ac-
cording to the vehicle speed.
Flashing interval according to the vehicle speed
Vehicle speed Flashing interval

below 1.8 km/h stays ON
below 40 km/h 1 second
below 60 km/h 0.8 seconds
over 100 km/h 0.2 seconds
4) Driving Time
- It indicates the driving time from start up to now.
- It can be reset to 0 when turning the ignition key to “OFF”
position or pressing UP or DOWN button for a specific
period of time.
- Indication range: 0:00 ~ 23:59
5) Average Speed
- It indicates the average vehicle speed from start up to
now.
- It can be reset to 0 km/h when turning the ignition key to
“OFF” position or pressing UP or DOWN button for a
specific period of time.
- Indication range: 0 ~ 120 km/h
AFFECTED VIN
2F 11
6) Parking Aid Signal Mode

The rearview display appears when placing the gear selector lever to “R” position.
This message appears when the

parking aid sensor is defective.
[Note]
The display returns back to previous mode screen when
placing the selector lever to other positions.
Display changes according to the distance between rear bumper and rear obstacle
Rear left sensor Rear center Rear right

sensor sensor
Detecting obstacle at rear Detecting obstacle at rear Detecting obstacle at rear Detecting obstacle at rear right
left of the vehicle center of the vehicle right of the vehicle and rear center of the vehicle
All displaying bars are displayed when the distance between rear bumper and obstacle is over 120 cm.
The number of displaying bars is decreased and the alarm interval becomes faster as the obstacle approaches.
Step Distance Alarm interval (msec) Display
Step 1 80 ~ 120 cm
Step 2 50 ~ 80 cm
Step 3 below 50 cm
AFFECTED VIN
12 2F
7) Battery Mode
- The screen shows fully charged battery when the battery voltage is over 12 V.
- It indicates the current battery voltage by 0.1 V.
- When the battery voltage goes below 9 V, current display is changed to battery voltage mode and “LOW VOLTAGE”
message flashes.
Charging level Battery voltabe
Charging Level
Battery voltage Indication
Over 12.0 V
(fully charged)
11.9 ~ 11.0 V
10.9 ~ 10.0 V
9.9 ~ 9.0 V
AFFECTED VIN
2F 13
REMOVAL AND INSTALLATION
1. Open the sunglasses box, remove two screws from the

box, and pry off the overhead console with a flat blade
screwdriver.
2. Disconnect the multi-meter connector and the room lamp

connector and remove the overhead console.
3. Unscrew three screws from the back of the overhead console and remove the multi-meter.
AFFECTED VIN
2G 1
2G - AV System
Table of Contents
AV SYSTEM ....................................................... 2G-3
1. AV system by vehicle model ....................................... 2G-3
2. System layout (based on DVD equipped system) ....... 2G-4
3. DVD system signals and data processing ................... 2G-6
4. System layout (based on DVD system) ...................... 2G-8
5. Removal and installation ............................................ 2G-20
AV SYSTEM CHANGED BY
AFFECTED VIN
2G 3
AV SYSTEM
1-DIN head unit equipped with cassette deck and radio is installed as a factory installed item and 2-DIN head unit
equipped with extra CD player (with MP3) and equalizer is installed as an optional item. There are 6 speakers in basic
and it can be 12 including tweeter if equipped with DVD system.
6-CD changer and 8-DVD changer can be installed as an extra item. DVD changer is available for the vehicle equipped
with DVD head unit and can play audio CD, video CD, MP3 CD and DVD CD.
Followings are AV systems and will be described based on the vehicle equipped with DVD system.
1. AV SYSTEM BY VEHICLE MODEL

1-DIN head unit and 2-DIN head unit equipped with CD player
Front door speaker Rear speaker
Tweeter CD changer
Head unit
Audio remote control

switch on steering wheel
DVD head unit + Navigation + DVD changer
Subwoofer with built-in amplifier

Tweeter
Front door speaker
Rear speaker
DVD changer
TV antenna module
Radio antenna module
GPS antenna
Rearview camera
AV head unit Rear monitor

(DVD)
Front center speaker Rear center Amplifier/tuner/navigation unit

Audio remote control switch speaker with built-in DSP function
on steering wheel Rear center
tweeter
AFFECTED VIN
4 2G
2. SYSTEM LAYOUT (BASED ON DVD EQUIPPED SYSTEM)
Tweeter speaker
Tweeter speaker
Center speaker
Center speaker
AV head unit
Audio remote
control switch
Front speaker (RH)
Subwoofer with
built-in amplifier
Front tweeter GPS antenna
speaker (RH)
Center speaker
(RH)
AV head unit
Center speake
DVD changer
Center speaker
(LH)
Front tweeter
speaker (LH)
Front speaker (LH)
CHANGED BY AV SYSTEM
AFFECTED VIN
2G 5
DVD changer
Rear tweeter speaker (RH)

TV antenna amplifier (RH)
Rear speaker (RH)
Radio antenna amplifier
Rearview camera
er
Rear monitor
Tuner/amplifier/navigation unit
Rear speaker (LH)
TV antenna amplifier (LH) Tuner

Rear tweeter speaker (LH)
Amplifier with built-in

DSP function
Navigation unit
AFFECTED VIN
6 2G
3. DVD SYSTEM SIGNALS AND DATA PROCESSING
DVD changer Rearview camera

It is installed in the center console. Audio signal of Even though the AV head unit is turned off, the rear-
DVD changer outputs to corresponding speakers view display always appears when placing the gear
through optical fiber cable. Video signal is transmit- selector lever to “R” position. The reverse driving
ted to the monitor of AV head unit and rear monitor. signal is prior to all other video signals.
Send Optical fiber cable
Receive
Tuner
TV sound (TV antenna, LH)
TV sound (TV antenna, RH)

Send
TV video data
Sound communication line

(Bus line)
AV head unit
(with built-in EGA 6.5” monitor)
AM/FM radio antenna AMP

The heated wire and radio antenna is integrated
in the tailgate glass. The antenna transmits AM/
FM audio signals to tuner.
TV antenna AMP (LH and RH)

The glass antennas at both rear quarter glasses
are to receive TV and AM radio (quarter RH
glass) signals and transmits each 2-channel
video and audio signals to tuner. Each AMP
amplifies receives TV signals and then trans-
mits to tuner.
AFFECTED VIN
2G 7
Navigation (DVD data)

Displays current vehicle position on the built-in map
after receiving vehicle position signal through GPS
antenna and then transmits to monitor. By using DVD-
ROM, it supports enormous convenience data and
3D view.
GPS satellite
GPS antenna (installed behind passen-

ger side instrument panel )
A device that receives and transmits current vehicle
position from and to GPS satellite to display the ve-
hicle position on the map as dot.
Audio signal
Front speaker (LH)
Video signal
Tweeter speaker (LH)
Front speaker (RH)
Tweeter speaker (RH)
Rear speaker (LH)

Optical fiber cable
Tweeter speaker (LH)
Receive
Rear speaker (RH)
Tweeter speaker (RH)

AMP (with built-in DSP)
Power AMP in the DVD system has built-in
DSP function that digitalizes sound to divide Center speaker (LH)
and control. It amplifies sound goes to each
speaker and has function of allowing dynamic
and vivid sound.
Center speaker (RH)
Center speaker
(back of center console)
Rear monitor
Video signal
Subwoofer (with built-in AMP)

Woofer with built-in amplifier is installed at
the bottom of passenger’s seat. It enforces
mid-low sounds and the amplifier built-in the
woofer amplifies sound signal received from
The rear monitor (7”) can be folded down approx. 25¡Æ
power AMP directly.
when the open button is pressed to display. When opened,
the angle can be adjusted up to 100¡Æ manually.
AFFECTED VIN
8 2G
4. SYSTEM LAYOUT (BASED ON DVD SYSTEM)

1) Front Head Unit
Functions
The AV head unit equipped with DVD system has two optical output terminals; one is to receive the sound signal from 8-
DVD changer and the other is to send the sound signal to amplifier with built-in DSP. The tuner unit transmits the TV and
video signals to the head unit through cable. However, the head unit receives the video signal or color and video signal
directly from the rearview camera and navigation without tuner.
If equipped with roof monitor, the AV head unit transmits the video signal to roof monitor through cable.
[Notice]
The DVD system drives the amplifier, tuner, head unit and 12 speakers and operates two monitors. Therefore, the battery
can be discharged easily if operate DVD system without engine running.
Rearview camera DVD NAVI
Audio signal
(Video signal)
AVC-LAN
AV head unit
(EGA/6.5”)
DVD changer Roof monitor (7”)
OPTIC
TX
Optical fiber cable
(Video signal)
OPTIC OPTIC
RX TX
Optical fiber cable
Tuner unit 5.1 channel

power amplifier
OPTIC
RX
AFFECTED VIN
2G 9
Appearance
Front view of head unit

Touch-screen panel
When cleaning the touch screen, turn off the system and clean
the surface with a dry and soft cloth. Never use any coarse
cloth, hard cloth, chemical agent, volatile cleaning solvent
(alcohol, benzene, thinner) for cleaning the touch screen.
[Notice]
Do not apply excessive force to adjust, open, and close the monitor. Do not impede the automatic
movement of the unit.
When removing LCD monitor
DVD deck
Tape deck Reset button
Forceful operation or impeding the

movement of AV system may
cause unstable operations. When
the system operation is unstable,
push the reset button with a sharp
object like a ball-point pen to initial-
ize the system.
Rear view of head unit
AFFECTED VIN
10 2G
Usable Discs (DVD Head Unit)

Following disc types can be used on the system.
Disc type and logo Disc size Play time

approx. 133 minutes (SS/SL)
approx. 242 minutes (SS/DL)
DVD video approx. 266 minutes (SD/SL)
approx. 484 minutes (DS/DL)
SS = Single side
SL = Single layer DL = Double layer
Video CD 5” (12 cm) approx. 74 minutes
Audio CD 5” (12 cm) approx. 74 minutes
CD-ROM 5” (12 cm) MP3 audio file
DVD head unit and DVD changer cannot play following discs.
• DVD-R
• DVD-RAM
• DVD-ROM
• DVD-Audio
• CD-G
• Mixed CD (Date)
• Active Audio (Date)
• VSD
• Multi-section disc
• DVD with region code other than (3) or (ALL)
Bulk CD-R or CD-RW that their quality cannot be secured may not be recognized.
Region code (3)

• DVD player and DVD videodisc has designated region code. If region code is different, the disc cannot be played.
This system cannot play the disc if the region code is other than (3) or (ALL).
PBC (Play back control) – compatible video CD

• This system can play PBC–compatible video CD.
• Typical audio and video CDs can be played and PBC-compatible video CD uses recorded PBC menu on the disc to
play the CD interactively.
Double layer DVD video disc

• When playing the double layer disc, there occurs time lag between at the end of first layer and start of second layer
causing broken display and sound for seconds. It normal for double layer disc so it is not malfunction of the system.
AFFECTED VIN
2G 11
Head Unit Operation Buttons
POWER
Turns ON/OFF AV system. NAVI (CURRENT LOCATION)
Available while the ignition key is in “ACC” or
“ON” position. This button is used for changing Mode in AV
mode. In NAVI screen, this button is used for
displaying the current location.
MODE
Changes AV mode and turns on/off the Mode
display with Power ON. The display returns back
to previous screen when pressing Mode button
over 2 seconds in NAVI mode. DESTINATION
This button is used for setting

VOL Destination in NAVI mode.
Volume Up/Down
MENU OPEN / CLOSE
AV MODE: Controls the display, tone and Moves the monitor to fully open or close position.
menu with Power ON. When pressing this button, the monitor moves to
fully open position if it is not in fully open position,
NAVI MODE: Displays menus in NAVI and moves to previously stored tilting position if it
mode. is in fully open position.
To control the display, volume and others,

TILT
press and hold the button for over 2
seconds. Moves the monitor to desired tilting position while
pushing this button.
UP button is not available when the fully close
position.
The down tilting angle can be precisely adjusted by
using Down button within a specified range. If it
reaches to its end, no more movement can be done.
AFFECTED VIN
12 2G
Descriptions of Terminals
Connector A (26-pin) Connector B (20-pin) Connector C (16-pin)
1. BUS 1 output 1. - 1. R–VSYNC

2. BUS 1 input 2. - 2. R–SYNC
3. BUS 1 ground 3. M. Ground 3. V–ground
4. TV LH- 4. Rearview camera battery output 4. R-G
5. TV RH- 5. Rearview camera V–ground 5. RGB ground
6. Remote control ground 6. Rearview camera video 6. R-Mode 1
7. S-Remote control 7. Navigation voice 7. Ground
8. V-ground 8. Navigation V–ground 8. Mute
9. TV-Video 9. Navigation CSYNC 9. Video
10. Illumination- 10. Navigation Gi 10. Power ON
11. Reverse signal 11. Remote control optic sensor ground 11. N.C.
12. ACC+ 12. Remote control optic sensor signal 12. R-SSW
13. Battery+ 13. Amp mute 13. R-B
14. BUS 2 output 14. Amp ON 14. R-R
15. BUS 2 input 15. Amp voice ON 15. R-Mode 2
16. BUS 2 ground 16. Amp ground 16. -
17. TV LH+ 17. Navigation voice output
18. TV RH+ 18. Navigation voice ON
19. Ground 19. Navigation voice BI
20. R-Remote control 20. Navigation GI
21. Remote control ground
22. VSYNC
23. Illumination +
24. Parking signal
25. Ground
26. Speed pulse
AFFECTED VIN
2G 13
Specifications
System Function
Radio/TV - Manual preset: FM1 (6), FM2 (6), AM (6), TV1 (6), TV2 (6)
- Manual channel up/down
- Seek up/down
- BSM (AM/FM), auto memory (TV)
- Local/DX (use with BSM: -20db)
Tape - Program/Play
- FF (fast forwarding)/REW (rewinding)
- DOLBY B-NR
- AUTO METAL
- Repeat
- Back-up eject function
- Auto power when tape is inserted
DVD player - Chapter, file, track up/down, direct
- FF (fast forwarding), FB (fast back), up/down
- Repeat
- PBC
- SCAN
- Compatible conversion between audio and caption
- MP3 file information display
- CD-DA, video CD, DVD audio, DVD video, MP3
Key input - Touch screen: touch panel
* Displays keys by each mode
- Front key: Potential difference type
* POWER, MODE, MENU
* Eject, slide up/down
* NAVI, Destination
* Volume up/down
- NAVI mode: NAVI graphic video switch shift
NAVI display - Touch screen key: full touch
Display OFF - If the display disturbs the driving conditions at night, possible to turn off just display.
- Cancellation of display OFF
* Screen touching
* Power key input
* NAVI key input
* MODE and MENU key input
Audio OFF - Operates only in NAVI mode
* Performs mute under AM, FM, TV, TAPE, DVD, DVDC mode
* Under TAPE mode, deck operation stops
* Under DVD changer and DVD player mode, it stops
Sliding memory - Sliding memory setting
* Set the desired position with slide up/down key
- Returning to slide position
* Open key input under full-open state
* When changing ACC OFF to ON, moves to the latest stored position
AFFECTED VIN
14 2G
Function Settings on Touch Panel (Example)

DSP control
* STADIUM: Turns off EQ mode and changes to STADIUM
* HALL: Turns off EQ mode and changes to HALL
* CHURCH: Turns off EQ mode and changes to CHURCH
* CLUB: Turns off EQ mode and changes to CLUB
* OFF: Turns off DSP mode and changes to EQ mode
* Finish: Changes to start page of each mode.
* Previous: Changes to basic control display
EQ control
* DEFEAT: Changes to DEFEAT in EQ mode
* CLASSIC: Changes to CLASSIC in EQ mode
* JAZZ: Changes to JAZZ in EQ mode
* ROCK: Changes to ROCK in EQ mode
* , : Up/down in selected band
* Finish: Changes to start page of each mode
FADER, BALANCE control
* , , , : Up/down in FADER/BALANCE
* Available in DSP OFF
* Finish: Changes to start page of each mode
POSITION control
* POS: Changes in order of ALL → F/R → F/L → REAR → ALL →

* Finish: Changes to start page of each mode.
* Can control if in DSP ON
DVDC DISC input
DVDC DISC input display

* 1~8: DISC selection
* Finish: Moves to normal video display
* Previous: Changes to basic 1 display of DVDC DVD OSD
AFFECTED VIN
2G 15
Terms on DVD System

5.1 channel
As the technology that can digitalize audio and video data and analog audio source, it became possible to separate
audio source into various speakers to realize vivid and dynamic sound.
In general, 5 from 5.1 channel means the function that can divide audio source into 2 front speakers, 1 center speaker
and 2 rear speakers. 0.1 means woofer speaker. Above explanation is based on home theater and has no relation with
the number of speakers. It can be said 5.1, 6.1 and 7.1 channel by the digital audio source dividing function and effect
comes out through speakers.
5.1 channel on the STAVIC has 2 front speakers, 3 center speakers and 2 rear speakers to realize 5 channels and
subwoofer with built-in AMP is in charge of 0.1 channel.
According to vehicle shapes and structures and how to deliver the sound, there can be 1 or 2 center speakers and 3
speakers like in STAVIC that carries a lot of people.
Dolby digital (AC-3)

It encodes/decodes by each 6 channels respectively. It has been developed from the technology called Dolby surround
(Dolby Pro Logic) that can divide current 2 channels into 4 channels.
DTS (Digital theater systems)

A system that developed by Digital Theater Systems, California, USA, and designed to play digitalized film audio tracks.
It is a sound track for DVD titles in NTSC.
DSP (Digital Signal Processor)

Audio source is digitalized and can set the atmosphere proper for the place. AV system on STAVIC has 4 fields -
STADIUM, HALL, CHURCH and CLUB.
DTS-DVD
Recently, it is using as music format for DVD titles. Dolby Digital or PCM type is poplar for DVD-VIDEO, but DTS
function is increasing for high-end AMP or players. In case of DTS, level of sound division and every details are recorded
(DVD title) and has 1/3 of compression ratio compared with Dolby Digital 5.1. So a title, having large capacity, that
formatted by DTS function cannot record other supplement and subtitles.
However, it is very sensitive to sound so people accustomed to 5.1 channel prefer DTS titles.
AFFECTED VIN
16 2G
2) Tuner / 5.1 Channel AMP with Built-in DSP / DVD Navigation

(DVD System Basic)
Tuner, AMP and navigation units are installed together at bot-
tom of driver side rear quarter door panel. Remove the lower
quarter trim panel to replace the units.
Tuner
A tuner filters and cuts unnecessary signals among
received signals and then precisely adjusts input
signals. Installed tuner has following functions.
Connecting terminal of the tuner receives amplified
signals from each TV antenna module locating rear
quarter glass that receives TV signals from glass
antenna and then inputs to left and right channel.
AM/FM radio module on the roof panel rear end re-
ceives amplified signals from glass antenna and then
transmits to tuner input (1 channel).
TV antenna module RH 2 channels
2 channels
TV antenna module LH
Radio antenna module
DVD Navigation
Navigation unit in this vehicle transmits huge amount of data on the
DVD CD directly to AV head unit, without via tuner and AMP. It has
3D view function for roads and buildings and supporting data. GPS
antenna to receive/send vehicle position from/to satellite is located
behind the Instrument panel.
AFFECTED VIN
2G 17
5.1 channel power amplifier with built-in DSP

DVD system displays high quality pictures and separates digital audio sources to give digital effects according to speaker
arrangement. A chipset that can treat digital audio source signal is installed on the exterior AMP and has following function.
1. DSP (Digital Signal Processor) function

* AC-3, DTS 5.1 channel decoder (Decoder: separates and analyzes
audio source)
* Dolby Pro Logic, Dolby Pro Logic II function
* Sound filed setting (HALL/CHURCH/STADIUM/CLUB)
* Equalizer mode (Classic/Jazz/Pop/Rock)
* Speaker output control (All/driver’s side/passenger’s side/rear seats)
Appearance 2. Speaker control (Basic function)

Terminals on the below connector control speaker output. Terminals de-
code according to speakers like front, rear, center and tweeter and out-
put separated sound. Decoded signal goes to subwoofer that has built-in
AMP and the AMP in the woofer outputs sound directly.
Optical fiber cable

(AV head unit)
Connector
AFFECTED VIN
18 2G
3) Rear Monitor (Roof Monitor)
Location
The size of rear monitor is 7 inch. When pressing the OPEN button, the power is supplied and the rear monitor slide
down by approx. 25°. After then, manually adjust the monitor to desired angle. Its angle can be adjusted by 100°.
Rear monitor
Front monitor
Monitor Control
Rear monitor Brightness / Tint / Color control dial OPEN switch
When pressing the OPEN button, the power is sup-
plied and the rear monitor slide down by approx. 25°.
OPEN switch (Power supply button)
AFFECTED VIN
2G 19
Location
Opening angle
When pressing the OPEN button, the power is supplied and the rear monitor slide down by approx. 25°. After then,
manually adjust the monitor to desired angle. Its angle can be adjusted by 100°.
Press OPEN (approx. 25°) Maximum opening angle (approx. 100 ° )
Remote controller for rear monitor

Remote controller for rear monitor is available. Point the remote controller’s LED toward rear monitor to operate the AV
system. Remote controller works normally when the monitor is closed. Therefore, the system can be operated without
opening the monitor in some modes (radio / tape / audio CD and MP3) that do not need to see display.
Receiver window
Remote controller’s LED
Rearview camera equipped vehicle

When moving the gear selector lever into R (Reverse) position while watching DVD or VCD, the rearview appears on the
front monitor but the rear monitor continues to show the current screen.
AFFECTED VIN
20 2G
5. REMOVAL AND INSTALLATION

Head Unit (Based on DVD System)
Preceding work: Removal of center panel assembly
1. Remove four screws from the AV head unit.

2. Disconnect the connectors and optical fiber cables from the back of the head unit.
[Note]
The unit with DVD changer has two optical fiber cables and the unit without it has one optical fiber cable.
3. Remove the AV head unit assembly.
AFFECTED VIN
2G 21
Tuner
1. Disconnect four TV antenna terminals, main connector
and radio antenna connector.
Main connector
TV antenna
Radio antenna
2. Unscrew eight bolts and remove the deck.

3. Unscrew bolts and remove the tuner unit.
[Tuner unit]
AFFECTED VIN
22 2G
Amplifier with Built-in DSP

Preceding work: Removal of Tuner/Amplifier deck
Main connector
Optical fiber cable
1. Disconnect the amplifier connector.

2. Unscrew bolts (3 x 2) at front and rear sides and remove the amplifier.
DVD Navigation
Preceding work: Removal of Tuner/Amplifier deck
• Unscrew the bracket bolts (2 x 2), disconnect the rear amplifier connector, and remove the navigation unit.
[Notice]
Make sure to remove the tuner/amplifier deck before

disconnecting the connector.
AFFECTED VIN
2G 23
Rear Monitor
1. Unscrew four fixing bolts (10 mm) with the rear monitor
lowered.
2. Disconnect the connector and remove the rear monitor assembly.
AFFECTED VIN
24 2G
Subwoofer Speaker
Preceding work: Removal of passenger’s seat
• Remove four bracket bolts and disconnect the connector and terminals.
Front Door Speaker
• Refer to “Body” section.
AFFECTED VIN
2G 25
Rear Door Tweeter Speaker
1. Remove the rear door trim.
2. Disconnect the connector from the door trim.
3. Unscrew the bolts from the removed door trim and remove the tweeter speaker.
AFFECTED VIN
26 2G
Rear Quarter Speaker

Preceding work: Removal of passenger’s seat
1. Remove the rear lower quarter panel. 2. Disconnect the connector A from the rear quarter
speaker.
3. Unscrew the screws and remove the rear quarter speaker.
AFFECTED VIN
2G 27
Front Center Speaker
1. Separate the front center speaker as shown in

below figure.
2. Disconnect the connector from the front center

speaker assembly.
3. Unscrew the screws from the removed front center speaker assembly and remove the front center
speaker.
AFFECTED VIN
28 2G
Front Tweeter Speaker
1. Remove the instrument panel.
2. Disconnect the tweeter speaker connector from the removed instrument panel, unscrew the screws and
remove the tweeter speaker.
AFFECTED VIN
2G 29
TV Antenna Module (LH/RH) Radio Antenna Module

Preceding work: Removal of rear quarter upper Preceding works:
panel Removal of luggage room lamp,Removal of third
and fourth row seats, Removal of rear quarter upper
and lower trims, Removal of rear headlining
TV antenna connections Radio antenna connection
AFFECTED VIN
MEMO
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2H 1
2H - Parking Assistance System
Table of Contents
COMPONENTS OF PARKING AID SYSTEM
(PARKING AID SYSTEM + REARVIEW CAMERA) 2H-3
1. Rearview camera equipped vehicle .............................. 2H-3
2. System control ........................................................... 2H-4
3. Parking aid system (PAS) ........................................... 2H-5
4. Component specifications ........................................... 2H-6
5. Removal and installation ............................................ 2H-10
REARVIEW CAMERA ..................................... 2H-12

1. Operational principle of rearview camera .................... 2H-13
2. Rearview camera operation ........................................ 2H-14
3. Rearview camera installation ..................................... 2H-14
PARKING ASSISTANCE SYSTEM CHANGED BY

AFFECTED VIN
2H 3
COMPONENTS OF PARKING AID SYSTEM

(PARKING AID SYSTEM + REARVIEW CAMERA)
1. REARVIEW CAMERA EQUIPPED VEHICLE

When moving the gear selector lever into R (Reverse) position while watching DVD or VCD, the rearview appears on the
front monitor but the rear monitor continuously shows current screen.
Multi-meter Front monitor ICM box
Even in other modes, it is changed to the parking When moving the gear selector lever into When moving the gear selector lever into “R”
aid screen when moving the gear selector lever into “R” position while watching DVD or VCD, position, the alarm buzzer in ICM box sounds
“R” position. the rearview appears on the front monitor. (installed at bottom of STICS).
Rearview camera
When selecting R position while A/V system is in use:
• The video mode in front A/V system is changed to rear-
view monitoring mode. However, the audio mode stays on.
• The video mode in front A/V system resumes when
shifting out from “R” position.
• The audio and video mode in rear A/V system are not
changed.
When selecting R position while A/V system is not in use:
• Both monitors are automatically turned on to display rearview.
• Both monitors are automatically turned off when shifting
out from “R” position.
Gear selector lever

(R position)
Applies power to parking aid system.
Parking aid sensor Rearview camera PAS unit

(Rear bumper)
The three parking aid sensors send the distance The rearview camera sends the rear- It is a control unit for the parking aid system (PAS)
data between rear bumper and obstacle to PAS view to the monitor by using wide angle and transmits the signals from sensors to multi-
unit. lens. meter and buzzer.
(installed in tuner/amplifier bracket)

AFFECTED VIN
4 2H
2. SYSTEM CONTROL
Parking Aid Unit
Send
Generates sensor
12 V
driving signals
Back Regulator
GND
sonar
Signal transmitter
AMP Receive
& BPF
Parking Aid Sensor
Back sonar
sensor
Reverse driving
(supplies power) (LH)
Back sonar
sensor
Buzzer (Center)
(ICM box)
Back sonar
sensor
(RH)
CHANGED BY PARKING ASSISTANCE SYSTEM

AFFECTED VIN
2H 5
3. PARKING AID SYSTEM (PAS)

1) System Configuration
Multi-meter Rear center obstacles Rear right obstacles Rear left obstacles
Rear left sensor Rear center sensor Rear right sensor
Parking aid
buzzer
PAS unit
Right sensor Left sensor
Center sensor
This unit controls the parking aid system. One of 3

Tuner
LEDs comes on when the corresponding parking
Amplifier with
aid sensor is defective and shows below mes-
built-in DSP
sage on multi-meter.
Navigation unit

AFFECTED VIN
6 2H
4. COMPONENT SPECIFICATIONS
The parking aid system emits the supersonic wave signals from the sensors on the rear bumper with a specific interval
and detects the reflected signals from obstacles while the gear selector lever is in “R” position.
The number of displaying bars is decreased and the alarm interval becomes faster as the obstacle approaches. This
supplementary system is to secure the safety distance for parking.
Descriptions Value Descriptions Value

Rated voltage DC 12 V Operating temperature -30°C ~ +80°C
Operating voltage DC 9 V ~ 16 V Storage temperature -40°C ~ +85°C
Current Unit Below 100 mA Relative humidity 95%RH max
consumption
Sensor Below 20 mA (each) Weight Unit 160g ± 10g max
Sensor insulating resistance Over 5 MΩ Sensor 70g ± 10g max
1) Parking aid unit

Detecting type: Super sonic wave
Detecting distance: 25 ~ 120 cm (distance between sensor
and obstacle)
2) Parking aid sensor

- Type: Piezo ceramic element
- Frequency: 40 KHz ± 2 KHz
- Detecting range (13.5 V)
* Horizontal: Min. 20° at 110 ± 5 cm Min. 100° at 50 ± 5 cm
* Vertical: Min. 20° at 110 ± 5 cm Min. 60° at 50 ± 5 cm

AFFECTED VIN
2H 7
3) Alarm interval
Alarm interval and display changes according to the distance as below:
While reversing, if obstacles are within stage 1, the warning beep sounds with long intervals. If within stage 2, the
warning beep sounds with short intervals and if within stage 3, the warning beep sounds continuously.
Stage L, C, R sensor Interval (msec) Remark

65
65
1 81 ~ 120 cm “Beep ”
195
195
65
65 65
65 “Beep ,
2 51 ~ 80 cm Beep ,
Beep ”
3 25 ~ 50 cm “Beep ”
Troubleshooting of Sensor
When the power is applied (gear selector lever is in “R” position), the sensor will be diagnosed once. If found any failure
due to open circuit to sensor or communication error, warning buzzer sounds for 3 seconds and the data on failed
sensor transmits to the instrument panel to light up the corresponding LED. If normal, the warning buzzer sounds only
for 65 ms.
1) Whenever the power is applied, the diagnosis mode is initiated.

2) Sensor failure conditions (conditions for warning beep due to failure)
(a) Sensor failure conditions (conditions for warning beep due to failure)
(b) Open in sending circuit
(c) Open in receiving circuit
(d) Open in power circuit (+, -)
Back sonar (RH) Back sonar (LH)
* Warning beeps Back sonar (center)
300ms
300ms
When failed
65ms
65ms
When normal

AFFECTED VIN
8 2H
4) Cautions on parking aid system
* Note that the display does not show everything in the rear area.
Always check nobody, especially animals and children, is behind the vehicle.
* Normal precautions when reversing should be maintained.
1. The parking aid system is just a supplemental device to help your parking operation.
2. Always keep the safety precautions.
3. Do not press or shock the sensors by hitting or high-pressure water gun while washing, or the sensors will be
damaged.
4. If the system is in normal operating conditions, a short beep sounds when the gear selector lever is moved into “R”
position with the ignition key “ON”.
5. If the system is in abnormal operating conditions, a beep sounds for 3 seconds when the gear selector lever is
moved into “R” position with the ignition key “ON” or engine running. However, it is also occurred when the obstacle
is within 50 cm from the rear bumper.
The parking aid system will not work or improperly work under following cases:
1) Certain obstacles that sensors can not detect

- Wires, ropes, chains.
- Cotton, sponge, clothes, snow that absorb ultrasonic waves.
- Obstacles lower than the bumper.
2) Not defective but improperly working

- When the sensing portion is frozen.
- When the sensing portion is covered by rain, water drops, snow or mud.
- When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles).
- When a high-power radio is turned on.
3) Narrowed sensing area

- When the sensing portion is partially covered by snow or mud.
- Surrounding temperature of sensor is too high (approx. over 80°C) or too low (approx. below -30°C)
4) Not defective but may occur improper working

- When driving on the rough roads, gravel road, hill and grass.
- When the bumper height is changed due to the heavy load.
- When the sensing portion is frozen.
- When the sensing portion is covered by rain, water drops, snow or mud.
- When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles).
- When a high-power radio is turned on.
- When some accessories are attached in detecting ranges

AFFECTED VIN
2H 9
5) Circuit Diagram

AFFECTED VIN
10 2H

Parking Aid Sensor
Preceding work: Removal of rear bumper
1. Remove the guide piece from the rear bumper and remove the bumper guide and energy shock absorber.
2. Remove the sensor cover and sensor while pushing and turning the sensor cover.

AFFECTED VIN
2H 11
Parking Aid Unit

Preceding work: Removal of rear lower quarter trim cover
Disconnect the unit connector and remove the parking aid unit.
- In AV system non-equipped vehicle
- In AV system equipped vehicle
PAS unit

AFFECTED VIN
12 2H
REARVIEW CAMERA
This is a supplementary parking aid system to display the rearview when the gear selector lever is moved into “R”
position.
“R” position Rearview camera
Power supply
Operates only when the gear selector lever is The rearview camera displays the rearview
in “R” position
Front monitor Rear monitor
The rear monitor displays the rearview only

when the A/V system is not in use.
The audio and video mode in rear A/V system are not changed when selecting R position while A/V system is in use.
[Notice]
• The real distance is different from what you see in monitor because the camera uses wide-angle lens.
• Note that the display does not show everything in the rear area.
• Keep the camera lens clean with a lens cleaner.

AFFECTED VIN
2H 13
1. OPERATIONAL PRINCIPLE OF REARVIEW CAMERA

In the rearview camera equipped vehicle, the monitors display when selecting “R” position for safe parking. The operating
conditions are as below:
General
When selecting R position while A/V system is in use:
• The video mode in front A/V system is changed to rearview monitoring mode. However, the audio mode stays on.
• The video mode in front A/V system resumes when shifting out from “R” position.
• The audio and video mode in rear A/V system are not changed.
When selecting R position while A/V system is not in use:
• Both monitors are automatically turned off when shifting out from “R” position.
Operating Conditions and Modes of Rearview Camera

The rearview camera cannot operate alone. If the gear selector lever stays in “R” position more than 3 seconds with
the ignition key “ON” or engine running, the rearview appears on the monitors automatically regardless of displays
by head unit.
[Notice]
When the rearview mode is activated, the AV system doesn’t work even though the buttons on the AV unit are pressed.
However, the monitor angle can be adjusted when the AV system is changed to the rearview mode with the head unit turned
off. And, the monitor angle and volume can be adjusted when the AV system is changed to the rearview mode with the head
unit turned on.
Auto mode
* Automatic operating mode
When selecting R position while A/V system is not in use (Ignition switch “ON”, engine running):
• Both monitors are automatically turned off when shifting out from “R” position.
When selecting R position while A/V system is in use (Ignition switch “ON”, engine running):
• The video mode in front A/V system is changed to rearview monitoring mode. However, the audio mode stays on.
• The video mode in front A/V system resumes when shifting out from “R” position.
• The audio and video mode in rear A/V system are not changed.
[Notice]
• The real distance is different from what you see in monitor because the camera uses wide-angle lens.
• Note that the display does not show everything in the rear area.
• Keep the camera lens clean with a lens cleaner.

AFFECTED VIN
14 2H
2. REARVIEW CAMERA OPERATION

The reverse signal works as an operation signal for rearview camera. If it receives reverse signal, the rearview camera is
turned on even though the AV unit is turned off.
The rearview camera consists of AV unit (including monitor), reverse signal, battery voltage and rearview camera.
The AV unit receives the power from battery and if it receives the reverse signal, supplies the power to rearview camera.
When the rearview camera operates, it transmits color video signal to the A/V unit then the rearview is displayed on the
monitor.
3. REARVIEW CAMERA INSTALLATION

The rearview camera is securely installed on the rear spoiler with high torque and strong adhesive. Do not apply exces-
sive force to remove it. Otherwise, it could be damaged.

AFFECTED VIN
2I 1
2I - Lamp
Table of Contents
EXTERIOR LAMPS ............................................. 2I-2
1. Locations of exterior lamps ........................................... 2I-2
2. Aiming and adjustment of front lamp .............................. 2I-4
3. Removal and installation of exterior lamps ..................... 2I-8
INTERIOR LAMPS............................................. 2I-18

1. Locations of interior lamps .......................................... 2I-18
2. Door coupled room lamp switch operation ................... 2I-20
3. Removal and installation of interior lamps .................... 2I-21
LAMP CHANGED BY
AFFECTED VIN
2 2I
EXTERIOR LAMPS
1. LOCATIONS OF EXTERIOR LAMPS
Front Lamps
Side turn signal lamp:

one at each side (12V - 5W)
Headlamp Headlamp
: one at each side (12V - 5W)
Fog lamp (LH) Fog lamp (RH)
Tail lamp:
Low beam:
Turn signal lamp:

High beam:
Tail lamp
Connector
3 2
4 Tail lamp/Turn signal lamp

connector
5
Headlamp Headlamp Turn signal lamp

(High beam) (Low beam)
CHANGED BY LAMP
AFFECTED VIN
2I 3
Rear Lamps
High mounted stop lamp
: center – 1 (12V – 5W)
Tail lamp assembly

License plate lamp
: center – 2 (12V – 5W)
Rear lamp
Rear fog lamp
Stop lamp: one at each side (12V - 8W)
Rear turn signal lamp: one at each side (12V - 27W)
Tail lamp: one at each side (12V - 8W)
Stop lamp
Tail lamp assembly

Rear turn signal lamp/Rear fog lamp
connector
Tail lamp
LAMP CHANGED BY
AFFECTED VIN
4 2I
2. AIMING AND ADJUSTMENT OF FRONT LAMP

Headlamp Aiming
An approved beam setting device should be used for a Headlamp aiming requirements:
correct headlamp aiming. - parking on a flat surface
Make sure to follow the operating instructions provided by - specified tire pressure
the manufacturer.
- one passenger (driver, 65 kg),
If not available to use the beam setting device, adjust the
- spare tire and OVM tools loaded (unlade all other loads)
headlamp aiming with a screen.
Adjustment of low beam

No.1 adjustment hole: Up and Down
No.2 adjustment hole: Left and Right
Adjustment of high beam

No.3 adjustment hole: Up and Down
No.4 adjustment hole: Left and Right
No.1 adjustment: No.2 adjustment: No.3 adjustment: No.4 adjustment:

Direction A - Up Direction C - Left Direction E - Up Direction G - Left
Direction B - Down Direction D - Right Direction F - Down Direction H - Right
CHANGED BY LAMP
AFFECTED VIN
2I 5
Cautions During the Aiming

Procedures
The headlamp angle should be within the adjustment range
as shown in the figure.
Adjust the headlamp aiming by rotating the direction control

levers (Up, Down, Left, Right) in turn with a screwdriver.
When using a beam setting device

1. Align the vehicle and beam setting device according to the operating instructions provided by the manufacturer.
2. Adjust the headlamp aiming by rotating the direction control levers (Up, Down, Left, Right) in turn with a screwdriver.
LAMP CHANGED BY
AFFECTED VIN
6 2I
When Using a Screen

1. Install a screen (2m X 1.5m) in front of the headlamps in vertical by 3m away and align the center lines of the vehicle
and the screen.
(Unit: mm)
Center line of
vehicle
Vertical line of headlamp bulb
Horizontal line of
headlamp bulb
Horizontal line of headlamp

focus
2. Run the engine with approx. 2,000 rpm and turn on the
(Unit: mm)
headlamp. At this moment, the focus of the headlamp
should aim the “A” point.
Allowable focusing Allowable focusing

area area
3. If the focus deviates the “A” point, adjust the headlamp

aiming by rotating control levers (Up, Down, Left, Right)
in turn with a screwdriver.
CHANGED BY LAMP
AFFECTED VIN
2I 7
Fog Lamp Aiming Adjustment
1. Down
The lamp aiming moves down
when the knob is turned to direc-
tion 1 (clockwise).
2 1
2. Up
The lamp aiming moves up when
the knob is turned to direction 2
(counterclockwise).
Knob
To adjust the fog lamp downwards
Fog lamp
1 - Clockwise
Down
Knob
To adjust the fog lamp upwards
Fog lamp
2 - Counterclockwise
Up
Knob
LAMP CHANGED BY
AFFECTED VIN
8 2I
3. REMOVAL AND INSTALLATION OF EXTERIOR LAMPS

Locations of Exterior Lamps
3. Side turn signal lamp
Connector
Bulb
Lamp cover
2. Fog lamp assembly

Lamp cover Lamp cover
1. Headlamp assembly
Bulb
4. High mounted stop lamp
7. Rear tail lamp assembly 5. License plate lamp 6. Tail lamp (back-up lamp)
CHANGED BY LAMP
AFFECTED VIN
2I 9
1) Headlamp Assembly
• The headlamp assembly consists of position lamp, headlamp low beam, headlamp high beam, and front turn signal lamp.
1. Remove two bolts on the lamp housing.
2. Remove one bolt in engine compartment, disconnect two connectors, and remove the lamp assembly.
3. Carefully remove the headlamp.

Cover rubber ring
[Notice]
If the cover rubber ring is worn, replace it with new one.
LAMP CHANGED BY
AFFECTED VIN
10 2I
Replacement of Headlamp Bulb

1. Remove the headlamp dust cover.
High beam cover
Low beam cover
2. Disconnect the headlamp bulb connector.
3. Push up the bulb clamp to remove it.
Push
Remove
CHANGED BY LAMP
AFFECTED VIN
2I 11
4. Remove the bulb and install new bulb with same

specifications.
Replacement of Tail Lamp/Turn

Signal Lamp
1. Disconnect the tail lamp/turn signal lamp connector from
the headlamp assembly.
2. Remove the tail lamp/turn signal lamp bulbs from the headlamp assembly and install new bulb with same
specifications.
Tail lamp bulb assembly
Turn signal lamp bulb assembly
Headlamp (low beam) bulb assembly
Headlamp (high beam) bulb assembly
LAMP CHANGED BY
AFFECTED VIN
12 2I
2) Fog Lamp Assembly
Removal and Installation of Fog Lamp Assembly

1. Disconnect the fog lamp connector.
2. Remove the mounting screws (when removing the 3. Remove the fog lamp bulb (when only removing
assembly). the bulb).
4. Remove the fog lamp assembly.
Lamp Lamp cover
Bulb connector
Mounting screws
Bulb
CHANGED BY LAMP
AFFECTED VIN
2I 13
3) Side Turn Signal Lamp Assembly
Removal and Installation of Side Turn Signal Lamp

1. Push the turn signal lamp forward and pull in the rear
side of the lamp to separate.
2. Disconnect the connector and remove the lamp.
Bulb connector
Lamp assembly
Bulb assembly
Bulb cover rubber ring:

If the cover rubber ring is defective,
replace it with new one.
LAMP CHANGED BY
AFFECTED VIN
14 2I
4) High Mounted Stop Lamp Assembly
Removal and Installation of High Mounted Stop Lamp

1. Remove the high mounted stop lamp cover from the tailgate spoiler.
[Notice]
Be careful not to damage the installation surface when removing the tailgate spoiler.
Adhesive area
Adhesive area
High mounted spoiler Adhesive area
Lamp
Mounting screw
Mounting screw
Lamp cover
2. Unscrew the screws from the high mounted stop lamp, disconnect the lamp connector, and remove the lamp assembly.
Tailgate spoilera
Rearview camera
High mounted stop lamp bulb
Rearview camera cover
High mounted stop lamp
High mounted stop lamp cover
CHANGED BY LAMP
AFFECTED VIN
2I 15
5) License Plate Lamp Assembly

1. Remove the license plate lamp assembly from the tailgate rear garnish.
2. Remove the bulb connector from the removed lamp assembly and pull out the bulb from the bulb connector.
3. Replace the bulb with new one and install the assembled lamp assembly into the mounting hole.
Bulb connector
Bulb
Lamp
License plate
lamp assembly
6) Tail Lamp (Back-up) Lamp Assembly (Rear Fog Lamp)

1. Remove the tailgate inner trim. 2. Disconnect the back-up lamp connector (1) and remove
the nuts (2) from the tail lamp (back-up lamp) assembly.
Fog lamp /
Back-up lamp
3. Remove the tail lamp (back-up lamp) assembly and pull out the bulb from the removed tail lamp assembly.
Bulb connector
Bulb connector
Tail lamp
(back-up lamp)
/ Fog lamp
LAMP CHANGED BY
AFFECTED VIN
16 2I
7) Tail Lamp Assembly

1. Open the tailgate and remove two screws from the tail lamp assembly.
Tail lamp assembly (RH)
Tail lamp assembly (LH)
2. Disconnect the connector and remove the tail lamp assembly.
CHANGED BY LAMP
AFFECTED VIN
2I 17
3. Remove the bulb connector by rotating it counterclockwise from the removed tailgate lamp assembly. Pull out the
bulb from the bulb connector and install the new bulb with same specifications.
Tail (stop) lamp
Rear fog lamp

/ Rear turn signal lamp
Bulb connector
Tail (position) lamp
LAMP CHANGED BY
AFFECTED VIN
18 2I
INTERIOR LAMPS
1. LOCATIONS OF INTERIOR LAMPS
1. Front room lamp
: one at both sides (12V – 5W)
Front room lamp switch Side (third row set) room lamp
(coupled operation with door)
Rear room lamp switch
(coupled operation with door)
Side (second row set) room lamp
The front room lamps (1, 2) are turned on when pushing the lamp
body regardless of the positions of front room lamp coupled switch.
Press the lamp body again to turn off.
Front room lamps (driver’s and passenger’s) are turned on when
opening one of front doors with this switch (A) pressed in.
2. Rear room lamp (in second and third row seats)

: one at both sides (12V – 5W)
3. Center console lamp

: one at back of center console (12V – 5W)
Rear room lamps are turned on and off when the switch (1) is
pressed in and out.
Four rear room lamps are turned on when opening a rear door
with this switch pressed in. The rear room lamps are turned off
when closing the door.
Center console lamp is turned on when opening

a door.
CHANGED BY LAMP
AFFECTED VIN
2I 19
4. Luggage room lamp

: one at center (12V – 5W)
Rear (third row set) room lamp
Rear (second row set) room lamp
Front room lamp
Luggage room lamp is turned on and off when the

switch (1) is pressed in and out.
Luggage lamp is turned on and off when opening
and closing one of rear doors with the front room
Glove box lamp lamp switch pressed in.
Center console lamp

5. Glove box lamp
: one at center (12V – 5W)
6. Door courtesy lamp

: one at each door (12V – 5W)
Door courtesy lamp is turned on when opening a door while

the ignition switch is in “ON” position.
LAMP CHANGED BY
AFFECTED VIN
20 2I
2. DOOR COUPLED ROOM LAMP SWITCH OPERATION

Front/Rear Door Coupled Operation
Door coupled room

lamp switch
1. Front door coupled

room lamp switch
Front room lamps (C) are turned on when open-
ing one of front doors with this switch (1)
pressed in. The front room lamps are dimmed out
after closing the door.
2. Rear door coupled room

lamp switch
1. Rear room lamps (A) and luggage room lamp (B) are turned on when
opening a rear door with this switch (2) pressed in. The lamps are
dimmed out after closing the door.
2. Rear and luggage room lamps are turned on only when the side room
lamp coupled switch is pressed in.
CHANGED BY LAMP
AFFECTED VIN
2I 21
3. REMOVAL AND INSTALLATION OF INTERIOR LAMPS

Locations of Interior Lamps
1. Door courtesy lamp 2. Luggage room lamp 3. Glove box lamp assembly
4. Interior room lamp assembly 5. Front room lamp assembly 6. Center console lamp assembly
LAMP CHANGED BY
AFFECTED VIN
22 2I
1) Door Courtesy Lamp Assembly

1. Remove the door courtesy lamp cover (1) from the door panel and pull out the bulb (2) with new one with same
specifications.
2) Glove Box Lamp Assembly

1. Open the glove box cover and push down the front portion of the lamp. Disconnect the connect and remove the
lamp assembly.
2. Disconnect the lamp connector and remove the lamp. However, it is not necessary to disconnect the connector
when removing only the bulb.
3. Install in the reverse order of removal. Replace the bulb with new one with same specifications.
CHANGED BY LAMP
AFFECTED VIN
2I 23
3. Luggage Room Lamp Assembly

1. Open the tailgate and remove the luggage room lamp cover with a flat blade screwdriver. At this time, be careful not
to damage the surroundings.
2. Remove the bulb from the luggage room lamp with new one with same specifications.
Bulb
LAMP CHANGED BY
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24 2I
4) Side Room Lamp Assembly

1. Unscrew the screws and remove the side room lamp

assembly.
[Notice]
1. Be careful not to damage the lamp cover when removing it.

2. Replace the bulb with new one with same specifications.
2. Disconnect the lamp connector (1), unscrew the screws from the removed room lamp assembly, and remove the
lamp.
* when removing the bulb

Remove the lamp cover (1) and pull out the bulb (2). Be careful not to damage the lamp cover when removing it.
CHANGED BY LAMP
AFFECTED VIN
2I 25
5. Front Room Lamp Assembly

Removal and Installation of Front

Room Lamp
1. Open the sunglasses box and remove two screws.
2. Remove the front room lamp assembly.
3. Disconnect the multi-meter connector (1) and bulb

connector (2).
4. Remove the bulb from the removed front room lamp. Install in the reverse order of removal.
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26 2I
* when replacing the bulb
Remove the lamp cover (1) and pull out the bulb (2).
[Notice]
1. Be careful not to damage the lamp cover when removing it.

2. Replace the bulb with new one with same specifications.
CHANGED BY LAMP
AFFECTED VIN
SECTION 03
AIRCONDITIONING
SYSTEM
CONTENTS
AIR CONDITIONING SYSTEM...................................... 3A
SUPPLEMENTARY HEATER SYSTEM ........................ 3B

3A 1
3A - Air Conditioning System
Table of Contents
AIR CONDITIONING SYSTEM ................................ 2
1. System layout and components ........................................ 2
2. Ventilation system ............................................................4
3. Air conditioner module wiring and layout ............................ 6
4. Air conditioner controller (Unit) ..........................................8
5. Self diagnosis (Only for FATC air conditioner) .................. 12
6. System diagram .............................................................. 15
7. Circuit diagrams in air conditioner system ....................... 16
8. Sensors and actuators .................................................... 21
9. Air quality system (AQS) ................................................ 24
10. Air conditioner module sensors and actuators ............... 28
11. Air conditioner and heater pipe layout ............................ 37
12. Removal and installation of the related components
........................................................................................... 40
AIR CONDITIONING SYSTEM CHANGED BY

AFFECTED VIN
2 3A
AIR CONDITIONING SYSTEM

1. SYSTEM LAYOUT AND COMPONENTS
Sun load sensor - instrument
Type Air conditioner controller panel upper left
FATC
Manual air
conditioner
It changes sun load coming through front
windshield into current to input to FATC
controller.
AQS/Air source selection

Compressor – engine right
switch
A function that turns on/off the air Driven by engine and transmits refriger-
source selection and air quality system. ant from condenser to inside of vehicle.
Front air conditioner module assembly – inside instrument panel
Air mix door Air source door

actuator actuator
PTC (If equipped)
Air conditioner filter
Duct temperature
sensor
Blower motor
Blower high
speed relay
Mode door
actuator
Thermo AMP
Air conditioner
Power transistor
wiring
CHANGED BY AIR CONDITIONING SYSTEM

AFFECTED VIN
3A 3
Receiver drier Sub-condenser –

Condenser
– Condenser right right wheel front
Absorbs moisture in the refrigerant and Installed in front of vehicle and condenses Condenses high temperature and high
reserves refrigerant to supply smoothly. vapor refrigerant into low temperature and pressure vapor refrigerant into low-tem-
high pressure liquid refrigerant. perature-high-pressure liquid refrigerant.
Engine ECU – passenger’s Coolant temperature sensor

footstep – on engine
Detects A/C AUTO switch position, cool- A sensor that detects coolant temperature
ant temperature, engine condition and driv- and transmits to engine ECU.
ing condition to control the air conditioner.
Rear air conditioner module assembly – bottom of rear left
Front
Blower motor
Air conditioner high

pressure/low pressure pipe Power transistor
Rear
Rear fan speed dial Air mix door
actuator
A switch that controls the rear air con-

ditioner module.

AFFECTED VIN
4 3A
2. VENTILATION SYSTEM
1) Locations of Vents
Front Ventilation
Rear ventilation
Air conditioned air flows
Heated air flows

Heater vent

AFFECTED VIN
3A 5
2) Ventilation Modes
* Vent mode * Bi-level mode
* Floor mode * Defrost and floor mode
* Defrost mode * Rear air conditioning mode

AFFECTED VIN
6 3A
3. AIR CONDITIONER MODULE WIRING AND LAYOUT

1) Front Air Conditioner Module
Wiring layout
C211A A/C
Mode motor
wiring
C211A A/C wiring (FATC)
(manual)
Duct sensor
Air source
selection motor
High speed relay
Blower motor
(FATC, manual)
Interior temperature
sensor (interior
humidity sensor)
C211B A/C wiring Air mix FATC: power transistor
motor Manual: blower resistance
C211 A/C wiring A/C control Thermo amp

A/C control (FATC, manual)
panel (FATC)
panel (manual)
Components
Air conditioner filter Evaporator
Air source selection

door actuator
Blower
motor
Blower high
speed relay
Heater core

AFFECTED VIN
3A 7
2) Rear Air Conditioner Module

Wiring layout
Rear blower motor
Rear blower relay (Hi)
Rear power transistor
Air mix motor C305 A/C

wiring
(RR)
Components
Roof air conditioner duct
Blower motor
Air mixer door actuator
Rear floor heater duct
Evaporator Mixer door
Heater & air conditioner

pipes
Heater core

AFFECTED VIN
8 3A
4. AIR CONDITIONER CONTROLLER (UNIT)

Full Automatic Air Conditioner Controller
Fan speed control switch and
AMP switch Display window (VFD)
- Each switch mode appears as a symbol on the fluorescent

display and malfunction of each sensor in air conditioner
control system is also displayed.
- When controlling the fan speed by rotating

this switch in AUTO mode, the mode is
Temperature control switch and
changed from AUTO to manual and the fan
AUTO button
speed can be changed in 6 stages.
- When pressing the air conditioner AUTO mode
- When pressing this switch, the outside tem- and temperature control dial switch, the system
perature measured by ambient temperature operates in AUTO mode and can set the desired
temperature (18 ~ 32°C) by rotating.
sensor comes on for 5 seconds and then
To get the desired temperature, the air conditioner
returns back to preset temperature. controls compressor, door mode, air source door,
air mix door and blower motor automatically.
Rear fan speed control switch

The positions that can control in
3 stages in front seat.
(cannot control the rear fan speed in rear seats)
Rear blower OFF
Rear air conditioner switch: ON (can control

the rear fan speed in rear seats)
Front/rear independent cooling/heating
1. Front: Air conditioner operation 2. Front: No air conditioner operation 3. Rear: Heater operation and control
Rear: Heater operation Rear: Heater operation
Front air conditioner: ON Front air conditioner: OFF Rear air conditioner switch: R position
Rear fan control switch: 1, 2, or 3 position Rear fan control switch: 1, 2, or 3 position Rear heater switch: ON
Rear heater switch: ON Rear heater switch: ON Fan control switch in rear seats: can con-
trol the rear fan speed

AFFECTED VIN
3A 9
Air conditioner OFF switch A/C switch: When pressing this switch, the air conditioner oper-
ates in manual mode and A/C ON indicator comes
on.
AQS system
- Air Quality System (AQS) changes the air source selection to
recirculation mode when polluted air is detected through AQS
sensor. The air source selection returns back to fresh air intake
mode after a specified period or the polluted air is disappeared
(refer to AQS and ambient temperature sensor).
Defroster switch
When pressing this switch, the airflow direction will be changed

to windshield and door glasses, the air conditioner operates auto-
matically and outside air comes in. At this moment, the defroster
indicator, air conditioner indicator and fresh air mode indicator
come on. When pressing the switch again, the air conditioner re-
turns back to normal operations.
When pressing the AUTO switch, the defroster mode appears

on the VFD until the coolant temperature reaches at a certain
level.
MODE switch
- By depressing this switch, the airflow mode is changed.

AFFECTED VIN
10 3A
Manual Air Conditioner Controller

Manual air conditioner controller controls the fan speed, air distribution direction, air source selection and temperature
control with motor actuators according to soft button and dial switch operations.
Fan switch
Temperature control switch
- Controls the airflow temperature. : Turns off the blower motor and compressor.
1~4: Controls the fan speed 1 to 4 stage.
32 °
18 °

The positions that can control in
3 stages in front seat.
(cannot control the rear fan speed in rear seats)
Rear blower OFF
Rear air conditioner switch: ON

(can control the rear fan speed
in rear seats)
Front/rear independent cooling/heating
1. Front: Air conditioner operation 2. Front: No air conditioner operation 3. Rear: Heater operation and control
Rear: Heater operation Rear: Heater operation
Front air conditioner: ON Front air conditioner: OFF Rear air conditioner switch: R position
Rear fan control switch: 1, 2, or 3 position Rear fan control switch: 1, 2, or 3 position Rear heater switch: ON
Rear heater switch: ON Rear heater switch: ON Fan control switch in rear seats: can
control the rear fan speed

AFFECTED VIN
3A 11
Defroster switch
A/C switch When pressing this switch, the airflow direction will be
Operates air conditioner by turning on blower mo- changed to windshield and door glasses, the air condi-
tor and compressor. tioner operates automatically and outside air comes in. At
this moment, the air source selection indicator goes off.
Mode switch
Vent mode
The air flows towards face and
the indicator comes on.
Defroster and floor mode

The air flows towards front windshield
and floor and the indicator comes on.
Floor mode
The air flows towards floor and
the indicator comes on.
Bi-level mode
The air flows towards face and
floor and the indicator comes on.
Air source selection switch

Rear heater switch
When pressing this switch, the air recirculates in the vehicle in-
side and indicator comes on. When pressing it again, the indicator When pressing this switch, the rear heater op-
goes off and the fresh air comes in. erates and the indicator comes on.
(However, under defroster mode or defroster/floor mode, it stays

in the fresh air mode.)

AFFECTED VIN
12 3A
5. SELF DIAGNOSIS (ONLY FOR FATC AIR CONDITIONER)

Self Diagnosis Code
The FATC controller has self diagnosis function that can diagnose the system by itself. Before checking each component,
be sure to check the default code by using self diagnosis function.
Code Malfunction Remark Code Malfunction Remark

0 Normal 1 8 - -
1 Defective interior temperature sensor 25 9 Defective AQS -
2 Defective ambient temperature sensor 25 10 Defective humidity sensor -
3 Defective duct sensor - 11 - -
4 Defective air mix door motor - 12 Defective intake door -
5 Defective sun sensor - 13 - -
6 Defective power transistor - 14 - -
7 Defective blower high relay - 15 - -
Self Diagnosis
1. Set the temperature to 26°C with the temperature control switch (AUTO), and press the OFF switch 3 times within
3 seconds after temperature setting while the AUTO switch is pressed.
AUTO switch Self diagnosis display
Press OFF switch 3 times.

AFFECTED VIN
3A 13
2. At this moment, the air conditioner controller performs the self diagnosis procedures.
3. The Micro computer integrated in controller displays the defect codes in turns on the VFD after performing self
diagnosis. Below figure shows the defect code caused by disconnecting the interior temperature sensor/humidity
temperature sensor connector.
Defect code ON
Defect code ON
4. After displaying defect code, operates again in AUTO mode.
[Note]
For sun sensor, the diagnosis for short circuit is only available. When the switch circuit is opened, the system recognize it
as a night.

AFFECTED VIN
14 3A
Phenomenon when Air Conditioner System is Defective

(Initial Automatic Diagnosis)
- If any sensor in the air conditioner system is defective, the temperature display blinks about 3 times during initial
operation of air conditioner controller.
Current setting
temperature blinks
- If the setting temperature starts to blink, the self diagnosis starts to check the conditions of defective sensor.

AFFECTED VIN
3A 15
6. SYSTEM DIAGRAM
User Setting Power

Control temperature
transistor Fan speed control
(Blower motor
Blower high control)
speed relay
Ambient
temperature
Duct
temperature
Air mix motor Temperature control

Environ- Interior
ments temperature Air
condi-
tioner
Sun loads Mode motor Air flow control
control-
ler
Air source Air source selection
AQS sensor selection motor control
Vehicle
Vehicle speed
informa-
tion Wiper
operation Engine ECM Compressor control
Air Conditioner Compressor Control by Engine ECU

In case of current vehicle models, the system turns ON/OFF the compressor switch according to refrigerant pressure,
ambient temperature and condenser temperature to protect air conditioner circuits. However, for the vehicle equipped
with DI engine, the engine ECU turns off air conditioner compressor as below in addition to above conditions.
1. Coolant temperature: below -20°C

2. Coolant temperature: over 115°C
3. For approx. 4 seconds after starting the engine
4. When engine speed is below 650 rpm
5. When engine speed is over 4,500 rpm
6. During abrupt acceleration for the vehicle equipped with manual transmission

AFFECTED VIN
16 3A
7. CIRCUIT DIAGRAMS IN AIR CONDITIONER SYSTEM

FATC (Full Auto Temperature Control)
1) Condenser fan, air mix motor, sun load, coolant temperature sensor

AFFECTED VIN
3A 17
2) Front blower, motor (mode/air source selection), inside air/humidity, outside air/AQS sensor

AFFECTED VIN
18 3A
3) Rear air conditioner (blower, mode actuator)

AFFECTED VIN
3A 19
Manual Air Conditioner

1) Power, air conditioner compressor, motors (mode, inside air/outside air, air mix)

AFFECTED VIN
20 3A
2) Blower motor (front, rear)

AFFECTED VIN
3A 21
8. SENSORS AND ACTUATORS

1) Sun Sensor
It is installed on the upper left end of instrument panel. It is using characteristics that the amount of current changes
according to amount of light on the photosensitive surface. Photo diode, converts the changes in light intensity into
electrical changes, detects the amount of light coming through windshield and changes it into current and then sends
the signal to FATC controller.
Inspection
1. Remove the sun sensor and measure the current between terminals under sunlight.
2. Measure the current again under shade. It is in normal conditions if the measured value is less than the measured
value under sunlight.
3. Turn the ignition switch to “ON” position.
4. Measure the voltage to the sun sensor from FATC connector. (approx. 2.5 V under sunlight and 4.8 V under shade.)
5. If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified
range, replace the FATC controller.

AFFECTED VIN
22 3A
2) Active Incar/Humidity Sensor (AIH Sensor)

The AIH sensor is installed at the driver side instrument panel undercover. It is a sensor that detects interior temperature
and humidity.
Location
Humidity sensor
Active incar sensor

(interior temperature
sensor)
Functions
Interior temperature sensor
This sensor is a negative temperature coefficient (NTC) thermistor and detects the interior temperature with air coming
from senor hole and then sends the voltage value according to the changed resistance to FATC controller.
Humidity sensor
This sensor detects the interior humidity with humidity cell and then sends the voltage value according to the changed
humidity to FATC controller.

AFFECTED VIN
3A 23
Inspection
If the active incar sensor defect code (DTC 1) and the humidity sensor defect code (DTC 10) are set, check as below:
Air conditioner controller
Air conditioner controller connector AIH sensor (based on sensor)

(based on wiring)
[Active incar sensor] [Humidity sensor]
1. Remove the integrated AIH sensor and measure the 1. Apply 5 V to terminal No. 1 and 3 on the humidity
resistance between terminal No. 5 and 6 on the sensor connector.
sensor connector.
2. Connect the positive (+) probe of a tester on No. 2
(standard: approx. 25°C, 2.2 kΩ)
terminal and the negative (-) probe on No. 3 terminal,
2. If the measured value is out of the specified range, and measure the output voltage while the voltage is
replace the AIH sensor. If the measured values are applied.
within the specified range, check as below. (output voltage: approx. 0.8 ~ 3.4 V)
3. Turn the ignition switch to ON position and measure 3. Check whether the output voltage is changed when
the voltage to active incar sensor from the FATC blowing into the inlet of the sensor. If there is a voltage
controller connector. change, the sensor is in normal condition. However,
(standard: approx. 2 V at 25°C) if the voltage is not changed, replace the humidity
sensor.
4. If the voltage value cannot be measured, check the
circuit for open. If the measured value is within the 4. In addition, if the output voltage is extremely high or
specified range, replace the FATC controller. low even in the specified range, replace the humidity
sensor.

AFFECTED VIN
24 3A
9. AIR QUALITY SYSTEM (AQS)

1) Components of AQS
Air Quality System (AQS) changes the air source selection to recirculation mode when polluted air is detected through
AQS sensor. The air source selection returns back to fresh air intake mode after a specified period or the polluted air is
disappeared.
AQS sensor and ambient tempera-

ture sensor
AQS sensor
Ambient temperature sensor
Connector
AQS and air source selection switch

The AQS switch is integrated with the air source selection switch.
AUTO Mode
The air source is not changed when pressing the AQS and air source
selection switch in “AUTO” mode. However, the indicator on the
switch turned ON/OFF. In other words, the air source cannot be
changed to recirculation mode in AUTO mode by just pressing the
switch.
To change the air source to recirculation mode in AUTO mode, get
into Manual mode first, then press the air source selection switch.
Manual Mode
To change the AQS mode to Manual mode from AUTO mode, use
the MODE switch or the fan speed control dial. In Manual mode, the
“AUTO” symbol on the display is disappeared. When pressing the
AQS and air source selection switch, the mode is changed in order
of AQS LED ON, AQS LED OFF (fresh air), and air source LED ON
(recirculation).
The figure shows that the mode has been changed to the recircula-
tion mode from fresh air mode under AQS mode (AQS LED ON)
after detecting the polluted outside air.

AFFECTED VIN
3A 25
2) AQS Operation
The AQS operates under air conditioner AUTO mode or when the AQS switch is pressed under manual mode. It requires
preheating time (for seconds) for operation and the module and sensor are integrated.
(However, it operates only when the DEF (defroster) switch on the air conditioner switch panel is not pressed in.)
1. Self diagnosis and preheating process during initial operation of A/C controller (AUTO mode)
1. When the air conditioner controller is operated in AUTO
mode during its initial operation, the air source is changed
to the recirculation mode and AQS LED comes on.
(This is the self diagnosis and preheating process for
AQS.)
2. After completing the above process, the AQS LED is

turned off and the air source is automatically changed to
the fresh air mode.
[Note]
If the AQS switch is pressed in, the AQS function works
regardless of air conditioner controller operation.
2. AQS operation (AQS switch is pressed in): detecting the polluted outside air
1. When pressing the AQS switch, the LED on the AQS
switch is turned on and the AQS function is activated.
2. When the polluted outside air is detected, the AQS
operates and converts the air source to recirculation mode
automatically. At this moment, the recirculation mode
indicator comes on in the display.
3. When driving out of polluted area

1. If the polluted air is disappeared, the air source is
automatically changed to the fresh air mode and AQS
LED stays on.
2. The air source is not changed when pressing the AQS
and air source selection switch in “AUTO” mode. To
change the air source to recirculation mode in AUTO
mode, get into Manual mode first, then press the air
source selection switch.

AFFECTED VIN
26 3A
3) AQS Operation Circuit
5. IGN2
3. AQS signal (Output)

1. Ambient temperature switch
2. Sensor ground
4. Ground
2. Sensor ground
3. AQS signal (Output)
4. Ground
5. IGN 2
[AQS sensor] [Ambient temperature sensor]

1. Measure the voltage value of AQS. 1. Remove the sensor and measure the resistance
(between connector terminal No. 3 and 4.) between terminal No. 5 and 6 on the sensor
connector.
2. If the measured voltage is out of 0.1 to 4.8 V, replace (standard: approx. 25°C, 2.2 kΩ)
the AQS.
In addition, if the resistance is extremely high or low,
replace the sensor.
3. If the measured voltage is out of the specified range,
replace the AQS. If it is within the specified range,
2. If the measured value is out of the specified range,
check as below.
replace the ambient temperature sensor. If the
measured value is within the specified range, check
4. Turn the ignition key to “ON” position.
as below.
5. Measure the voltage between terminal B9 and B15
3. Turn the ignition switch to ON position and measure
on the air conditioner controller.
the voltage to ambient temperature sensor from the
6. If the voltage value cannot be measured, check the FATC controller connector.
circuit for open. If the measured value is within the (standard: approx. 2 V at 25°C)
specified range, replace the FATC controller.
4. If the voltage value cannot be measured, check the
circuit for open. If the measured value is within the
specified range, replace the FATC controller.

AFFECTED VIN
3A 27
4) Removal and Installation

1. Disconnect the negative battery cable and remove the front bumper assembly.
2. Disconnect the AQS sensor connector, unscrew two bolts (10 mm) and remove the AQS sensor assembly.
(Install in the reverse order of removal.)
AQS sensor
Ambient temperature
sensor
Connector

AFFECTED VIN
28 3A
10. AIR CONDITIONER MODULE SENSORS AND ACTUATORS

1) Duct Temperature Sensor
The duct temperature sensor is installed on the top of heater unit. It detects the inside temperature of duct and transmits
the voltage value that is changed according to resistance value (NTC) to FATC controller.
Inspection
If the duct temperature sensor defect code (DTC 3) is set, check as below.
1. Remove the duct temperature sensor and measure the resistance between terminals on the sensor connector.
(standard: approx. 25°C, 2.2 kΩ)
In addition, if the resistance is extremely high or, replace the sensor.
2. If the measured value is out of the specified range, replace the duct temperature sensor. If the measured value is
within the specified range, check as below.
3. Turn the ignition switch to ON position and measure the voltage to duct temperature sensor from the FATC controller
connector.
(standard: approx. 2 V at 25°C)

AFFECTED VIN
3A 29
2) Power Transistor
The power transistor controls the fan speed. It controls the blower motor operating speed without stages by changing
the current value to the base of power transistor when receiving the fan control signal from FATC.
Front air conditioner power transistor
Rear air conditioner power transistor

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Inspection
If the power transistor defect code (DTC 6) is appeared, check as below.
1. Turn the ignition switch to ON position.

2. Measure the voltage between terminals while changing the fan speed from stage 1 to stage 6.
3. The specified voltage value in each stage:
Stage Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Stage 6

Blower (V) 4.5 6.0 7.5 9.0 11 Max. HI
4. If the voltage is out of specified value, check the circuit for open. If the circuit is in normal condition, replace the
power transistor.

AFFECTED VIN
30 3A
3) Mode Door Actuator

The mode door actuator is an actuator that closes, opens and adjusts the mode door for VENT, FLOOR and DEF mode
to change the air flow directions according to FATC controller. Under the FATC controller AUTO mode, it stays on DEF
mode until the engine coolant temperature reaches at normal operating level and the mode is changed as below when
the MODE switch is pressed.

AFFECTED VIN
3A 31
Inspection
Terminal arrangement
Circuit diagram
If the intake door mode on FATC is different from the actual intake door mode, check as below.

2. Measure the voltage between each terminal (P1 through P5)and positive (+) terminal in respective mode.
(If the voltage is changed from 0 V to 12 V after selecting the mode, it is normal.)
3. If the voltage value is out of the specified value, check the related circuits for open.
4. If the circuits are in normal condition, replace the FATC.
5. If the voltage is within the specified value, replace the mode door actuator assembly.
6. Connect the positive (+) and negative (-) cables of temporary power supply to the door mode actuator. And, connect
the negative cable to each terminal (P1 through P5) to check its operation.
(If it operates as shown in above figure, it is normal.)

AFFECTED VIN
32 3A
4) Air Door Actuator

The air door actuator sets the intake door mode according to the control signals from FATC.

AFFECTED VIN
3A 33
Inspection
Circuit diagram
If the intake door mode on FATC is different from the actual intake door mode, check as below.

2. Measure the voltage between terminal P1 and P2 (approx. 12 V) and terminal a and b (approx. 5V).
4. If the circuits are in normal condition, replace the air door actuator assembly.
5. If the voltage is within the specified value, replace the mode door actuator assembly.
6. Connect the positive (+) and negative (-) cables of temporary power supply to the air door actuator. And, connect
the cable to each terminal (P1 and P2) in turn to check the motor operation and terminal output.
Air source Mode Bc resistance

Fresh air P1 (-), P2 (+) below 300 Ω
Recirculation P1 (+), P2 (-) over 2.4 kΩ

AFFECTED VIN
34 3A
5) Air Mix Door Actuator

The air mix door actuator controls the discharging air temperature properly by closing/opening the damper according to
the control signals from FATC.

AFFECTED VIN
3A 35
Inspection
Circuit diagram
If the air mix door defect error is indicated, check as below.

2. Measure the voltage between terminal P1 and P2 (approx. 12 V) and terminal a and b (approx. 5V).
4. If the circuits are in normal condition, replace the air mix door actuator assembly.
5. Connect the positive (+) and negative (-) cables of temporary power supply to the air mix door actuator. And,
connect the cable to each terminal (P1 and P2) in turn to check the motor operation and terminal output.
AMD Mode Bc resistance

Cool P1 (-), P2 (+) below 300 Ω
Hot P1 (+), P2 (-) over 2.4 kΩ

AFFECTED VIN
36 3A
6) Thermo AMP
The thermo AMP outputs the compressor ON or OFF signal to ECU to prevent evaporator from freezing. The sensing part
of the thermistor is the evaporator fin contact type.
If the air conditioner does not turn on, check as below.

1. Remove the thermo AMP and measure the voltage between terminal No. 1 and 2 on the connector.
2. Check whether the output voltages (ON: approx. 12 V, off: 0 V).
3. If the voltage value is out of the specified value, replace the thermo AMP. If the circuit is in normal condition, check
as below.
4. Turn the ignition switch to ON position and turn on the air conditioner by pressing the A/C button. And measure the
voltage between terminal A12 and A11 on the FATC controller connector. (standard: approx. 12 V)

AFFECTED VIN
3A 37
11. AIR CONDITIONER AND HEATER PIPE LAYOUT

AFFECTED VIN
38 3A
Removal and Installation of Sensors and Actuators

Preceding work: Disconnection of negative battery cable and removal of instrument panel
Air mix door actuator * Removal and installation

All removal and installation operations for sensors and actuators
have similar procedures.
1. Disconnect the corresponding connector (1).

2. Remove the mounting bolts for each mode actuator.
However, the thermo AMP and blower high speed relay can be
removed only after removing the air conditioner module.
Duct temperature sensor
Mode door actuator
Mode door actuator:

Disconnect the door link (A) and then disconnect the
connector and remove the bolts.

AFFECTED VIN
3A 39
Thermo AMP
The thermo AMP is installed on the
heater core inside of air conditioner
module.
Air door actuator
Make sure that the parts (2) of air door actuator is securely
seated when installing it.
Power transistor

AFFECTED VIN
40 3A
12. REMOVAL AND INSTALLATION OF THE RELATED COMPONENTS

1) Control Switch Assembly
* Preceding works: Disconnection of negative battery cable
Removal of cup holder assembly and gear selector lever cover
1. Remove the center instrument panel.
2. Unscrew the screws and remove the air conditioner switch assembly .

AFFECTED VIN
3A 41
2) Air Duct Assembly

1. Instrument panel assembly
1) Remove the instrument panel.
2) Unscrew the screws and remove the air duct assembly.
2. Lower air duct assembly

1) Unscrew the screws and remove the lower air duct.
2) Unscrew the screws and remove the air duct assembly.

AFFECTED VIN
42 3A
3. Rear air duct assembly

1) Remove the rear quarter panel.
2) Unscrew the mounting screw from the rear cooler duct and heater duct and remove the air duct assemblies.
Rear air conditioner duct
Rear heater duct

AFFECTED VIN
3A 43
3) Air Conditioner Module Assembly

Front air conditioner module
* Preceding works: 1. Disconnection of negative battery cable and removal of instrument panel
2. Collection of air conditioner refrigerant (dispose the wasted refrigerant to designated place)
1. Disconnect the heater hose and remove the high and low pressure pipes from the air conditioner. (in case of FFH
equipped vehicle, remove the FFH assembly.)
Tightening torque: 10 ~ 15 Nm
2. Disconnect the air conditioner module connector , unscrew the mounting screws and remove the blower unit
assembly.
A B

AFFECTED VIN
44 3A
3. Disconnect the ground cable , unscrew the mounting screws and remove the heater unit assembly.
Heater pipe mounting nut
Ground cable (A) and mounting nut

Heater module mounting nuts (side) (bottom)

AFFECTED VIN
3A 45
Rear Air Conditioner Module

Preceding works: 1. Disconnection of negative battery cable and removal of rear quarter panel
1. Remove the rear cooler duct and heater duct .

AFFECTED VIN
46 3A
2. Remove the rear air conditioner module assembly with the sequence as below:
1) Remove the heater hose/pipe .
2) Remove the air conditioner high and low pressure pipes .
3) Disconnect the connector .
4) Remove the rear air conditioner module mounting screws .
5) Unscrew the lower mounting screw and remove the rear air conditioner module assembly.
Heater/air conditioner pipe
Lower mounting screw

AFFECTED VIN
3A 47
3. Remove the rear air conditioner module assembly.
4. Install in the reverse order of removal. Make sure that no air leaks on the connections of heater and cooler duct.
Top of A/C duct
Top of heater duct
Bottom of A/C duct

AFFECTED VIN
48 3A
4) Receiver Drier and Condenser

Preceding works: 1. Collection of air conditioner refrigerant (dispose the wasted refrigerant to designated place)
2. Removal of front bumper assembly
1. Remove the turbo charger cooler assembly.

- Tightening torque for hose: 6 ~ 7 Nm
2. Disconnect the cooling fan (condenser) connector , unscrew the mounting bolts and remove the condenser
cooling fan.

AFFECTED VIN
3A 49
3. Disconnect the receiver drier connector and remove the condenser mounting bolts. Remove the condenser
assembly.
Detailed of “A”
4. Unscrew the receiver drier mounting bolt from the removed

condenser.

AFFECTED VIN
50 3A
5. Unscrew the lower mounting bolt and remove the receiver drier. The O-rings on the pipes should be replaced with
new ones. (Tightening torque: 20 ~ 30 Nm)

AFFECTED VIN
3A 51
5) Compressor Assembly
Preceding works: 1. Disconnection of negative battery cable and removal of fan belt
1. Remove the two air conditioner pipe flange bolts at compressor side and disconnect the connector .
(At this moment, the sealing washer on the pipe flange bolt should be removed. And, it should be replaced with new
one during installation)
B. Connector
A. High/Low pressure pipe flange bolt C. Compressor mounting bolt (20 ~ 30 Nm)
(10 ~ 15 Nm)
2. Unscrew the compressor mounting bolt remove the compressor from the engine.

AFFECTED VIN
52 3A
6) Sub condenser
Preceding works: 1. Disconnection of negative battery cable and removal of fan belt
1. Remove the wheel cover, disconnect the sub condenser connector and remove the air conditioner pipe .
2. Unscrew four mounting bolts and remove the sub condenser.
Install in the reverse order of removal. Tightening torque of A/C pipe mounting bolt: 10 ~ 15 Nm

AFFECTED VIN
3A 53
Composition of sub condenser
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Sub condenser
Fan cover bracket
Fan
Protective mesh
Fan motor

AFFECTED VIN
MEMO
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3B 1
3B - Supplementary Heater System

FFH & PTC
Table of Contents
FFH (Fuel Fired Heater) SYSTEM .................... 3B-3
1. General information ..................................................... 3B-3
2. Components and locations .......................................... 3B-4
3. System layout ............................................................. 3B-5
4. FFH specification ........................................................ 3B-8
5. FFH operating process ................................................ 3B-9
6. FFH assembly .......................................................... 3B-14
7. Removal and installation ............................................ 3B-15
8. Trouble diagnosis ...................................................... 3B-25
PTC (Positive Temperature Coefficient) SYSTEM

......................................................................... 3B-32
1. General information ................................................... 3B-32
2. PTC components ...................................................... 3B-33
3. PTC operating Process ............................................. 3B-34
FFH & PTC CHANGED BY

AFFECTED VIN
3B 3
FFH (FUEL FIRED HEATER) SYSTEM

1. GENERAL INFORMATION
The system is to increase the coolant temperature quickly by firing diesel fuel in the burner that is installed in engine
cooling system when in winter time the ambient temperature and engine coolant temperature is low. (Option)
FFH System consists of independent fuel lines, fuel pump, coolant circuit, coolant ciculation pump, electrical glow plug
and exhaust system by driver’s intention because FFH system is automatically.
Operated according to the coolant temperature and the ambient temperature.
FFH system operates up to more than 2 minutes to burn the residual fuel inside the system when driver stop the engine
during its operation. Therefore, a certain period of FFH operation after stopping the engine is not a malfunction.
Diagnostic connector Ambient temperature switch
Fuel tank and fuel pump for FFH FFH assembly
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AFFECTED VIN
4 3B
2. COMPONENTS AND LOCATIONS
Ambient temperature switch
FFH coolant pump

FFH assembly
Heater / A/con module (front)
PTC (If applied)

Front duct
Air conditioner control panel
Rear floor duct
FFH fuel pump
Roof duct (A/con)
Rear duct (heater)

Fuel tank
Heater / A/con module (rear)
CHANGED BY FFH & PTC

AFFECTED VIN
3B 5
3. SYSTEM LAYOUT
FFH Overview
1. FFH assembly 8. Ambient temperature switch

2. Water pump & bracket 9. Suction hose
3. FFH NO.1 bracket assembly 10. Fuel pipe NO.1
4. FFH NO.2 bracket assembly 11. Fuel pipe NO.2
5. Silencer & pipe assembly 12. Pump outlet hose assembly
6. Fuel pump assembly 13. FFH inlet hose assembly
7. Fuel pump bracket assembly A. FFH assembly

AFFECTED VIN
6 3B
FFH Heater Disassembly

AFFECTED VIN
3B 7
1. Jacket 18. Surface sensor with cable

2. Jacket cover 19. Controller connector -14-pin connector (waterproof)
3. Combustion air fan 20. Pressure spring for surface sensor
4. Combustion chamber 21. Pressure spring for control and overheating sensor
5. Combustion chamber with flame tube 22. O-ring
6. Heat exchanger 23. Coolant hose (inlet)
7. Controller 24. Coolant hose (outlet)
8. Seal (between combustion chamber and 25. Tooth ring (2x)
combustion air fan) 26. Cable harness cover
9. O-ring 27. Rubber seal
10. Glow plug with cable 28. O-ring
11. Seal (between combustion chamber and heat 29. Screw (M4 x 55 TORX/2x)
exchanger) 30. Screw (M4 x 16 TORX/2x)
12. Upper bush for fuel pipe 31. Screw (M4 x 12 TORX/2x)
13. Lower bush for fuel pipe 32. Screw (M4 x 16 TORX/4x)
14. Flame sensor 33. Screw (M4 x 44 TORX/4x)
15. Bush for flame sensor (graphite) 34. Controller cable harness
16. Control and overheating sensor with cable 35. Insulation washer
17. O-ring

AFFECTED VIN
8 3B
4. FFH SPECIFICATION
Heater D 5 S-H
Heating medium Coolant
Control of the heat flow Large (full load) Small (small load)
Heat flow 5000 W 2300 W
Fuel consumption per hour 0.63 0.28
Mean electric power consumption in operation 35 W 11 W
at start 100 W
after-running 12 W
Rated voltage 12 V
Operating range
• Lower voltage limit: An undervoltage protection
10 V
device in the controller switches the heaters off at
approx. 10 volt.
• Upper voltage limit: An overvoltage protection device
in the controller switches the heaters off at approx. 15 V
15 volt.
Tolerable operating pressure up to 2.5 bar overpressure
Minimum water flow through the heater 300 L/H
Fuel In the main fuel tank
Tolerable ambient temperature operation -40°C ~ 80°C
storage -40°C ~ 125°C (2h for 125°C)
Weight
approx. 2.7 kg
(with controller, water pump and fuel pump)

AFFECTED VIN
3B 9
5. FFH OPERATING PROCESS

Operating Condition
FFH is operated according to the ambient temperature and coolant tempreature.
Initial and repeat operating conditions of FFH

Initial Operating Conditions of FFH:
Ambient temperature: below 5°C
Coolant temperature: below 75°C
Repeat Operating Conditions of FFH:
Coolant temperature: below 75°C
When the difference between the ambient temperature at initial operation and current ambient temperature is
over 3°C (to reduce the hysteresis with the temperature difference when operating FFH), FFH is operated
again. For example, if the initial operating temperature was 4°C, the ambient temperature at repeat operation
should be below 1°C and the coolant temperature should be below 75°C.
FFH operations according to the changes of coolant temperature
Above graph shows the FFH control process while the FFH is operating.
The control element is coolant as shown in the graph.
The FFH is operated in HI mode (high output: approx. 5000 W) until the coolant temperature reaches at 80°C and starts
to be operated in LO mode (low output: approx. 2300 W) from 81°C.
When the coolant temperature reaches at approx. 85°C, FFH stops its operation until the operating conditions will be
met again.

AFFECTED VIN
10 3B
Coolant Circulating Route
Rear
Water pump
Engine
Fan
Heater module
Front
Heater
Blower fan
Heater module
Heating system
Connecting the Coolant Circuit

The heater is connected to the coolant circuit in the coolant feed pipe from the vehicle engine to the heat exchanger.
[Notice]
• Parts conveying coolant must be routed and fastened in such a way that they pose no temperature risk to person or
material sensitive to temperature from radiation and direct contact.
• Before working on the coolant circuit, disconnect the negative battery cable and wait until all components have cooled
down completely.
• When installing the heater and the water pump, note the direction of flow of the coolant circuit.
• Fill the heater and water hoses with coolant before connecting to the coolant circuit.
• When routing the coolant pipes, observe a sufficient clearance to hot vehicle parts.
• Protect all coolant hoses/coolant pipes from chafing and from extreme temperatures.
• Secure all hose connections with hose clips.

AFFECTED VIN
3B 11
Circuit Diagram
The FFH has various sensors in FFH unit, and the FFH unit is connected to the water pump, the fuel circulation pump
and the ambient temperature sensor (switch) that provides important signals for the initial and repeat operations.
For diagnosis, remove the FFH system connector and install the scan tool. Currently, the K-Line that is connected to
the diagnostic connector is not available.

AFFECTED VIN
12 3B
Control and Safety Mode

Heater operations and safety mode
* If the fuel pump 5. The fuel pump does not start when the glow plug is
1. If the fuel pump fails to ignite within 90 seconds after defect or electrical lead to the dosing pump is
fuel pumping starts, the start procedure is repeated interrupted.
as described. If after a further 90 seconds fuel pumping 6. The fan motor speed is monitored continuously.
the fuel pump still fails to ignite, the heater is switched If the fan motor does not start up, is blocked or if the
off in fault mode. speed falls below 40% of the nominal speed, the
The controller is locked after a certain number of failed heater is switched off in fault mode after 60 seconds.
starts. 7. It is possible to diagnose the system by connecting
2. If the flame does out by itself during operation, firstly the diagnostic device to controller. For details, refer
a new start is activated. If the fuel pump fails to ignite to the “Diagnosis Procedures” section.
within 90 seconds after fuel pumping has started
again, the heater is switched off. [Emergency shutdown]
3. If the heater is overheated (lack of water, poorly vented If an emergency shutdown -EMERGENCY OFF- is
cooling circuit), the overheating sensor triggers, the necessary during operation, proceed as follows;
fuel supply is interrupted and the heater is switched
• Pull the fuse (Ef6: 20A) out.
off.
• Disconnect the heater from the battery.
4. The heater is switched off if the lower or upper voltage
limit is reached.
Specification - Water Pump

Rated voltage 12 V
Operating voltage 9 V ~ 15 V
Power consumption 16 W
Pumping capacity (0.1 bar) 800 l/h
Operating temperature -40°C ~ 135°C
Weight 0.28 kg
Characteristic Curve of Water Pump (12 V)

AFFECTED VIN
3B 13
Function Diagram
Control stage
Control stage large small
Sectional Drawing According to the Temperatures

AFFECTED VIN
14 3B
6. FFH ASSEMBLY
[Notice]
There is no need to disassemble the FFH unit for repair. This section is to show the internal components of the FFH unit.
Jacket cover
- The O-rings are installed between jacket cover and two
coolant hoses.
- The coolant hoses should be connected to right side.
1. Jacket
2. Jacket cover
3. Cable harness cover
Control and overheating sensor

The Control and overheating sensor and cable harness make
up one component.
1. Control and overheating sensor

2. Mounting spring
Check control and overheating sensor

Check the control and overheating sensor with a digital
multimeter. If the resistance according to the changes of flame
Resistance (Ohm)
sensor temperature is out of specified values, the flame sen-

sor is defective.
Temperature (°C)
Specified value
Temperature [°C] 0 10 20 30 40 50 60 70 80 90 100 110 120
Resistance [Ω] 32.54 19.87 12.48 8.06 5.33 3.60 2.48 1.75 1.25 0.91 0.67 0.50 0.38

AFFECTED VIN
3B 15
Surface sensor
The surface sensor and cable harness make up one
component.
1. Surface sensor
2. Mounting spring
Check surface sensor

Check the surface sensor with a digital multimeter.
If the resistance of flame sensor is out of specified
Resistance (Ohm)
values, the flame sensor is defective.
Temperature (°C)
Specified value
Temperature [°C] 0 10 20 30 40 50 60 70 80 90 100 110 120
Resistance [Ω] 30.00 19.53 13.03 8.90 6.20 4.41 3.19 2.34 1.75 1.32 1.02 0.79 0.62
Controller
The surface heater and cable harness make up one
component.
3. Combustion chamber housing

4. Surface sensor assembly

AFFECTED VIN
16 3B
Glow plug
1. Glow plug
2. Combustion chamber with flame pipe
Combustion chamber housing

1. Jacket
2. Combustion chamber
3. Combustion chamber housing
4. Insulation washer
5. Seal - combustion chamber / combustion air fan
6. Seal - combustion chamber / heat exchanger
Flame sensor
1. Flame sensor
2. Graphite bush
3. Bush

AFFECTED VIN
3B 17
Check flame sensor

Check the surface sensor with a digital multimeter. If the re-
sistance of flame sensor is out of specified values, the flame
Resistance (Ohm)
sensor is defective.
Temperature (°C)
Specified value
Temperature [°C] -50 0 10 20 30 50 80 90 100 130 150 200 250 300 350 400
Resistance [Ω] 803 1000 1022 1062 1097 1194 1309 1347 1385 1498 1573 1758 1941 2120 2297 2470
Combustion air fan

2. O-ring
3. Rubber seal
4. Combustion air fan
5. Screw

AFFECTED VIN
18 3B
Combustion chamber
2. Heat exchanger
3. Jacket
4. O-ring
Heat exchanger
1. Jacket
2. Heat exchanger
3. Combustion chamber with flame tube
5. O-ring (for heat exchanger)
Heat exchanger
1. Heat exchanger
2. Jacket
3. Stopper
4. Groove (bottom of heat exchanger)

AFFECTED VIN
3B 19

Preceding Work: Disconnection of negative battery cable
[Notice]
• This supplementary heater is a fuel burning type and improves the heating effect by increasing the engine coolant
temperature.
• This device is automatically operated by conditions of the coolant temperature and the ambient temperature.
• In initial operating stage, the fuel pump generates the operating sound and the FFH heater produces white smoke. These
are normal states to fill the fuel into the FFH fuel line.
Fuel Pump
1. Fuel pump connector
2. Fuel supply hose (FFH)
4. Fuel pump
3. Fuel supply hose
Removal and Iinsallation of Fuel Pump

1. Disconnect Fuel Pump Connector as the vehicle lifted.
2. Disconnect both left (2) and right (3) fuel supply hose
in above picture. Fuel Tank
3. Unscrew fuel pump mounting bolt (10M-1EA) and
disassemble fuel pump.
Tightening torque 10 ± 1.0 Nm
FFH
[Notice]
Cap the fuel supply hose to prevent oil leakage

AFFECTED VIN
20 3B
Ambient Temperature Switch

Preceding Work: Disassemble the front bumper assy
3. Connector pin
4. Connector
2. Holder
1. Disassemble the ambient temperature sensor (1) from

holder (2).
2. Disconnect connector (4) as push the connector pin (3).

AFFECTED VIN
3B 21
FFH Assembly
Preceding Work: Disconnect the battery terminal (-)
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AFFECTED VIN
22 3B
1. Disconnect FFH coolant circulation pump connector.

2. Disconnect FFH connector (2).
3. Disassemble the fuel pump hose and pipe.
[Notice]
Use cap to prevent fuel leakage and be careful in handling
the hose & pipe.
4. Unscrew the bracket nut (1) & clamp and disassemble

the inlet (3) & outlet (2) hose in coolant circulation pump.
5. Disconnect the coolant outlet hose (1).

AFFECTED VIN
3B 23
6. Disconnect the FFH assembly. (Install in the reverse order of removal)

( Fuel feeding process should be done)
: Silence braket bolt
: Left/ Right (10mm - 2EA)
1. FFH Mounting
bolt (10mm - 6EA)

AFFECTED VIN
24 3B
Fuel Feeding Process

Fuel Feeding job should be followed after changing FFH assy or after fuel line job.
[Notice]
Picture B
Without feeding job, FFH system could make white
smoke with abnormal noise.
1. Disconnect the ambient temperature switch as

shown in picture (A).
2. Check if the fuel comes out after engine starting
as the FFH fuel supply hose is disconnected.
(Picture B)
Picture A 3. If the fuel is sprayed out, connect the fuel pipe to

FFH assembly and keep the engine running for
1 minute.
4. Connect the ambient temperature connector.

AFFECTED VIN
3B 25
8. TROUBLE DIAGNOSIS
1. FFH Heater Trouble Diagnosis Precedure
When Faults Occur, First Check…

• Faulty wiring?
(short circuits, interruptions)
• Visual check for
- corroded contacts
- defect fuses
- damaged electrical leads, links and connections
- damaged exhaust and combustion air guidance
• Check battery voltage
Battery voltage < 10 volt: the undervoltage protection has triggered
• Check fuel supply
Check Voltage Supply Ubatt (terminal 30)

Disconnect the 10-pin connector and measure the voltage present in connector between chamber 1 and chamber 2.
For deviations in the battery voltage, check the fuses, supply lines, ground connection and plus point on battery for loss
of voltage (corrosion / interruption).
Check Key-ON signal (D+)

Disconnect the 10-pin connector and measure the voltage present in connector 1 between chamber 6 and chamber 2.
[Notice]
Heater operating conditions
• Ambient temperature: below 5°C
• Engine coolant temperature: below 75°C
Controller Lock
• The controller is locked when the following faults occur:
Overheating
• If FFH overheats 10 times in succession, error code 015 appears and the controller is locked.
Too many start attempts

If FFH performs 10 start attempts in vain, error code 050 appears and the controller is locked.

AFFECTED VIN
26 3B
SCAN100 Diagnosis
1. Vehicle 2. Choose No.11 item FFH
3. Choose trouble code checking.

AFFECTED VIN
3B 27
DTC (Diagnosis Trouble Code)

Trouble
Trouble Description Remedies
Code
0 No faults • Measure battery voltage (must be < 15.9V)
10 Shutdown for overvoltage • Check alternator
• Check alternator over voltage
11 Shutdown for undervoltage • Measure battery voltage (must be > 10.2V under load)
• Check alternator
• Check lead
12 Overheating (software threshold) Temperature at overheating sensor >125°C
• Check cooling system:
• Check the temperature sensor and overheating sensor, replace
if necessary
14 Overheating (difference evaluation) Difference in temperature values between surface sensor and con-
trol overheating sensor is too large. (Prerequisite for this trouble
code display is that the heater is in operation and the water tem-
perature at the overheating sensor has reached min. 80°C)
• Check cooling system
if necessary
15 Overheating (operating block) The controller is locked.
• Delete the fault memory to release the controller
if necessary
16 Difference evaluation 2 If the surface sensor has a far higher temperature value than the con-
trol overheating sensor, then the system proceeds with a fault shutdown.
17 Overheating (hardware, device) Temperature at control overheating sensor > 125°C
• Check the temperature sensor and overheating sensor,replace
if necessary
20 Glow plug interruption • Check cable harness for this component for damage and
through current and replace component if necessary
• Check plug-in connection, replace component if necessary
21 Overload, short-circuit or ground • Check cable harness for this component for damage, replace
contact, glow plug output component if necessary
22 Glow plug output defect • Check cable harness for this component for damage, replace
component if necessary
25 Comunication line short • Check the line

AFFECTED VIN
28 3B
Trouble
Code
30 Speed of combustion fan motor out- Fan wheel or combustion air fan motor blocked (frozen,
side tolerable range contaminated, stiff, cable harness scrapes on shaft end, …)
• Eliminate blockage
• Measure speed of combustion air fan motor:
- dismantle combustion air fan
- check with 8.2 V + 0.2 V, to do so, unclip the cable 0.752
black from chamber 13 of the 14-pin connector and the
cable 0.752 brown from chamber 14. Apply marking (white
paint) to the fan wheel and measure speed with contactless
speed meter.
If the measured speed is outside a range of 8,800 rpm to
10,400 rpm, then replace the combustion fan. If the mea-
sured speed is within a range of 8800 rpm to 10400 rpm,
then replace the controller.
31 Burner motor interruption • Check cable harness for this component for damage and
through current
• Check plug-in connection, replace component if necessary
32 Overload, short-circuit or ground • Fan wheel or combustion air fan motor blocked
contact, burner motor (contaminated, stiff)
• Check cable harness of this component for damage, if neces-
sary replace component
34 Burner motor output defect • Check whether the lead to this component has a short-circuit
to GND, if not, check component for ground contact, if neces-
sary replace controller
47 Overload, short-circuit or ground • Check cable harness to the external component for damage
contact, fuel pump and through current and replace external component if neces-
sary
48 Fuel pump interruption • Check cable harness to the external component for damage
and through current
• Check plug-in connection, replace external component if
necessary
49 Fuel pump output defect • Check whether lead to this component has short-circuit to
+Ub, if not, check component for ground contact, replace
controller if necessary
50 Operating block because too many Too many start attempts, the controller is locked
start attempts in vain (10 start • Delete the fault memory to release the controller
attempts, also one start repeat for
• Check fuel quantity and fuel supply
every start attempt)
51 Time exceeded for cold blowing • During start (no flame formed yet), the flame sensor reports
temperature value too high for too long
• Check exhaust and combustion air
• Check flame sensor

AFFECTED VIN
3B 29
Trouble
Code
52 Safety time exceeded • Check exhaust and combustion air system
• Clean or replace sieve used in fitting of fuel pump
53 Flame aborted from “power” stage
Warning
54 Flame aborted from “large” stage In the case of flame aborted in “power”, “large” and “small”
56 Flame aborted from “small” stage stage and with still tolerable start attempts, the heater proceeds
with a new start or with subsequent start repeat. If the new
start or start repeat is successful, the trouble code display goes
off.
Fault(because no more start attempt allowed )

• Check exhaust and combustion air system
• Check flame sensor - see trouble code 64 and 65
60 Control overheating sensor interrup- • Check cable harness to this component for damage and through
tion current
• Check plug-in connection
• Check sensor resistance value, replace component if necessary
61 Short circuit or ground contact con- • Check cable harness to this component for damage
trol overheating sensor • Check sensor resistance value, replace external component if
necessary
64 Flame sensor interruption • Check cable harness to this component for damage and
through current
65 Short circuit flame sensor • Check cable harness to this component for damage
• Check sensor resistance value, replace external component if
necessary
71 Surface sensor interruption • Check cable harness to this component for damage and through
current
72 Short circuit surface sensor • Check cable harness to this component for damage
• Check sensor resistance value, replace external component if
necessary
74 Overheating hardware defect, operating • Replace controller
block
87 Internal temperature sensor short-circuit • Replace controller
88 Internal temperature sensor interruption • Replace controller
89 CAN error • Check CAN interface
90 Watch dog reset • Replace controller

AFFECTED VIN
30 3B
Trouble
Code
91 Too many resets • Replace controller
92 ROM error • Replace controller
93 RAM error • Replace controller
94 Transistor fault occurs too frequently • Remedy short-circuit of the component to +Ub to GND, replace
- operation block controller if necessary
95 Software stack overflow • Replace controller
96 No valid process, operation lock • Replace controller
97 Resonator/quartz faulty, • Replace controller
wrong processor cycle
98 Main relay faulty • Replace controller
99 EEPROM error • Replace controller

AFFECTED VIN
3B 31
General Trouble Causes and Remedies

Condition Causes Remedies
Coolant leakage Change the radiatior
Leakage in coolant auxiliary tank Change the coolant auxiliary tank
Leakage in heater core Change heater core
Leakage in joint junction of coolant hose Check the condition of hose and changing clamp
Leakage in defective coolant hose Change the hose
Low coolant
level Leakage in water pump gasket Change the gasket
Leakage in water pump sealing Change the water pump
Leakage in water inlet cap Change the water inlet cap gasket
Leakagein thermostat housing Change the thermostat sealing
Insufficient tightening torque of cylinder head bolt Fasten the bolt to specified torque
Damaged cylinder head gasket Change the head gasket
The coolant leakage (Check the coolant level) Add coolant
excessive anti-freezer Check the density coolant (Anti-freezer)
Bad coolant hose condition Check the bent area of hose or change if needed
Defective themostat Change thermostat
Defective water pump Change water pump
Abnormally
Defective radiator Change radiator
high coolant
temperature Defective coolant auxiliary tank or tank cap Change coolant auxiliary tank or tank cap
Crack in cylinder head or in cylinder block Change cylinder head or cylinder block
Clogged water flow in cylinder head or block Clean the coolant flow line
Clogged water flow in radiator core Clean the radiator core
Defective cooling fan Change or check the cooling fan
Defective temp.sensor, wiring, and lamp cluster Chaange the sensor and related area
Abnormally Defective thermostat Change the thermostat

loow coolant Defective cooling fan Change or check the cooling fan
temperature Defective tem.sensor, wiring, and lamp cluster Change the sensor and related area

AFFECTED VIN
32 3B
PTC (POSITIVE TEMPERATURE COEFFICIENT) SYSTEM

The supplementary electrical heater is installed in D27DT engine equipped vehicle as a basic equipment. The PTC
system is operated according to two temperature values measured at the coolant temperature sensor and HFM sensor.
This device is mounted in the heater air outlet and increase the temperature of air to the passenger room.
Because PTC system is heated by electrical power, high capacity alternator is required. (Alternator of 12V 75A/90A has
changed to 12V 140A)
Non-opeational Condition
- During engine cranking
- When too low battery voltage (Below 11V)
- During preheating process of glow plugs
PTC Assembly Engine ECU

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AFFECTED VIN
3B 33
2. PTC COMPONENTS
Radiator Element Frame
Connector Spring clip
PTC-Ceramic
Characteristics of PTC
P.T.C Heater
Heating type Air heating type
Heating efficiency Excellent
Element Ceramic PTC (BaTio3)
Weight approx. 500g
Durability Excellent
Safety Excellent
Advantages - Stable output regardless of voltage changes
- Block the overcurrent with switch effect of PTC element
- High heating capacity in a moment
- Excellent durability of heating element against high current

AFFECTED VIN
34 3B
3. PTC OPERATING PROCESS

PTC Operating (ON) Condition
The operating condition of PTC is controlled by two step.
Generally, ECU control the power relay for PTC depending on the coolant temperature and ambient temperature sensor.
1st step (Initial PTC operating condition)

When coolant temperature < 15°C, PTC is operating (ON).
When coolant temperature ≥ 15°C, tow conditions decribed below must be satisfied.
2nd step (Coolant temperature: 15°C)

When coolant temperature 65°C ≤ and ambient temperature ≤ 10°C PTC operates (ON)
When coolant temperature 65 ~ 60°C and ambient temperature -10°C ~ 0°C PTC operates (ON)
When coolant temperature ≤ 60°C and ambient temperature ≤ 0°C ~ 5°C, PTC operates (ON)
PTC “OFF” Condition

Airconditioner blower switch OFF
Ambient temperature sensor error (wiring short or open)
When engine craking
Battery voltage is lower than 11V
When preheating the engine (Glow indicator “ON”)

AFFECTED VIN
3B 35
Circit Diagram

AFFECTED VIN
36 3B

Preceding work: - Disconnect battery terminal (-)
- Remove I/P panel
1. Unscrew cable mounting bolt (1) 2. Disconnect PTC connector
3. Unscrew PTC mounting bolt and disassemble the PTC assembly.

AFFECTED VIN
SECTION 04
CHASSIS SYSTEM
CONTENTS
DC5-SPEED AUTOMATIC TRANSMISSION................ 3A
TSM 54/52 MANUAL TRANSMISSION ........................ 3B
CLUTCH ASSEMBLY .................................................... 3C
TOD (Torque On Demand) ........................................... 3D
FRONT SUSP. & AXLE ................................................. 3E
REAR SUSP. & AXLE ................................................... 3F
POWER STEERING ...................................................... 3G
WHEELS & TIRE ........................................................... 3H
PROPELLER SHAFT ..................................................... 3I
BRAKE - GENERAL ...................................................... 3J
ABS/ESP SYSTEM ........................................................ 3K

4A 1
4A
DC 5-Speed Automatic Transmission
Table of Contents
GENERAL INFORMATION ...................... 4A-3 TROUBLE CODE AND DIAGNOSIS ..... 4A-52
Overview ..............................................................4A-3 Trouble diagnosis with scanner ......................... 4A-52
Structure ............................................................. 4A-4
Performance curve and general characteristics .... 4A-5 HYDRAULIC SYSTEM .......................... 4A-63
Specifications .....................................................4A-6
Structure of valve body ...................................... 4A-63
Power flow .......................................................... 4A-8
Hydraulic circuit ................................................ 4A-64
FUNCTION AND DESCRIPTION .......... 4A-17 Hydraulic circuit when starting engine ............... 4A-69
Selector lever .................................................... 4A-17 Structure of electro-hydraulic control module
Torque converter ................................................ 4A-18 (Shift plate) ....................................................... 4A-75
Lockup clutch ................................................... 4A-20 REMOVAL AND INSTALLATION

Planetary gear set ............................................. 4A-22 (DC 5-SPEED A/T) ................................. 4A-78
Multiple-disc clutch ........................................... 4A-23 Components ...................................................... 4A-78
Freewheel ......................................................... 4A-24 Removal and installation .................................... 4A-79
Sensors and controls ........................................ 4A-25 DISASSEMBLY AND REASSEMBLY
OTHER FUNCTIONS ............................ 4A-47 (DC 5-SPEED A/T) ................................. 4A-89
Oil level control .................................................. 4A-47 Components ...................................................... 4A-89
Shift rod adjustment .......................................... 4A-49 Disassembly and reassembly ........................... 4A-91
Circuit diagram .................................................. 4A-50 Components of each assembly ....................... 4A-106

Measurement and adjustment ......................... 4A-110
SPECIAL TOOLS AND EQUIPMENT .. 4A-120
DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY

AFFECTED VIN
4A 3
GENERAL INFORMATION
OVERVIEW
2WD 4WD
34: D27DT (2WD)

1.
7202700600 DC Part Number Without Torque Converter 722 600 0 61: D27DT (4WD)
Blank 62: E3.2 Engine (4WD)
722 600 0 DC Variant Number
Engine Code Number
377900 Serial Number
Transmission Type
2. Bar Code: Automatic Transmission for
Passenger Car
3. Marked Number: 107 : 34 (D27DT, 2WD)
A/T Part Number A/T Serial # A/T Variant 105 : 61 (D27DT, 4WD)
with Torque Converter 100 : 62 (E3.2 GS1, 4WD)
DC 5-Speed Automatic Transmission

DCAG 5-speed automatic transmission is an electronically controlled 5-speed transmission with a lockup clutch in the
torque converter.
The ratios for the gears are realized by three planetary gear sets. The 5th gear is designed with a step-up ratio of 0.83
as an overdrive. The selector lever is controlled by electronically and mechanically. The gears are shifted by the corre-
sponding combination of three hydraulically actuated multiple-disc brakes, three hydraulically actuated multiple-disc
clutches and two mechanical one-way clutches.
This electronically controlled automatic transmission adjusts the operating pressure to provide proper shifting in relation
to engine power. This function improves shifting quality significantly. And, the driver can select “S” (Standard) mode or
“W” (Winter) mode according to the driving conditions.
This automatic transmission provides two gears even during reverse driving. The internal sensors and controls are
connected to TCU by cylindrical 13-pin connector.
* DCAG 5-speed automatic transmission offers the following advantages:

1. Improved shifting quality
2. More gears
3. Extended working life and reliability
4. Reduced fuel consumption

AFFECTED VIN
4 4A
STRUCTURE
Basic structure of DC 5-speed automatic transmission
1. Torque converter 7. Disc brake B3 13. Freewheel F2

2. Oil pump 8. Disc clutch C3 14. Center planetary gear set
3. Input shaft 9. Disc brake B2 15. Electric control unit (valve body)
4. Disc brake B1 10. Output shaft 16. Freewheel F1
5. Disc clutch C1 11. Parking lock gear 17. Stator shaft
6. Disc clutch C2 12. Intermediate shaft 18. Converter lockup clutch
CHANGED BY DC 5-SPEED AUTOMATIC TRANSMISSION

AFFECTED VIN
4A 5
PERFORMANCE CURVE AND GENERAL CHARACTERISTICS
Standard mode Lockup mode (open/sleeping)
Vehicle speed (kph)

Pedal value (%)
4-LOW mode
Vehicle speed (kph)
Vehicle speed (kph)
Pedal value (%)
Pedal value (%)

Note
1. Based on DI Engine + A/T equipped vehicle 4. FAST OFF
specifications • When abruptly releasing the accelerator pedal, the
• Gear ratio transmission remains at 4th gear other than 4 → 4
1st gear: 3.595 shift (when slowly releasing the accelerator pedal, the
Rev. 1st gear: 3.167 transmission is shifted to 5th gear).
2nd gear: 2.185
Rev. 2nd gear: 1.926
3rd gear: 1.405
4th gear: 1.000 Axle ratio: 3.31
5. Dynamic shift range
5th gear: 0.831 • When operating the accelerator pedal, the 4 → 3 shift
2. WINTER Mode: Standard Mode is completed by kick-down signal after completion of
4 → 4 shift.
3. Allowable shifting point:
• When promptly operating the accelerator pedal, the 4
Upshift
→ 3 shift is done in shaded arae.
Downshift
Lockup (sleeping)
Unlock (open)
FAST OFF
Dynamic shift range

AFFECTED VIN
6 4A
SPECIFICATIONS
Item W5A330 (300) W5A580 (400)
Input torque 330 Nm 580 Nm
Weight (including ATF) 78 kg 78 kg
Diameter (Torque converter) 270 mm 270 mm
Lockup function Yes Yes
Gear ratios 1st 3.951 3.595
2nd 2.423 2.186
3rd 1.486 1.405
4th 1.000 1.000
5th 0.833 0.831
Reverse: S mode / W mode 3.147/1.93 3.167/1.926
Driving type 2WD (4WD)
Fluid specification Fuchs ATF 3353
or Shell ATF 3353
Fluid capacity approx. 8
Selector lever position P.R.N.D Mechanical
D+/D- Electrical
Parking lock system Brake switch (signa) → TGS lever
Reverse lock system CAN → TGS lever
Selected lever indication P.R.N.D Lever position
4, 3, 2, 1 CAN
Oil temperature sensor Resistance: R, D 0.5 ~ 2.5 kΩ
Resistance: P, N 20 kΩ
TCU EGS 52
Shift solenoid valve Resistance 3.8 ± 0.2 Ω
(25°C) Operating distance 0.2 mm
Operating current 1.5 ~ 2 A
M/P, S/P solenoid valve Resistance 5.0 ± 0.2 Ω
Operating current 0~1A
Lockup solenoid valve Resistance 2.5 ± 0.2 Ω
Operating current 1.5 ~ 2.0 A
Operating range 3rd to 5th gears
RPM sensor Resistance HALL type
Operating voltage 6V
Start lockout switch Switch contact ON (D, R position )
Switch contact OFF (P, N position)

AFFECTED VIN
4A 7
Item W5A330 (300) W5A580 (400)

Mode switch W (Winter)
S (Standard)
One-way clutch F1, F2
Planetary gear set Plain planetary gear: 3 (number of pinion) 3, 4, 3 4, 4, 4
Friction plates C1, B1, B3 Single side friction plate
C2, C3, B2 Double side friction plate

AFFECTED VIN
8 4A
POWER FLOW
Sectional View
Shifting elements
Gear C1 C2 C3 B1 B2 B3 F1 F2
1 z 3)
z 3)
z z z
2 z z 3)
z z
3 z z z
4 z z z
5 z z z 3)
z
P/N 1)
z z
P/N 2)
z z
R 1) z z 3)
z z
R 2)
z z z
1) Selector program switch: “S” mode

2) Selector program switch: “W” mode
3) Overrun
AFFECTED VIN
4A 9
Torque
converter
lockup Flywheel
clutch
Torque Automatic Final drive Output

Engine torque
converter transmission gear torque
Multiple disc Multiple disc

clutch brake

AFFECTED VIN
10 4A
1st Gear (3.932)
Input Output
16. Torque converter lockup clutch E. 3rd gear ratio M. Center planetary gear set
A. Engine speed F. Mounting elements P. Impeller
B. Transmission, input shaft H. Rear planetary gear set T. Turbine wheel
C. 1st gear ratio L. Stator V. Front planetary gear set
D. 2nd gear ratio
* Input shaft: Clockwise rotation

* Front sun gear: Locked by F1 and B1, Planetary gear carrier: Rotation with reduced speed
* Rear ring gear: Counterclockwise rotation
* Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Clockwise rotation with reduced speed
* Center ring gear: Clockwise rotation
* Center sun gear: Locked by B2, Rotation with reduced speed
* Output shaft: Clockwise rotation
Gear C1 C2 C3 B1 B2 B3 F1 F2 Lockup clutch

1 z 3)
z 3)
z z z
3) Overrun

AFFECTED VIN
4A 11
2nd Gear (2.408)
Output
16. Torque converter lockup clutch D. 2nd gear ratio M. Center planetary gear set
A. Engine speed E. Mounting elements P. Impeller

* Sun gear and planetary gear carrier: Clockwise rotation by C1 activation
* Rear ring gear: Clockwise rotation
* Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Rotation with reduced speed
* Center ring gear: Clockwise rotation
* Sun gear: Locked by B2, Planetary gear carrier: Rotation with reduced speed
2 z z 3)
z z
3) Overrun

AFFECTED VIN
12 4A
3rd Gear (1.486)
Input Output
16. Torque converter lockup clutch D. Mounting elements P. Impeller

A. Engine speed H. Rear planetary gear set T. Turbine wheel
B. Transmission, input shaft L. Stator V. Front planetary gear set
C. 1st gear ratio M. Center planetary gear set

* Front ring gear: Clockwise rotation
* Center ring gear: Clockwise rotation by clutch 2 activation (direct connection)
* Center sun gear: Locked by B2, Planetary gear carrier: Clockwise rotation with reduced speed
3 z z z

AFFECTED VIN
4A 13
4th Gear (1.000)
Output
16. Torque converter lockup clutch L. Stator T. Turbine wheel

A. Engine speed M. Center planetary gear set V. Front planetary gear set
B. Planetary gear set P. Impeller

* Center ring gear and rear planetary gear carrier: Clockwise rotation
* Front sun gear and planetary gear carrier: Clockwise rotation (direct connection)
* Rear sun gear: Rotation by ring gear and planetary gear carrier (direct connection)
* Center ring gear: Clockwise rotation by C3 activation
* Planetary gear carrier: Clockwise rotation by center sun gear and ring gear (direct connection)
4 z z z

AFFECTED VIN
14 4A
5th Gear (0.830)
Output
16. Torque converter lockup clutch E. 3rd gear ratio M. Center planetary gear set
D. 2nd gear ratio

* Front sun gear: Locked, Planetary gear carrier: Rotation with reduced speed
* Rear planetary gear carrier: Clockwise rotation with reduced speed
* Center ring gear and rear planetary gear carrier: Clockwise rotation by clutch C2 activation
* Rear sun gear: Clockwise rotation because rear planetary gear carrier rotates faster than rear ring gear (increased
speed)
* Center sun gear: Clockwise rotation with increased speed by C3 activation
* Center planetary gear carrier: Clockwise rotation (increased speed)
* Output shaft: Clockwise rotation (increased speed)
5 z z z 3)
z
3) Overrun

AFFECTED VIN
4A 15
Reverse 1st Gear (3.160, “S” Mode)
Input Output
16. Torque converter lockup clutch E. Mounting elements M. Center planetary gear set
D. 2nd gear ratio

* Front sun gear: Locked by one-way clutch F1
* Front planetary gear carrier: Clockwise rotation (reduced speed)
* Rear planetary gear ring gear: Clockwise rotation
* Rear planetary gear carrier: Locked by B3
* Rear sun gear and center sun gear: Counterclockwise rotation (increased speed)
* Center ring gear: Locked by B3
* Center planetary gear carrier: Counterclockwise rotation (reduced speed)
* Output shaft: Counterclockwise rotation
R (S) z z 3)
z z
3) Overrun
AFFECTED VIN
16 4A
Reverse 2nd Gear (1.930, “W” Mode)
Input Output
16. Torque converter lockup clutch D. 2nd gear ratio M. Center planetary gear set
A. Engine speed E. Mounting elements P. Impeller

* Front planetary gear carrier: Clockwise rotation by clutch C1 activation (direct connection)
* Rear planetary gear carrier and center ring gear: Locked by brake B3
* Rear sun gear and center sun gear: Counterclockwise rotation (increased speed)
* Center planetary gear carrier: Counterclockwise rotation (reduced speed)
* Output shaft: Counterclockwise rotation
R (W) z z z

AFFECTED VIN
4A 17
FUNCTION AND DESCRIPTION

SELECTOR LEVER
P: Parking and starting position
This position is used when the vehicle is parking, starting the engine or stationing the vehicle. In this position, the driving
wheels are locked by parking pawl. To shift into any other positions, must depress the brake pedal (parking lock system).
R: Reverse driving
Conversion between Standard and Winter switch changes the reverse gear ratio but must be operated before the
selector lever is moved. Pressing on the Winter switch allows to have effective driving when driving on the slippery road
surface and, also, possible to have smooth driving in reverse as it starts in 2nd gear.
N: Neutral, starting and towing position
The engine can be started in this position. And, this position is used in temporary stop. If it is necessary to tow a vehicle,
use a professional tow truck service. If not available, use emergency towing by towing vehicle and lope. In this case, the
towing distance should be limited by 50 km with 50 km/h of towing speed.
D: All forward gears (1st ~ 5th)

This position is for all normal forward
driving in 1st to 5th gear. At 5th gear, the
gear ratio is 0.83:1. When driving for-
ward at the speed of over 10 km/h, the
selector lever cannot be changed to “P”
or “R” position by parking reverse block
function.
4: Up shifting only up to 4th gear
In general, up to 4th gear is automati-
cally shifted at the normal road driving
position. In “D” position, while driving,
pushing the lever in the left (–) direction
once makes down shift to 4th gear,
which is the same function as the O/D
OFF (Over Drive OFF) of normal vehicle.
3: Up shifting only up to 3rd gear
Automatically shifts up to only 3rd gear
and able to achieve engine brake effect
on long slope/down hill and, in “D”
position, pushing the lever in the left (–)
direction twice makes down shift from
5th gear to 3rd gear.
1←2←3←4←D -D+ 1→2→3→4→D

2: Up shifting only up to 2nd gear
Automatically shifts up to only 2nd gear and used in
mountain road, unpaved road and while being towed
by trailer. It can achieve engine brake effect and, in D
position, pushing the lever in the left (–) direction 3
times makes down shift from 5th gear to 2nd gear.
1: Driving in 1st gear only

Drives only in 1st gear, and used in long mountainous
terrain, steep heel and unpaved road. It is used when
engine brake effect for driving down hill is required.
To shift gear lever from “P” position to other positions,
depress the location shown above picture

AFFECTED VIN
18 4A
TORQUE CONVERTER
Function (4WD)
Torque converter is installed between engine and automatic transmission. It consists of pump impeller, turbine and
stator. The pump impeller is welded at converter housing and the converter housing is bolted at the drive plate.
The torque converter converts the mechanical energy from engine to hydraulic energy, and the turbine connected to
transmission input shaft converts this hydraulic energy to mechanical energy again. The stator between pump and
turbine increases the output torque from turbine by converting the flowing direction.
The stator has a torque converter area that changes the flowing direction and a fluid coupling area where the stator
rotates. And, the lockup clutch integrated in torque converter prevents the power from losing and reduces fuel consumption.

AFFECTED VIN
4A 19
Installation and Inspection

• Place the automatic transmission upright as shown in
figure and install the torque converter by rotating the torque
converter. When installing from sideway, the torque
converter sealing ring may be damaged by driving flange
which could cause oil leaks.
• Use special tools when removing and installing torque

converter.
[Notice]
Place the automatic transmission upright when removing

and installing torque converter.
If not, the oil seal may be damaged when servicing the torque
converter.
• The distance between the upper end of torque converter

and the mating surface of automatic transmission housing
should be within specified value as follows:
Specified installation height (A) below 6.5 mm
* Torque converter
P/NO Diameter Clutch disk Engine
A210 250 05 02 270 mm 2 EA E23/E28/E32/D27DT

AFFECTED VIN
20 4A
LOCKUP CLUTCH
1. Impeller wheel 10. Multiple disc clutch pack

2. Turbine wheel 11. Piston
3. Stator wheel
4. Stator shaft A : Closed (lockup clutch activates)
5. Multiple disc clutch drum B : Slipping
6. Multiple disc clutch hub C : Open (lockup clutch deactivates)
7. Converter cover n : Transmission output speed
8. One-way clutch d : Accelerator pedal position
9. Input shaft
Lockup clutch consists of multiple disc clutches as shown The characteristic curves shown in the diagram illustrate
in the figure and is activated in 3th, 4th and 5th gears. The the different operating states of the torque converter lockup
aim of using torque converter lockup clutch is to reduce clutch in relation to the accelerator pedal position and the
the fuel consumption and exhaust gas emissions of the transmission output speed, plotted for one transmission
vehicle by reducing torque converter slip. This stands in gear.
contradiction to the ride comfort demands made on the
drive train with regard to its vibration behaviors. The task of • Variables influencing the states of the torque converter
the electronic transmission control is therefore to close lockup clutch:
the clutch in all driving situations relevant to fuel
1. Accelerator pedal movement
consumption, if possible, and ensure that the engine vi-
2. Uphill and downhill gradients
brations are isolated from the drive train.
3. Transmission shift functions
4. Transmission oil temperature
5. Load conditions
6. Engine control influences

AFFECTED VIN
4A 21
Lockup Clutch Regulating Valve
Torque converter Torque converter Transmission

Lockup clutch output input lubrication points
Torque converter lockup

solenoid valve
Oil sump
drain
Oil cooler
Working
pressure
Oil sump drain
Lubrication pressure
Shift valve
pressure
Oil sump drain
Lockup clutch regulating valve controls the lockup clutch in torque converter and distributes the lubricating oil to the
friction parts. TCU generates the lockup clutch control pressure by duty controlling the lockup solenoid valve, and this
pressure is applied to the lockup clutch regulating valve to engage, disengage and slip the lockup clutch. When the
lockup clutch control pressure is increased, the lockup clutch regulating valve moves up and the working pressure is
applied to lockup clutch. In its regulating position (slipping, torque converter lockup clutch pressurized), a reduced
volume of lubricating oil flows through the annular passage bypassing the torque converter and passing direct through
the oil cooler into the transmission. The rest of the lubricating oil is directed via the throttle “a” into the torque converter
in order to cool the torque converter lockup clutch.

AFFECTED VIN
22 4A
PLANETARY GEAR SET
Ring gear
Pinion gear
Sun gear
Planetary gear carrier
Output Locked Input

Input
Locked Output Output
Relatively high Relatively low Direction reversal and

step-down ratio step-down ratio step-down ratio
Relatively high step-down ratio

Ring gear locked
Sun gear driving (clockwise)
Planet gears driven (rotating counterclockwise)
Planet carrier driven (revolving clockwise)
Relatively low step-down ratio

Sun gear locked
Ring gear driving (clockwise)
Planet gears driven (rotating clockwise)
Planet carrier driven (revolving clockwise)
Direction reversal and step-down ratio

Planet carrier locked
Sun gear driving (clockwise)
Planet gears driven (counterclockwise)
Ring gear driven (counterclockwise)
Gear ratio: teeth of sun gear / teeth of ring gear

AFFECTED VIN
4A 23
MULTIPLE-DISC CLUTCH
1. Input shaft C1c. Internally toothed disc carrier C1 M1. Middle sun gear
9. Externally toothed disc C2a. Piston C2 M3. Middle planet carrier
10. Internally toothed disc C2b. Externally toothed disc carrier C2 M4. Middle ring gear
H1. Rear sun gear C3a. Piston C3 V1. Front sun gear
C1a. Piston C1 C3b. Externally toothed disc carrier C3 V3. Front planet carrier
C1b. Externally toothed disc carrier C1 C3c. Internally toothed disc carrier C3 V4. Front ring gear
Location
Three multiple-disc clutches, the front, middle and rear multiple-disc clutches K1, K2 and K3, are located in the plan-
etary gear sets in the transmission housing.
Funtion and description

A multiple-disc clutch consists of a number of internally toothed discs (10) on an internally toothed disc carrier and
externally toothed discs (9) on an externally toothed disc carrier.
If the piston (C1a) on multiple-disc clutch K1 is subjected to oil pressure, it presses the internal and external discs of the
disc set together. The sun gear (V1) is locked with the planet carrier (V3) via the externally toothed disc carrier (C1b) and
the internally toothed disc carrier (C1c). The front planetary gear set is thus locked and turns as a closed unit. If the
multiple-disc clutch C2 is actuated via the piston (C2a), the piston compresses the disc set. The ring gear (V4) of the
front planetary gear set is locked with the ring gear (M4) of the middle planetary gear set via the externally toothed disc
carrier (K2b) and the middle planet carrier (M3) on which the internally toothed discs are seated. Ring gear (V4) and ring
gear (M4) turn at the same speed as the input shaft (1). If the multiple-disc clutch C3 is actuated via the piston (C3a), the
piston compresses the disc set. The sun gear (M1) of the middle planetary gear set is locked with the sun gear (H1) of
the rear planetary gear set via the externally toothed disc carrier (C3b) and the internally toothed disc carrier (C3c). Sun
gear (M1) and sun gear (H1) turn at the same speed.
AFFECTED VIN
24 4A
FREEWHEEL
1. Outer race A. Rotation direction “A”

2. Inner race B. Rotation direction “B”
3. Locking elements V1/H1. Front or rear sun gear
4. Locking element cage
Location
Freewheels are installed in the front planetary gear set between the sun gear and the stator shaft, and in the rear
planetary gear set between the sun gear and the intermediate shaft.
Function and description

The freewheel consists of an outer race (1), an inner race (2), a number of locking elements (3) and a cage (4) for these
locking elements.
If the inner race (2) of the freewheel is locked and the outer race (1) turns in direction “A”, the locking elements (3) adopt
a diagonal position on account of their special contours, allowing the freewheel function.
The outer race (1) slides over the locking elements (3) with negligible friction. If the rotation of the outer race (1) changes
to direction “B”, the locking elements (3) stand up and lock the outer and inner races (1, 2) together.

AFFECTED VIN
4A 25
SENSORS AND CONTROLS

Components
Valve body assembly
1. Cap 5. Lockup PWM solenoid valve 9. 1-2/4-5 shift solenoid valve

2. Socket bolt (M6 x 32) 6. 2-3 shift solenoid valve 10. 3-4 shift solenoid valve
3. Socket bolt (M6 x 30) 7. Shift pressure (SP) solenoid valve 11. Electronic control module
4. Leaf spring 8. Modulating pressure (MP) solenoid valve 12. Lockup clutch control solenoid valve

AFFECTED VIN
26 4A
Shift Pressure Control Solenoid Valve
1. Leaf spring 7. Solenoid valve

2. Contact spring A. 1-2, 4-5 shift solenoid valve
3. Conductor track B. 3-4 shift solenoid valve
4. O-ring 8. Solenoid valve
5. O-ring C. Shift pressure control solenoid valve
6. Shift plate D. Modulating pressure control solenoid valve
9. Solenoid valve
E. Lockup PWM solenoid valve
F. 2-3 shift solenoid valve
Function
The plastic Electric Hydraulic Control Unit (EHU) is installed on the top of valve body. RPM sensor, start lock-out switch
and oil temperature sensors are integrated in EHU.
The 13-pin connector is connected to automatic transmission via PCB.
Three up/downshift solenoid valves are installed on the top of hydraulic control unit.
The solenoid valves are sealed with two O-rings against the valve body. The solenoid valves are pressed against the valve
body by the leaf springs.
AFFECTED VIN
4A 27
Characteristics of up/downshift solenoid valve

The solenoid valve remains energized and therefore open until
I (Current)
the shift process is completed according to the engine and
transmission conditions. If a solenoid valve is energized, it
opens and transmits shift valve pressure to the corresponding
command valve. 2.5A
Working Current 1.5 ~ 2.0 A

Operating distance 0.2 mm
Resistance 3.8 ± 0.2 Ω (25°C) 1.5A
60mA T (Time)
Circuit diagram
3-4 shift S/V 2-3 shift S/V 1-2, 4-5 shift S/V

AFFECTED VIN
28 4A
Modulating Pressure (MP) and Shift Pressure (SP) Control Solenoid Valve
Solenoid valve
1. Leaf spring 4. MP control solenoid valve

2. Shift plate 5. SP control solenoid valve
3. Strainer
Function
These valves control the modulating pressure and the shift Working Current 0 ~ 1.0 A
pressure by applying appropriate electric current to sole-
noid valves according to driving condition of engine and Operating distance 0.6 mm
transmission. Resistance 5 ± 0.2 Ω (25°C)
When the electric current from TCU is high/low, the regu-
lated pressure decreases/increases.
Regulated
pressure
Regulated pressure
Drain line
Drain line Line pressure

AFFECTED VIN
4A 29
Circuit diagram

AFFECTED VIN
30 4A
Lockup Solenoid Valve
1. Leaf spring 3. Shift plate

2. O-ring
Function
This valve activates and releases the lockup clutch by
Working Current 1.5 ~ 2.0 A
adjusting the current to solenoid valve according to engine
throttle opening value and output shaft speed. The lockup Operating distance 0.2 mm
clutch operates in 3rd, 4th and 5th gear with steps to re- Resistance 2.5 ± 0.2 Ω (25°C)
duce shift shocks.
Operating range 3, 4, 5 shift
Circuit diagram
Lockup S/V

AFFECTED VIN
4A 31
Speed Sensor
Speed Speed
sensor (n3) sensor (n2)
1. Leaf spring 3. Pulse ring

2. Valve body
Function
The speed sensors are fixed to the shell of the hydraulic control unit via the contact tabs. A leaf spring, which rests
against the valve body, presses the speed sensors against the transmission housing. This ensures a precise distance
between speed sensors and impulse rings. speed sensor (n3) detects the speed of the front sun gear and speed sensor
(n2) detects the speed of the front planetary carrier. If the speed sensor is defective, the transmission is operated in
emergency driving mode. Below table shows the detection of speed sensor.
Gear N2 N3
1 • -
2 • •
3 • •
4 • •
5 • -
R (S mode) • -
R (W mode) • •

AFFECTED VIN
32 4A
Circuit diagram
Speed Speed
sensor sensor
n3 n2

AFFECTED VIN
4A 33
Oil Temperature Sensor
Oil temperature sensor
Function
The oil temperature sensor is installed in hydraulic control unit and is connected in series with the starter lock-out
contact.
This means that the temperature signal is transferred to TCU when the starter lock-out contact is closed.
The oil temperature has a considerable effect on the shifting time and therefore the shift quality. By measuring the oil
temperature, shift operations can be optimized in all temperature ranges.
Circuit diagram
Starter lock-out contact

AD converter

AFFECTED VIN
34 4A
Starter Lock-out Contact Switch
1. Plunger 3. Reed contact

2. Permanent magnet
Function
The starter lock-out contact is installed beside oil temperature sensor and is actuated by a cam rail, which is located on
the latching plate.
In the selector lever positions “P” and “N”, the permanent magnet is moved away from the reed contact. This opens the
reed contact and the transmission control module receives an electrical signal. The transmission control module acti-
vates the starter lock-out relay module. This closes the electrical circuit to the starter in selector lever positions “P” and
“N” via the starter lock-out relay module. In other words, when the selector lever is in driving positions, the contact is
closed and the starter cannot be operated.
Circuit diagram
Ignition switch 50
Start lock-out contact
AD converter
Starter

AFFECTED VIN
4A 35
Kick-down Control
Function
When the throttle valve is partially opened, the shifting point gets faster. When the throttle valve is widely opened,
shifting point is delayed because the system needs low speed gear with bigger driving force.
Kick-down control is a system that enables to get bigger driving force as the down shift occurs by suddenly increasing
the throttle openings during constant driving. It has no separate kick-down switch where the down shift operates when
a certain point (about 1 second) lapses after opening of full throttle. The signal recognition allows to send control signal
to TCU from engine ECU via CAN communication.
Circuit diagram
Accelerator pedal module

( ) : For gasoline engine

AFFECTED VIN
36 4A
Mode Switch
Function
The mode switch is installed beside the selector lever and it has two modes of “S” mode (Standard
Mode) and “W” mode (Winter Mode).
- “S” mode is used in normal driving (starts off with 1st gear). TCU (Transmission Control Unit)
provides pleasant driving by changing the shifting pattern according to the driving habits
(downhill gripping: approx. 11 ~ 13.5 %)
- When “W” mode is selected, the Winter mode indicator in meter cluster comes on, and the
vehicle starts off with 2nd gear to achieve smooth starting on the icy or slippery road.
In winter mode, the up shift becomes faster and the down shift becomes slower for improving fuel consumption. The “W”
mode is automatically changed to “S” mode in full throttle or kick-down operation. The vehicle can starts off with 2nd
reverse gear (gear ratio: 1.92 ~ 1.93) when the “W” mode is selected. It is very useful on icy and slippery road. However,
in this case, the “W” switch should be selected before placing the selector lever to “R” position.
Even though “W” mode is selected, the vehicle starts off with 1st gear in following:
When the system recognizes the mode switch operation, the selector lever control unit sends the control signal TCU via
CAN communication.
1. When the selector lever is in “1” position.
2. When fully depressing the accelerator pedal or when starting off with kick-down condition.
Circuit diagram
Instrument panel
Selector lever control unit

AFFECTED VIN
4A 37
Reverse/Parking (R/P) Lock System
12
1. Selector lever 7. Locking lever

2. Shift pattern display 8. Shift detene spring
3. Parking lock release flap 9. Potentiometer for detecting selector lever position
4. Selector lever control unit 10. Base body
5. Mode switch 11. Spring of shift detent mechanism
6. Locking disc 12. Solenoid valve
Function
Reverse (R) lock system is a safety system that prevents the selector lever from shifting to “P” or “R” position by
activating the solenoid valve when the selector lever unit determines that the vehicle speed exceeds 10 km/h by check-
ing the speed signal from wheel speed sensor via CAN communication.
Parking (P) lock system uses the signals from brake switch other than conventional cable system to shift to other
positions. The wiring harness for detecting brake switch operation is connected to selector lever control unit.

AFFECTED VIN
38 4A
Circuit diagram
Brake switch
Selector lever control unit
Function of reverse (R) lock

Above a speed of approx. 10 km/h, the R/P locking solenoid
is actuated by the selector lever control unit. The R/P lock
lever (8) is turned to the lock position. The tab on lock lever
(10) locks the locking disc (1). The selector lever (1) cannot
be shifted into selector position “R”.
1. Locking disc 7. R/P locking solenoid

2. Cam (P lock) 8. Locking lever
3. Cam (R lock) 9. Tab on lock lever (P lock)
4. Selector lever 10. Tab on lock lever (R lock)
5. Base body 11. Potentiometer for detecting
6. Mode switch selector lever position
12. Intermediate lever

AFFECTED VIN
4A 39
Function of parking (P) lock

The selector lever position “P” is locked whenever the R/P
locking solenoid is not actuated by selector lever control unit.
The prerequisites for this are as follows:
* No voltage supply to the selector lever control unit (Ignition
switch is not positioned to “ON”)
* Brake pedal not depressed
Under these conditions, the locking lever (8) is in the locking

position. The tab on lock lever (9) locks the locking disc (1). It
is not possible to shift the selector lever out of selector lever
position “P”.
1. Locking disc 7. R/P locking solenoid

2. Cam (P lock) 8. Locking lever
3. Cam (R lock) 9. Tab on lock lever (P lock)
4. Selector lever 10. Tab on lock lever (R lock)
5. Base body 11. Potentiometer for detecting
6. Mode switch selector lever position
12. Intermediate lever
Parking Lock Mechanism

Location and function
The parking lock gear (6) is located on the output shaft in the
rear section of the transmission housing. In selector lever po-
sition “P”, the cone (3) slides between the parking lock pawl
(4) and the guide sleeve (5). The parking lock pawl (4) is there-
fore pushed against the parking lock gear (6). If the tooth of
the parking lock pawl (4) does not engage in a tooth space
when the vehicle is stationary, but rather touches a tooth of
the parking lock gear (6), the cone (3) is pre-tensioned by the
spring (2) and positioned ready for operation. If the parking
lock gear (6) continues to turn, the parking lock pawl (4) en-
gages in the next tooth space. To prevent damage due to
misuse, the widths of the tooth spaces are designed such
1. Detent plate 4. Parking lock pawl
that the parking lock pawl (4) can only engage when the ve-
2. Spring 5. Guide sleeve
hicle is stationary or moving very slowly. If the vehicle rolls
faster, the shape of the teeth prevents the parking lock pawl 3. Cone 6. Parking lock gear
(4) from engaging.

AFFECTED VIN
40 4A
Selector Lever Control Unit

Function
Selector lever control unit functions as follows:
A. Informing the selector lever’s position to other units via CAN.
B. Turning on the selector lever indicator while tail lamp is turning on.
C. Turning on the back-up lamp during reverse driving.
D. Operating the parking/reverse lock system.
Terminals
Pin No. Use For Remark

8 Selector lever unit power
6 CAN HI Connected to HECU, ECU, TCU,
7 CAN LO instrument panel etc.
5 Brake switch signal Parking lock operation

3 Self diagnosis
2 Tail lamp Turning on position indicator
9 Back-up lamp power
10 Back-up lamp
4 Ground

AFFECTED VIN
4A 41
Circuit diagram
Ignition switch Ignition switch

Tail lamp relay
Self diagnostic 10
Brake switch
Selector lever
control unit
Backup lamp
Instrument panel,
HECU, ECU

AFFECTED VIN
42 4A
CAN (Controller Area Network )

Function
CAN input signal CAN output signal
Accelerator pedal position Selected gear

Wheel speed (all wheels) Shifted status
Engine rpm, Engine torque Lock-up clutch status
Coolant temperature Automatic transmission
Downshift Kick-down status
Speed control (constant) TCU Driving conditions
Meshed gear Engine torque control
2nd gear start up control Dangerous status (changes to
emergency mode when
Selected gear in transfer case overloading, dangerous conditions,
Selector lever position and internal fault exists)
Odometer (I/P) ATF Temperature
Circuit diagram
Self diagnostic 11
Instrument panel Selector lever unit

AFFECTED VIN
4A 43
TCU (Transmission Control Unit)
TCU
TCCU
Function
TCU controls the gear groups according to the driving conditions. It receives the driving data from many sensors and
switches as input signals. It is also connected with ECU, HECU, instrument panel and selector lever control unit.
1. Shifting Method
Basic shift operation includes up-shift and down-shift for all gear groups. Shift control unit determines driving
resistance, accelerator pedal position, vehicle speed and some parameters (road surface condition, up hill and
down hill gradients, trailer driving conditions, catalytic converter conditions, driving habits and automatic transmission
oil temperature) to select a shift gear.
2. Down Shift
When engine speed increases excessively, the down shift does not occur.
3. Engine RPM Adjustment
During shifting, the engine torque is reduced to optimize the shift operation by delaying the ignition time.
4. Lock-Up Clutch Control
The lockup clutch in torque converter is activated in 3rd, 4th and 5th gear and operates in sequence via PWM
solenoid valve.
5. Others
The transmission is automatically controlled to compensate durability and wear.
The shift control values such as shifting point, shifting time, pressure during shifting, and lockup clutch control are
permanently saved and the diagnosis is partially available.

AFFECTED VIN
44 4A
TCU block diagram
Engine torque M/P S/V

36
Max. Engine torque S/P S/V
37
Engine power loss
Engine rpm Power supply (valves)

38
Engine Sol.
control ACC pedal position 1-2/4-5 gears S/V valve
14
Shift pattern changes 3-4 gears S/V
D 15
Engine control status 2-3 gears S/V
16
Engine torque
reduction I Lockup clutch S/V
17
T G
Wheel speed (FR, FL)
Sensor power supply
Wheel speed (RR, RL) I 13
Sensor
Sensor fround
HECU C 33
Shift pattern changes
T
Driving force control
A
Start signal Starter
Posi. Identifi. signal WO A C 7 relay
L
Posi. Identifi. signal W1
Selector Posi. Identifi. signal W2

angle N N2 speed
Posi. Identifi. signal W3 12
N3 speed
W/S mode signal input 35 T/M
Shift pattern changes
U Driving force controls
W/S mode indication
Selector lever indication Diagnosis Diag.

I/P 1
Conn.
Mileage
TCU (EGS) power

29
Part- P/N starting recognition IGN1
25, 27
time
TOD Selected T/C gear
TCCU TCU (EGS) ground Power

30
ground

AFFECTED VIN
4A 45
Characteristics of TCU and Automatic Transmission (LHM: Limp-Home

Mode)
The emergency driving mode is to minimize vehicle’s operation when is a mode for maintaining minimum driving condi-
tion when the automatic transmission is defective. In emergency driving mode, excessively long driving and unreason-
able driving should be avoided to prevent bigger fault occurring in advance. Emergency driving mode can largely be
divided in electrical defective and hydraulic pressure/mechanical defective.
Electrical defect
• If an electrical defective occurs in transmission during driving, current shift gear position is held.
A. Shut off of various solenoid valves
B. Internal pressure in transmission increases (shift shock gets bigger when changing selector lever due to
maximized MP and SP)
C. Lockup clutch is released
• If the shift operation cannot be activated, the driver must reset the system as follows:
A. Stop the vehicle and place the selector lever to “P” position.
B. Wait for 10 seconds after stopping the engine (release hydraulic pressure)
C. Start the engine.
D. Place the selector lever to “D” or “R” position.
Mechanical/hydraulic pressure defect

• Characteristics that appears in the vehicle are as below:
A. Holds at 3rd gear (It can be held at proper gear if the fault occurs at 3rd gear)
B. Electrical devices operate normally and the shift shock is acceptable during shift operation.
• If the shift operation cannot be activated, the driver must reset the system as follows:
A. Stop the vehicle.
B. Put the selector lever in “P” or “N” position.
C. Stop the engine.
D. In most cases, it is reset when the engine is started and the vehicle operate normally.
If, however, hydraulic or mechanical problem is not cleared, shifting is hold in 3rd or most stable gear range.

AFFECTED VIN
46 4A
Connector arrangement and pin functions
○
○
○
○
○
○
○
○
○
○
Connector A
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○ Connector B
Connector A Connector B
○
○
Pin No. Description Connected to

1 Diagnostic Diagnostic connector pin No.11
7 Initiating the starter relay Starter relay
12 RPM sensor N2 13-pin plug No.3
13 RPM sensor voltage supply 13-pin plug No.7
14 1-2, 4-5 solenoid valve 13-pin plug No.13
15 3-4 solenoid valve 13-pin plug No.9
16 2-3 solenoid valve 13-pin plug No.11
17 Lockup clutch solenoid valve 13-pin plug No.11
29 TCU voltage supply -
30 Ground -
33 RPM sensor ground 13-pin plug No.12
34 ATF temperature, Starter lock-out contact 13-pin plug No.4
35 RPM sensor N3 13-pin plug No.1
36 Modulating pressure solenoid valve 13-pin plug No.2
37 Shift pressure solenoid valve 13-pin plug No.10
38 Each solenoid valve voltage 13-pin plug No.6
L CAN Low ECM, HECU, selector lever unit, instrument panel
H CAN High ECM, HECU, selector lever unit, instrument panel

AFFECTED VIN
4A 47
OTHER FUNCTIONS
OIL LEVEL CONTROL
Function
This is the function that closes the opening between oil chamber and planetary gear set chamber, so that the gear set
does not splash in oil if the oil level rises.
The lubricating oil flowing continuously out of the gear sets returns through the opening (2) into the oil chamber. If the oil
level rises, the oil forces the float (1) against the housing.
The float separates the oil chamber from the gear set chamber. The lubricating oil which escapes further from the gear
sets is thrown against the housing wall by the rotating parts and flows now through the upper opening (arrow) back into
the oil chamber.
Reduction of power losses and prevention of fluid loss from the transmission at high fluid level.
1. Float A. Oil chamber

2. Opening B. Planetary gear set chamber

AFFECTED VIN
48 4A
Oil Check and Specification
Lock pin
Lock pin
Cap
Checking and adding Tip Automatic transmission fluid capacity and

A. Place the vehicle on level ground. Pull out the lock specification
pin and remove the cap (add 4 to 5 liter if oil has
Fluid capacity Approx. 8
been completely drained out).
Specification Fuchs ATF 3353 or Shell ATF 3353
B. Place the selector lever to “P” position. Start the
engine and leave it idling (add 2.5 liter if oil has been
completely drained out).
C. Warm the engine up while moving the selector lever
to all positions. Check if the oil temperature is approx.
80°C with a scanner (apply the parking brake).
: Selector lever position - R or D
D. Check the oil level with oil dipstick while engine is
running in “P” position.
E. Check several times with attention, and add or drain
the oil as required.
[Notice]
1) Use only specified ATF oil.

2) Measure the ATF oil temperature as the shift lever is in
“R” or “P”.

AFFECTED VIN
4A 49
SHIFT ROD ADJUSTMENT

Adjustment
1. Range lever D. “D” range

2. Shift rod P. “P” range
3. Selector lever
A. Disengage the shift rod from range lever and place the range lever at “D” position.
B. Place the selector lever at “D” position.
C. Insert the shift rod into range lever and tighten nut.
[Notice]
Lock the selector lever so that it will not move.
D. Check if the indication lamp in meter cluster indicates correct gear position while moving the selector lever to “P”,
“R”, “N”, and “D” position.
E. Check if the engine can be started at selector lever “P” or “N” position.

AFFECTED VIN
50 4A
CIRCUIT DIAGRAM
Starter, Selector Lever, CAN Communication

AFFECTED VIN
4A 51
Solenoid, Oil Temperature Sensor, RPM Sensor (N2, N3)

AFFECTED VIN
52 4A
TROUBLE CODE AND DIAGNOSIS

TROUBLE DIAGNOSIS WITH SCANNER
Scanner Diagnosis Procedure

1. Connect the scanner connector to the diagnostic socket.
3. Select [DIAGNOSTICS] in [MAIN MENU] screen and press [ENTER].
4. Select [STAVIC] in [VEHICLE SELECTION] screen and press and press [ENTER].
5. Select [TCU] in [CONTROL UNIT SELECTION] screen and press [ENTER].
6. Select [TROUBLE CODE] in [FUNCTION SELECTION] screen and press [ENTER].
7. Determine the DTC and locate the trouble cause.
[Reference]
Choose “data list” item to check sensors and other
informative data.

AFFECTED VIN
4A 53
TCU Coding for DC 5-Speed Automatic Transmission
If the TCU or automatic transmission has been replaced, the TCU should be coded with SCAN 100.
Entering the diagnosis procedures
1. Select “1] DIAGNSTICS” and press in MAIN

MENU.
2. Select “6] STAVIC” and press in VEHICLE

SELECTION screen.
3. Select “2] TCU” and press in CONTROL UNIT

SELECTION screen.

AFFECTED VIN
54 4A
4. Select “5] TCU CODING” and press in FUNCTION

SELECTION screen.
5. If the message as shown in the figure appears, select

the drive type .
6. Select “YES” to start TCU coding.
7. If the message as shown in the figure appears, turn the

ignition key to “OFF” position and then turn it “ON” again.

AFFECTED VIN
4A 55
TCU SCN Coding

To satisfy the vehicle diagnosis regulation(OBD II & EOBD), TCU SCN coding is supplemented to the conventional TCU
Item list on the SCAN100 SCN Coding is to clarify the identity of vehicle software and to check if any software coding is
performed
SCN(Software Calibration Number)

SCN are composed of 16Byte ASCII code to identify the software version.
TCU part number is included.
CVN(Calibration Verification Number)

CVN is made by TCU inner coding algorithm to check any software change of TCU
Procedure
1. Vehicle selection 2. Control unit selection
3. Select “TCU SCN” 4. Select the vehicle

AFFECTED VIN
56 4A
5. Select “Yes” 6. Ignition key off and on and then, wait 50 seconds
Going in to TCU original number mode.
7. Check the TCU SCN and CVN number

(CVN specified number will be distrubuted to you soon)
[Notice]
• CVN number which is shown right after SCN coing is

not available.
• Check only the CVN number which is taken after waiting
50seconds, after ingintion Key is turned to “On” from
“Off”.

AFFECTED VIN
4A 57
DTC (Diagnosis Trouble Code) of DC5AT

Trouble
Defectives Action
Code
P2000 Faulty TCU internal watchdog test - Self-diagnosis with IGN ON.
- Cycle the IGN switch from OFF to ON. Check and replace TCU if the
trouble still exists.
P2001 Faulty TCU internal watchdog - Self-diagnosis.
function - Cycle the IGN switch from OFF to ON. Check and replace TCU if the
P2002 Faulty TCU external watchdog test - Self-diagnosis with IGN ON.
P2003 Faulty TCU external watchdog - Self-diagnosis.
function - Cycle the IGN switch from OFF to ON. Check and replace TCU if the
P2004 Faulty TCU Clock - Self-diagnosis.
P2005 Faulty TCU RAM - Self-diagnosis with IGN ON.
P2006 Faulty TCU RAM CAN-Controller 1 - Self-diagnosis with IGN ON.
P2007 Faulty TCU RAM CAN-Controller 2 - Self-diagnosis with IGN ON.
P2008 Faulty TCU ROM - Self-diagnosis with IGN ON.
- When the TCU internal checksum is different from scanner checksum.
P200A Faulty TCU EEPROM - Self-diagnosis with IGN ON.
P200B Faulty TCU CPU (internal) - Self-diagnosis.
- Check harness contact.
P200C Faulty TCU program control - Self-diagnosis.
- Check harness contact.
P2010 No TCU variant coding - Self-diagnosis with IGN ON.
- When the TCU coding is not exist.
- Check again after TCU coding.
P2011 Faulty TCU variant coding - Self-diagnosis with IGN ON.
- When the TCU coding is faulty.
- Check again after TCU coding.
P2012 Faulty TCU checksum - Self-diagnosis with IGN ON.
P2013 Faulty TCU (internally) - Self-diagnosis with IGN ON.

AFFECTED VIN
58 4A
Trouble
Defectives Action
Code
P2100 Defective 1-2, 4-5 shift solenoid valve - When 1-2 or 4-5 shift solenoid valve is defective.
- Measure the resistance of 1-2 or 4-5 shift solenoid valve (turn the IGN
OFF, then and disconnect TCU connector).
• TCU connector terminals: B12, B3
• Specified value: 3.8 ± 0.2 Ω
- Triggered emergency mode when the defective is detected.
• Fixed at 2nd gear in “D” range.
- Check the related harness for open, short and contact.
P2101 1-2, 4-5 shift solenoid valve - short - When 1-2 or 4-5 shift solenoid valve is defective.
- Measure the resistance of 1-2 or 4-5 shift solenoid valve (turn the IGN
OFF, then disconnect TCU connector).
P2102 Defective 2-3 shift solenoid valve - When 2-3 shift solenoid valve is defective.
- Measure the resistance of 2-3 shift solenoid valve (turn the IGN OFF,
then disconnect TCU connector).
P2103 2-3 shift solenoid valve - short - When 2-3 shift solenoid valve is defective.
- Triggered mechanical emergency mode when the defective is detected.
P2104 Defective 3-4 shift solenoid valve - When 3-4 shift solenoid valve is defective.
P2105 3-4 shift solenoid valve - short - When 3-4 shift solenoid valve is defective.

AFFECTED VIN
4A 59
Trouble
Defectives Action
Code
P2106 Defective lockup clutch solenoid valve - Measure the resistance of lockup clutch solenoid valve (turn the IGN
OFF, then disconnect TCU connector).
P2107 Defective modulator pressure sole- - Measure the resistance of modulator pressure solenoid valve (turn the
noid valve IGN OFF, then disconnect TCU connector).
P2108 Defective shift pressure solenoid - Measure the resistance of shift pressure solenoid valve (turn the IGN
valve OFF, then disconnect TCU connector).
• Electrical error: Fixed at 2nd gear in “D” range.
P2200 Faulty rpm sensor N2 signal - When the rpm sensor N2 detects 0 rpm of front sun gear speed.
• TCU connector terminal B6: rectangular wave signal
B8: signal ground
B13: 6V
P2203 Faulty rpm sensor N3 signal - When the rpm sensor N3 detects 0 rpm of planetary gear carrier speed.
• TCU connector terminal B6: rectangular wave signal
B8: signal ground
B13: 6V
P220A Abnormal rpm sensor output signal - When the rpm difference between rpm sensor N2 and N3 is over
(N2, N3) 150 rpm.
P2220 Oil temperature sensor - short - Turn the IGN OFF, then disconnect TCU connector.
- Selector lever position: R or D
- Measure the resistance of oil temperature sensor.
P2221 Abnormal oil temperature sensor - Turn the IGN OFF, then disconnect TCU connector.
signal - Selector lever position: R or D

AFFECTED VIN
60 4A
Trouble
Defectives Action
Code
P2222 Abnormal oil temperature sensor signal - Turn the IGN OFF, then disconnect TCU connector.
- Selector lever position: R or D
P2300 Faulty CAN communication - Turn the IGN OFF, then disconnect TCU connector.
- Check the communication line for open, short and contact.
- Measure the resistance of CAN line: B1, B2
• Specified value: approx. 60 Ω
P2301 Faulty CAN communication - Turn the IGN OFF, then disconnect TCU connector.
- Check the communication line for open, short and contact.
- Measure the resistance of CAN line: B1, B2
• Specified value: approx. 60 Ω
P2310 CAN: Faulty brake system communi- - Check CAN communication line H and L.
cation - Check ABS/ESP unit.
P2311 CAN: Faulty ECU communication - Check CAN communication line H and L.
- Check engine ECU.
P2312 CAN: Faulty ECU communication - Check CAN communication line H and L.
- Check engine ECU.
P2313 CAN: Faulty selector lever control - Check CAN communication line H and L.
communication - Check selector lever.
P2315 CAN: Faulty instrument panel commu- - Check CAN communication line H and L.
nication - Check instrument cluster.
P2317 CAN: Faulty communication between - Check CAN communication line H and L.
TCCU/TOD and CAN - Check TCCU/TOD unit.
P2330 CAN: Faulty brake system signal - Check CAN communication line H and L.
- Check ABS/ESP unit.
P2331 CAN: Faulty ECU message - Check CAN communication line H and L.
- Check engine ECU.
P2332 CAN: Faulty ECU message - Check CAN communication line H and L.
- Check engine ECU.
P2333 CAN: Faulty selector lever signal - Check CAN communication line H and L.
- Check selector lever.
P2335 CAN: Faulty instrument cluster signal - Check CAN communication line H and L.
- Check instrument cluster.

AFFECTED VIN
4A 61
Trouble
Defectives Action
Code
P2337 CAN: Faulty TCCU/TOD - Check CAN communication line H and L.
- Check TCCU/TOD unit.
P2400 CAN: Faulty rear RH wheel speed - Check CAN communication line H and L.
sensor signal - Check ABS/ESP unit.
• Check wheel speed sensor connector.
• Check the air gap between tooth wheel and wheel speed sensor.
Check tooth wheel installation. (specified air gap: 0.309~0.958 mm).
• Check the numbers of tooth wheel: 48
P2401 CAN: Faulty rear LH wheel speed - Check the related harness for open, short and contact.
sensor signal - Check CAN communication line H and L.
Check tooth wheel installation. (specified air gap: 0.309~0.958 mm).
P2402 CAN: Faulty front RH wheel speed - Check CAN communication line H and L.
Check tooth wheel installation. (specified air gap: 0.335~0.945 mm)
P2403 CAN: Faulty front LH wheel speed - Check CAN communication line H and L.
Check tooth wheel installation. (specified air gap: 0.335~0.945 mm)
P2404 CAN: No brake signal - Check CAN communication line H and L.
P2405 CAN: No accelerator pedal signal - Check CAN communication line H and L.
- Check engine ECU.
P2406 CAN: No engine torque signal - Check CAN communication line H and L.
- Check engine ECU.
P2407 CAN: No ESP signal - Check CAN communication line H and L.
- Check engine ECU.
P2408 CAN: No minimum engine torque signal - Check CAN communication line H and L.
- Check engine ECU.
P2409 CAN: No maxmum engine torque signal - Check CAN communication line H and L.
- Check engine ECU.

AFFECTED VIN
62 4A
Trouble
Defectives Action
Code
P240A CAN: No engine rpm signal - Check CAN communication line H and L.
- Check engine ECU.
P240B CAN: No engine coolant temperature - Check CAN communication line H and L.
signal - Check engine ECU.
P240C CAN: No selector lever position signal - Check CAN communication line H and L.
- Check selector lever.
P240D CAN: No transfer case position signal - Check CAN communication line H and L.
- Check TCCU/TOD unit.
P2500 Invalid transmission gear ratio - Cycle the IGN switch from OFF to ON. Check A/T system again after a
certain period of driving.
- If the trouble still exists, replace A/T assembly.
- To protect transmission, any shift is not available.
P2501 Excessive engine rpm - Check CAN communication line H and L.
- Check engine ECU.
P2503 Current selected gear - Check selector lever.
P220B Excessive N2, N3 rpm - Check rpm sensor N2 and N3.
P2510 Torque converter lockup clutch stuck - Check the hydraulic lines for leaks (valve No.22 in valve body).
- Check the resistanve of lockup clutch solenoid valve (Turn the
IGN OFF, then disconnect TCU connector).
P2511 Faulty torque converter lockup heat - Check the hydraulic lines for leaks.
control
P2520 Faulty recognition of torque reduction - Check ECU.
P2502 Poor gear mesh, transmission slip - Check the hydraulic lines for leaks.
- Check oil filter.
P2600 Too low TCU supplying voltage - Check TCU supplying voltage.
P2601 Too high TCU supplying voltage - Check TCU supplying voltage.
P2602 Abnormal solenoid valve supplying - Check solenoid supplying voltage.
voltage
P2603 Abnormal speed sensor supplying - Check speed sensor supplying voltage.
voltage • TCU connector terminals B13: 6V

AFFECTED VIN
4A 63
HYDRAULIC SYSTEM
STRUCTURE OF VALVE BODY
Torque converter
Oil pump
Input shaft Output shaft

B1 C1 C2 B3 C3 B2
Parking lock gear

Intermediate shaft
F2
F1 Center planetary gear
Valve body
Stator shaft
Lockup clutch
1. Shift housing 8. Shift valve pressure control valve

2. 1-2/4-5 command valve 9. Torque converter lockup clutch control valve
3. 1-2/4-5 holding pressure shift valve 10. 2-3 shift pressure shift valve
4. 1-2/4-5 shift pressure shift valve 11. 2-3 command valve
5. 1-2/4-5 overlap control valve 12. 2-3 holding pressure shift valve
6. Shift pressure control valve 13. Shift valve B2
7. Regulating pressure control valve

AFFECTED VIN
64 4A
HYDRAULIC CIRCUIT
M/P S/V S/P S/V 1-2/4-5 shift 3-4

S/V shift
S/V
Lockup S/V 2-3 shift S/V

AFFECTED VIN
4A 65
1. Selector valve 21. Shift valve pressure control valve

2. 2-3 overlap control valve 22. Lock-up clutch control valve
3. Lubricating pressure control valve 24. 2-3 shift valve
4. Operating pressure control valve 25. 2-3 command valve
5. Holding pressure shift valve 26. 2-3 holding pressure shift valve
6. Command valve 27. B 2 shift valve
7. 3-4 shift valve 28. Modulating pressure solenoid valve
8. 3-4 overlap control valve 29. Shift pressure solenoid valve
9. One-way throttle valve 30. 1-2/4-5 shift solenoid valve
10. Ball change over valve 31. 3-4 shift solenoid valve
11. Ball change over valve 32. Lock-up solenoid valve
12. Filter screen 33. 2-3 shift solenoid valve
13. Ball change over valve 50. Oil pump
14. 1-2/4-5 command valve 51. Oil cooler
15. 1-2/4-5 holding pressure shift valve 52. Oil pan
16. 1-2/4-5 shift valve 53. Oil filter
18. 1-2/4-5 overlap control valve 54. Oil sump
19. Shift pressure control valve
p-A. Operating pressure

p-Sm. Lubricating pressure
p-KUB. Lock-up clutch operating pressure
p-RV. Control valve pressure
p-Mod. Modulating pressure

p-S/RMV. Solenoid valve shift pressure
p-S. Shift pressure
p-SV. Shift valve pressure

p-S/KUB. Lock-up clutch control pressure
Huile. Reserved oil

AFFECTED VIN
66 4A
Oil Pressure
Modulating pressure Shift pressure control

control solenoid valve solenoid valve
1. Lubricating pressure control valve 6. Shift pressure control valve

2. Operating pressure control valve 7. Oil pump
3. One-way throttle valve 8. Drain
4. Shift valve pressure pressure control valve p-A. Operating pressure
5. Control valve pressure control valve
Operating Pressure (p-A)

The inscribed gear type oil pump is installed into torque converter housing and is driven via the drive flange of the torque
converter.
The operating pressure produced from oil pump supplies oil pressure to mail line in hydraulic system to operate the
actuator. The operating pressure is the highest pressure in the hydraulic system. All other pressures are derived from it.
The operating pressure is regulated at the operating pressure control valve depending on load (modulating pressure) and
driving range (C1, C2 pressure). The spring in the operating pressure control valve adjusts a minimum pressure level
(base pressure).

AFFECTED VIN
4A 67
Lubricating Pressure (p-SM)

This pressure limits the pressure in torque converter and lubricates and cools the mechanical transmission parts.
At the operating pressure control valve, excess fluid is diverted to the lubricating pressure control valve (1) and, from
there, regulated for transmission lubrication use (including torque converter).
Control Valve Pressure (p-RV)

The control valve pressure is set at the control pressure regulating valve (5) in relation to the operating pressure up to 8
bar.
This pressure supplies oil to modulating pressure (MP) solenoid valve, shift pressure (SP) solenoid valve, shift valve
pressure control valve (6).
Modulating Pressure (p-M)

The modulating pressure is adjusted at the modulating pressure control solenoid valve. The height of modulating pres-
sure is dependent on engine load by TCU. It acts on the operating pressure control valve and the pressure overlap control
valve. It increases the operating pressure (line pressure) when the load is heavy.
Shift Pressure (p-S)

The shift pressure is adjusted at the shift pressure control solenoid valve and shift pressure control valve (4). Additional
pressure from clutch C2 acts on the shift pressure control valve. As a result, the shift pressure in 2nd gear is reduced.
Shift Valve Pressure (p-SV)

The shift valve pressure converts the control valve pressure (p-RV) to shift valve pressure. Then it supplies oil to com-
mand valve, lockup solenoid valve, and shift pressure control solenoid valves.

AFFECTED VIN
68 4A
Shift Groups
The hydraulic control range (including shift elements), which is responsible for the pressure distribution before, during
and after a gear change, is designated a shift group.
The hydraulic system consists of 3 shift groups.
A shift group can be in two phases.
• Shift phase
• Stationary phase
In the shift phase, a change takes place in one shift group of the engaged clutch/brake. The other two shift groups are
then in the stationary phase.
Shift group C1/B1 (gear change 1-2/4-5) is responsible for the up/down shifts 1-2/2-1 and 4-5/5-4.
It includes:
• Clutch C1
• Brake B1
• Command valve
• Holding pressure shift valve
• 1-2/4-5 shift solenoid valve
• Pressure overlap control valve
• 1-2/4-5 shift solenoid valve
Shift group C2/C3 (gear change 2-3) is responsible for the up/down shifts 2-3/3-2.
It includes:
• Clutch C2
• Clutch C3
• Command valve
• 2-3 shift solenoid valve
• Pressure overlap control valve
Shift group C3/B2 (gear change 3-4) is responsible for the up/down shifts 3-4/4-3 and the engagement process.
It includes:
• Clutch C3, 3-4 pressure overlap control valve
• Brake B2, 3-4 shift solenoid valve
• Brake B3
• Command valve

AFFECTED VIN
4A 69
HYDRAULIC CIRCUIT WHEN STARTING ENGINE

Selector Lever “N”
3-4 shift
solenoid valve
1. Selector valve B2a. B2 piston

5. 3-4 holding pressure shift valve B2b. Opposite face of B2 piston
6. 3-4 command valve m. Annular surface
7. 3-4 shift pressure shift valve p-A. Operating pressure
8. 3-4 overlap control valve p-Mod. Modulating pressure
10. Ball valve p-RV. Control valve pressure
13. Ball valve p-S. Shift pressure
14. 1-2/4-5 command valve p-S/RMV. Shift pressure/control solenoid valve
19. Shift pressure control valve p-SV. Shift valve pressure
27. B2 shift valve
The operating pressure (p-A) is formed and travels via the 2-3 holding pressure shift valve, the 2-3 command valve and
ball valve (13) to clutch C3 and via the 3-4 command valve (6) to the end face of the 3-4 shift pressure shift valve (17). The
3-4 shift pressure pressure shift valve is moved against the force of the spring towards the right. At the same time, the
3-4 solenoid valve is energized. This allows shift valve pressure (p-SV) to enter the spring chamber of the shift valve B2
(27) and to reach the end face of the 3-4 command valve (6). The shift valve B2 (27) is held in the upper position and the
3-4 command valve (6) switches towards the right. At the end face of the 3-4 shift pressure shift valve (7), the operating
pressure (p-A) is replaced by shift valve pressure (p-SV).

AFFECTED VIN
70 4A
Hydraulic Circuit when Moving Selector Lever from “N” to “D”

(Shift Phase)
3-4 shift
solenoid valve
1. Selector valve
5. 3-4 holding pressure shift valve B2a. B2 piston
6. 3-4 Command valve B2b. Opposite face of B2 piston
7. 3-4 shift pressure shift valve m. Annular surface
8. 3-4 overlap control valve p-A. Operating pressure
10. Ball valve p-Mod. Modulating pressure
14. 1-2/4-5 Command valve p-S. Shift pressure
19. Shift pressure control valve p-S/RMV. Shift pressure/control solenoid valve
27. B2 shift valve p-SV. Shift valve pressure
The selector valve (1) opens the shift pressure (p-S) feed connection from the ball valve (10) with the shift valve B2 (27).
With the shift valve B2 (27) in the upper position, shift pressure (p-S) travels behind the piston B2 (B2a) and simulta-
neously to the opposing face of the piston B2 (B2b). The brake B2 begins to close.

AFFECTED VIN
4A 71
Hydraulic Circuit when Selector Lever is in “D” Position (1st Gear)
3-4 shift
solenoid valve
1. Selector valve B2a. B2 piston

5. 3-4 holding pressure shift valve B2b. Opposite face of B2 piston
6. 3-4 Command valve m. Annular surface
7. 3-4 shift pressure shift valve p-A. Operating pressure
8. 3-4 overlap control valve p-Mod. Modulating pressure
13. Ball valve p-S. Shift pressure
14. 1-2/4-5 Command valve p-S/RMV. Shift pressure/control solenoid valve
19. Shift pressure control valve p-SV. Shift valve pressure
27. B2 shift valve
32. Pressure holding valve
The pressure on the opposing face of the piston B2 (B2b) ensures a soft activation of the brake B2. The TCU monitors
the activation sequence via the speed of input shaft, which slows down as the frictional connection in the brake increases.
When the speed drops to the specified level, TCU shuts off the power to the 3-4 shift solenoid valve. The spring chamber
of the shift valve B2 (27) is depressurized and switches downwards. This connects the line to the opposing face of the
piston B2 (B2b) with the pressure holding valve (32). The pressure on the opposing face of the piston B2 (B2b) drops to
a residual pressure. The 3-4 command valve (6) moves to the left. The operating pressure (p-A) travels via the holding
pressure shift valve (5) and the 3-4 command valve (6) to the piston of brake B2 (B2a). The activation sequence is
completed and 1st gear is engaged.

AFFECTED VIN
72 4A
Hydraulic Circuit after Shifted to 1st Gear
1-2/4-5 shift solenoid valve
14. 1-2/4-5 command valve 0. Return flow to oil sump

15. 1-2/4-5 holding pressure shift valve p-A. Operating pressure
16. 1-2/4-5 shift valve p-MOD. Modulating pressure
18. 1-2/4-5 pressure overlap control valve p-S. Shift pressure
The end face of 1-2/4-5 command valve (14) is kept unpressurized via the 1-2/4-5 solenoid valve. The operating pressure
is applied to the brake B1 via the holding pressure shift valve (15). The clutch C1 is unpressurized. The operating
pressure from brake B1 acts against the holding pressure shift valve (15) and the end face of 1-2/4-5 shift pressure shift
valve (16).

AFFECTED VIN
4A 73
Hydraulic Circuit During Shift Phase

16. 1-2/4-5 shift valve p-MOD. Modulating pressure
The shift valve pressure (p-SV) is directed onto the end face of the 1-2/4-5 command valve (14) via the 1-2/4-5 shift
solenoid valve. The command valve (14) moves up and the shift pressure (p-S) coming from the 1-2/4-5 shift pressure
shift valve (16) is routed via the command valve (14) to clutch C1. Overlap pressure is simultaneously applied to brake
(B1) from the pressure overlap control valve (18). The B1 pressure acting on the end face of shift pressure shift valve (16)
is replaced by operating pressure (p-A). The increasing shift pressure (p-S) on clutch C1 acts on the annular surface of
the pressure overlap control valve (18) and reduces the overlap pressure controlled by the pressure overlap control valve
(18). It will shift at a corresponding pressure on the holding pressure shift valve (15).

AFFECTED VIN
74 4A
Hydraulic Circuit after Completed Gear Change

16. 1-2 /4-5 shift valve p-MOD. Modulating pressure
The 1-2/4-5 shift solenoid valve interrupts the pressure on the end face of the command valve (14) and it returns to its
base position. The operating pressure (p-A) is now applied to clutch C1 via the holding pressure shift valve (15) and the
command valve (14). The brake B1 is disengaged (unpressurized). The spring of the shift pressure shift valve (16) moves
it into base position.

AFFECTED VIN
4A 75
STRUCTURE OF ELECTRO-HYDRAULIC CONTROL MODULE (SHIFT PLATE)
A. Adjusting valve: Operating pressure, Lubricating C. 3-4 shift group

pressure, 2-3 group overlap D. 2-3 shift group, Clutch lockup control valve, shift
B. 1-2/4-5 shift group, control valve: Control valve valve B2
pressure, Shift valve pressure
Rear Section
1. Dowel pin 3. Valve ball (steel) 5. Plastic valve

2. Valve ball (plastic) 4. Filter

AFFECTED VIN
76 4A
Left Section
1. Shift housing 8. Shift valve pressure control valve

2. 1-2/4-5 command valve 9. Torque converter lockup clutch control valve
3. 1-2/4-5 holding pressure shift valve 10. 2-3 shift pressure shift valve
4. 1-2/4-5 shift pressure shift valve 11. 2-3 command valve
5. 1-2/4-5 overlap control valve 12. 2-3 holding pressure shift valve
6. Shift pressure control valve 13. Shift valve B2
Right Section
1. Valve housing 4. Lubricating pressure control valve 7. 3-4 command valve

2. Selector valve 5. Operating pressure control valve 8. 3-4 shift pressure shift valve
3. 2-3 overlap control valve 6. 3-4 holding pressure shift valve 9. 3-4 overlap control valve

AFFECTED VIN
4A 77
Disassembly and Reassembly

1. Remove the leaf spring (5).
2. Remove the bolt (1).
Installation Notice
Tightening torque 8 Nm
3. Remove the shift housing (4) from valve housing (2).
[Notice]
Before installation, make sure to insert the dowel pin into

correct position.
4. Remove the sealing plate (3).
[Notice]
Be careful not to lose 4 plastic balls and 8 steel balls in shift

housing.
5. Unscrew the bolts from shift housing and valve housing

and remove the side cover. 1. Bolts (29) 4. Shift housing
Installation Notice 2. Valve housing 5. Leaf spring
3. Sealing plate
[Notice]
Check the valves for damage, and replace if necessary.

AFFECTED VIN
78 4A
REMOVAL AND INSTALLATION (DC 5-SPEED A/T)

COMPONENTS
4WD 2WD
4WD 2WD
1. Torque converter housing 1. Oil filler pipe
2. Plug connector 2. Drain plug
3. Oil line 3. Union bolt
4. Shield 4. Shield
5. Bolts 5. Plug connector
6. Transfer case adapter housing 6. Torque converter bolts
7. Union plugs 7. Transmission assembly
8. Drain plug 8. Shift rod
9. Torque converter bolts 9. Oil line
10. Oil line

AFFECTED VIN
4A 79

Transmission Assembly
Preceding Work: 1) Disconnect battery negative cable
2) Make sure the vehicle stand stable with safty wedge under tires
3) Put the shifting lever in “N”
4) Remove skid plate
* Check point
Make sure that the oil cooler pipe hose is not twisted, oil cooler pipe (radiator side) is not clogged. If it is contami-
nated with foreign materials, thoroughly clean before replacing transmission assembly (This work is necessary
when removing and installing the radiator).

AFFECTED VIN
80 4A
1. Remove the front and rear propeller shaft from the transfer Bolt No Tightening torque
case.
M17 4 81 ~ 89 Nm
M14 4 70 ~ 80 Nm
Front
Rear
Oil draining
If necessary, drain the oil. However, when removing or install-
ing the transmission without any other processes, just add oil
excluding drainage.
Installation Notice

AFFECTED VIN
4A 81
2. Disconnect T/C motor connector, T/M plug connector, T/M shift lever, air bleeder hose and other attachments.
1. T/C motor connector (1) & plug connector (2). 2. Air bleeder hose (3).
3. T/M shift lever.

* Locate the shift lever in “N”.
“P”
“N”

AFFECTED VIN
82 4A
3. Remove T/M oil return pipe (A), supply pipe (B), oil filler pipe (C) from T/M.
A. Oil return pipe B. Oil supply pipe C. Oil filler pipe
* Transmission Assembly
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
[Notice]
1. Collect the dropping oil from removed pipes in the oil collecter and seal the pipes with caps.
2. Be careful not to contaminate the body and work space.

AFFECTED VIN
4A 83
4. For easier removal, unscrew the stabilizer mounting bolts (B) and put it down to the sub frame.
5. Support the transmission with hydraulic jack.
A. Stabilizer bar link

AFFECTED VIN
84 4A
6. Unscrew the center cross member mounting bolts.
A.Center bolts-center cross frame (14 mm - 2 EA) B.Side bolts-center cross frame (14 mm - 8 EA)

AFFECTED VIN
4A 85
7. Unscrew the T/M insulator bracket bolts and remove the bracket.
8. Unscrew the transfer case mounting bolts (12 mm - 11 EA) and remove the T/C from the T/M.
Tightening torque 20 ~ 25 Nm

AFFECTED VIN
86 4A
9. Remove the torque converter hole cover and unscrew torque converter bolts one by one as rotating the engine crank
shaft clockwise. (14 mm - 6 EA)
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○
○
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○
○
○
○
○
○
○
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○
○

AFFECTED VIN
4A 87
10. Unscrew the mission housing bolts and drop the transmission slowly with hydraulic jack (17 mm - 8EA, Tightening
torque: 50 - 60 Nm)
[Notice]
Be careful not to drop the torque converter
11. Remove the torque converter with special tool.
[Notice]
When install the torque converter on the mission, apply

small amount of ATF oil to the input shaft & frange.
[Notice]
• Add the ATF oil and check the oil lever.

• Before reinstallation, clean the T/M and related
components.

AFFECTED VIN
88 4A
Selector Lever Assembly

1. Separate the selector. [Notice]
Place the selector lever at “P” position when removing

installing selector lever and wire cable.
A. Shift rod
: Remove the shift rod pin (1) and separate the shift
rod from selector lever
2. Remove the selector lever cover (1) and the center

console (2).
3. Remove the selector lever lower duct (1) and connector

(2).
4. Unscrew the selector lever assembly mounting bolts.

AFFECTED VIN
4A 89
DISASSEMBLY AND REASSEMBLY (DC 5-SPEED A/T)

COMPONENTS
Torque converter
Oil pump
C3 assembly
Input shaft
Output shaft
B1 C1 C2 B3 C3 B2
C2 assembly
Parking lock gear
F2 Intermediate shaft
Center planetary gear
F1
Valve body
Stator shaft
B3 assembly Lockup clutch
Housing assembly
C1 assembly
B2 assembly
B1 assembly
Output flange Oil pump
Adaptor plug
Valve body and oil pan (transmission wiring connection) Torque converter

AFFECTED VIN
90 4A
Friction Disc
Transmission Friction Disc C1 C2 C3 B1 B2 B3 Remark
Numbers 4 4 4 3 5 4
W5A300
Single Dual Single Single Dual Dual
(G32D: 4WD) Type
face face face face face face
Numbers 5 5 4 4 5 5
W5A400
Single Dual Single Single Dual Dual
(D27DT: 4WD) Type
face face face face face face
Tightening Torque
Tightening
No. Description Remark
Torque (Nm)
1 Oil drain plug (oil pan) 14 Heaxgon, 5 mm
2 Oil filler pipe (upper) 12 ~ 14 -
3 Oil filler pipe (lower) 7~8 -
4 Oil cooler pipe 30 ~ 38 -
5 Oil pan 8 T 30
6 Torque converter housing/oil pump 20 -
7 Transmission rear mounting bracket (both sides) 36 ~ 44 -
8 Transmission rear mounting bracket (center) 20 -
9 Torque converter bolt 42 -
10 Converter housing/engine 50 ~ 60 -
11 Converter housing/transmission housing 20 T 45
12 Valve body 8 T 30
13 Valve body side cover 4 T 30
14 Solenoid valve 8 -
15 12-Angle collar nut 200 12-Angle, each 30 mm
16 B2 housing bolt 16 T 45
17 Selector lever unit bolt 6 -

AFFECTED VIN
4A 91
DISASSEMBLY AND REASSEMBLY

Valve Body Assembly
5. Valve body
1. Guide bush 5-3. Pin 5-9. Solenoid valve

2. Drain plug 5-4. Plate leaf spring 5-10. Plate spring
3. Bolts 5-5. Bolts 5-11. Screw
4. Oil filter 5-6. Electric kit 5-12. Screw
5. Valve body 5-7. Solenoid valve 5-13. Bolts
5-1. Valve body assembly 5-8. Lifting solenoid valve 6. Oil pan
5-2. Body assembly

AFFECTED VIN
92 4A
Preceding work:
Install the transmission on the fixture stand.
[Note]
• To eliminate unnecessary working time and process,

prepare general tools, special tools, and gaskets before
starting work.
• The automatic transmission is very precise equipment.
Keep the transmission clean and tighten the bolts with
specified tightening torque.
1. Unscrew the bolt and remove the guide bush (1).

(7 mm - 1EA)
2. Unscrew the oil pan bolts and remove the oil pan (6).
Installation Notice
3. Remove the oil filter.

AFFECTED VIN
4A 93
4. Unscrew the bolts and remove the valve body from

transmission housing.
Installation Notice
5. Disassembly and reassemblt the valve body assembly.

5-1. Remove the solenoid valve cap.
5-2. Unscrew the bolts on solenoid valve and remove the leaf
springs.
Installation Notice
[Notice]
The socket bolts do not have same length. Be careful not to

mix up.
5-3. Remove the solenoid valves from valve body.

AFFECTED VIN
94 4A
[Notice]
1. Make sure to install the solenoid valves at correct

locations.
2. Check the O-rings, and replace if necessary.
5-4. Remove the electronic control module (Y3/6) from shift

plate.
[Notice]
Correctly align the electronic control module onto the shift

plate by using two central pins when installing.

AFFECTED VIN
4A 95
Converter Housing and Transmission Housing
Transmission housing
Converter housing assembly
1. Install the transmission assembly on the fixture stand.
Fixture stand 116 589 06 59 00
2. Remove the rear extension housing from transmission

housing.
Installation Notice

AFFECTED VIN
96 4A
3. Stretch out the bent point in 12-sided collar nut on output

shaft.
4. Unscrew the collar nut with special tool and remove

output shaft flange.
Installation Notice
* Bend the collar nut to lock it during installation.
5. Remove the rear oil seal ring.
6. Remove the snap ring with snap ring pliers and remove
the washer.

AFFECTED VIN
4A 97
7. Remove the ball bearing from transmission housing.

• Install the flare clamping pliers.
• Install the puller onto inner bearing race.
• Rotate the clamping pliers counterclockwise (arrow
direction) to tighten.
Puller 001 589 50 33 00

Collet chuck 140 589 06 34 00
• Remove the ball bearing from transmission housing

with spanner.
8. Unscrew the socket bolts fastening converter housing

and transmission housing and remove the transmission
housing from converter housing.
Installation Notice
[Note]
Slightly turn the transmission housing to left and right

direction to make the removal process easier.
[Notice]
• Apply loctite to the bolts from T/C housing to T/M. (15EA)

• No loctite to the bolts from T/M to T/C housing. (2EA)

AFFECTED VIN
98 4A
Converter Housing Assembly
Clutch C3
Clutch C2
Clutch C1
Brake B1
Oil pump

AFFECTED VIN
4A 99
1. Remove the clutch C3 from converter housing assembly.
4. Remove the brake B1.

4-1. Remove the bolts on brake B1.
Installation Notice

AFFECTED VIN
100 4A
4-2. Remove the bolts in converter housing.

Installation Notice
4-3. Remove the brake B1 from converter housing.
4-4. Separate the plate from valve body.
[Notice]
• Install two bolts on the opposite side of disc brake B1 and

tap the surface of disc brake B1 with plastic hammer to
remove it ftom converter housing.
• Align the dowel pin (arrow) on disc brake B1 and groove
in converter housing when installation.
• Apply the sealant on the socket bolts and tighten them.
5. Unscrew the bolts and remove the oil pump.

Installation Notice
[Notice]
Install two bolts on the opposite side of oil pump housing

and tap the surface of oil pump with plastic hammer to
remove it from converter housing.

AFFECTED VIN
4A 101
5-1. Remove the pump gears (1, 2) from pump housing.
5-2. Check the radial seal ring (3), and replace if necessary.
5-3. Replace the O-ring (4) with new one.
[Notice]
• Lubricate the pump gears (1, 2) before installation.

• Place the pump gear (2) into pump housing and install the
pump gear (1) onto the pump housing chamber.

AFFECTED VIN
102 4A
Transmission Housing Assembly
Parking lock gear
Brake B2 Brake B3
Snap ring
Components of selector lever

AFFECTED VIN
4A 103
1. Install the transmission assembly on fixture stand.
Fixture stand 116 589 06 59 00
2. Remove the snap ring from transmission housing.
3. Remove the spring washer and disc pack B3 from

[Notice]
• To make the removal easier, remove the disc pack B3 while

compressing it.
• Check each disc for wear and burnt out.
4. Remove the fixing bolts for brake B2 from transmission

housing.
Installation Notice

AFFECTED VIN
104 4A
5. Remove the disc brake B2 from transmission housing.
6. Remove the parking lock gear.
7. Remove the fixing bolts for range selector lever.

Installation Notice
[Notice]
Check the sealing ring for damage.
8. Remove the range selector lever, rod and detent plate.

AFFECTED VIN
4A 105
9. Remove the snap rings from parking lock pawl.
10. Remove the pin from transmission housing.
11. Remove the parking lock pawl from transmission housing.

AFFECTED VIN
106 4A
COMPONENTS OF EACH ASSEMBLY
Clutch C1
Clutch C2
Clutch C3

AFFECTED VIN
4A 107
Clutch C1 Clutch C2 Clutch C3

1. Sealing ring in disc carrier 11. Front planetary gear set 24. Clutch C3
2. Piston 12. Gear wheel 25. Sealing ring
3. Sealing ring in piston 13. Snap ring 26. Piston
4. Return spring 14. Thrust bearing 27. Disc spring
5. Spring plate 15. Clutch C2 and input shaft 28. Snap ring
6. Snap ring 16. Piston 29. Disc pack
7. Disc and steel plate 17. Inner sealing ring in piston 30. Snap ring
8. Snap ring 18. Outer sealing in piston
9. Snap ring 19. Return spring
10. One-way clutch F1 20. Spring plate
A. Oil gallery in clutch C1 21. Snap ring
22. Disc and steel plate
23. Snap ring

AFFECTED VIN
108 4A
Multi-disc brake B1
Multi-disc brake B2
Multi-disc brake B1 Multi-disc brake B2

1. Disc brake B1 8. Disc carrier B2 15. Spring plate
2. Piston 9. Sealing ring 16. Snap ring
3. Return spring 10. Sealing ring 17. Piston guides in B2 and B3
4. Snap ring 11. Piston in B2 18. O-ring
5. Cushion spring 12. Sealing ring in piston guide ring 19. Disc and steel plate
6. Disc and steel plate 13. Sealing ring in piston guide ring 20. Snap ring
7. Snap ring 14. Return spring 21. Cushion plate

AFFECTED VIN
4A 109
Rear gear set and center output shaft
Rear freewheel and rear hollow shaft
Rear gear set and center output shaft Rear freewheel and rear hollow shaft
1. Output shaft in center gear set 12. Hollow shaft
2. Needle bearing 13. O-ring
3. Teflon ring 14. Snap ring
4. Thrust washer 15. Freewheel
5. Thrust needle bearing 16. Inner disc carrier and rear sun gear/clutch C3
6. Shim 17. Thrust needle bearing
7. Snap ring 18. Shim
8. Rear gear set 19. Snap ring
9. Thrust washer
10. Clutch C3
11. Rear hollow shaft
C. Oil outlet port in clutch C3
D. Oil inlet port in clutch C3

AFFECTED VIN
110 4A
MEASUREMENT AND ADJUSTMENT

Shaft Axial Clearance Adjust
1. Measure the clearance between the ball bearing and the
parking lock gear.
• Place the measuring bridge on top of transmission
housing and measure the distance from the parking
lock gear (a) to the measuring bridge.
• Measure the distance from measuring bridge to the
ball bearing groove on mating surface with gauge (b).
• Adjust the axial play “E” with adjusting shim.
ex) Distance “a” 49.90 mm

Distance “b” 49.00 mm
Difference 0.90 mm
Axial play “E” 0.40 mm
Shim size 0.50 mm
Axial play (specified value) 0.3 ~ 0.5 mm
[Notice]
Select a proper thickness of shim:

0.2, 0.3, 0.4, 0.5 mm
2. Install a shim.
Measuring bridge 126 589 04 31 00
3. Insert the ball bearing into rear part of transmission

housing.
[Notice]
Measure the clearance between ball bearing (2) and snap

ring. Install the appropriate size of snap ring.
(2.0, 2.1, 2.2 mm)

AFFECTED VIN
4A 111
4. Install the radial sealing with a tool.
Arbor 140 589 12 15 00

AFFECTED VIN
112 4A
Measurement of Disc Brake B1 (Figure 1)
(1) Sectional drawing of brake B1

6b External disc carrier
6c Piston
6f Disc spring
6h Snap ring
69 Friction disc
70a External disc (1.8 mm)
70b External disc (2.8 mm)
70c External disc (4.0 mm)
L Clearance
(2) Procedure (Figure 2)

1. Soak new discs into ATF for one hour before installation.
2. Install the brake B1 discs with the order as shown in
(Figure 1).
3. Install the compressor (078) on external discs (70c) and
apply the 1200N of force to the disc pack. This force is
applied on the marking ring point (small arrow in figure
2). Do not apply excessive force.
4. Determine the clearance (L) at three points between
external disc (70c) and snap ring (6h) with feeler gauge.
• The snap ring (6h) should be contacted to top of the
external disc carrier (6b) during installation.
5 adjust the clearance with proper snap rings if needed.
Specified clearance (L): No. of single face friction disc No. of dual face friction disc
- 2 : 2.2 ~ 2.6 mm - 2.3 ~ 2.7 mm
- 3 : 2.4 ~ 2.8 mm - 2.7 ~ 3.1 mm
- 4 : 2.6 ~ 3.0 mm - 3.0 ~ 3.4 mm
Thickness of B1 snap ring: 2.6, 2.9, 3.2, 3.5, 3.8, 4.1 mm

AFFECTED VIN
4A 113

14a External disc carrier
27 Piston
134d Friction disc
134e Disc spring
144a Snap ring
L Clearance

(Figure 1).
3. Install the compressor (078) on external discs (134a) and
external disc (134a) and snap ring (144a) with feeler gauge.
• The snap ring (144a) should be contacted to top of the
external disc carrier (14a) during installation.
5. adjust the clearance with proper snap rings if needed.
Specified clearance (L): No. of friction disc

- 3 : 1.9 ~ 2.3 mm
- 4 : 2.0 ~ 2.5 mm
- 5 : 2.0 ~ 2.4 mm
Thickness of B2 snap ring: 2.9, 3.2, 3.5, 3.8 mm

AFFECTED VIN
114 4A

2 Automatic transmission housing
(External disc carrier)
14a Piston
133d Disc spring
133e Friction disc
133f Snap ring
L Clearance
(Figure 1).
external disc (133c) and snap ring (133a) with feeler gauge.
• The snap ring (133a) should be contacted to top of the
external disc carrier (133c) during installation.
4. Adjust the clearance with proper snap rings if needed.
Specified clearance (L): 1.0 ~ 1.4 mm

Thickness of B3 snap ring: 3.2, 3.5, 3.8, 4.1, 4.4, 4.7 mm

AFFECTED VIN
4A 115
Measurement of Disc Clutch C1 (Figure 1)
(1) Sectional drawing of clutch C1

86 Piston
86b Disc spring
89d Friction disc
90 Snap ring
L Clearance

2. Install the brake C1 discs with the order as shown in
(Figure 1).
external disc (89c) and snap ring (90) with feeler gauge.
• The snap ring (90) should be contacted to top of the
5. Adjust the clearance with proper snap rings if needed.
- 3 : 2.4 ~ 2.8 mm - 2.7 ~ 3.1 mm
- 4 : 2.6 ~ 3.0 mm - 3.0 ~ 3.4 mm
- 5 : 2.8 ~ 3.2 mm - 3.3 ~ 3.7 mm
- 6 : 2.9 ~ 3.3 mm - 3.6 ~ 4.0 mm
Thickness of C1 snap ring : 2.6, 2.9, 3.2, 3.5, 3.8, 4.1 mm

AFFECTED VIN
116 4A

101 Piston
105d Friction disc
106 Snap ring
107 Disc spring
L Clearance

(Figure 1).
external disc (105c) and snap ring (106) with feeler gauge.
• The snap ring (106) should be contacted to top of the
Specified clearance (L): No. of dual face friction disc

- 3 : 2.3 ~ 2.7 mm
- 4 : 2.4 ~ 2.8 mm
- 5 : 2.5 ~ 2.9 mm
- 6 : 2.7 ~ 3.1 mm
Thickness of C2 snap ring: 2.3, 2.6, 2.9, 3.2, 3.5, 3.8 mm

AFFECTED VIN
4A 117

37 Friction disc (2.1mm)
41a External disc (4.0mm)
44c Piston
44g Snap ring
44h Disc spring
L Clearance

(Figure 1).
3. Install the compressor (078) on external discs (41a) and
external disc (41a) and snap ring (44g) with feeler gauge.
• The snap ring (44g) should be contacted to top of the
- 3 : 2.3 ~ 2.7 mm - 2.3 ~ 2.7 mm
- 4 : 2.4 ~ 2.8 mm - 2.4 ~ 2.8 mm
- 5 : 2.5 ~ 2.9 mm - 2.5 ~ 2.9 mm
Thickness of C3 snap ring: 2.0, 2.3, 2.6, 2.9, 3.2, 3.5 mm

AFFECTED VIN
118 4A
[Notice]
* Free play of each disc - This value is measured by special

tool(208 589 00 21 00)
- Exept “B3”
Component Number of friction plate Single side disk No single side disk
3 2.4 - 2.8 mm 2.7 - 3.1 mm
4 2.6 - 3.0 mm 3.0 - 3.4 mm
C1
5 2.8 - 3.2 mm 3.3 - 3.7 mm
6 2.9 - 3.3 mm 3.6 - 4.0 mm
3 2.3 - 2.7 mm
4 2.4 - 2.8 mm
C2
5 2.5 - 2.9 mm
6 2.7 - 3.1 mm
3 2.3 - 2.7 mm 2.3 - 2.7 mm
C3 4 2.4 - 2.8 mm 2.4 - 2.8 mm
5 2.5 - 2.9 mm 2.5 - 2.9 mm
2 2.2 - 2.6 mm 2.3 - 2.7 mm
B1 3 2.4 - 2.8 mm 2.7 - 3.1 mm
4 2.6 - 3.0 mm 3.0 - 3.4 mm
3 1.9 - 2.3 mm
B2 4 2.0 - 2.5 mm
5 2.0 - 2.4 mm
3 1.0 - 1.4 mm
B3 4 1.0 - 1.4 mm
5 1.0 - 1.4 mm
[Notice]
1) Approximately 1,200 Nm must be applied to keep the piston

down (B1, B2, C1, C2, C3)
2) 10 Nm is to be applied for “B3”

AFFECTED VIN
4A 119
722.6 Circlip thickness Circlip part number Clearance spec.

Shift member in mm in mm
# frictions/spec
C1 2.6 140 994 87 40 (3) 0.5 - 1.8
2.9 140 994 88 40 (4) 0.5 - 1.8
3.2 140 994 89 40 (5) 0.5 - 1.9
3.5 140 994 29 35 (6) 0.5 - 2.0
3.8 140 994 30 35
C2 2.3 140 994 92 40 (3) 0.7 - 1.7
2.6 140 994 93 40 (4) 0.7 - 1.7
2.9 140 994 94 40 (5) 0.7 - 1.8
3.2 140 994 32 35
3.5 140 994 33 35
C3 2.0 140 994 99 40 (3) 0.7 - 1.9
2.3 140 994 10 35 (4) 0.7 - 1.9
2.6 140 994 11 35 (5) 0.7 - 2.0
2.9 140 994 35 35
3.2 140 994 36 35
B1 2.6 140 994 87 40 (2) 0.5 - 1.7
2.9 140 994 88 40 (3) 0.5 - 1.7
3.2 140 994 89 40 (4) 0.5 - 1.8
3.5 140 994 29 35
3.8 140 994 30 35
B2 2.9 140 994 63 35 (4) 0.2 - 1.3
3.2 140 994 62 35 (5) 0.2 - 1.4
3.5 140 994 61 35
3.8 140 994 60 35
4.1 140 994 59 35
B3 3.2 140 994 15 35 (ALL) 1.0 - 1.4
3.5 140 994 16 35
3.8 140 994 17 35
4.1 140 994 41 35
4.4 140 994 42 35
4.7 140 994 43 35

AFFECTED VIN
120 4A
SPECIAL TOOLS AND EQUIPMENT

Special Tool
Name and Part Number Application
W 126 589 01 62 00 Removal and installation of torque converter

Handle
W 116 589 06 59 00 Fixing automatic transmission

Assembly stand
W 140 589 12 15 00 Installation of sealing ring

Arbor
W 001 589 50 33 00 Removal and installation of

Puller transmission housing ball housing

AFFECTED VIN
4A 121
W 140 589 34 63 00 Fixing automatic transmission

Fixing plate
W 140 589 06 34 00 Removal and installation of transmission housing ball bearing

Collet chuck
W 140 589 13 43 00 Removal and installation of B1, B2, B3 piston

Piston puller
W 126 589 02 09 00 Removal and installation of

Socket collar nut for output shaft

AFFECTED VIN
122 4A
128 589 04 31 00 Measuring the clearance between ball

bearing and parking lock gear
Measuring bridge
W 208 589 00 21 00 Compressing clutch and disc brake

Compressor
W 140 589 15 21 00 Measuring the oil level

Pipstick guage

AFFECTED VIN
4A 123
Fixing Plate Assembly Stand W 140 589 34 63 00

AFFECTED VIN
MEMO
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4B 1
4B
TSM54/52 MANUAL TRANSMISSION
Table of Contents
GENERAL INFORMATION ................................ 4B-3
1. Overview ...................................................................... 4B-3
2. Specifications ............................................................. 4B-5
3. System components ................................................... 4B-6
4. Shifting mechanism ................................................... 4B-16
5. Diagnostic information and procedures ...................... 4B-24
6. Circuit diagram (Backup lamp) .................................. 4B-27
ON-VEHICLE SERVICE .................................. 4B-28

1. Oil check/Change ..................................................... 4B-28
T/M ASSEMBLY ............................................... 4B-35

1. Assembly overview .................................................... 4B-35
2. Disassembly ............................................................. 4B-38
3. Inspection before reassembly .................................... 4B-48
4. Reassembly .............................................................. 4B-51
INSPECTION/MAINTENANCE ....................... 4B-68

Shim adjustment ........................................................... 4B-68
SPECIAL TOOLS AND EQUIPMENT ............. 4B-71
TSM54/52 MANUAL TRANSMISSION CHANGED BY

AFFECTED VIN
4B 3
GENERAL INFORMATION
1. OVERVIEW
4WD 2WD
1. TSM54/52 transmission is designed to link the gear ratio, installation dimensions and shapes with current T5
transmission and BTRA automatic transmission. It provides maximum drivability by the optimized engine torque
and gear ratio.
2. TSM54/52 transmission uses linkage type shift elements directly connected to the transmission. It prevent the
transmission from shifting to the reverse gear from 5th gear when shifting to reverse gear. It also prevents the break
and wear.

AFFECTED VIN
4 4B
Features
3. All gears use the helical type and high strength
materials.
[Notice]
The helical type gear provides less noise.
4. The synchronizing devices are installed in 1/2,

3/4, 5/R gears. To prevent the double engagement,
the independent interlock devices are installed.
[Notice]
TSM54/52 transmission uses the inertia lock type key to
make smooth gear engagement and to provide silent gear
engagement.
5. The clutch release system is available to use CSC

(Concentric Slave Cylinder) or Fork type according
to the vehicle model. New Rexton uses the fork type
clutch release system.
6. The semi-remote control type gear shift mechanism
is used to prevent incorrect shifting.
CHANGED BY TSM54/52 MANUAL TRANSMISSION

AFFECTED VIN
4B 5
2. SPECIFICATIONS
General Specifications
Description DI ENGINE
Length (mm) 4WD: 628.3, 2WD: 672
Distance between shafts (mm) 81
Input torque (kgxm) 34.7 (340 Nm)
Transmission control type Semi-remote
Weight (kg) - not including transmission fluid (kgxm) 4WD: 44, 2WD: 45
Gear ratio/Gear teeth 1st gear 4.315
(input gear: main gear) 2nd gear 2.475
3rd gear 1.536
4th gear 1.000
5th gear 0.807
Reverse gear 3.591
Transmission fluid Specification ATF DEXRON II or III
Capacity ( ) 4WD: 3.6, 2WD: 3.4
Change interval Inspect at every 10,000 km, replace at every
60,000 km (add or replace if necessary)
Tightening Torque
Description Tightening Torque
Oil drain plug 4 ~ 5 kgfxm 39.22 ~ 49.03 Nm
Backup lamp switch (24mm) 3 ~ 4 kgfxm 29.42 ~ 39.22 Nm
Extension housing bolt (14mm) 4.2 ~ 5.7 kgfxm 41.18 ~ 55.89 Nm
Shift top cover bolt (12mm) 1.7 ~ 2.6 kgfxm 16.67 ~ 25.48 Nm
Extension housing spring plug (19mm) 7 ~ 10 kgfxm 68.6 ~ 98 Nm
Offset plate countersunk screw 0.4 ~ 0.6 kgfxm 3.92 ~ 5.88 Nm

AFFECTED VIN
6 4B
3. SYSTEM COMPONENTS
Gear Combinations
5/R shift fork 1/2 shift fork 3/4 shift fork

1st gear 2nd gear
Input gear
Output shaft Input shaft
5th gear Counter shaft 3rd gear 4th gear
Shift Fork and Rail Combinations
Speedometer gear (2WD) Transmission adaptor Interlock plate
Reverse lock plate

AFFECTED VIN
4B 7
Sectional View
4WD

AFFECTED VIN
8 4B
1. Transmission front housing 38. Reverse idler gear

2. Input shaft oil seal 39. Reverse idler spacer
3. Front cover 40. Reverse idler bracket
4. Hexagon flange bolt (17 ~ 26 Nm) 41. Retainer ring
5. Oil drain plug 42. Reverse lock nut
6. Sealing 43. Transmission adaptor
7. Pin 44. Input shaft spacer
8. Input shaft 45. Counter spacer
9. Clutch 4th gear 46. Reverse needle bearing
10. Taper roller bearing (main) 47. Reverse gear
11. Taper roller bearing 48. Reverse clutch gear
12. Counter shaft 49. Reverse counter gear
13. Taper roller bearing (counter) 50. Synchro hub
14. Output shaft 51. Counter 5th gear
15. Inner race (reverse) 52. 5th needle bearing
16. Inner race (1st) 53. 5th gear
17. Needle bearing 54. 5th clutch gear
18. 1st gear 55. Thrust washer
19. 1st clutch gear 56. Spring pin
20. Synchro outer ring 57. 5th outside retainer ring
21. Synchro - middle cone 58. 5th retainer ring
22. Synchro inner ring 59. Counter shaft bushing
23. Synchro spring 60. Counter roller bearing assembly
24. Synchro key 61. Retainer ring
25. Synchro hub 62. Extension housing
26. Double synchro sleeve 63. Output shaft oil seal
27. 2nd gear 64. Offset plate
28. 3rd gear 65. Counter screw
29. 3rd clutch gear 66. Top cover
30. Synchro hub (3 & 4th) 67. Counter oil seal
31. Synchro ring (4/5/R) 68. Shift shaft
32. Single synchro sleeve 69. Shift lever
33. Retainer ring 70. Detent pin
34. Adaptor dowel pin 71. Joint pin
35. Reverse idler shaft 72. Retainer ring
36. Dowel pin 73. Semi remote lever assembly
37. Needle bearing

AFFECTED VIN
4B 9
2WD

AFFECTED VIN
10 4B
1. Transmission front housing 39. Reverse idler spacer

2. Input shaft oil seal 40. Reverse idler bracket
3. Front cover 41. Retainer ring
4. Hexagon flange bolt (17 ~ 26 Nm) 42. Reverse lock nut
5. Oil drain plug 43. Transmission adaptor
6. Sealing 44. Input shaft spacer
7. Pin 45. Counter spacer
8. Input shaft 46. Reverse needle bearing
9. Clutch 4th gear 47. Reverse gear
10. Taper roller bearing (main) 48. Reverse clutch gear
11. Taper roller bearing 49. Reverse counter gear
12. Counter shaft 50. Synchro hub
13. Taper roller bearing (counter) 51. Counter 5th gear
14. Output shaft 52. 5th needle bearing
15. Inner race (reverse) 53. 5th gear
16. Inner race (1st) 54. 5th clutch gear
17. Needle bearing 55. Thrust washer
18. 1st gear 56. Spring pin
19. 1st clutch gear 57. 5th outside retainer ring
20. Synchro outer ring 58. 5th retainer ring
21. Synchro - middle cone 59. Counter shaft bushing
22. Synchro inner ring 60. Counter roller bearing assembly
23. Synchro spring 61. Retainer ring
24. Synchro key 62. Extension housing
25. Synchro hub 63. Output shaft oil seal
26. Double synchro sleeve 64. Offset plate
27. 2nd gear 65. Counter screw
28. 3rd gear 66. Top cover
29. 3rd clutch gear 67. Counter oil seal
30. Synchro hub (3 & 4th) 68. Shift shaft
31. Synchro ring (4/5/R) 69. Shift lever
32. Single synchro sleeve 70. Detent pin
33. Retainer ring 71. Joint pin
34. Adaptor dowel pin 72. Retainer ring
35. Reverse idler shaft 73. Semi remote lever assembly
36. Dowel pin 74. Rear flange
37. Bearing 75. Ball bearing
38. Reverse idler gear 76. Lock nut

AFFECTED VIN
4B 11
Front View and Rear View
Front view
Rear view
1. Oil filler plug 8. Interlock bolt 16. Reverse idler assembly

(tightening torque: 40 ~ 50 Nm) (tightening torque: 40 ~ 50 Nm) 17. Spring pin (6 x 25)
2. Shift rug (3 & 4th) 9. Shift lever 18. Spring pin (6 x 25)
3. Spring pin (6 x 25) 10. Interlock plate 19. Backup lamp switch
4. Shift rug (5 & reverse) 11. Shift rail (1 & 2nd) 20. Concentric slave cylinder adaptor
5. Shift rail (5 & reverse) 12. Shift rug (1& 2nd)
6. Backup lamp switch 13. Shift fork (3 & 4th) (8) Apply Loctite 243
(tightening torque: 30 ~ 40 Nm) 14. Input shaft (6) Apply Loctite DRI LOC 200
7. Shift rail (3 & 4th) 15. Counter shaft

AFFECTED VIN
12 4B
Cross Sectional Diagram of Major Components
Shift rail and 5/R gear
1/2 shift rail
5/R shift rail
3/4 shift rail
Offset lever
5. Apply Loctite DRI LOC 200

10. Apply Loctite 5900
A. Apply Long-term grease MoS2
1. Reverse lock spring 7. TGS bushing 13. Rolling plunger

2. Reverse lock plate 8. Outer spring pin 14. Return spring
3. Reverse lock bolt 9. TGS pin 15. Spring plug
4. Stopper plate 10. Lock bolt (tightening torque: 30 ~ 35 Nm)
5. Air vent (tightening torque: 17 ~ 26 Nm)
(tightening torque: 30 ~ 40 Nm) 11. Offset lever A. Apply Long-term grease MoS2
6. Lock washer 12. Offset lever bushing when installing the offset lever.

AFFECTED VIN
4B 13
Power Flows
1st gear
Counter shaft
4th 3rd 2nd 1st Reverse 5th

gear gear gear gear gear gear
2nd gear


AFFECTED VIN
14 4B
Power Flows (Cont’d)
3rd gear

4th gear


AFFECTED VIN
4B 15
Power Flows (Cont’d)
5th gear

Reverse gear
Reverse
gear

gear gear gear gear idler gear
gear

AFFECTED VIN
16 4B
4. SHIFTING MECHANISM
Interlock System
Interlock system prevents the gears from meshing over two sets.
Interlock bolt
Interlock plate Inner shift lever
1/2 3/4 5/R

(3/4 & 5/R lock) (1/2 & 5/R lock) (1/2 & 3/4 lock)
Reverse Interlock System

Reverse interlock system prevents the gear from shifting to reverse driving position while driving forward.
Neutral 5/R select 5/R shift 5th gear disengaged

AFFECTED VIN
4B 17
Offset Lever and Rolling Plunger

To make the next shift easier, the offset lever applies a reaction force to shift lever toward center position of gear
selection gate after a gear has been selected.
1. Offset lever 3. Shift shaft

2. Shift lever 4. Rolling plunger (rolling plunger return spring and ball)

AFFECTED VIN
18 4B
1. Shift check device

It determines the shift fork position (N or each gear) and Detent pin
gives a detent movement to notice a shift lever seating
when operating the shift lever.
Adaptor - T/M
Also, it prevent the selected gear from getting out of its
meshed position.
3 & 4 Rall Set ball
2. Gear jump out locking device

It prevents the shift lever is beyond the correct shift Hub spline Sleeve spline
position while shifting.
Clutch gear spline
3. Guiding a control direction and preventing an over stroke.
Offset lever Offset plate
Backup Lamp Switch

It is normal open type switch. Its circuit is formed when the
reverse gear is selected.
[Notice]
Installation Notice
• Sealant: Loctite DRI LOC 200
• Tightening torque: 3 kg•m ~ 4 kg•m

AFFECTED VIN
4B 19
Synchronizer
Composition
It consists of synchronizer hub, sleeve, ring, key and spring (1/2, 5/R, and 3/4 synchronizer are different from each
other).
- 3/4 and 5/R shift: Single cone type
- 1/2 shift: Double cone type - Improving the capacity to bigger engine torque of 1/2 shift (added synchronizer inner
cone and middle cone)
Single cone type Double cone type
1/2 shift 3/4 shift 5/R shift

1/2 shift 3/4 shift 5/R shift
1. Synchronizer sleeve 5. Synchronizer key locking ring

2. Synchronizer hub 6. Synchronizer inner cone
3. Synchronizer ring 7. Synchronizer middle cone
4. Synchronizer key
[Notice]
Be careful not to mix up the 1/2 shift synchronizer sleeve with 3/4 or 5/R shift synchronizer sleeve.
The 3/4 synchronizer hub also different from 1/2 and 5/R synchronizer hub (different oil gallery).

AFFECTED VIN
20 4B
Synchronizer element
A cone or sleeve that slides to and fro on the transmission main shaft and makes the gears rotate at the same speed to
prevent clash when the gears are about to mesh. Whenever a vehicle is rolling, the transmission main shaft is turning
and the clutch gear is spinning. Even though the clutch is disengaged, the clutch gear continues to spin until friction
slows it down or stops it. Thus when the driver shifts into another gear he is trying to mesh gears that may be moving at
different speeds. By using synchronizers, the possibility of broken or damaged teeth is reduced and shifting effort is
lowered.
[1st step]
Sleeve Synchronizer ring

Gear spline area
Projected area
Synchronizer key
Spline area of sleeve

Spline area of synchronizer ring

[2nd step]
Gear spline area
Synchronizer key
Spline area of sleeve Spline area of synchronizer ring

[3rd step]
Gear spline area
Synchronizer key
Spline area of sleeve
Spline area of synchronizer ring

AFFECTED VIN
4B 21
Bearing
The needle bearings are introduced to each gear and the taper roller bearings are used for input and counter shaft in
Taper roller bearing Needle bearing
1. Taper roller bearing 3. Needle bearing for reverse gear

(input shaft, counter shaft and output shaft) (with cut out area)
2. Needle bearings for 1/2 and 3/4 shift 4. Needle bearing for 5th gear
End Play of Taper Roller Bearing
1. Taper roller bearing for input shaft A. End play A: 0.85 ~ 2.28 mm
2. Taper roller bearing for counter shaft B. End play B: 1.17 ~ 1.97 mm
[Notice]
Use the following spacers to adjust the end play (A or B) between input shaft and counter shaft.
(Specified range of end play: 0.05 ~ 0.1 mm)
• For input shaft: 0.75 ~ 1.45 mm (15 spacers with increment of 50 µm)
• For output shaft: 0.4 ~ 1.45 mm (10 spacers with increment of 50 µm)

AFFECTED VIN
22 4B
Thrust Ring (Washer)

When the driving force from engine is transmitted to the output shaft of transmission, each shaft and gear assembly
receives the axial force and this force acts as a resistance to rotating gears.
Input shaft Thrust ring 1 3/4 1/2 5/R Thrust washer Output shaft
synchronizer synchronizer synchronizer
Thrust washer
Counter gear assembly
Head set 3rd 2nd 1st Reverse 5th

Lubrication
Transmission oil: ATF DEXRON II or III
Initial installation for taper roller bearing and needle roller bearing, lubrication for shift rail: MoS2 Grease
Oil level
Oil drain screw
Installation Notice
Sealant on oil drain screw during installation: Loctite DRI LOC 200

AFFECTED VIN
4B 23
4WD 2WD
1. Oil filler plug

2. Air vent
[Notice]
Sealant on oil drain screw during installation: Loctite DRI LOC 200

AFFECTED VIN
24 4B
5. DIAGNOSTIC INFORMATION AND PROCEDURES

Trouble Diagnosis
Symptom Cause Action
Will not shift Control lever assembly broken or damaged. Replace control lever and housing assembly.
(control lever moves) Damaged offset lever, shift fork, selector Remove extension, adapter or case cover.
place or selector arm. Check or replace damaged parts.
Hard shift or control lever Clutch not releasing. Adjust or replace clutch.
will not move into gear Improper or low transmission oil. Add or replace with specified oil.
Shift or shift rail binding. Remove extension, adapter or case cover.
Check or replace damaged parts.
Binding of sliding synchronizers or gears. Remove extension, adapter or case cover.
Check synchronizers and gears and replace
damaged parts.
If reverse only, faulty backup switch. Check or replace backup switch.
Worn or damaged flywheel pilot bushing. Replace pilot bushing.
Gears crash when shift- Engine idle speed too high. Adjust idle speed to specified speed.
ing Damaged or faulty clutch. Adjust or replace clutch.
Pilot bearing between input shaft and output Replace or check roller bearings.
shaft binding.
Damaged synchronizer. Check or replace synchronizer parts.
Bell housing misaligned. Align bell housing and bore.
Damaged gear(s). Check or replace gear(s).
Worn or damaged flywheel pilot bushing. Replace pilot bushing.
Transmission jumps out Loosened transmission or flywheel housing Tighten bolts to specified value. Realign if
bolts, improper alignment. necessary.
Synchronizer damaged or excessively worn. Check or replace synchronizer parts.
Blocking ring damaged, worn index slots or Check or replace blocking ring.
friction surfaces worn or damaged.
Excessive countershaft end play. Check worn or damaged parts. Adjust shim
thickness using roller bearings if necessary.
Worn or damaged fork due to loosened shaft, Check for wear or damaged. Replace worn
rail or shifting fork. or damaged parts.
Transmission locked in Fork or offset lever loose on shaft or rail. Replace extension, adapter or case cover.
one gear Check or replace loose parts on shaft or rail.
Replace roll pin(s).
Worn or damaged forks, offset lever, shaft Remove extension, adapter or case cover.
or rail. Check for wear or damaged. Replace dam-
aged parts.

AFFECTED VIN
4B 25

Transmission locked in Worn or damaged synchronizer. Check worn or damaged synchronizer parts
one gear and replace if necessary.
Worn or damaged gears. Check worn or damaged gears and replace
if necessary.
Transmission noise Improper or low transmission oil. Add or drain and replace with proper oil.
Loose bolts or other attaching parts. Tighten as specified.
Improper flywheel housing to engine crank- Realign correctly.
shaft alignment.
Noisy transmission bearing. Check bearings, bearing rollers and parts for
wear or damage. Replace if necessary.
Noisy gears. Check for worn or damaged gears(including
speedometer gear). Replace if necessary.
Transmission leakage Leakage from transmission. Clean all exposed surfaces, then check for
leaks.
Vent or breather clogged. Clean or replace vent or breather.
Too much oil. Check oil level.
Loose bolts at sealing faces. Tighten as specified.
Improperly applied sealant. Clean leaking surfaces. Reapply sealant.
Worn or damaged oil seal. Replace oil seal.

AFFECTED VIN
26 4B
Diagnosis Table
Applicatio
1 Shift Hop-out
2 Shift Gear Crash
3 Shift Block-out
4 Hard Shift
5 Noise in Reverse Gear
6 Noise in 5th Gear
7 Noise in 4th Gear
8 Noise in 3rd Gear
9 Noise in 2nd Gear
10 Noise in 1st Gear
11 Noise in All Speeds
12 Leak at Transmission Rear Part
13 Leak at Transmission Center Part
14 Leak at Transmission Front
Possible Faulty Part
Transmission Case
Extension Housing
Shift Cover / Shift Shaft
Shift Control Lever
Input Bearing Retainer
Input Gear Set
3rd Speed Gear Set
2nd Speed Gear Set
Reverse Speed Gear Set
1st Speed Gear Set
5th Speed Gear Set
Clutch Housing and Release Derive
Crankshaft Pilot Bushing and Release Bearing
Input Bearing
Main Shaft Input Bearing
Main Shaft Thrust Bearing
3rd Speed Gear Bearing
2nd Speed Gear Bearing
1st Speed Gear Bearing
Reverse Idler Gear Bushing
Counter Shaft Front Bearing
Counter Shaft Rear Bearing
Counter Shaft Thrust Bearing
5th Speed Drive Gear Bearing
Slip Yoke Bushing
Slip Yoke Seal
Speedometer Drive / Driven Gears
Speedometer Driven Gear Housing
Input Shaft Seal
1 - 2 Synchronizer Assembly
3 - 4 Synchronizer Assembly
5th Synchronizer Assembly
AFFECTED VIN
4B 27
6. CIRCUIT DIAGRAM (BACKUP LAMP)

AFFECTED VIN
28 4B
ON-VEHICLE SERVICE
1. OIL CHECK/CHANGE
[Notice]
Do not check or change the oil Immediately after driving off.

It may cause serious hurt.
Place the vehicle on the flat and even ground and stop the
engine. After 5 minutes, check the oil level.
1. Remove the oil level plug (1) and check the oil level.
[Notice]
If the oil level is up to the bottom line of plug hole, it is OK.
1. Oil level check plug

2. If needed, add the oil through the oil level plug hole (1). 2. Oil drain plug
3. Fully tighten the plug and check the oil leaks.
4. If the oil level is up to the bottom line of plug hole, it is
OK.
[Notice]
• The oil in manual transmission is major element for mechanical durability of transmission. Check the oil level with a
specific interval and add if needed.
• The oil replacement should be done at the qualified and authorized service station.

AFFECTED VIN
4B 29

4WD
Propeller shaft - Rear
Transfer case
Mounting insulator
Propeller shaft - Front
Cross member -Center

T/M assembly
2WD
Propeller shaft - Rear
Mounting insulator
Cross member -Center

T/M assembly

AFFECTED VIN
30 4B

Preceding work: Disconnect the battery negative cable.
1. Remove the center cup holder assembly (1), shifting lever nob (2) and center console cover (3).
2. Unscrew the shifting lever mounting nut (A) and the shifting lever cover mounting nut (12 mm - 2 EA) (B).
[Notice]
IIf the oil should be changed, remove the oil drain plug in
transmission housing and fully drain the oil. And, retighten
the plug.
Installation Notice
3. Unscrew extension bar - sem remote mounting nut (1) and remove a pin (A) which connects the shifting lever and
extension rod.

AFFECTED VIN
4B 31
4. Unscrew 6 bolts at T/M output shaft flange, and fix the

propeller shaft on the body.
5. Disconnect the back up lamp switch connector and air bleeder hose from the T/M assembly.

AFFECTED VIN
32 4B
6. Disconnect the clutch oil hose (Fix the hose with a tool to prevent oil leakage) at “A” marked position.
7. For easier work, unscrew three T/M housing bolts (1) and disconnect stabilizer bar from link (A) to have the
stabilizer bar down to sub frame.

AFFECTED VIN
4B 33
8. Securely support the T/M with a hydraulic jack and then, remove center cross member.
- Center cross member mounting

bolts (A) (14 mm - 8EA)
- T/M mounting insulator bracket
bolts (B) (14 mm - 4EA)
9. Unscrew the T/M housing bolts.

AFFECTED VIN
34 4B
10. Drop the hydraulic jack with T/M slowly.


AFFECTED VIN
4B 35
T/M ASSEMBLY
1. ASSEMBLY OVERVIEW
Top Cover Assembly
1. Top cover assembly - semi remote 7. Pin 13. Stud bolt

2. Nut 8. Joint housing 14. Bolt
3. Remote shift lever 9. Offset lever 15. Shift top cover
4. Shift boot - inner 10. Control housing arm insulator 16. Offset control lever
5. Snap ring 11. Semi remote kit assembly 17. Control shift spring
6. Lining shift socket 12. Shift rail

AFFECTED VIN
36 4B
T/M Housing & Adaptor, Extension Housing
1. Front cover 10. Bolt 18. Shift lever rail-inner 26. 3rd/4th shift rail
2. Spacer 11. Extension housing 19. 1st/2nd shift fork 27. Reverse lock nut
3. T/M housing 12. Oil seal 20. 3rd/4th shift fork 28. 5th/R shift rail
4. Filler plug 13. Rear cover 21. Inner lock plate 29. Spacer
5. Back up lamp S/W 14. Lock nut 22. Shift lug 30. Roller bearing
6. Drain plug 15. Rear flange 23. T/M adaptor 31. Reverse idler shaft
7. Adaptor 16. Bearing 24. 5th/R shift fork 32. Reverse idler gear
8. Clutch cylinder 17. Shift lug 25. 1st/2nd shift rail 33. Reverse idler bracket
9. Pipe

AFFECTED VIN
4B 37
Gear Assembly
1. Input shaft assembly 8. Synchronizer assembly (1st/2nd) 15. Taper bearing

2. 4th shift gear 9. Reverse shift gear 16. Counter gear assembly
3. Synchronizer assembly (3rd/4th) 10. Synchronizer assembly (5th/Reverse) 17. Retainer ring-counter
4. 3rd shift gear 11. 5th shift gear gear
5. 2nd shift gear 12. Ball bearing 18. Taper bearing
6. Main shaft 13. Counter gear-5th 19. counter reverse spacer
7. 1st shift gear 14. Counter gear-Reverse

AFFECTED VIN
38 4B
2. DISASSEMBLY
Preceding work: 1. Drain the T/M oil.
2. Remove the T/M from vehicle.
1. Remove the T/M top cover assembly.
[ 2WD Manual Transmission ]

1) Unscrew the rear flange lock nut (1) and bolts (2) to
remove rear flange.
2) Remove the T/M rear cover (A).
2. Remove the spring pin (6 x 25), as the offset lever pulled

side and remove the offset lever.

AFFECTED VIN
4B 39
3. Remove the bolts from the extension housing.
4. Remove the extension housing with a special tool.
[Notice]
Remove the offset lever and rolling plunger with the extension
housing. Be careful not to drop them.
5. Remove the rear ball bearing with a puller and remove

the speedometer driven gear.
6. Remove the 5/R shift fork spring pin (6 x 28).

AFFECTED VIN
40 4B
7. Pull the counter gear (5th gear) retainer ring out from the
ring groove with a ring pliers.
[Notice]
Be careful not to stiffen the retainer ring.
8. Spread the retainer ring and remove the counter 5th gear
with a puller.
9. Remove the counter reverse spacer.

AFFECTED VIN
4B 41
10. Remove the 5th gear retainer ring with a ring pliers.
11. Remove the thrust washer from the shaft.
12. Remove the 5th gear and pull out the spring pin.
[Notice]
Be careful not to lose or mix the spring pins.
13. Remove the 5th gear needle bearings (2).
[Notice]
Be careful not to lose or mix the needle bearings.

AFFECTED VIN
42 4B
14. Remove the 5th gear synchronizer ring.
[Notice]
Store at a safe place not to be mixed with other synchronizer

rings.
15. Remove 5/R gear retainer ring from the shaft with a ring
pliers.
[Notice]
Store the ring with the relevant gear to prevent incorrect

installation.
16. Remove the 5/R synchronizer hub assembly, the reverse

gear and the shift fork at a time.
17. Remove the counter reverse gear.

AFFECTED VIN
4B 43
18. Remove the counter reverse gear needle bearing.
[Notice]
Store the needle bearing with the relevant gear.
19. Remove the interlock bolt.
20. Remove the transmission adaptor from the transmission

housing.
[Notice]
Be careful not to damage the adaptor mating surface.
21. Remove the gear assembly from the housing.
[Notice]
Do not forcefully remove the gear assembly. It may damage

the level grooves resulting in incorrect installation. Carefully
remove the gear assembly.

AFFECTED VIN
44 4B
22. Remove the main and counter gear assembly.

• Pull out the pins from 5/R and 1/2 shift rails and
remove the shift rails through rear section of adaptor.
• Pull out the locking pins from shift forks.
23. Remove the shift rail and shift fork. Place the output shaft
and counter gear on the special tool.
24. Place the output shaft assembly with the 1st gear facing
down and remove the intermediate taper roller bearing
with a special tool.
[Notice]
• To prevent the bearing damage, securely seat the special

tool before removing the intermediate taper roller bearing
that is pressed in.
• Do not use general bearing puller.
25. Remove the 3/4 gear retainer ring.
[Notice]
Be careful not to lose or mix the retainer ring.

AFFECTED VIN
4B 45
26. Remove the 3/4 gear synchronizer hub and single

synchronizer sleeve and 3rd gear with a special tool.
Pull out the needle bearing.
27. Loose the 1/2 gear and hub and double synchronizer
sleeve with a press.
28. Remove the reverse gear inner race.
29. Remove the main taper roller bearing.

AFFECTED VIN
46 4B
30. Remove the inner race and 1st gear from 1st gear, and
remove the needle bearing from the shaft.
[Notice]
Store the disassembled gears by relevant components.
31. Remove the synchronizer inner intermediate cone and

outer ring in 1st gear side.
Synchronizer Synchronizer Synchronizer

under ring intermediate outer ring
cone
32. Remove the 1/2 gear synchronizer hub along with double
synchronizer sleeve.
33. Remove the synchronizer inner intermediate cone and

outer ring in 2nd gear side.
Synchronizer Synchronizer Synchronizer

outer ring intermediate under ring
cone

AFFECTED VIN
4B 47
34. Remove the 2nd gear and needle bearing.
35. Remove the oil seal from the extension housing.

AFFECTED VIN
48 4B
3. INSPECTION BEFORE REASSEMBLY

1. Clean all the disassembled components with solvent and
dry them with compressed air.
Check the components for crack, wear and damage.
• Case, extension housing, shift lever
• Input bearing retainer
• Counter shaft rear bearing retainer
2. Check the bearing and shaft supporting area for wear
and replace if needed.
3. Check the surface conditions on:

• Input shaft
• Main shaft and gears
• Counter shaft and 5th drive gear
4. Reverse idler shaft and gears
[Notice]
Replace the excessively worn components. Do not grind the

precisely machined components.
5. Check the following components for wear:

• Selector arm
• Interlock plate
• 1/2 and 3/4 shift fork
• Shift shaft
• Detent/guide plate and offset lever
• Each shift lever shift fork

AFFECTED VIN
4B 49
• Hub and sleeve

• 1/2 shift fork, pads, synchronizer sleeve
• 3/4 shift fork, pads, synchronizer sleeve

• 5th gear shift rail/fork, pads, synchronizer sleeve
• Reverse fork and reverse idler gear sleeve
6. Check the following components for excessive wear:

• Crankshaft bushing in front of input shaft
• Clutch release bearing
• Main shaft pilot bearing roller
• Main shaft thrust bearing mating surface
• Main shaft speed gear roller bearing
• Main shaft rear bearing
• Counter shaft front and rear bearing
7. Check the gear sets for wear in teeth surface.

8. Check the gear sets for excessive wear, crack and break
and replace if needed.

AFFECTED VIN
50 4B
9. Check the conditions of each synchronizer sleeve and

hub.
• Engagement of hub and sleeve
• Wear on cone clutch surface in blocking ring (brass)
engaging the gears
10. Measure the clearance between blocking ring and speed

gear.
• New 1/2 gear blocking ring: 1.1 ~ 1.5 mm
• New 3/4 gear blocking ring: 1.1 ~ 1.5 mm
[Notice]
If the clearance is excessive, replace it with new one. Otherwise,

it may cause the missing or breakage of the gears.
11. Check the speed gear clutch and synchronizer sleeve

for damage in teeth surface.
12. Check the engagement of synchronizer sleeve and speed
gear clutch.

AFFECTED VIN
4B 51
4. REASSEMBLY
1. Install the 2nd gear needle bearing.
[Notice]
The 1st/2nd/3rd gear needle bearings have one bearing row

and the sizes of them are same. The reverse needle bearing
has two bearing rows. The 5th needle bearing is smaller than
others and consists of two bearings.
2. Install the 2nd gear and synchronizer outer ring,

intermediate cone and inner ring in regular sequence.
3. Insert three keys into 1/2 synchronizer hub and double

synchronizer sleeve. Install the synchronizer spring in
offset so that it should not be missed out.
[Notice] Groove
1/2 gear double synchronizer sleeve doesn’t have a step at

edge, however, 3/4 and 5/R gears have it.
No step

AFFECTED VIN
52 4B
4. Install the 1/2 synchronizer hub and double synchronizer

sleeve into the output shaft by using a press.
[Notice]
Make sure that the hub groove faces to 2nd gear. Align the
synchronizer key and the synchronizer ring groove in 2nd
gear.
5. Install the synchronizer outer ring, intermediate cone and

inner ring in regular sequence.
6. Install the 1st gear.
7. Install the 1st gear needle bearing.

AFFECTED VIN
4B 53
8. Install the 1st gear inner race by using a press.
[Notice]
The 1st inner race doesn’t have a step at edge.
9. Install the main taper roller bearing by using a press.
10. Install the reverse fear inner race by using a press.
[Notice]
The reverse gear inner race has a step at edge.
11. Place the output shaft assembly with the 1st gear facing
downward and install the 3rd gear.

AFFECTED VIN
54 4B
12. Install the 3rd gear.
13. Install the synchronizer ring on the 3rd gear.
14. Insert three keys into 3/4 synchronizer hub and

[Notice]
3/4 gear synchronizer sleeve have a step at edge. Place the

groove in hub to face the 3rd gear and align the synchronizer
key and the synchronizer ring groove in 3rd gear.

AFFECTED VIN
4B 55
15. Install the 3/4 gear retainer ring.
[Notice]
Adjust the end play between retainer ring and hub to a range
of 0.05 to 0.1 mm by using a thickness gauge.
16. Install the intermediate taper roller bearing by using a

press.
[Notice]
Apply the force on the inner race other than other points.
17. Install the input shaft along with the 4th synchronizer
ring. Place the input shaft to face downward on the work
bench.

AFFECTED VIN
56 4B
18. To relieve the load to the shaft bearing, insert a special

tool.
19. Place the counter gear on the work bench with the same
manner.
20. Install the transmission adaptor on the input shaft and

the counter gear.
21. Install the reverse gear needle bearing.
[Notice]
The reverse gear needle bearing has two bearing rows and
the others consist of two bearings.

AFFECTED VIN
4B 57
22. Install the reverse gear in the shaft.
23. Install the synchronizer ring on the reverse gear.
24. Insert three keys into 5/R synchronizer hub and

[Notice]
Place the groove in hub to face the 5th gear and align the
synchronizer key and the synchronizer ring groove in reverse
gear.
25. Install the 5/R gear retainer ring.
Notice
[Notice]

AFFECTED VIN
58 4B
26. Install the counter reverse gear by using a press.
[Notice]
Place the counter reverse gear with a longer protrusion facing

to the adaptor.
27. Install the counter reverse spacer.
28. Install the 5th synchronizer ring.
29. Install two 5th gear needle bearings in line.

AFFECTED VIN
4B 59
30. Install the 5th gear.
31. Install the counter 5th gear by using a press. At this

time, place it with a longer protrusion facing to the adaptor.
32. Install the counter 5th gear retainer ring.
33. Install the locking ball.

AFFECTED VIN
60 4B
34. Install the thrust washer (t= 5.0) while aligning the key
grooves.
35. Install the retainer ring.
[Notice]
36. Install the inner race of counter roller bearing by using a

press.
[Notice]
Place it with a protrusion facing to the adaptor
37. Place the gear assembly on a work bench in parallel.

AFFECTED VIN
4B 61
38. Install the inner shift lever and interlock plate in the 3/4
gear shift rail. Interlock plate Inner shift lever
[Notice]
The spring pin for locking the inner shift lever is small (6 x
22) and its slot should face to the shaft.
39. Install the 3/4 hear shift rail in the transmission adaptor.
40. Install the 3/4 gear shift fork.
[Notice]
The 1/2 and 5/R shift fork are compatible, but 3/4 shift fork
isn’t. Also, the 3/4 shift fork is chamfered, but 1/2 and 5/R
aren’t.
41. Install the 3/4 shift fork and shift rail while aligning the
grooves.

AFFECTED VIN
62 4B
42. Install the 1/2 gear shift rail in the transmission adaptor.
43. Partially engage the 1/2 shift fork to the shift rail.
44. Install the shift lug on the 1/2 shift rail. Install the reverse
lock spring, reverse lock plate and reverse lock bolts.
[Notice]
Align the 1/2 gear shift lug and interlock plate mating surface.
45. Partially engage the 5/R gear shift fork to the shift rail.

AFFECTED VIN
4B 63
46. Install the 5/R shift lug and 5/R shift fork on the shift rail.
[Notice]
Align the 5/R shift lug and the interlock plate surface.
47. Install the spring pin into the 1/2 shift lug. (intermediate
size: t= 6 x 25)
[Notice]
Place the spring pin with the pin slot facing to the shaft.
48. Install the spring pin into the 5/R shift lug. (intermediate
size: t= 6 x 25)
[Notice]
49. Install the spring pin into the 1/2 shift fork. (longer size:
t= 6 x 28)
[Notice]

AFFECTED VIN
64 4B
50. Install the spring pin into the 5/R shift fork. (longer size:
t= 6 x 28)
[Notice]
51. Install the reverse lock plate and reverse lock spring on
the 1/2 shift rail.
52. Install the stopper plate on the 3/4 shift rail and insert the
spring pin. (intermediate size: t= 6 x 25)
[Notice]

AFFECTED VIN
4B 65
53. Apply the sealant to the transmission housing.
[Notice]
Sealant: LOCTITE 5900
54. Install the gear assembly and the adaptor to the

55. Install the speedometer driven gear on the output shaft
and install the ball bearing by using a press.
56. Apply the sealant to the extension housing. Press down

the extension housing against the adaptor.
[Notice]
Sealant: LOCTITE 5900

AFFECTED VIN
66 4B
57. Tighten the extension housing bolts.
58. Insert the offset lever into the 3/4 rail and install the spring
pin. (intermediate size: t= 6 x 25)
59. Apply the grease into the offset lever bushing.
60. Apply the grease to the interlock bolt and insert it into
the interlock plate hole and bolt hole.
[Notice]
Make sure that the gear is at neutral position. If not, the

interlock bolt cannot be inserted into the interlock plate
hole.
Sealant LOCTITE 243


AFFECTED VIN
4B 67
Transmission Adaptor
1. Remove the reverse idler retainer ring.
2. Remove the components as follows and install in the

reverse order of removal.
• Unscrew the reverse lock nut and idler bracket bolts
and remove the bracket and spacer.
• Remove the reverse idler gear and the needle bearing.
• Pull out the dowel pin and remove the reverse idler
shaft.
Installation Notice
Reverse idler bracket bolt 17 ~ 26 Nm

Reverse lock nut 70 ~ 100 Nm
Backup Lamp Switch

Remove the backup lamp switch with 24 mm wrench. Apply
the sealant when installing.
Installation Notice
Sealant LOCTITE DRI LOC 200


AFFECTED VIN
68 4B
INSPECTION/MAINTENANCE
SHIM ADJUSTMENT
1. Unscrew the bolts and remove the front fork cover.
[Notice]
The shim adjustment is necessary when replacing the

housings, counter gear, input shaft and output shaft.
2. Separate the front fork cover from the housing.
3. Remove the input spacer.

AFFECTED VIN
4B 69
4. Remove the counter spacer.
5. Prepare the special tools and dial gauge.
6. Place the transmission with the output shaft facing

downward and set the special tool on the counter gear
and input shaft. Apply a proper force to the counter gear
and input shaft so that the end plays for bearings are
maximized.
7. Tighten the adjusting bolt on the special toll to hold the

bearings.

AFFECTED VIN
70 4B
8. Set up the dial gauge on the transmission housing surface

and put the gauge needle to “0” point.
9. Put the probe end of the gauge on the taper roller bearing
outer race in counter gear and measure the end play.
* If the measured value is out of the specified range,
adjust it by using spacers.
End play 0 ~ 0.05 mm
10. Put the probe end of the gauge on the main taper roller
bearing outer race and measure the end play.
* If the measured value is out of the specified range,
adjust it by using spacers
End play 0 ~ 0.05 mm
11. Apply the sealant to the front fork cover and tighten the
bolts. Measure the starting torque after installation.
Starting torque 20 ~ 25 Nm
Sealant LOCTITE 5900

AFFECTED VIN
4B 71
661 589 04 62 00 (W 99 31 007 0B) Removal/installation of transmission

Transmission fixture
W 99 31 001 1B Removal of pressed in taper roller bearing

Bearing puller
W 99 31 002 1B Pressing of the bearing and gear

Pressure pipe
W 99 31 003 1B Providing a space to input shaft

Insert key bearing

AFFECTED VIN
72 4B
W 99 31 004 1B Assembly of gears and bearings on

Die the shafts
W 99 31 005 2B Measurement of taper roller

Holder bearing end play
W 99 31 006 1B Measurement of taper roller

Dial gauge holder bearing end play
W 99 31 007 1B Removal of 5/R synchronizer hub

Drift assembly, reverse gear and shift fork

AFFECTED VIN
4C 1
4C
Clutch Assembly
Table of Contents
GENERAL INFORMATION ................................ 4C-3
1. Overview ...................................................................... 4C-3
2. Components................................................................ 4C-5
3. Air bleeding ................................................................ 4C-11
MAINTENANCE............................................... 4C-12
1. Removal and installation ............................................ 4C-12
2. Inspection ................................................................. 4C-18
3. Special tools and equipment ..................................... 4C-20
TROUBLE DIAGNOSIS ................................... 4C-21

1. Diagnostic information and procedures ...................... 4C-21
CLUTCH ASSEMBLY CHANGED BY

AFFECTED VIN
4C 3
GENERAL INFORMATION
1. OVERVIEW
Driving Elements Operating Elements
The driving elements consist of two flat surfaces machined The clutch control system consists of the clutch pedal,
to a smooth finish. clutch master cylinder, concentric slave cylinder.
One of these is the rear face of the engine flywheel and This system directly releases the clutch by using hydrau-
the other is the clutch cover pressure plate. The clutch lic pressure while the conventional clutch system releases
pressure plate is fitted into a clutch steel cover, which is the clutch by using release lever and release fork.
bolted to the flywheel. This system provides higher efficiency than conventional
clutch system, and its durability is superior.
Driven Elements
The driven element is the clutch disc with a splined hub Adaptor (mounted on transmission case)
which is free to slide lengthwise along the splines of the Concentric slave cylinder pipe (mounted inside of
input shaft. transmission)
The driving and driven elements are held in contact by Concentric slave cylinder (mounted inside of transmission)
spring pressure. This pressure is exerted by a diaphragm
spring in the clutch cover pressure plate assembly.
B. Concentric slave cylinder pipe
A. Adaptor
D. Clutch assembly C. Concentric slave cylinder

AFFECTED VIN
4 4C
SAT (Self Adjusting Technology)

: SAT is new clutch which adjusts the clutch free play according to the wearness of clutch disc.
Operation description
Diaphram spring rotates the adjusting equipment as clutch disc is wearing and so, pressure plate is pushed to clutch
disc side at the amount of wearness.
* Disc wear (Free play) → Diaphram spring (1) → Adjusting equipment (2, 3) → Pressure plate (4)
Clutch assembly Adjusting equipment
Clutch replacement
1) Replacement of cluch disc → Replace the clutch cover assembly together.
2) Reinstallation of clutch disc & cover → Apply the zig set (SST) on the clutch cover set.
(Engine removal and reinstallation, Flywheel related job, Checking the clutch assy)
[Notice]
When reinstall the clutch assembly without the special zig, Disc can be slip and worn easily.
Installation of special zig

1) Identify the SAT clutch with adjusting equipment around the clutch cover.
2) Adapt the zig set(4 pieces) between the clutch cover and diaphram spring around (Refer to the picture).
Diaphram
Adjusting
equipment
Cover
Zig for clutch removal

and installation
CHANGED BY CLUTCH ASSEMBLY

AFFECTED VIN
4C 5
2. COMPONENTS
1. Concentric slave cylinder cover 7. Hose 12. Clutch housing

2. Concentric slave cylinder 8. Pipe 13. Switch
3. Clutch cover 9. Clutch fluid chamber 14. Bracket
4. Clutch disk 10. Clutch hydraulic line 15. Clutch pedal
5. Adaptor 11. Clutch pin (B) 16. Clutch pedal pad
6. Clutch master cylinder

AFFECTED VIN
6 4C
Clutch Fluid Reservoir Tank

(Common Usage with Brake Oil Reservoir Tanks)
Clutch / Brake fluid

reservoir tank
• Operation
Concentric
Clutch master
Clutch pedal Pusha rod (piston) slave Clutch cover Clutch disk
cylinder
cylinder

AFFECTED VIN
4C 7
Clutch Release Chamber

• Clutch release chamber keeps the oil pressure stable in the clutch hose & pipe and also helps the oil pressure
transfer quickly by keeping some oil pressure every moments.
Clutch Pedal
Clutch pedal
• Pendant type clutch pedal (leverage effect is applied to reduce the effort to the feet).
• Clutch pedal has freeplay to prevent the clutch disk heated and damaged.
If this freeplay is too wide, engine power disconnection is difficult and arise the gear damage with abnormal noise.

AFFECTED VIN
8 4C
Clutch Assembly
• Clutch assembly is composed of clutch cover (diaphram spring, pressure plate), clutch disk.
[Notice]
Because self adjust clutch includes compensation function

to make up for the wearness of clutch disk, this clutch
assembly applied to the vehicle can be oprated with constant
force in the clutch pedal.
• Clutch disk connect the power from engine flywheel to the

transmission input shaft by the diaphram spring
compressing the clutch disk which has spline in the middle
frinction disk.

AFFECTED VIN
4C 9
Cross Sectional View of Clutch Assembly
1. Transmission housing 4. Bolt

2. Clutch disc assembly 5. Washer
3. Clutch disc cover assembly 6. Bolt

AFFECTED VIN
10 4C
Specifications
Description Specification
Operating type Hydraulic
Clutch pedal Type Suspended
Maximum pedal stroke Diesel engine equipped vehicle: 140 mm
Gasoline engine equipped vehicle: 150 mm
Pedal free play 5 ~ 10 mm
Clutch disc Type Single dry diaphragm
Dimension of facing 240 X 155 X 4.0 mm
Facing size/quantity 263 cm2/2
Thickness of disc Free: 9.4 ~ 10.0 mm
When loaded: 9.0 ± 0.3 mm
Clutch cover assembly setting force Min. 720kgf
Clutch master cylinder Stroke 28.4 mm
Inner diameter φ 17.46 mm
Concentric slave cylinder Stroke 7.0 mm
Sectional area 706.2 mm2
Clutch fluid DOT 4
Tightening Torque
Description Tightening Torque
Clutch housing bolt (8 locations) 5.0 ~ 6.0 kgf•m 50 ~ 60 Nm
Clutch cover (pressure plate) bolt 2.1 ~ 2.7 kgf•m 21 ~ 27 Nm
Concentric slave cylinder bolt (3 locations) 1.7 ~ 2.6 kgf•m 17 ~ 26 Nm
Concentric slave cylinder flare nut 2.0 ~ 2.5 kgf m
• 20 ~ 25 Nm
Adaptor flare nut 1.0 ~ 1.6 kgf•m 10 ~ 16 Nm
Clutch oil pipe flange nut 1.52 ~ 1.83 kgf•m 15 ~ 18 Nm
Master cylinder bolt 3.05 ~ 4.07 kgf•m 30 ~ 40 Nm
Fulcrum (clutch pedal bushing) bolt/nut 1.63 ~ 2.24 kgf m• 16 ~ 22 Nm
Clutch pedal bracket mounting bolt 0.81 ~ 1.83 kgf•m 8 ~ 18 Nm
Stopper bolt 1.63 ~ 2.24 kgf•m 16 ~ 22 Nm

AFFECTED VIN
4C 11
3. AIR BLEEDING
[Notice]
• Keep the fluid level over MAX in reservoir during bleeding

operation.
• Do not let the fluid contact a painted surface.
Specified oil DOT 4

Capacity Between Max and ADD
Procedure
1. Remove the air bleed bolt cap on the release cylinder. [Notice]
2. Put the other side of the tube into a empty container.
• This work has to be done by two service persons.
3. Slowly pump the clutch pedal several times.
• After bleeding, check the clutch system for operation
4. With clutch pedal fully depressed, open the air bleed and noise.
bolt and bleed the air and fluid from the fluid line.
• Use only Ssangyong genuine clutch fluid, and check
5. Repeat step 3 through 4 until no more air bubbles are the clutch fluid level in reservoir.
in the escaping fluid.

AFFECTED VIN
12 4C
MAINTENANCE
Clutch Assembly
Preceding Work: Remove the transmission assembly.
1. Insert the centering pin (special tool) into center spline. Loosen the clutch cover bolts 1/2 turns in cross sequence
until the spring tension is released.
Tightening torque 2.4 ± 0.3 kgfxm
[Notice]
1) Do not remove the bolts at a time, or clutch cover may be damaged or deformed.
2) If the clutch disk is to be reused, insert a mounting plate between the dia phram spring and cover plate when uninstall.
2. Unscrew the bolts and remove the clutch cover, pressure

plate and clutch disc.
[Notice]
1) Be careful not to drop the pressure plate and clutch disc.

2) Replace the clutch cover and disk at every disassembly.
Tightening torque 21 ~ 27 Nxm

AFFECTED VIN
4C 13
Concentric Slave Cylinder

Preceding Work: Remove the transmission assembly.
1. Unscrew the oil pipe nut(1), adaptor mounting bolt(3) and oil pipe nut(2) which connected to concentric slave(A)
from the inside of clutch housing.
2. Remove the oil pipe from the clutch housing.
3. Unscrew the concentric slave cylinder mounting bolts (3EA) and remove the concentric slave cylinder
assembly in the clutch housing.

AFFECTED VIN
14 4C
Clutch Master Cylinder

1. Drain the clutch fluid.
2. Pull out the snap pin and clevis pin from the clutch pedal
connection.
3. Remove the clutch tube.
Installation Notice
[Notice]
Be careful not to contact the fluid into a painted surface.
4. Remove the master cylinder mounting nuts and pull off

the master cylinder.
Installation Notice

6. Check the clutch pedal operation.
7. Perform the air bleeding job.

AFFECTED VIN
4C 15
Clutch Fluid Pipe

1. Draw out the fluid.
2. Unscrew the bolt and remove the supply pipe from clutch
master cylinder.
3. Unscrew the supply pipe bolt and remove primary oil pipe
from clutch fluid chamber.
4. Unscrew the bolt and remove the secondary clutch fluid

pipe from clutch release chamber.
5. Install the pipes. Be careful not to mix the pipes.
[Notice]
• Make sure to bleed the air from the system after

installation.
• Check each pipe bolt for oil leaks.
• Clutch pipes are reusable. However, must check the pipes
for damages and cracks.

AFFECTED VIN
16 4C
Clutch Pedal
1. Remove the snap pin from master cylinder push rod and
remove the clevis pin from pedal.
2. Remove the turnover spring.
3. Unscrew the fulcrum bolt and remove the clutch pedal

from bracket
4. Unscrew the bolts and remove the master cylinder.

AFFECTED VIN
4C 17
5. Unscrew the mounting bolts and remove the clutch pedal

bracket.
Installation notice
1. Install in the reverse order of removal. Adjust pedal stroke Description Tightening Torque
after installation.
Fulcrum bolt/nut 16 ~ 22 Nm
[Notice] Bracket mounting bolt 8 ~ 18 Nm

Stopper bolt 16 ~ 22 Nm
1. Apply long-life grease (T/M DBL 6611.00) to the connections.
2. Remove foreign materials.
3. Keep the tightening torque.
4. Replace the bushings with new ones.
Inspection and adjustment

1. Pedal Stroke (A)
Maximum pedal stroke 158 mm
2. Pedal Height (B)
Height (from carpet) 192 ± 5 mm
[Notice]
To adjust the pedal stroke, loosen the lock nut (C) of the
stopper bolt (D) and turn the stopper bolt until the stroke is
correct. After adjustment, tighten the lock nut.
3. Pedal Free Play (E).

Free play 5 ~ 10 mm
[Notice]
To adjust the pedal free play, loosen the lock nut (F) of the
master cylinder and turn the push rod until the free play is
correct.
4. Check the fulcrum bolt and the bushing for wear, the
pedal for bending and the spring for damage.

AFFECTED VIN
18 4C
2. INSPECTION
Concentric Slave Cylinder
• Check any heat damage, abnormal noise, poor rotation
and wear of the concentric slave cylinder bearing.
Clutch Cover Assembly

• Check the diaphragm spring tip for wear and height
unevenness.
Unevenness limit 0.8 mm
• Check the pressure plate surface for wear, crack and

discoloration.
• Check the strap plate rivet for looseness and replace if
necessary.
Clutch Disc
• Check the facing for rivet looseness, sticks, oil and grease.
• Measure the rivet head depth. If out of limit, replace the
disc.
Wear limit 0.3 mm

AFFECTED VIN
4C 19
Clutch Disc Run-Out

• Measure the clutch disc run-out and replace if necessary.
Run-out limit 0.7 mm
Pressure Plate
1) Check the pressure spring for wear.
[Notice]
The excessively worn components should be replaced.
2) Check the alignment conditions of clutch housing as

follows:
• Install the magnetic holder on pressure spring.
• Alignment check for housing bore
A. Install a dial gauge in the housing bore.
B. Measure and record the pointer value while
rotating the crankshaft.
• Alignment check for clutch housing surface

A. Install a dial gauge on the clutch housing surface.
B. Measure and record the pointer value while
rotating the crankshaft.
[Notice]
If the pointer indicates beyond 0.010 inch, align the clutch

housing by inserting shims between the housing and clutch.

AFFECTED VIN
20 4C
3. SPECIAL TOOLS AND EQUIPMENT

661 589 00 15 00 (L 99 30 001 0B) Centering the clutch disc

Centering pin
601 589 02 40 00 (A 99 10 014 0B) Locking the crankshaft

Engine lock

AFFECTED VIN
4C 21
TROUBLE DIAGNOSIS
1. DIAGNOSTIC INFORMATION AND PROCEDURES
Check Possible Cause Action
Clutch slips Excessive wear of facing Replace
Hard or oily facing Repair or replace
Damaged pressure plate or flywheel Replace
Damaged or burnt diaphragm spring Replace
Clutch pedal free play insufficient Adjust
Faulty operation of clutch pedal Repair or replace
Worn or damaged clutch disc Replace
Poor disengagement Vibration or excessive run-out of disc Replace
Rust or wear of disc spline Repair or replace
Oily facing Repair or replace
Damaged diaphragm spring Replace
Excessive clutch pedal free play Adjust
Hard to shift or will not shift Excessive clutch pedal free play Adjust pedal freeplay
Faulty clutch release cylinder Repair release cylinder
Worn disc, excessive run-out, damaged lining Repair or replace
Dirty or burred splines on input shaft or clutch disc Repair as necessary
Damaged clutch pressure plate Replace
Clutch chatters when starting Oily facing Repair or replace
Hard or faulty facing Replace
Burnt torsion spring Replace
Faulty pressure plate Replace
Bent clutch diaphragm spring Replace
Hard or bent flywheel Repair or replace
Engine mounts loose or burnt lever Tighten or replace
Difficult pedal operation Poor lubrication on clutch cable Lubricate or replace
Poor lubrication on pedal shaft Lubricate or replace
Poor lubrication on clutch pedal Repair
Not using the clutch Insufficient clutch pedal free play Adjust
Excessive wear of facing Replace
Clutch noisy
After disengagement Worn or damaged release bearing Replace

When disengaging Poor lubrication contact surface of bearing Replace
Faulty installation of clutch assembly or bearing Repair
Clutch pedal is partially Damaged pilot bushing Replace
depressed and vehicle
speed is reduced
[Notice]
Clutch cover and disk should be replaced altogether.

AFFECTED VIN
MEMO
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4D 1
4D - TOD (Torque On Demand)
Table of Contents
ENERAL INFORMATION .................................. 4D-3
1. Layout ......................................................................... 4D-3
2. General description ..................................................... 4D-4
3. Circuit diagram ...........................................................4D-11
4. Operation .................................................................. 4D-12
COMPONENTS ............................................... 4D-14

1. TOD assembly .......................................................... 4D-14
2. TCCU (Transfercase Control Unit) .............................. 4D-15
3. Speed sensor and clutch coil .................................... 4D-26
4. Shift motor connector ................................................ 4D-27
REMOVAL AND INSTALLATION .................... 4D-28

1. TCCU ........................................................................ 4D-28
2. Shift motor ................................................................ 4D-29
3. Speed sensor ............................................................ 4D-31
4. TOD assembly .......................................................... 4D-34
TOD ASSEMBLY ............................................. 4D-37

1. Crosse sectional diagram .......................................... 4D-37
2. Disassembly procedure ............................................. 4D-40
3. Assembly procedure ................................................. 4D-45
SPECIAL TOOLS AND EQUIPMENT ............. 4D-53
TROUBLE DIAGNOSIS ................................... 4D-54

1. Self diagnosis test .................................................... 4D-54
2. Coding on TOD control unit ....................................... 4D-57
3. Diagnostic trouble code ............................................. 4D-58
TOD CHANGED BY
AFFECTED VIN
4D 3
GENERAL INFORMATION
1. LAYOUT
Sub frame
T/M
Front propeller shaft
Exaust pipe
Transfer case (TOD)
Rear propeller shaft
TOD CHANGED BY
AFFECTED VIN
4 4D
2. GENERAL DESCRIPTION
TOD system means the full time 4WD system and the Distribution of Driving Force
registered trade mark of Borg Warner. TOD is an abbre-
viation of Torque On Demand.
According to Road Surface
TOD (Torque On Demand) system, which is superior than 1. On normal road surface
existing Full Time 4WD, checks the road surface and ve- In vehicle with existing part time transfer case, when
hicle conditions via various sensors and, subsequently, a driver turns the steering wheel to park in the 4WD
according to the situations and conditions, distributes the mode, the vehicle may halt sensation of tight corner
most optimal driving force to front wheels and rear wheels braking phenomena. However, in vehicle with TOD
by activating the electro-magnetic clutch located inside of system, this phenomena does not occur and the
TOD Transfer Case. driving force is properly and automatically distributed.
TOD receives the speed signals from speed sensors in- 2. On paved road with high speed
stalled in front axle and rear axle, the TPS signals from Driving at high speed on roads such as highway
engine, and the operating signals from ABS control unit mainly uses rear wheels as driving wheel. At this
via CAN. Based on these data, TOD control unit controls moment, some of torques is also distributed to front
the electro-magnetic clutch to distribute the 3:97 ~ 44:56 wheels so that the vehicle could maintain safe ground
of driving force to front wheels and rear wheels. grab capacity against side winds and rain. Distribution
The conventional system uses “FR driving” (theoretically, ratio: 15 % for front wheels and 85% for rear wheels.
the 100 % of driving force is transferred to rear wheels) on 3. When turning on the road with low friction rate
normal paved road. When the system detects a slip in the During cornering on roads such as unpaved, snowy,
rear wheels, a proper percentage of driving force is trans- icy and muddy, ground grab capacity is increased
ferred to front wheels. by distributing required torque and, at the same time,
TOD control unit receives the wheel speed signals from comfortable steering operation is maintained by
the speed sensors in propeller shaft of transfer case and controlling the ground grab capacity at high level.
engine output information from the engine control unit. TOD Distribution ratio: 30 % for front wheels and 70 % for
control unit changes the pressure force of the electro- rear wheels.
magnetic clutch based on the analyzed data. 4. When climbing or starting off on the road with low
friction rate
In order to secure the maximum ground grab capacity
and driving force during climbing or starting off on the
roads such as unpaved, snowy and icy road, the
system controls the driving force to distribute properly
in full 4WD mode. Distribution ratio: 44 % for front
wheels and 56 % for rear wheels.
CHANGED BY TOD
AFFECTED VIN
4D 5
Transfer Case
Planetary gear set
Planetary Gear set consists of sun gear, ring gear and carrier. It is engaged with the gear in “HIGH-LOW” collar to
increase the driving force by reducing vehicle speed.
Sun gear is connected to input shaft and ring gear is fixed into the transfer case.
Splined rear output shaft is able to slide on the “HIGH - LOW” collar.
The inside and outside ends of “HIGH - LOW” collar have machined gear. The input shaft transmits the power to driving
wheels by engaging with sun gear and carrier gear.
If the 4WD switch is at “4WD HIGH”, the TOD control unit operates the shift motor to engage “HIGH - LOW” collar
directly with input shaft for transmitting the driving force to front and rear propeller shafts.
When a driver selects “4WD LOW”, the TOD control unit controls the electro-magnetic clutch and operates the shift
motor to engage “HIGH - LOW” collar with carrier. The power from transmission is increased up to 2.48:1 by reduction
ratio from planetary gear, and then is sent to front and rear propeller shafts.
Ball type slant cam and clutch disc pack

If the speed sensors installed on front and rear propeller shafts
detect the slips at front and rear wheels, and these slips ex-
ceed the specified range, TOD control unit controls electro-
magnetic clutch to transmit driving force to front wheels. At
this time, ball slant cam is moved to compress multi-disc
located in clutch disc to transmit driving force to front wheels.
TOD CHANGED BY
AFFECTED VIN
6 4D
Electro Magnetic Clutch (EMC)

EMC consists of coil and housing. TOD control unit controls EMC by controlling duty cycle according to the road and
driving conditions. These controls use the continuity time and amount of electric current to determine the torque to be
transmitted to front wheels.
Measuring the rotating speed

of front propeller shaft
Measuring the rotating

speed of rear propeller shaft
NO
Is the wheel slip exceeded
allowable limits?
YES
Decreases clutch engagement
Increases clutch engagement
Basic controls in EMC
CHANGED BY TOD
AFFECTED VIN
4D 7
Signal Flow
Instrument Panel
4WD Switch
Output
TOD Control
Unit
Input
Rear Speed
Manetic Clutch
Motor
Front Output Front Speed
TOD CHANGED BY
AFFECTED VIN
8 4D
Power Flow
4H Mode (4WD Drive - High Speed)
Transmission Rear Axle

(Rear Wheel)
Front Axle
(Front Wheel)
Front Speed
Sensor
Rear Speed Transmission

TOD Control Unit
Sensor Input Shaft
Throttle Open
Rate
(TPS Value)
Magnetic Clutch Output Shaft
Force Distribution Unit

BALL RAMP
Driving Sprocket Multi-Plate Clutch
Chain
Front Propeller Rear Propeller

Shaft Shaft
CHANGED BY TOD
AFFECTED VIN
4D 9
4H Mode (4WD Drive - Low Speed)
Transmission Rear Axle

(Rear Wheel)
Front Axle
(Front Wheel)
Front Speed Transmission

Sensor Input Shaft
Rear Speed TOD Control Unit

Sensor
Throttle Open
Rate
(TPS Value)
Magnetic Clutch Planetary Gear
MAX DUTY (2.483)
Force Distribution Unit

BALL RAMP
Driving Sprocket Multi-Plate Clutch Output Shaft
Chain
Front Propeller Rear Propeller

Shaft Shaft
TOD CHANGED BY
AFFECTED VIN
10 4D
Specifications
TOD Model TOD transfer case
Overall length 343.0 mm
Weight (including oil) 37.9 kg
Shifting mode 4H and 4L
Gear ratio High 1:1
Low 2.48:1
Oil specification Specification Ssangyong genuine oil
(ATF S-3, S-4 or Dexron II/III)
Capacity 1.4
Change interval Check at every 15,000 km,
replace at every 60,000 km
TOD Maximum torque (front) Approx. 76 kg•m

control Voltage Normal operating
unit 9 ~ 16 V
range
CAN communication 6 ~ 16 V
Current (below maximum IG switch OFF 2 mA
operating voltage) IG switch ON 1A
Maximum operating Motor OFF 7A
current Motor ON 20 A
CHANGED BY TOD
AFFECTED VIN
4D 11
3. CIRCUIT DIAGRAM
TOD CHANGED BY
AFFECTED VIN
12 4D
4. OPERATION
System Layout
Combi meter
4WD switch
TOD control unit
Output
Input
Rear speed
Magnetic clutch
Motor
Front output shaft Front speed
CHANGED BY TOD
AFFECTED VIN
4D 13
4WD Operation Overview

Application Mode Position Operation Condition
Driving type 4H 4WD Drive Normal Driving on the normal road or highway, or high speed driving.
(High Speed) Slipped road such as snow, rainy, sand, mud etc.
4L 4WD Drive Max driving force requiring condition such as towing, rough road.
(Low Speed) Same function as part time transfer case 4L.
Transferring 4H ↔ 4L 4WD Drive A vehicle should stop for transfer.
High Speed ↔ Manual Transmission
Low Speed
• Transfer starts after the vehicle stops and the clutch is applied
Automatic Transmission
• Transfer starts after the vehicle stops and the shift lever is shifted
[N] position.
[Notice]
To make the mode shift easier, stop the vehicle, depress the brake pedal, select the mode switch, and move the selector
lever with the sequence of [N-P-N].
Mode Switch
Selection Mode 4L Mode
The TOD system has 2 selectable mode, 4H and 4L. When selecting 4L mode, EMC is locked to apply maximum
4H is the normal operating mode when drive of which torque into front and rear propeller shafts (when the wheel
gear ratio is 1:1 and 4L mode distributes power to front speed is more than 87Hz). Shift motor rotates also 4L posi-
and rear wheels 50:50 of which gear ratio is 2.48:1. tion by rotation of cam thus propeller shaft torque changes
from 1:1 to 2.48:1 by planetary gear set.
Releasing the 4L Mode

When selecting 4H mode, 4L drive mode is released and 4H
mode is resumed.
• “4H” switch: Self-return type
• “4L” switch: Push lock type
TOD CHANGED BY
AFFECTED VIN
14 4D
COMPONENTS
1. TOD ASSEMBLY
Front case
Rear cover
T/M RR. Propeller shaft
Frt. Propeller shaft
Front & rear Shift motor/Electronic

speed sensor magnetic clutch
Input shaft Rear cover
Companion flange
Air bleeder cap
Shift motor
Rear speed sensor

Front companion flange
CHANGED BY TOD
AFFECTED VIN
4D 15
2. TCCU (TRANSFERCASE CONTROL UNIT)

Location Under Driver’s Seat
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
Item TCCU
Vehicle speed signal CAN
Cluster lamp CAN
Clutch signal (M/T) CAN
Neutral signal (A/T) CAN
TOD CHANGED BY
AFFECTED VIN
16 4D
TCCU
Description New TCCU

Connector type Two separated connectors
Number of pins 30
Weight 0.22 kg
CAN-BUS O
Vehicle speed signal CAN communication
Lamp CAN communication
Clutch signal (M/T) CAN communication
Neutral signal (A/T) CAN communication
Appearance and Function

Pin No. Description Pin No. Description
1 Motor HI - LO 16 Speed sensor voltage supply
2 Motor LO - HI 17 Ground
3 EMC 18 Ground
4 Battery 19 Battery
5 Ignition 20 K-Line
6 Position ground 21 N/A
7 N/A 22 CAN H
8 N/A 23 CAN L
9 4H-4L switch 24 N/A
10 Position 2 25 ABS operation
11 Front speed sensor 26 N/A
12 N/A 27 Position 1
13 Ground – speed sensor 28 Position 3
14 Motor HI-LO 29 Rear speed sensor
15 Motor LO-HI 30 Position 4
CHANGED BY TOD
AFFECTED VIN
4D 17
Transfer Case Block Diagram
4 2 Shift motor output

Battery voltage
19 15 (Motor LO-HI)
T
Ignition switch ON/
5 O 1 Shift motor output
OFF
14 (Motor HI-LO)
Position 1 27
Position 2 10 3 EMC
C
Position 3 28
Position 4 30 O
Position encoder
N 6 ground
(Return position)
4H/4L switch signal 9

T
O
Front speed Speed sensor ground
11 13
sensor signal (Return position)
L
Front/rear speed
Rear speed 29 16 Sensor 5V power
sensor signal U supply
CAN HIGH 22 I 20 Self diagnosis
CAN LOW 23 17
18
TOD CHANGED BY
AFFECTED VIN
18 4D
Section Pin No. Name Description

Power 17, 18 Ground TOD control unit ground
supply 4, 19 B+ TOD control unit battery voltage input
Input side 5 Ignition switch Ignition switch power
: ON - over 4 V, OFF - below 0.9 V
27 Position 1 Position encoder – shift motor position recognition
HIGH - over 4 V, LOW - below 0. 9 V
10 Position 2 Same as above
9 4H and 4L switch Mode input according to 4H and 4L selection
: HIGH - over 4 V, LOW - below 0.9 V
11 Front speed sensor Front speed sensor (hall effect) signal input
29 Rear speed sensor Rear speed sensor (hall effect) signal input
25 ABS operation ABS operating signal input (ABS ON/OFF)
Operation - over 4 V, Not operation - below 0.9 V
(NON CAN ABS model)
Both sides 22 CAN HIGH CAN bus HIGH line
23 CAN LOW CAN bus LOW line
20 K - LINE Connected to trouble diagnosis connector
Output side 16 Speed sensor voltage Supplying 5V to front/rear speed sensors
1, 14 Motor HI-LO Motor output port
- Connected to battery when shifting to LO from HI
- Connected to ground when shifting to HI from LO or
braking the motor
2, 15 Motor LO-HI Motor output port
- Connected to battery when shifting to HI from LO
- Connected to ground when shifting to LO from HI or
braking the motor
3 EMC Supplying the voltage to clutch coil
- Frequency: 50 Hz, - Duty ratio: 6 ~ 88 %
6 Speed return Providing the ground to position encoder
13 Speed return Providing the ground to speed sensor
CHANGED BY TOD
AFFECTED VIN
4D 19
SYSTEM OPERATION
TCCU Initialization
• TCCU sends relevant data to meter cluster via CAN to diagnose and check the indicators when the ignition switch is
turned to ON. At this time, the 4WD indicators (4WD LOW, 4WD HIGH, 4WD CHECK) comes on for 0.6 seconds.
• If the selector switch position and the shift motor position code does not match when the IG power is turned ON, the
shift is controlled to move in the direction of the selector switch position
Interpretation of Position Sensor

- When the 4H/4L switch is operated and the position sensor recognizes the shift motor position while the system is
energized, the system operates as follows:
4H/4L Switch Input Motor Position Operation

4H Left stop Does not operate, 4L lamp off
4H Left top Does not operate, 4L lamp off
4H Top Does not operate, 4L lamp off
4H Right top - 4L lamp flickers
- Tries shifting to 4H if shifting conditions are satisfied.
- After shifting to 4H the flickering of 4L lamp stops.
4H Zone 1 Same as above
4H Neutral Same as above
4H Zone 2 Same as above
4H Bottom Same as above
4H Right stop Same as above
4L Left stop - 4L lamp flicker
- Tries shifting to 4L if shifting conditions are satisfied.
- After shifting to 4L the 4L lamp lights on.
4L Left top Same as above
4L Top Same as above
4L Right top Same as above
4L Zone 1 Same as above
4L Neutral Same as above
4L Zone 2 Same as above
4L Bottom Does not operate, 4L lamp lights on
4L Right stop Does not operate, 4L lamp lights on
TOD CHANGED BY
AFFECTED VIN
20 4D
If 4H/4L switch position is not matched with shift motor position code with the ignition switch “ON”, the shift require-
ments operate to the direction of 4H/4L switch. However, the shifting requirements should be met to shift.
• Shifting requirements:
- The transmission is in neutral for 2 seconds after the shift is requested.
- Both propeller shaft speeds are below 43 Hz.
A command to shift will only be acted upon if the TOD is reading a valid code at the time the command to shift is made.
After a shift has started, the TOD will power the shift motor until the code for the requested position is read. If an invalid
code is read, the TOD will go into a default mode.
During a shift attempt, the shift motor will be energized for a maximum of 5 seconds.
In case of manual transmission, the clutch pedal should be depressed.
CHANGED BY TOD
AFFECTED VIN
4D 21
ELECTRIC SHIFT SYSTEM OPERATION
The electric shift system is responsible for changing the transfer case gear ratio by controlling the electric shift motor.
The TOD monitors the 4H/4L switch, neutral switch, speed sensors, position encoder, and ignition switch.
A range change is initiated when:
1. The 4H/4L switch is changed from 4H to 4L or from 4L to 4H.
2. The motor position (as indicated by the position encoder) does not match the 4H/4L switch immediately after the
ignition is turned on.
Shift Requirements
When a range change is initiated a diagnostic test will be completed on the motor, speed sensors, and position
encoder. If the diagnostic test fails, the shift will not be attempted. If all components are operating properly, the TOD will
attempt a range change after the following shift requirements are met:
1. The transmission is in neutral for 2 seconds after the shift is requested.
In case of manual transmission, the clutch pedal should be depressed.
2. Both propeller shaft speeds are below 43 Hz.
If the transmission is taken out of neutral before 2 seconds has elapsed, or either propeller shaft speed increases above
the limit, the shift will be suspended and the 4L indicator will continue to flicker until the requirements are met again or
the 4H/4L switch is returned to the original position. However, if the initial switch position is “4L”, “4L” indicator remains
on. If the shift requirements are met, the shift motor attempt to shift again.
Range Change
When the shift requirements are met, the motor rotates to the appropriate direction (as determined by the selector
switch) until one of the following occurs:
1. The motor reaches its destination.
2. The motor is on for 5 seconds without reaching its destination. The shift has failed and the TOD will respond as
default mode.
3. A fault occurs with either the motor or position encoder. Refer to the diagnosis requirement.
When the motor is energized, the Ignition, 4H/4L switch, propeller shaft speeds, and transmission neutral inputs are
ignored.
Shift operation is only allowed when some conditions are satisfied. These shift conditions should be satisfied for 2
seconds before starting motor. The motor has three seconds of delay at its initial operation to do trouble diagnosis.
Once the motor starts, the shift conditions are no longer checked.
Shift conditions are as follows:
- Normal battery voltage and shift motor for all gears
- Shift operation between 2H/4H and 4L is only available when the vehicle speed is below 43 Hz.
- No defective speed sensor
- The selector lever should be in “N” position (in case of manual transmission, the clutch pedal should be depressed).
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Shift Conditions
Shift is allowed only when certain conditions for the vehicle are satisfied. This means that the shift conditions must
satisfy the operating conditions for 2 seconds before motor starts and 2 seconds of delay at initial stage is to diagnose
the system.
The shift requirements are as follows:

- There should be no fault with battery voltage and shift motor for all shifts.
- Shift between 4H and 4L is operated only under the vehicle speed of below 43 Hz.
- There should be no fault with speed sensors.
- Transmission must be in neutral position (In case of manual transmission, the clutch pedal should be depressed).
Motor Controls
• The shift steps have the sequence of 4H → 4L and 4L → 4H → 2H. TCCU operates the shift motor until it reads
required position code. If it detects the faulty code, the system is operated with the compensation mode.
• Once the shift operation is started, it is completed regardless of ignition power. If there are not operating signals from
position sensor, the shifting failure due to timeout occurs. This failure appears when the shifting time between 2H
and 4H and between 4H and 4L is delayed over 5 seconds compared to normal shift. Once the shifting time exceeds
the specified time, TCCU cannot properly supply the voltage to shift motor and is operated in compensation mode.
• Even though the system recognize a fault before motor starts, it is considered as fault.
• Motor stops operation when it reaches at target range.
Compensation Mode
The motor stops when the encoder related troubles are detected during shift operation. It moves toward LOW-HIGH
direction for 5 seconds so that the motor is not left in unidentified position.
Indicator Function on Shifting

Once a range change has been initiated the 4L Indicator will
0.3 seconds
begin to blink at a rate of 0.3 seconds on, 0.3 seconds off until
the shift is completed or canceled. Shift completed
4L Indicator illuminates as below figure.
Electric Shift Default Mode

If the motor fails to reach its destination, the TOD will attempt 0.3 seconds
the following (in order):
1. The TOD will wait 3 seconds then attempt the shift again. (4H → 4L)
2. If the second attempt to reach the destination fails the

TOD will wait 3 seconds then attempt to rotate the motor
back to the original position. If successful, all future shifts
will be inhibited until the Ignition is cycled. 0.3 seconds
3. If the attempt to return to the original position fails, the Shift completed
TOD will wait 3 seconds then attempt to rotate the motor
to the original position again. If the second attempt to
return to the original position is successful, the “4WD
CHECK” indicator will be illuminated, and all future shifts
will be inhibited until the Ignition is cycled. 0.3 seconds
4. If the second attempt to return to the original position

fails the motor will be turned off, the “4WD CHECK” (4L → 4H)
indicator will be illuminated, and all future shifts will be
inhibited until the Ignition is cycled.
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Etc
The TOD system is responsible for distributing torque between the front and rear axles. The TOD monitors the propeller
shaft speeds, operating range (High/Low), and ABS activity and then applies a calculated amount of torque to the front
axle by Pulse Width Modulating the current applied to the EMC.
Touch-off torque
The minimum EMC Duty Cycle is based on the vehicle speed and throttle position.
The TOD receives the TPS signal from the following sources:
On vehicles equipped with CAN, the TOD receives the TPS signal from the CAN bus.
When slip detection

The TOD continuously monitors the front and rear propeller shaft speeds to detect wheel slip.
Wheel slip control

When wheel slip is detected the TOD controls the EMC duty cycle as necessary until the wheel slip is reduced below
the allowable limit. The EMC Duty Cycle will then be reduced to the Touch-Off value.
Brake/ABS strategy
When the ABS System is active, the EMC Duty Cycle is set to a fixed duty cycle (30 %) to aid in braking without
counteracting the ABS System.
4L strategy
When the system is operating in 4L, the TOD continues TOD (operation provided that the propeller shaft speed is below
87 Hz). When the speed increases above 10 Hz, the EMC Duty Cycle is set to the maximum value (88 %) which applies
the maximum available torque to the front axle.
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Shifting Sequence
Flow chart
Start No
Shift Yes Check shift Satisfied shift

requirements conditions conditions for 2
seconds
Yes
Analyzing position
No encoder
Canceling general encoder

Is the position No DTC Shift is not available
code valid? during ignition cycle
Yes
Move further to
requested direction
Does the motor Yes

Motor stops Shift
operate for
time out DTC
maximum limit?
No
Is the position Moto stops

No
code valid and General
sequential? encoder DTC
Yes
No
Motor ON to L-H
Reached at
during maximum limit
target location?
Shift is not available

during ignition cycle
Yes
Shift motor OFF
Completed
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Shift Requirements
• If 4H/4L switch position is not matched with shift motor position code with the ignition switch “ON”, the shift requirements
operate to the direction of 4H/4L conversion switch.
• The next shift requirements are identified only when those are different from current operation.
Shift Conditions
Shift is allowed only when certain conditions for the vehicle are satisfied. This means that the shift conditions must
satisfy the operating conditions for 2 seconds before motor starts and 2 seconds of delay at initial stage is to diagnose
the system.
The shift requirements are as follows:

- There should be no fault with battery voltage and shift motor for all shifts.
- Shift between 4H and 4L is operated only under the vehicle speed of below 43 Hz.
- There should be no fault with speed sensors.
- Transmission must be in neutral position (In case of manual transmission, the clutch pedal should be depressed).
Reading position encoder

The position encoder is the code that TCCU can determine the shift motor position.
Position
Motor Position Remark
1 2 3 4
1 1 1 0 Left Stop
1 0 1 0 Left top
0 0 1 0 Top
0 0 0 0 Right top
Input voltage
1 0 0 0 Zone 1
1 : above 4.5V (HIGH)
1 0 0 1 Neutral
0 : below 0.5V (LOW)
0 0 0 1 Zone 2
0 1 0 1 Bottom
0 1 0 0 Right stop
1 1 1 1 Off State
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3. SPEED SENSOR AND CLUTCH COIL

The front and rear speed sensor utilizes the hall effect. These sensors generate 0V and 5V of square type digital
wave according to the rotation of the wheel with teeth of transfer case front and rear output shaft. The speed
signal from front and rear propeller shaft is entered into TOD control unit.
Pin Function
4 Clutch coil
6, 7 Sensor power supply (5V)
1, 2, 5 Sensor signal 1(G) 2(G)
3 Sensor ground 3(B) 5(Sb)
6(Gr/R)
7(Gr/R)
4(Br)
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4. SHIFT MOTOR CONNECTOR

When selecting a position in 4WD switch (4H/4L), TOD control unit exactly changes the motor position to 4H and 4L by
detecting the electric signals from position encoder that monitors motor position.
Pin Function
1 Position A
2 Position B
3 Position C 1(Br/W) 2(P/W)
4 Position D
3(W) 5(Y/W)
5 Position ground
6(Y) 7(P)
6 Control (4L - 4H)
7 Control (4H - 4H)
4(V)
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1. TCCU
1. Move the driver’s seat to for front and open the seat cover.
2. Unscrew TCCU mounting nuts (M5-2EA)
3. Disconnect the TCCU connector and seperate the unit.
[Notice]
Be careful not to apply any impact to TCCU body.
Installation Notice
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2. SHIFT MOTOR
2. Disconnect the shift motor/electronic magnetic clutch connector (black, 7-pin) and front and rear speed sensor
connector (white, 4-pin) at the rear top section of the transfer case.
3. Disconnect the front and rear speed sensor connector (white, 7-pin) from bracket.
4. Remove shift motor mounting bolts.

5. Remove bracket mounting bolt.
[Notice]
Remove two bolts for fixing the motor and bracket before
removing the shift motor and bracket.
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6. Pull the shift motor assembly out while keeping the level.
7. Clean the mating surface of the transfer case and shift

motor.
[Notice]
Do not disassemble the shift motor since it is replaced as an
assembled unit.
8. Apply sealant on the mating surface if new shift motor

assembly.
9. Install in the reverse order of removal. Make sure that
the mode switch selection is matched with the motor’s
driving position before installation.
[Notice]
To do that, install a new shift motor on the same location
that the used shift motor was on.
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3. SPEED SENSOR
Rear speed sensor
Front speed sensor
Rear speed sensor connector

2. Remove the shift motor assembly.
3. Disconnect the front and rear speed sensor connector (white, 7-pin) at the rear top section of the transfer case.
4. Disconnect the speed sensor connector from the locking sleeve.
5. Remove the wire fixing retainer at the rear side of disconnected connector.
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6. Remove the rear speed sensor bolts on the rear case flange.
7. Remove the rear speed sensor with a suitable tool.
[Notice]
Do not apply excessive force to protect mounting area and sensor.
8. Remove the tapings in both sides of protective tube.

9. Remove the tube.
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10. Hold the “L” pin in speed sensor connector with long nose pliers and push it rearward to disconnect from the
connector.
11. Disconnect the “M” and “N” pin and wire from the
connector with same manner.
[Notice]
EMC wire cannot be disconnected from outside, therefore do
not try to disconnect it.
12. Get a new speed sensor.

13. Insert three pins and wires into each location from rear
side of the connector.
14. Hold each pin with long nose pliers and pull it to securely
install in the connector.
15. Insert each rubber cap into the connector to prevent the
pins from disconnecting.
16. Insert the protective tube for connector into the harness.
17. Bind both ends of the protective tube with tape.
18. Install the rear speed sensor into the mounting hall and
press both ends of it to be securely seated.
19. Tighten the bolts.
Installation Notice
20. Install the speed sensor connector. Insert the connector

into the locking sleeve.
[Notice]
Remove the shift motor first before removing the front
propeller shaft speed sensor. When replacing the sensor
assembly after removing the shift motor, use the same manner
for removal of rear speed sensor.
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4. TOD ASSEMBLY
2. Lift up the vehicle and fix it safely.
3. Place the empty container to collect the draining oil.
4. Remove the drain plug and drain the oil. Reinstall the
drain plug.
[Notice]
Oil drain should be along with whole transfer case
disassembly and assembly.
5. Disconnect transmission extension wiring connector from

rear side of transfer case.
[Notice]
When disconnect connector, make sure on direction of
locking tab towards inside.
6. Disconnect the shift motor/clutch coil connector (black,

7-pin) and front and rear speed sensor connector (white,
7-pin) at the rear top section of the transfer case.
7. Remove the breather hose.

8. Support the transfer case with jack and remove the front
propeller shafts bolts (4ea).
Installation Notice
9. Remove the rear propeller shaft mounting bolts (4).
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10. Unscrew the bolts and remove the crossmember from

the transmission.
L/R Mounting Bolt 21 ~ 35 Nm

Center Mounting Bolt 62 ~ 93 Nm
11. Remove the insulator mounting bolts.

Installation Notice
12. Unscrew the bolts and remove the transfer case.

Installation Notice
[Notice]
Apply long-life grease to the inner spline of transfer case
input shaft.
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4D 37
TOD ASSEMBLY
1. CROSSE SECTIONAL DIAGRAM
4H-4L planetary gear set Chain Clutch pack EMC
Ball lamp
Input shaft
Oil pump
4H-4L shift motor
Front wheel
output shaft
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Exploded View
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4D 39
1. Snap ring 35. Breather

2. Snap ring 37. Output shaft
3. Snap ring 38. Dust shield
4. Bearing 39. Magnet
5. Hub 40. Snap ring
6. Input shaft assembly 41. Lower sprocket
7. Thrust plate 42. Tone wheel (lower)
8. Sun gear 43. Chain
9. Snap ring 44. Thrust bearing assembly
10. Carrier assembly 45. Retaining ring
11. Reduction hub 46. Bearing
12. Main shaft assembly 47. Bearing
13. Geroter pump assembly 48. Cover
14. Thrust washer 49. Clip
15. Hose clamp 50. Bolt
16. Hop 51. Oil seal
17. Filter 52. Washer
18. Electric coil assembly 53. Nut
19. Cam/coil housing assembly 54. Companion flange
20. Ball 55. Oil seal
21. Cam 56. Spacer
22. Spring 57. Tone wheel (upper)
23. Armature 58. Nut
24. Insulator washer 59. “J” clip
25. Retaining ring 60. Hexagon bolt
26. Clutch pack assembly 61. Clip
27*. Sprocket assembly 62. Connector
28. Shift rail 63. Connector lock
29. Shift fork assembly 64. Hexagon cap screw
30. Electric shift cam 65. Speed sensor (upper)
31. Torsion spring 66. Electric motor assembly
32. Shift shaft 67. Oil seal
33. Retaining ring 68. Pipe plug
34*. Transfer case assembly 69. Speed sensor (lower)
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2. DISASSEMBLY PROCEDURE
1. Disconnect transfer case from vehicle
2. Using a 30 mm thin-wall socket, first remove the rear
output nut, output shaft yoke washer, oil seal then the
case flange.
3. Disconnect shift motor/clutch coil connector and speed
sensor connector from upper bracket of transfer case.
[Notice]
When disconnect connector, pull forwards grasping
connector housing.
4. Remove outer tube on speed sensor connector.

5. Remove wire supporting cape back side of speed sensor
connector.
6. Disconnect pin of clutch coil wire (yellow) from speed

sensor connector (7 pin) using long-nose plier.
03E-019
7. Remove shift motor.
[Notice]
When remove shift motor, pay attention to the location of
triangular slot and shaft in transfer case inside motor.
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4D 41
8. Disconnect front and rear speed sensor as needed.

9. Remove the 17 bolts that retain the front case to the rear
case.
10. Make sure that the front case is facing downward so

that the rear cover is facing upwards.
11. Remove the rear front case from the rear case.
12. Remove all traces of gasket sealant from the mating
surfaces of the front case and rear case.
13. If the speedometer drive gear is to be replaced, first
remove the flange seal by prying and pulling the curved-
up lip of the flange seal.
[Notice]
Be careful not to damage the bearing, bearing cage or case.
Remove and discard the flange seal.
14. Remove the speedometer drive gear and upper tone wheel.
15. If the rear output shaft bearing requires replacing, remove
the internal snap ring that retains the bearing in the bore.
16. From the outside of the case, drive out the bearing using
the driver.
17. Remove the three nuts and washers retaining the clutch
coil assembly to the rear case.
18. Pull the assembly, along with the O-ring and wire, from
the case.
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19. Remove bearing assembly from output shaft.

20. Remove the clutch housing from the output shaft.
21. Remove the balls and apply cam and wave washer from
the output shaft.
22. Remove snap ring from output shaft.
23. Remove clutch pack assembly from output shaft.
24. Remove the chain, driven sprocket and drive sprocket as

an assembly.
25. Remove thrust washer from output shaft.
26. Remove the magnet from the slot in the front of the case
bottom.
27. Remove the output shaft and oil pump as an assembly.
28. If required, to remove the pump from the output shaft,
rotate the pump to align.
29. Pull out the shift rail.
30. Remove the helical cam from the front case.
31. If required, remove the helical cam, torsion spring and
sleeve from the shaft.
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32. Remove the high-low range shift fork and collar as an

assembly.
33. Expand the tangs of the large snap ring in the case.
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 the input shaft and front planet from the case.
36. If required, remove the oil seal from the case by prying
and pulling on the curved-up lip of the oil seal.
[Notice]
37. Remove the internal snap ring from the planetary carrier.
38. Separate the front planet from the input shaft.
39. Remove the external snap ring from the input shaft.
40. Place the input shaft in a vise and remove the bearing.
41. Remove the thrust washer, thrust plate and the sun gear
off the input shaft.
42. Inspect the bushing and needle bearing in the end of the
input shaft for wear or damage.
[Notice]
Under normal use, the needle bearing and bushing should
not require replacement. If replacement is required, the
bushing and needle bearing must be replaced as a set.
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43. If replacement of the needle bearing and bushing is

required, press the bearing and bushing is required, press
the bearing and bushing out as follows:
• Position the input shaft on Axle Bearing/Seal plate,
and using Pinion Bearing Cone Replacer as a spacer.
• Insert Input Shaft Bearing Remover into the input shaft
so it is resting on top of the bearing cage.
• Tighten the actuator pin until it stops, then press the
bearing and bushing out together.
44. If required, remove the front yoke to flange seal by prying

and pulling on the curved-up lip of the yoke to flange
seal.
[Notice]
45. If required, remove the internal snap ring retaining the

front output shaft ball bearing and remove the bearing.
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3. ASSEMBLY PROCEDURE
1. Before assembly, lubricate all parts with Automatic
Transmission Fluid or equivalent.
2. If removed, drive the bearing into the front output case
bore.
[Notice]
Drive the bearing in straight, making sure it is not cocked in
the 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 case bore.
5. If removed, install the yoke to flange seal into the mounting
adapter bore.
6. If the input shaft needle bearing and bushing were

removed, install a new bearing and bushing as detailed
in the following steps:
Press a new needle bearing, then a new bushing in the
input shaft as follows:
• Position the input shaft on Axle Bearing/Seal Plate
or equivalent, and Pinion Bearing Cone Replacer as
a spacer.
• Press a new needle bearing into the end of the input
shaft until it seats in the input shaft.
• Press in a new bushing.
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7. The recessed face of the sun gear and the snap ring
groove on the bearing outer race should be toward the
rear of the transfer case.
8. The stepped face of the thrust washer should face toward
the bearing.
9. Slide the sun gear, thrust plate and thrust washer into
position on the input shaft.
10. Press 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 carrier.
14. Place the tangled snap ring in the case. Expand snap
ring with snap ring pliers and install planetary carrier
assembly. Check installation by holding the case and
carefully tapping the face of the input shaft against a
wooden block to make sure the snap ring is installed.
15. Remove all traces of gasket sealant from the front case
and mounting adapter mating surfaces. Install a bead of
gasket sealant on the surface of the front case.
16. Install the high-low shift fork and high-low collar as an

assembly into the front planet.
17. If new pump is used, align the flat of the output shaft and
the flat of the pump. Slide the pump onto the output shaft.
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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 ouput shaft
engage the internal splines of the high-low shift collar.
Make sure that the oil pump retainer arm and oil filter leg
are in the groove and slot of the front case.
20. Install the magnet in the slot in the front case just above
the oil filter leg.
21. Install the front 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.
[Notice]
The driven sprocket (on the front output shaft) must be
installed with the marking REAR facing toward the rear case,
if so marked.
Drive sprocket has a bushing pressed into it.
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24. Install tone wheel onto the front output shaft. Make sure
the spline on the tone wheel engages the spline on the
front output shaft.
25. Install clutch pack assembly onto the rear output shaft.
Make sure the spline of the clutch pack engages to the
spline of the sprocket.
26. Install snap ring onto the rear output shaft. 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 seated properly.
27. Install wave spring, insulator washer and armature. (Three
offset slots must align with housing to be installed)
[Notice]
Three slots on the thrust washer must be aligned with the
three tabs on the clutch pack housing.
28. Install apply cam onto the rear output shaft,

29. Install three balls into the apply cam.
30. Install cam and coil housing assembly onto rear output
shaft.
31. Install thrust bearing assembly onto output shaft.
32. If removed, drive the front output shaft ball bearing into
the rear cover bore with Front Shaft Needle Bearing
Replacer and Driver Handle.
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33. If removed, install the rear output bearing in the rear case
bore. Drive the bearing into the rear case bore with Output
Shaft Bearing Replacer and Driver Handle. Make sure
that the bearing is not cocked in the bore.
34. Install the internal snap ring that retains the bearing to
the rear case.
35. Install the clutch coil from inside the rear case until the
wire and studs extend through the cover.
[Notice]
Do not kink or trap the wire while seating the clutch coil to
the case.
36. Install the washers and nuts and tighten.

Installation Notice
8 - 11 Nm
Tightening torque
(71 - 97 lb-in)
37. Slide the spring spacer on the camshaft and position it

beneath the drive tang.
38. Place the torsion spring on the camshaft. Position the
first spring tang to the left of the camshaft drive tang.
39. Rotate the second spring tang clockwise past the drive
tang.
43a
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40. Push the torsion spring and sleeve in as far as it will go.
41. Install the helical cam and slide the drive tang between
the torsion spring tangs as far as it will go.
42. Install the pin on the tang end of the helical cam into the
hole in the front case. Position the torsion spring tangs
so that they are pointing toward the top side of the
transfer case and just touching the high-low shift fork.
[Notice]
Do not bend the helical cam during installation to the front
case because of possible damage to the pin at the tang end of
the motor shaft.
43. Install the shift rail through the high-low shift fork and
make sure that the reverse gear shift rail is seated in the
front case bore.
44. Install upper and lower speed sensors into the cover.
Feed the coil wire through the upper speed sensor wire
shield.
45. Install upper tone wheel, speedometer gear and rear

output seal. Use Output Shaft Seal Replacer and Driver
or equivalent to install seal.
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46. Coat the mating surface of the front case with a bead of
Black Non-Acid Cure Silicone Rubber or equivalent.
47. The following procedure must be followed prior to installing
the rear case onto the front case half:
• Align the output shaft with the rear case output shaft
bore.
• Align the helical cam with the rear case motor bore.
• If difficulty is encountered with seating the rear case,
tap the rear output shaft with a sharp blow using a
rubber mallet in a direction away from the triangular
shaft while pushing down on the rear case.
48. Install the bolts retaining the case halves and tighten.
Installation Notice
25 - 37 Nm
Tightening torque
(8 - 27 lb-in)
49. Install shift shaft oil seal if it is not installed.
50. Using pliers equipped with soft jaws, rotate the triangular
shaft so it is aligned with the triangular slot in the transfer
case shift motor.
[Notice]
If triangular shaft will not rotate, rotate the rear output shaft.
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51. Tighten manually the two nuts that attach the slotted
support bracket to the end of the motor house.
52. Apply Black Non-Acid Cure Silicone Rubber or equivalent
to motor housing base and install on transfer case.
53. Install the transfer case shift motor and three bolts along
with speed sensor wire harness bracket and tighten.
Installation Notice
8 - 11 Nm
Tightening torque
(71 - 97 lb-in)
54. Holding the slotted support bracket tight against the motor
housing end, secure the bracket to the transfer case,
tightening the bolt with lock washer.
Installation Notice
8 - 11 Nm
Tightening torque
(71 - 97 lb-in)
55. Retighten the two nuts that attach the slotted support
bracket to the end of the motor.
Installation Notice
3 - 6 Nm
Tightening torque
(27 - 53 lb-in)
56. Install the clutch coil wire terminal(brown) and other shift
motor wires to the 7-pin connector(black).
57. Install the connector retainer at the connector end.
58. Connect the front and rear speed sensors wiring to the
7-pin connector(white).
59. Install the rear case flange on the output shaft.
60. Install the rubber seal, output shaft yoke washer and nut.
Tighten the nut.
Installation Notice
Tightening torque 137 - 196 Nm
61. Install the drain plug and tighten.
19 - 30 Nm
Tightening torque
(14 - 22 lb-in)
62. Fill the transfer case with 1.4 liters of Automatic

Transmission Fluid or equivalent.
63. Install the fill plug and tighten.
Installation Notice
19 - 30 Nm
Tightening torque
(14 - 22 lb-in)
64. Install the transfer case as outlined in removal and

Installation.
CHANGED BY TOD
AFFECTED VIN
4D 53
661 589 01 37 00 (W 99 31 001 1B) Removal/installation of carrier

Pliers assembly in transfer case
DW 220 - 080 (W 99 31 005 0B) Installation of oil seal to

Oil seal installer transmission case
TOD CHANGED BY
AFFECTED VIN
54 4D
TROUBLE DIAGNOSIS
TCCU periodically monitors the input and output while the system is in operation. When a fault is detected, the trouble
code is stored into TCCU memory.
If the ignition switch is turned to “OFF”, TCCU stops monitoring for input and output, however, when the ignition switch
is turned to “OFF” before shifting completes, TCCU continues monitoring for input and output required for the shifting.
1. SELF DIAGNOSIS TEST

Shift Motor Test
When TOD control unit detects a fault in shift motor or position encoder for over 1 second, “4WD CHECK” warning lamp
comes on and the trouble code is stored into memory.
• Shift motor fault occurs when the motor is in “OFF” state:
- short to ground in motor HI-LO circuit
- short to ground in motor LO-HI circuit
- open in motor circuit
• Shift motor fault occurs when the motor is in normal operation state:
- short to ground in motor HI-LO circuit
- short to ground in motor LO-HI circuit
- short between motor LO-HI and motor HI-LO circuit
- open in motor circuit
• Position encoder fault occur when
- Detected unmatched code with 9 valid position codes
- An encoder circuit is short to ground
• When the fault occurs before the shift operation is started, the TOD control unit does not respond to any shift
command.
• When, after receiving shift command, the fault occurs without any operation, the TOD control unit cancels the
command and does not respond to any following shift command.
• If TOD control unit, even while shift command is in progress, detects an invalid position code, it stops the operation
and turns motor to “HIGH” position. After then, TOD control unit does not respond to any shift command.
• When the shift motor and position encoder assembly fault (fault other than motor fault that is caused when normal
power supply is applied) is restored continuously for 1 second, the TOD control unit function becomes normal. At
this time, “4WD CHECK” warning lamp comes on but the trouble code is stored into memory.
• The trouble code being detected in shift motor during its operation is defined as timeout.
• The trouble code for shift motor can be erased by using scanner.
Position Encoder Test

• When the system detects a fault in shift motor for over 1 second, “4WD CHECK” warning lamp comes on and the
trouble code is stored into memory.
• Position encoder fault can be divided into general encoder fault and short to ground of position encoder circuit.
- General encoder fault: Invalid position code input
- Short to ground of position encoder circuit: Ground for encoder circuit
CHANGED BY TOD
AFFECTED VIN
4D 55
Front Sensor Speed Test

When the system detects a fault from front speed sensor for over 0.5 second, “4WD CHECK” warning lamp comes on.
At this time, the responds from TOD control unit are as follows:
• If the system is in “4H” state, the TOD control unit uses rear speed sensor value to determine the amount of EMC
touch off and the wheel slip control stops.
• If the system is in “4L” state, the EMC duty cycle is set at maximum value (according to the vehicle speed) until
system stops “4L” operation.
• All electrical shift operations are stopped until ignition switch is cycled from “OFF” to “ON” position. Any shift
operation in progress completes the process. When the front speed sensor is restored continuously for 0.5 seconds,
the TOD control unit becomes normal status. At this time, “4WD CHECK” warning lamp comes on but the trouble
code still remains in the memory.
Rear Speed Sensor Test

When the system detects a fault from rear speed sensor for over 0.5 second, “4WD CHECK” warning lamp comes on.
At this time, the responds from TOD control unit are as follows:
• If the system is in “4H” state, the TOD control unit uses front speed sensor value to determine the amount of EMC
touch off and the wheel slip control stops.
operation in progress completes the process. When the rear speed sensor is restored continuously for 0.5 seconds,
All Troubles from Speed Sensor

When the system detects a fault from front and rear speed sensors for 0.5 seconds, “4WD CHECK” warning lamp
comes on. At this time, the responds from TOD control unit are as follows:
• If the system is in “4H” state, the TOD control unit is set up based on EMC touch off amount and the wheel slip
control stops.
operation in progress completes the process. When the rear speed sensor is restored continuously for 0.5 seconds,
EMC Test
The EMC tests whether the circuit is short or open to ground. When the system detects a fault for 0.8 seconds, “4WD
CHECK” warning lamp comes on and TOD stops its operation. When the EMC is restored continuously for 0.8 seconds,
the TOD control unit functions normally. At this time, “4WD CHECK” warning lamp comes on but the trouble code still
remains in the memory.
TOD CHANGED BY
AFFECTED VIN
56 4D
CAN TPS Test

• When TCCU receives CAN message including TPS value of over 100 % continuously for 1 second, TCCU determines
it as signal error and “4WD CHECK” warning lamp comes on.
When the system is in TOD mode, the TOD control unit considers that the throttle is in idle.
• When the TPS value is restored continuously for 1 second, the TCCU functions normally and “4WD CHECK” warning
lamp comes on but the trouble code still remains in the memory.
• TCCU receives CAN TPS messages periodically. If TCCU cannot receive the messages for 4 periods, TCCU determines
it as signal loss. If it happens continuously for 1 second, TCCU considers it as the invalid signal and “4WD CHECK”
warning lamp comes on.
• When the CAN message including ABS value is restored continuously for 1 second, TCCU functions normally and
“4WD CHECK” warning lamp comes on but the trouble code still remains in the memory.
Transmission Neutral Test

• If TCCU cannot receive the messages for 4 periods, TCCU determines it as signal loss. If it happens continuously for
1 second, TCCU considers it as the invalid signal and “4WD CHECK” warning lamp comes on. And TCCU determines
that the transmission is not in neutral position.
• When CAN message including indication of transmission in neutral is restored continuously for 1 second, TCCU
functions normally and “4WD CHECK” warning lamp comes on but the trouble code still remains in the memory.
Stuck in Low Test

• Stuck in low DTC is set when the shift conditions are satisfied, no encoder trouble exists and the TCCU is not
formed outside of shift range. Stuck in low trouble completing time is 1 second longer than the maximum shift. If the
trouble is detected, “4WD CHECK” warning lamp comes on and shifting is not possible.
• If stuck in low fault is not valid, it is erased at the next ignition cycle and the “4WD CHECK” lamp lights out but fault
code remains in the memory.
CAN Bus Off Test

• CAN bus off trouble is set when the transferring trouble exceeds 255 times and CAN bus in TCCU goes to off
condition. When the trouble counter exceeds 255 times, the signal is recognized as invalid and the “4WD CHECK”
warning lamp comes on.
• If CAN bus in TCCU goes to reset condition while in Bus off condition, the transferring and receiving signals are
interrupted and the synchronization for bus disappears. Once it is reset, TCCU tries to resynchronize with CAN bus.
When the resynchronization stops, the communication is resumed. At this time, the trouble is erased and “4WD
CHECK” warning lamp comes on but the trouble code still remains in the memory.
CHANGED BY TOD
AFFECTED VIN
4D 57
2. CODING ON TOD CONTROL UNIT

What’s Coding?
An input activity of data for the proper performance by match-
ing specification, devices and system with control unit.
Coding required
1. Replacement of TOD control unit.
2. Adjustment by input error.
Coding method
1. Check and record engine type, axle ratio and tire size.
2. Turn the ignition switch to “OFF” position.
3. Connect the scanner with diagnosis connector.
5. Select “TOD” from “CONTROL UNIT SELECTION” screen
and press “ENTER”.
6. Read the current memorized specification in TOD control
unit.
7. Compare memorized specification with the checked
record. If not matched, perform a coding.
8. Read again memorized coding specification in TOD
control unit for confirmation of coding.
9. Turn the ignition switch to “OFF” position.
10. After 5 seconds, turn the ignition switch to “ON” position.
11. Check coding specification whether it matches with
vehicle or not. If not, perform a coding again.
TOD CHANGED BY
AFFECTED VIN
58 4D
3. DIAGNOSTIC TROUBLE CODE

Code Description Action
P1806 CAN Bus OFF - Check communication line.
- Check the relevant connectors for contact.
- Replace TOD unit if necessary.
P1816 CAN: abnormal TPS signal - Check communication line.
- Check engine ECU.
P1814 CAN: no TPS signal - Check communication line.
- Check engine ECU.
P1815 CAN: no neutral signal - Check communication line.
- Check TCU.
P1817 CAN: no ABS signal - Check communication line.
P1821 Open or short to battery in magnetic clutch - Check communication line.
coil circuit - Replace TOD unit if necessary.
P1822 Short to ground in magnetic clutch coil cir- - Voltage at TCCU pin No.11: 11 ~ 15 V
cuit - EMC resistance: 2.5 Ω
P1830 Abnormal rear speed sensor signals - The indicator is flickering even after IG switch ON.
- The indicator is flickering over 0.5 seconds.
- Check the relevant harnesses.
- Replace sensors if necessary.
P1831 Too low front speed sensor voltage - Too low front speed sensor voltage
P1832 Too high front speed sensor voltage - Too high front speed sensor voltage
P1833 Too low rear speed sensor voltage - Pin voltage: below 0.9 V
- Check the rear speed sensor harness for contact.
- Replace TCCU if necessary.
P1834 Too high rear speed sensor voltage - Pin voltage: 4.75 ~ 5.25 V
CHANGED BY TOD
AFFECTED VIN
4D 59
Code Description Action

P1835 Too low speed sensor reference voltage - Reference voltage: below 4 V
P1836 Too high speed sensor reference voltage - Reference voltage: over 8 V
P1841 Open to ground in shift motor circuit - When TCCU detects the motor failure for 1 second
(Action: IG switch ON)
- Check the relevant harnesses for contact.
- Replace shift motor if necessary.
P1842 Short to ground in shift motor output circuit - When TCCU detects the motor failure for 1 second
(Action: IG switch ON)
P1843 Shift system timeout - 2H-4H: after 1.5 seconds
- 4H-4L: after 3 seconds
P1844 Too low position encoder voltage (Stuck in - When no signals from the position encoder
Low) - Check the relevant harnesses for contact.
TOD CHANGED BY
AFFECTED VIN
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4E 1
4E - Front Susp & Axle
Table of Contents
GENERAL INFORMATION ................................ 4E-2
1. System overview ......................................................... 4E-2
2. Specification ............................................................... 4E-4
3. Front axle assembly ................................................... 4E-6
4. Front suspension ........................................................ 4E-7
REMOVAL AND INSTALLATION .................... 4E-12

1. Components .............................................................. 4E-12
2. Preceding work for sub frame removal ....................... 4E-14
3. Removal of sub frame ................................................ 4E-16
4. Front axle assembly ................................................. 4E-22
5. Front suspension assembly ...................................... 4E-27
FRONT SUSP & AXLE CHANGED BY

AFFECTED VIN
2 4E
GENERAL INFORMATION
1. SYSTEM OVERVIEW
4WD
Power steering pipe
Sub frame
assembly
Brake assembly Brake assembly
Front axle
assembly
Power steering assembly
Rear propeller shaft
C.G.P
(Center Gravity Point)
CHANGED BY FRONT SUSP & AXLE

AFFECTED VIN
4E 3
When the sub frame needs to be removed
* 4WD * 2WD
1. Engine oilpan replacement. 1. Engine oilpan replacement.

2. Front axle replacement.
3. Power steering assembly replacement.
2WD
Power steering pipe
Sub frame
assembly
Brake assembly
Brake assembly
Stabilizer bar Power steering assembly

AFFECTED VIN
4 4E
2. SPECIFICATION
Suspension type Double wishbone
Spring type Coil spring : K = 8.8 (kgf/mm)
Shock absorber type Gas type
Stabilizer type Torsion bar : ∅ 30
Camber : 0° ± 30′
Wheel alignment Caster : 4.5° ± 30′
Toe-in : 0 ~ 4 (mm)
Axle size 214 (mm)
Axle ratio 3.7 3.9 4.1 4.3 4.6 4.9 5.4 5.9
Pinion 11 11 9 11 9 9 8 7
Number of tooth
Gear 41 43 37 47 41 44 43 41
Weight 34 (kg)
Length 250.43 (mm)
Oil capacity 1.4 ( )
Specified oil SAE 90

AFFECTED VIN
4E 5
Dimension (Sub Frame)

(Unit : mm)

AFFECTED VIN
6 4E
3. FRONT AXLE ASSEMBLY

Front axle assembly located between left and right wheel transfer the power from the transmission to both wheel when
4-wheel drive mode is chosen.
At the end of axle sides, axle shafts are connected by constant velocity joint and differential carrier is located in the axle
housing.
Mounting Point Mounting Point
Left drive shaft Right drive shaft
Mounting Point
Front propeller shaft
Drive Shaft Assembly

Left and right axle have same over length and removal and Location Grease capacity
maintenance are easily performed.
In boot 140 ~ 160g
Out boot 200 ~ 220g
Wheel side
Diffential carrier side
Out boot In boot

AFFECTED VIN
4E 7
4. FRONT SUSPENSION
Coil spring
Upper arm
Knuckle
Stabilizer bar Lower arm
* Characteristics of front suspension

1. Upper arm mounted relatively high.
2. Coil spring and shock absorber mounted.
3. Maximzed torsion bar effciency.
4. Big rubber bush for better comfort.
5. Minimized king pin offset to decrease vehicle movement.
6. Increased effective wheel base.
7. Diversfied type (2WD, 4WD)

AFFECTED VIN
8 4E
1) Knuckle (4WD)
1. There are two types of knuckle (4WD, 2WD)
2) Upper arm
1. Minimized gap between coil spring and tire (15mm).

2. Optinized ball joint angle against fluctuating.
3) Lower arm assembly

1. Shock absorber mounted on the bush is
connected to the sub frame with upper arm and
lower arm. It suports the load, at the same time,
it absorbs shock and vibration transferred to the
vehicle.
2. Front mount bush is set on the sub frame and
camber bolt for camber/caster adjustment is
assembled to the lower arm
Cam bolt

AFFECTED VIN
4E 9
5) Shock absorber and coil spring

Shock absorber and coil spring is a device for damping
sudden and rapid motion, as the recoil of a spring-
mounted object from shock.
4) Stabilizer bar assembly
Stabilizer bar
Mounting bracket Mounting bracket
Stabilizer link Stabilizer link
Stabilizer bars are part of a car’s suspension system.

They are sometimes also called anti-sway bars or anti-roll bars.
Their purpose in life is to try to keep the car’s body from “rolling” in a sharp
turn.

AFFECTED VIN
10 4E
Structure of Shock Absorber and Coil Spring
1. Coil spring
Specification
4WD 2WD
Spring constant (kg/mm) 8.8 ± 5 % 8.8 ± 5 %
Coil diameter (mm) 16.7 16.6
Coil inner diameter (mm) D1 75.0 75.0
D2 105.0 105.0
Pitch (mm) 85.0 85.0
Number of winding 9.36 9.36
Number of active winding 7.86 7.86
C.V.W Height (mm) 256.0 256.0
(Curved vehicle weight) Weight (kg) 1047 ± 5 % 905 ± 5 %
Strength (kg/mm) 65.8 68.2
Winding direction Rightward Leftward

AFFECTED VIN
4E 11
2. Shock Absorber Assembly

Specification
Max. working distance 540 (mm)

Min. working distance 452 (mm)
Working distance 88 (mm)

AFFECTED VIN
12 4E

1. COMPONENTS
Front Syspension Assembly
1. Coil spring
16. Upper arm bush
3. Upper bracket
5. Lower bush
15. Upper arm
6. Spring-upper rubber sheet
14. Upper arm ball joint
2. Shock absorber
7. Dust cover
13. Knuckle
9. Stopper-bumper
8. Cam bolt
11. Lower arm 12. Lower arm ball joint
4. bush
10. Lower arm rubber bush
4WD 2WD
23. Hub assembly
13. Knuckle
18. Brake dust shield

22. Brake disk
19. Lock nut
19. Lock nut 13. Knuckle 22. Brake disk

17. Axle shaft
18. Brake dust shield
20. Hub assembly 21. Washer

21. Washer

AFFECTED VIN
4E 13
Front Axle Assembly
Air bleeder
Carrier cover
Ring gear
Axle mounting bracket
Ball bearing
Shim
Pinion gear
Oil seal Ball bearing

Pinion drive seal
Axle mounting bracket
Axle housing
Snap ring Shim

Flage
Ball bearing
Lock nut
Inner shaft
Axle shaft assembly

AFFECTED VIN
14 4E
2. PRECEDING WORK FOR SUB FRAME REMOVAL
1. Install the safety wedge under both rear wheels

(Put the shifting lever in “P” position and apply the parking brake)
2. Additional safety jack

Because the weight balance move to rear when the sub
frame is removed, safe working condition must be
prepaired.
For this reason, Installing the safety jack to both under
body is important to avoid unexpectable accident.
(The height of safty jack to both side must be same)
16.5 cm
3. The mounting location of suplement lift

The supplement lift is used when you remove or install the sub frame
(Keep in mind the center of gravity of sub frame locate near front axle mounting point)
Front Rear

AFFECTED VIN
4E 15
4. Remove the engine lnsulating brackets from the front sub frame as the
engine hung by an additional lift (crane)
5. Install the engine mounting bracket
Before removal of sub frame, install the special tool (Engine mounting
brackets) on the body frame
RH LH RH LH
Engine insulating Engine mounting

brackets on the sub frame brackets on the body
Part number : A9912 008 2B
RH LH

AFFECTED VIN
16 4E
3. REMOVAL OF SUB FRAME

Preceding Work: 1. Secure the frame and remove the tires
2. Remove the front propeller shaft.
Sub Frame Connected Area

1. Remove the power steering pipes 2. Remove the front calier (C) and wheel speed sensor (D)
(A: High, Low pressure) and lower arm (Fix the caliper and speed sensor on the body. Disconnect the brake
shaft (B) at the rear side of syb frame. hose clip)
Wheel
Power steering
pipes (Front)
3. Unscrew the power steering pipe (A) mounting bracket 4. Unscrew the knuckle upper bolt (E) and
(1, 2) and release them shock absorber lower bolt/nut (F) and then,
remove the shock absorber from knuckle.

AFFECTED VIN
4E 17
5. Leave mark with a marking painter on the sub frame mounting bolts (19mm - 4EA).
(Tightening torque: 95 ~ 142 Nm)
6. Locate two sypplement lifts under sub frame (Front/Rear) and unscrew the sub frame mounting bolts (19mm -
6EA). And then, drop the lifts slowly.
[Notice]
Apply rubber blocks under sub frame to prevent the frame and other components from damage.

AFFECTED VIN
18 4E
Rubber block at the front side
Rubber blocks at the rear side

AFFECTED VIN
4E 19
7. Installation is in the reverse order of removal (Keep the exact mount holes and tightening torque)

AFFECTED VIN
20 4E
Removal of Sub Frame with Two Colume Lift

1. Since two column type lift does not have supplementary lift, special tool to support the sub frame is required. When
install, apply the special tool with guide pin on the sub frame 3rd cross member and fix the guide bar of special tool
on the 2nd cross member.
2nd cross member
Guide bar Guide bar
3rd cross member
Guide pin

AFFECTED VIN
4E 21
2. Do the same preceding work to remove the sub frame (page 624 ~ 626).
3. Remove the sub frame mounting bolts (19mm - 6EA)
4. Drop the special tool with sub frame slowly.

AFFECTED VIN
22 4E
4. FRONT AXLE ASSEMBLY

Preceding Work: 1. Remove the tires.
2. Remove the brake calipers and wheel speed sensors (Fix to the body).
Axle Shaft (Drive Shaft)
Coil spring & shock absorber assembly
Upper arm
Knuckle
Brake caliper
Stablilizer
Power steering assembly
Brake disk
1. Unscrew axle shaft lock nut (30 mm - 1EA) and remove

washer.
[Notice]
• Axle shaft lock nut can not be reused. Replace it with new
one when reinstall.
• Keep the tightening torque and cock the nut.

AFFECTED VIN
4E 23
2. Unscrew the knuckle upper bolt & nut (19mm - 1EA).
3. Remove the knuckle from axle shaft and lay outward.
4. Pull out the axle shaft.

AFFECTED VIN
24 4E
Axle Housing Oil Seal

Preceding Work: Remove the axle shaft.
1. Unscrew the axle mounting bracket bolts and nut, and remove the axle mounting bracket.
Tightening torque
Mounting bolts (4EA) 10 ± 1.0 Nm

Mounting bolt / nut (1EA) 95 ~ 142 Nm

AFFECTED VIN
4E 25
Axle Housing Assembly

Preceding Work: Remove the sub frame assembly and disassemble the axle shaft from axle assembly.
Axle assembly
Removal of axle shaft
Diffential carrier &

Housing assembly
Bolt
Bolt
Bush
Bush
Washer
Bush
Washer Nut
Bush
Nut
Washer
Nut

AFFECTED VIN
26 4E
1. Unscrew the axle housing mounting bolt on the sub frame and disassemble the axle.
A. Axle mounting bolt/nut

* Keep the right direction of busing when install
Upper bush
Spacer
Color coke
Lower bush coated
Lower bush
Bracket on the sub frame
B. Axle housing mounting nut - Left C. Axle housing mounting nut - Right
(Tightening torque : 95 ~ 142 Nm) (Tightening torque : 95 ~ 142 Nm)

AFFECTED VIN
4E 27
5. FRONT SUSPENSION ASSEMBLY

Preceding Work: 1. Remove the tires.
2. Remove the brake calipers and wheel speed sensors (Fix to the body).
Upper Arm Assembly
Upper arm assembly
Upper arm assembly
Upper arm bush

AFFECTED VIN
28 4E
1. Remove wheel speed sensor and cable. (10 mm - 1EA, Tightening torque : 6 ~ 8 Nm)
Cable
Speed sensor mounting bolt
2. Unscrew knuckle upper mounting bolt/nut (19 mm - 1EA) and upper arm mounting bracket bolts (14 mm - 4EA) to
remove upper arm assembly.
Knuckle upper bolt (Upper arm ball joint) Upper arm mounting bracket bolts
Tightening torque : 140 ~ 160 Nm Tightening torque : 140 ~ 160 Nm

AFFECTED VIN
4E 29
Lower Arm Assembly

Check point before removal
When you need to remove lower arm assembly, leave a mark on the lower arm mounting bolts (Front /
Rear) for wheel alignment job.
Front
Rear
Lower arm assembly
Lower arm
Ball jont
Ball joint
mounting bolt Cam bolt
Washer / Bolt Cam bolt

AFFECTED VIN
30 4E
1. Unscrew the shock absorber lower mounting bolt/nut (1) and stabilizer link low nut (2).
Shock absorber lower bolt/nut : 110 ~ 130 Nm

Tightening torque
Stabilizer link lower nut : 110 ~ 120 Nm
2. Unscrew lower arm ball joint bolt/nut (Knuckle).
3. Unscrew lower arm bolt/nut (Frame).
4. Remove lower arm assembly from the sub frame.

AFFECTED VIN
4E 31
Coil Spring & Shock Absorber Assembly

Preceding Work: Remove the tire and wheel speed sensor.
Coil spring & shock absorber
1. Use a special tool to remove the coil spring

from shock absorber assembly.
2. Keep the specified end gap between shock

absorber and adjust bolt (10 mm).

AFFECTED VIN
32 4E
1. Unscrew knuckle upper bolt and then, lay the knuckle

outward.
2. Unscrew the coil spring upper seat mounting nuts (1) at

the top of the shock absorber (10 mm x 3EA).
[Reference]
RH Under FFH
LH Under brake oil reservoir tank
3. Unscrew the shock absorber lower bolt and pull upward as putting down the assembly.

AFFECTED VIN
4E 33
Stabilizer Bar Assembly
Stabilizer bar assembly
Stabilizer bar assembly
Mounting bracket
Mounting bracket
Stabilizer bar link

Stabilizer bar link

AFFECTED VIN
34 4E
Stabilizer bar link Stabilizer bar link
Mounting bracket
Mounting bracket
2. Unscrew the stabilizer bar cap bolts (3) and 1. Unscrew the stabilizer bar link upper nut (1) and
remove the stabilizer bar. lower bolt (2) to remove the link.
Tightening torque 110 ~ 120 Nm Upper bolt : 60 ~ 80 Nm

Tightening torque
Lower bolt : 110 ~ 130 Nm

AFFECTED VIN
4E 35
Knuckle Assembly
Preceding Work: 1. Removal of tires.
2. Removal of brake caliper and wheel speed sensor (Fix the sensor to the body).
Knuckle assembly

AFFECTED VIN
36 4E
1. Unscrew the lock nut (1) and brake disk mounting bolts Tightening torque 8 ~ 12 Nm
(2: 5 mm - 2EA) and then, remove the disk from knuckle
assembly.
2. Unscrew the brake dust shield mounting bolts (3EA).
3. Remove the knuckle mounting bolts in the following order

A. Tie rod end nut (19mm - 1EA)
: Remove the pin first (A)
[Notice]
Keep the tightening torque and if the position of pin hole is

improper, rotate the nut to the tightening direction.
B. Lower arm bolt nut (19mm - 1EA)

: Release the bolt first. Remove after upper arm bolt
(C) is removed.
C. Upper arm bolt/nut (19mm -1EA)

AFFECTED VIN
4E 37
4. Remove the front wheel nuckle from the drive shaft.

(Replace the brake disk lock nut with new one for every disassembly and do the cocking job for the nut)

AFFECTED VIN
38 4E
TROUBLE DIAGNOSIS
Vehicle rolling Broken stabilizer bar Replace
Faulty shock absorber Replace
Abnormal noises Loosening mountings Re-tighten
Damaged or worn wheel bearing Replace
Damaged shock absorber Replace
Damaged tire Replace
Poor riding Over inflated tire Pressure adjust
Faulty shock absorber Replace
Loosened wheel bolt Tighten as specified torque
Bent or broken coil spring Replace
Damaged tire Replace
Worn bushing Replace
Vehicle pulls to right or left Deformed arm assembly Replace
Worn bushing Replace
Bent or broken coil spring Replace
Hard steering Incorrect front wheel alignment Repair
Excessive resistance of lower arm ball joint Replace
Insufficient tire pressure Adjust
Faulty power steering Repair or replace
Steering instability Incorrect front wheel alignment Repair
Worn or loosened lower arm bushing Re-tighten or replace
Vehicle bottoming Worn or broken coil spring Replace

AFFECTED VIN
4F 1
4F - Rear Susp & Axle
Table of Contents
REAR AXLE CARRIER (MODULE) .................. 4F-2
1. System overview ......................................................... 4F-2
2. Specification ............................................................... 4F-4
3. Removal and installation .............................................. 4F-5
REAR SUSPENSION SYSTEM ........................ 4F-9

1. System overview ......................................................... 4F-9
2. Components............................................................... 4F-11
REAR AXLE HOUSING & AXLE SHAFT ........ 4F-28

1. System overview ........................................................4F-28
2. Rear axle differential assembly ...................................4F-29
3. Removal and installation ............................................. 4F-31
REAR SUSP & AXLE CHANGED BY

AFFECTED VIN
2 4F
REAR AXLE CARRIER (MODULE)

1. SYSTEM OVERVIEW
Shock absorber
Camber link
Coil spring Axle shaft
Wheel carrier
Tension link
Track rod
Thrust link
Stabilizer
Axle mounting
Front View
CHANGED BY REAR SUSP & AXLE

AFFECTED VIN
4F 3
Rear View
Axle mounting
Rear brake cable
Rear Axle & Axle Shaft
Rear axle Axle shaft
Spring link

AFFECTED VIN
4 4F
2. SPECIFICATION
Suspension type Multi-link
Spring type Coil spring K=120 kgf/mn
Shock absorber type Gas
Stabilizer type Torsion bar Ø14
Toe-in 0.04° ± 0.08°
Wheel alignment
Camber -1.0° ± 0.5°
Diameter (Axle) (mm) Ø 230
Gear ration 37 3.9 4.1 4.3 4.6 4.9 5.4 5.9
Pinion 11 11 9 11 9 9 8 7
Number of tooth
Gear 41 43 37 47 41 44 43 41
Weight (kg) 40
Length (mn) 250.43
Oil capacity ( ) 1.7
Specified oil TOTAL-ISU EP- B85W-90

AFFECTED VIN
4F 5

1. Move the 2nd raw seat to te front end and unscrew the 2. Remove the rear shock absorber upper nut (2),
rear shock absorber upper cover mounting screw (1). washer and bush.
Keep the specified end gap between shock absorber.

(A: 7 ~ 12 mm)

AFFECTED VIN
6 4F
3. Remove the rear propeller shaft. 4. Disconnect the parking brake cable.
5. unscrew the frame mounting bolt on the rear axle 6. Remove the wheel speed sensor (LH/RH).
carrier module front side.

AFFECTED VIN
4F 7
7. Unscrew the stabilizer mounting bolt (A) and remove it from the vehicle.
8. Remove rear frome mounting bolt (B) at the rear axle carrier module.

AFFECTED VIN
8 4F
9. Remove the rear axle carrier module from the vehicle.
Front
Rear

AFFECTED VIN
4F 9
REAR SUSPENSION SYSTEM

1. SYSTEM OVERVIEW
Camber link
Tension link
Track rod
Thrust link
Stabilizer bar

AFFECTED VIN
10 4F
Spring link
Wheel carrier
Stabilizer link
Coil spring
Shock absorber

AFFECTED VIN
4F 11
2. COMPONENTS
1) Rear Shock Absorber
• Keep the suitable distance when compressed and
expanded.
• Minimum length is 10 mm longer than the minimum length
under compression.
Specification
Max. length Min. length Working distance
487 mm 326.6 mm 160.4 mm
Marking Point
X : Part No.
Y : Lot Number
Ex : 3 C 12
12 ......... Day
3 ........... Month
2003 ...... Year

AFFECTED VIN
12 4F

1. Move the 2nd raw seat to the front end and unscrew 2. Remove the rear shock absorber upper nut (2), washer
the rear shock absorber upper cover mounting bolt (1). and bush.
3. Unscrew the lower mounting nut on the spring link (17 mm).

AFFECTED VIN
4F 13
4. Remove the shock absorber as pushing upward.
Shock absorber assembly

AFFECTED VIN
14 4F
2) Coil Spring
• Steel for high tensional spring is adapted.
• Maintain more than 20 mm of freeplay when compressed.
• Spring seat applied.
Specification
4WD
Part Number 45110-21000
Spring constant (kg/mm) 12.0 ± 5%
Coil diameter (mm) 15.9
Coil inner diameter (mm) 69.1
Pitch (mm) 85.0
Number of winding 9.55
Number of active winding 8.35
C.V.W Height (mm) 250
Weight (kg) 880.0
Strength (kg/mm/mm) 62.1
Winding direction Right
Spring length (mm) 323.3

AFFECTED VIN
4F 15

Compress the coil spring with special tool and then, disas-
semble the spring.
[Notice]
For easier removal, remove the spring seat first.
[Notice]
Pay attention to use special tool and coil spring.
Sudden release of coil spring could cause a serious accident.

AFFECTED VIN
16 4F
3) Thrust Link / Tension Link
Thrust Link
Tension Link

AFFECTED VIN
4F 17
Thrust Link
1. Unscrew the thrust link mounting bolts (19 mm-2EA) and remore the link.
2. When install, apply two washers to the thrust link mounting bolt/nut (A. Wheel carrier)
Tightening torque (A, B) 70 ± 8 Nm
A. Wheel carrier B. Body
[Reference]
1. Keep the right position when reinstall (faced outward).
2. Apply the longer bolt to the thrust link wheel carrier side.

AFFECTED VIN
18 4F
Tension Link
1. Unscrew the tension link mounting bolt (B. Body-19 mm).

2. Unscrew the tension link mounting bolt (A. Wheel carrier-19 mm).
Body: 70 ± 8
Tightening torque
Wheel carrier: 70 ± 8
[Reference]
1. Keep the right position when reinstall.
2. Apply the longer bolt to the tension link wheel carrier side.

AFFECTED VIN
4F 19
4) Track Rod
1. Unscrew the track rod mounting bolt (A. Body-19 mm)
Tightening torque 70 ± 8
2. Unscrew the track rod mounting bolt (B. Wheel carrier-17 mm)
A. Body B. Wheel carrier

AFFECTED VIN
20 4F
5) Camber Link
1. Unscrew the camber link mounting bolt (B. Body-19 mm)
2. Unscrew the camber link mounting bolt (A. Wheel carrier-19 mm)
[Notice]
1. When install, apply two washer to the camber link mounting
bolt/nut (A. Wheel carrier).
2. Keep the right position when reinstall.

AFFECTED VIN
4F 21
6) Stabilizer Bar / Stabilizer Link
Stabilizer Link
Stabilizer bar
Stabilizer link
1. Unscrew the stabilizer link upper mounting bolt (17 mm) and lower mounting bolt (13 mm).
A B

AFFECTED VIN
22 4F
Stabilizer Bar
Preceding work: Removal of stabilizer link
- Remove stabilizer bar mounting bracket to seperate the stabilizer bar from the vehicle.

AFFECTED VIN
4F 23
7) Spring Link
1. Compress the spring with special tool for easier removal and installation.
2. Unscrew the wheel carrier mounting bolt (A), stabilizer link mounting nut (B) and shock absorber mounting nut (C).
Wheel carrier: 20 Nm
Tightening torque Stabilizer link: 120 Nm
Shock absorber: 55 Nm

AFFECTED VIN
24 4F
3. Unscrew the spring link mounting bolt on the rear axle

carrier and remove the spring link.
Spring Link
Wheel carrier
Shock absorber
Stabilizer link
Body

AFFECTED VIN
4F 25
8) Wheel Carrier Assembly

1. Remove the wheel speed sensor.
2. Remove the brake caliper.
3. Unscrew the brake disk mounting unt (2 EA) and remove the disk.

AFFECTED VIN
26 4F
4. Remove the lock nut (30 mm).
[Notice]
Lock nut can not be reused. Replace by every disassembly.
5. Remove the parking brake shoe (Refer to the wheel &

tire).
6. Remove the parking brake cable from the wheel carrier.
7. Unscrew the wheel carrier mounting nut and remove it

from the spring link.
8. unscrew the tension link, track rod, thrust link mounting
nuts on wheel carrier.

AFFECTED VIN
4F 27
9. Remove the wheel carrier from drive shaft.
A. Front view B. Rear view

AFFECTED VIN
28 4F
REAR AXLE HOUSING & AXLE SHAFT

1. SYSTEM OVERVIEW
Front mounting point Drive shaft
Rear mounting point Axle housing
Specification
Axle size Ø 214
Gear ratio 3.3 3.9 4.1 4.3 4.6 4.9 5.4 5.9
Pinion 13 11 9 11 9 9 8 7
Number of tooth
Gear 43 43 37 47 41 44 43 41

AFFECTED VIN
4F 29
2. REAR AXLE DIFFERENTIAL ASSEMBLY

Sectional Diagram

AFFECTED VIN
30 4F
1. Rear axle housing 19. Spring pin

2. Gear set (HAG 230, i = 3.31) 20. Bearing cover
3. Gear set (HAG 230, i = 3.54) 21. Bearing cover shim
4. Gear set (HAG 230, i = 3.73) 22. Differential side seal
5. Gear set (HAG 230, i = 3.91) 23. Bearing cover O-ring
6. Gear set (HAG 230, i = 4.11) 24. SOC/HD bolt
7. Gear set (HAG 230, i = 4.27) 25. Drive pinion shim
8. Gear set (HAG 230, i = 4.56) 26. Rear drive pinion bearing assembly
9. Gear set (HAG 230, i = 4.89) 27. Drive pinion tube spacer
10. Differential spider gear 28. Drive pinion support disk
11. Differential side gear 29. Drive pinion front bearing assembly
12. Spiral washer 30. Drive pinion seal
13. Differential spider shaft 31. Drive pinion flange assembly
14. Differential case - i = 3.31 - 3.73 32. Two-welled side lock nut
15. Differential case - i = 3.91 - 4.89 33. Inner flange assembly
16. Differential thrust washer 34. Inner axle shaft shim
17. Differential side bearing assembly 35. Differential assembly snap ring & shaft
18. Ring gear safety bolt 36. Rear axle housing cover

AFFECTED VIN
4F 31

Rear Axle Shaft
Preceding work: Removal of wheel and tire
1. Unscrew rear axle shaft mounting bolts from axle housing
(6 EA).
Initial: 70 ~ 80 Nm [Notice]
Tightening torque
Secondary: 90 ± 5° Replace the bolts by every removal
2. Unscrew lock nut (30 mm) from wheel disk side and
remove the axle shaft.
[Notice]
Replace the lock nut to new one by every disassembly.

AFFECTED VIN
32 4F
Rear Axle Housing

Preceding work: Removal of rear axle shaft
1. Support the axle housing with mounting jack.

2. Unscrew one front mounting bolt and two rear mounting bolts to remove the axle housing from the rear sub frame.

AFFECTED VIN
4F 33
Replacement of Radial Sealing and

O-ring
Preceding work: Removal of rear axle housing
1. Drain oil in the axle housing.
2. Remove the axle mounting damper
[Notice]
Damper bolt should be replaced by ecery removal.
Tightening torque 90 ± 110 Nm
3. Remove the axle housing cover and damper bracket.
4. Remove the connecting flange snap ring with special tool.

AFFECTED VIN
34 4F
5. Pull out the inner flange.
6. Remove the radial sealing with a tool.
7. To replace the O-ring, unscrew the side bearing cover

mounting bolts.
Tightening torque 20 ± 4 Nm
8. Remove shim and replace the O-ring.
Inner flange
Radial sealing
Shim
O-ring
Snap ring
Back lash adjust shim

AFFECTED VIN
4F 35
Replacement of Radial Sealing and

O-ring on Propeller Shaft Flange
1. Unscrew the lock nut with socket wrench (30 mm).
[Notice]
Replace the lock nut to new one by every disassembly.
2. Remove the radial sealing with a tool.
Lock nut
Inner flange
Radial sealing

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4G 1
4G - Power Steering
Table of Contents
GENERAL INFORMATION ................................ 4G-3
1. Overview ...................................................................... 4G-3
2. Specification ............................................................... 4G-3
3. Components ................................................................ 4G-4
GENERAL INSPECTION .................................. 4G-6

1. Steering wheel ............................................................ 4G-6
2. Oil pump pressure ....................................................... 4G-8
3. Oil level check ............................................................. 4G-8
4. Oil change .................................................................. 4G-9
5. Belt tension check and adjustment ............................. 4G-9
6. Air bleeding ............................................................... 4G-10
REMOVAL AND INSTALLATION .................... 4G-11

1. Components .............................................................. 4G-11
2. Column shaft and lower shaft .................................... 4G-13
3. Steering gear box ...................................................... 4G-18
4. Steering gear pump and oil pipe ................................ 4G-30
TROUBLE DIAGNOSIS ................................... 4G-33

SPECIAL TOOLS AND EQUIPMENT ............. 4G-35
POWER STEERING CHANGED BY

AFFECTED VIN
4G 3
GENERAL INFORMATION
1. OVERVIEW
The power steering system consists of pump, oil reservoir, rack and pinion gear. The power steering pump is a vane type
and delivers hydraulic pressure to operate the power steering system. The pressure relief valve in pump controls the
discharging pressure.
The rotary valve in rack and pinion gear directs the oil from the power steering pump to one side of rack piston.
The integrated rack piston converts the hydraulic pressure to linear movement.
The operating force of rack moves the wheels through tie rod, tie rod end and steering knuckle.
Even though the hydraulic pressure cannot be generated, a driver can steer the vehicle without power assist but it needs
very high steering force.
In this case, the operating force of steering wheel is conveyed to pinion, and the movement of pinion moves the rack
through pinion gear combined to rack gear.
2. SPECIFICATION
Item Specification
Steering wheel Number of spoke 4 spokes
Outer diameter 390 mm
Rotation 3.6 rotations
Gear box Type Rack & Pinion
Gear ratio ∞
Steering Inner 37° 42′
angle Outer 32° 56′
Tilting angle ±2
Minimum turning radius 5.882 m
Oil pump Type Clustered in reservoir tank
Displacement 11.3 cc/rev
Max. pressure 90 bar
Oil Specified oil ATF Dexron II, III
Capacity Approx. 1 liter

AFFECTED VIN
4 4G
3. COMPONENTS
Steering wheel
Power steering Column shaft

pump assembly
Power steering
oil pipe & hose
Lower shaft
Tie rod end
assembly
Tie rod end

assembly
Steering gear
box assembly
CHANGED BY POWER STEERING

AFFECTED VIN
4G 5
Power Steering Gear Box Assembly
Gear box assembly
Clamp mounting
Tie rod end
Tie rod end
Tie rod
Tie rod
Boot Bush mounting Boot
The power steering gear consists of power cylinder and Additionally, the safety check valve is installed so that the
control valve. system can be operated manually when the system is
The power cylinder has cylinder, piston and piston rod. defective.
The control valve directs the oil to one end face of the pis-
ton to enhance the steering force. Sub frame mounting Clamp mounting (2EA)
The control valve controls the directions and operations of (4 points) Bush mounting (2EA)
power cylinder.
Power Steering Pump

The vane type pump that is connected to engine by belt is
used for the power steering system. This pump generates
and controls a proper hydraulic pressure and flows by us-
ing the flow control valve and pressure relief valve.
The flow control valve regulates the excessive amount of
discharging oil. When the steering wheel is stationary or
the oil circuit is blocked, the pressure relief valve returns
the over pressurized oil to the oil reservoir.
Oil Reservoir
The oil reservoir sends the oil to the power steering pump
and receives the oil from the power steering gear.
The oil level in the reservoir depends on the steering wheel Steering pump Reservoir tank
positions. therefore, measure the oil level when the steer-
ing wheel is positioned at straight ahead direction (neutral).

AFFECTED VIN
6 4G
GENERAL INSPECTION
1. STEERING WHEEL
Power Steering Wheel Free Play
Check
1. Start the engine and place the wheels at straight ahead
direction.
2. Turn the steering wheel until the tires starts to move and
measure the distance on the circumference of the
steering wheel.
Specified value 30 mm
[Notice]
If the free play is out of the specified value, check the

clearance in steering column shaft connection and steering
linkage. Replace or repair if necessary.
Steering Effort Check

1. Park the vehicle on a paved and flat ground and place
the front wheels at straight ahead direction.
2. Start the engine and let it run around 1,000 rpm.
3. Install the spring scale on the circumference of the
steering wheel and measure the steering effort in both
directions.
Tightening torque Below 3.0 kg
[Notice]
The difference between both sides should be within 0.6 kg.
Steering Angle Check

1. Place the front wheel on a turning radius measuring tool.
2. Turn the steering wheel to the its both ends and measure
the maximum steering angle.
Inner 37° 42′

Specified value
Outer 32° 56′
[Notice]
If the free play is out of the specified value, check and adjust
the toe-in.

AFFECTED VIN
4G 7
Power Steering Gear Preload

Adjustment
1. Place the steering wheel at straight ahead direction.
2. Lift up the vehicle very carefully.
3. Remove the adjusting plug lock nut.
4. Measure the torque of adjusting plug.
5. If the measured torque is out of range, adjust it to the

specified value.
• Place the rack gear in center position.
• Tighten the adjusting plug by 100 kg.cm
• Turn the pinion gear to move the rack gear between
both ends by 5 times.
• Remove the adjusting plug.
• Tighten the adjusting plug by 45 ~ 55 kg.cm
• Release the adjusting plug by 67.5°.
6. Tighten the adjusting plug lock nut.

AFFECTED VIN
8 4G
2. OIL PUMP PRESSURE

Check the oil pump pressure to locate any defect in oil pump.
[Notice]
Before checking the pressure, check the oil level and belt
tension. Prepare the empty container to collect the spilled
oil during the service.
1. Unscrew the pressure line fitting in power steering pump.

2. Install the pressure gauge between the power steering
pump and the power steering oil pressure line.
3. Place the shift lever to neutral position.
4. Apply the parking brake.
5. Open the valve in pressure gauge.
6. Start the engine and let it run at idle speed.
7. Turn the steering wheel several times so that the oil
temperature reaches to normal operating level. (50 ~ 80°C)
8. Fully close the valve in pressure gauge and measure the
oil pressure.
[Notice]
To prevent internal damage, do not close the gauge valve

over 10 seconds.
Pump relief valve pressure 89 ~ 97 kg/cm2
9. Measure the oil pressure with the gauge valve fully closed.
Pump pressure at no load 3 ~ 5 kg/cm2
10. If the pump pressure is in specified range, the pump is

normal. If not, replace the power steering pump.
3. OIL LEVEL CHECK

The power steering oil level have to be checked by two
Displacement of oil level
conditions; one is checked at normal operating temperature,
and the other one is checked when it is cooled. If the differ-
ence between two measurements is below 5 mm and the level
is between HOT and ADD level, it’s normal. If it is over 5 mm,
HOT
bleed air from the system.
HOT
1. Place the vehicle on a flat ground and start the engine
and let it run at idle speed. ADD
ADD
2. Turn the steering wheel several times so that the oil
temperature reaches to normal operating level.
3. Place the steering wheel at straight ahead direction. Engine off Engine on
4. Measure the oil level in the power steering oil reservoir.
5. Adjust the oil level between HOT and ADD.
AFFECTED VIN
4G 9
4. OIL CHANGE
1. Lift up the vehicle carefully.
2. Disconnect the oil supply hose from the power steering
pump.
3. Drain the oil from the power steering oil reservoir.
4. Connect the oil supply hose to the power steering pump.
5. Disconnect the oil return line from the power steering oil
reservoir.
6. Periodically crank the starting motor and turn the steering
wheel to its both ends to drain the oil in the reservoir
through the return line.
7. Connect the return line to the steering oil reservoir.
8. Fill the oil into the steering oil reservoir to the specified
level. H. MAX - when the oil is hot
9. Bleed the air from the system. C. Leverage value - when the oil is cooled
ADD. MIN
[Notice]
Always keep the oil level over the ADD line.
5. BELT TENSION CHECK AND

ADJUSTMENT
1. Check the belt for wear, crack and damage. Replace it if
needed.
2. Press the center of belt with around 10 kg of force and
check the deflection.
[Notice]
If the deflection is too large:

• Replace the auto tensioning assembly.
• Check the belt and replace.

AFFECTED VIN
10 4G
6. AIR BLEEDING
After the power steering repairing, do the air bleeding job.
Checking bubble is foune
1. Lift up the vehicle ( A load to the steering wheel) .

2. Add the specified oil in the reservoir tank up to max level.
3. Turn the steering wheel to its both ends several times.
4. Check if bubble is found and do the previous job several times.
5. If bubble can not be found, add the specified oil in the reservoir tank to the specified level.
6. Start the engine and operate the second and third job to air bleed clearly.
[Notice]
If the air bleeding is not properly performed, the life span of

the power steering pump may be shortened.

AFFECTED VIN
4G 11

1. COMPONENTS
Airbag
Lock nut
Bolt
Steering wheel
Washer
Wheel damper
Cover
Bolt
Column shaft Power steering high pressure hose
Lower shaft
Power steering return pipe
Bolt
Cot pin
Nut
Bolt
Nut
Tie rod
Tie rod end
Power steering gear assembly
Bolt

AFFECTED VIN
12 4G
Tightening Torque
Item Kgfxxm Nxx m
Power steering column Steering column mounting bolt 2.0 ~ 2.5 20 ~ 25
shaft
Steering wheel and column shaft lock nut 4.0 ~ 6.1 40 ~ 60
Airbag module mounting bolt 0.7 ~ 1.1 7.0 ~ 11
Steering column and lower shaft mounting bolt 1.8 ~ 2.5 18 ~ 25
Power steering gear Steering gear box and sub frame mounting bolt 7.0 ~ 9.0 70 ~ 90
box
Steering box and lower shaft mounting bolt 1.8 ~ 2.5 18 ~ 25
Tie rod end nuckle 3.5 ~ 4.5 35 ~ 45
Tie rod end lock nut 6.5 ~ 8.0 65 ~ 80
Steering gear box and high pressure pipe 1.2 ~ 1.8 12 ~ 18
Steering gear box and return(Low pressure) line 1.2 ~ 1.8 12 ~ 18
Power steering pump Power pump bracket and timing gear case cover 2.0 ~ 2.3 20 ~ 23
mounting bolt
Power pump and high pressure pipe 4.0 ~ 5.0 40 ~ 50
Power steering oil pipe Return line and mounting bolt 1.2 ~ 1.8 12 ~ 18

AFFECTED VIN
4G 13
2. COLUMN SHAFT AND LOWER SHAFT

1. Disconnect the battery negative cable and place the tires to straight ahead direction.
2. Unscrew the screws at both sides of steering wheel and remove the horn pad (air bag module). Disconnect the
airbag module connector.
3. Unscrew the steering wheel lock nut and remove the wheel with special tool.
[Notice]
Leave marks on the column shaft and steering wheel for

correct installation.
4. Remove the instrument lower panel and disconnect all related connectors.

AFFECTED VIN
14 4G
5. Unscrew the steering column cover bolts and remove it.
6. Disconnect five connectors in the cover.
1. Key switch connector 4. Airbag connector

2. Key hole lamp connector 5. Steering wheel angle sensor
3. Contact coil connector

AFFECTED VIN
4G 15
7. Unscrew the contact coil mounting screw and remove it from multi function switch.
8. Disconnect both left and right connectors of multi function switch and unscrew the multi function switch mounting
bolt to disassemble from steering column.

AFFECTED VIN
16 4G
9. Leave marks on the column shaft and lower shaft.

10. Unscrew the column shaft upper mounting bolts(A) and lower shaft mounting bolt.
Column shaft upper mounting bolts (4-EA) Column shaft upper mounting bolts (2-EA)
11. Remove the steering column shaft from lower shaft.

AFFECTED VIN
4G 17
12. Unscrew the lower shaft housing floor mounting bolt(A) and lower shaft mounting bolt on the steering gear box.

AFFECTED VIN
18 4G
3. STEERING GEAR BOX

Preceding Work
1. Install the safety wedge under both rear wheels

(Put the shifting lever in “P” position and apply the parking brake)
2. Additional safety jack

Because the weight balance move to rear when the sub
frame is removed, safe working condition must be
prepaired.
For this reason, Installing the safety jack to both under
body is important to avoid unexpectable accident.
(The height of safty jack to both side must be same)
16.5 cm
3. The mounting location of suplement lift

The supplement lift is used when you remove or install the sub frame
(Keep in mind the center of gravity of sub frame locate near front axle mounting point)
Front Rear

AFFECTED VIN
4G 19
4. Remove the engine lnsulating brackets from the front sub frame as the
engine hung by an additional lift (crane)
5. Install the engine mounting bracket
Before removal of sub frame, install the special tool (Engine mounting
brackets) on the body frame
RH LH RH LH
Engine insulating Engine mounting

brackets on the sub frame brackets on the body
Part number : A9912 008 2B
RH LH

AFFECTED VIN
20 4G
1. Remove the power steering pipes 2. Remove the front calier (C) and wheel speed sensor (D)
(A: High, Low pressure) and lower arm (Fix the caliper and speed sensor on the body. Disconnect the
shaft (B) at the rear side of syb frame. brake hose clip)
Wheel
Power steering
pipes (Front)
3. Unscrew the power steering pipe mounting 4. Unscrew the knuckle upper bolt (E) and
bracket (1, 2) and release them shock absorber lower bolt/nut (F) and then,
remove the shock absorber from knuckle.

AFFECTED VIN
4G 21
5. Leave mark with a marking painter on the sub frame mounting bolts.
6. Locate two sypplement lifts under sub frame (Front/Rear) and unscrew the sub frame mounting bolts (19mm -
6EA).
And then, drop the lifts slowly.

AFFECTED VIN
22 4G
7. Unscrew the clamp mounting bolt of stabilizer bar and fix to the upper side of axle flange.
8. Remove the coat pin and nut(1), and unscrew the gear box clamp bolt(2) and bush mounting nut(3).
1. Coat pin and nut 2. Clamp mounting bolt
Tightening torque 25 ~ 30 Nm Tightening torque 100 ~ 130 Nm
A. Stabilizer
2. Clamp mounting bolt
1. Tie rod end 1. Tie rod end
3. Bush mounting nut
Upper bolt : 70 ~ 90 Nm
Tightening torque
Lower bolt : 70 ~ 90 Nm

AFFECTED VIN
4G 23
9. Disassemble the steering gear box as shown below with arrow mark.
Gear box mounting bolt(Clamp)

: 70 ~ 90 N.m
Sloted nut
Sloted nut : 25 ~ 30 N.m
: 25 ~ 30 N .m
Gear box mounting bolt
(Bushing)
: 70 ~ 90 N.m

AFFECTED VIN
24 4G
Disassembly and Reassembly of

Steering Gear Box
Disassembly
* Describes the basic power steering assembly.
1. Remove the tie rod end boot (a).
2. Remove the feed lines (2) from the cylinder tube in gear
box.
3. Remove the feed lines (1) from the valve housing in gear
box.
4. Unscrew the lock nut (1) and remove the plug (2) and
spring (3).
5. Remove the dust cover (1) and retainer ring (2).

AFFECTED VIN
4G 25
6. Remove the pinion dust cover (lower, 3) and unscrew the

pinion lock nut (4).
[Notice]
Before removing the pinion lock nut, make sure to lock the
pinion gear to prevent it from damaging.
7. Remove the steering pinion (5) from pinion bearing by

tapping the bottom end of steering pinion with a flat drift
and plastic hammer.
[Notice]
Align the center of the drift and the bottom end of steering
pinion.
8. Remove the pinion bearing (6) by tapping it with a long

and flat head drift and plastic hammer.
9. Remove the pinion shaft seal (7), needle bearing (8) and
retaining ring (9).
[Notice]
Do not disassemble the power steering gear housing and

rack gear. Replace it as an assembly if needed.

AFFECTED VIN
26 4G
Reassembly
1. Install the steering pinion gear.
1) Install the retaining ring.
2) Install the needle bearing.
3) Install the pinion shaft seal by tapping it with a long
and flat end drift.
2. Tighten the steering pinion lock nut (4) with a specified

tightening torque.
[Notice]
Make sure that the pinion bearing is not offset with the
steering pinion lock nut.
3. Tighten the steering pinion dust cover (5) with a specified

tightening torque.
1) Install the retaining ring (6).
2) Install the plastic dust cover (7).
4. Install the rack bearing.

• Install the adjusting spring.
• Tighten the adjusting plug with a specified tightening
torque.
• Tighten the lock nut.
• Adjust the preload of steering gear.

AFFECTED VIN
4G 27
5. Install the hydraulic pipes.
6. Install the tie rod end boot.
[Notice]
Apply grease into the ball joint of tie rod end and the boot.

AFFECTED VIN
28 4G
Inspection
Rack Gear Shaft
1. Check the rack gear for deformation and damage.
• Place the V-blocks (1) on the flatten plate.
• Put the rack gear (2 and 4) on the V-blocks.
• Measure the straightness of rack gear with a dial
gauge.
• Check the rack gear for abnormal wear and damage.
2. Check the steering pinion gear for damage.

• Check the pinion gear (1) for abnormal wear and
damage.
• Check the bearing (2) for looseness and operation.
3. Check the tie rod end and the rack and pinion bellows for
damage.
• Check the tie rod end boot (1) for crack and abnormal
wear.
• Check the rack and pinion boot (2) for crack and
abnormal wear.
4. Check the steering gear housing (a) for crack, distortion

and abnormal wear.

AFFECTED VIN
4G 29
5. Check the tie rod end and the tie rod ball joint for damage.
• Check the tie rod end ball joint for operation.
• Check the tie rod ball joint for operation. Check the
tie rod for deflection due to its weight.
6. Replace all the defective components with new ones.
7. Check the tie rod end and the rotating area (1) of tie rod
ball joint for damage.
8. Check the tie rod end and the rack and pinion boot for
crack and abnormal wear.
9. Check the metal components for wear.
• Check the pinion gear for abnormal wear and damage.
• Check the rack gear for abnormal wear and damage.
• Check the steering gear housing for wear and damage.
10. Check the bearings and oil seals for damage.

• Check the pinion shaft seal (1) for wear and leakage.
• Check the needle bearing (2) for wear.
• Check the steering pinion bearing (3) for wear.
11. Replace all the defective components with new ones.

AFFECTED VIN
30 4G
4. STEERING GEAR PUMP AND OIL PIPE

Power Steering Gear Pump Assembly
Preceding Work: 1. Disconnect the battery negative cable.
2. Remove fan belt and drain the power steering oil.
1. Unscrew th pump mounting bolt/nut(1) and disconnect

the oil pipes(2, 3).
Mounting nut (1): 2.0 ~ 2.3 kgm

Tightening torque
Oil pump (2): 4.5 ~ 5.0 kgm
2. Remove the pump clip and disassemble the pump from reservoir tank.
Mounting clip
Reservior tank
Mounting clip
Pump assembly

AFFECTED VIN
4G 31
Power Steering Oil Pipes

Preceding Work: Drain the power steering oil.
1. Disconnect the oil pipes(High, low pressure) frame the steering oil pump, power steering and sub framegear box.
1.Oil pump 2. Gear box
Oil return pipe

(Low pressure)
High pressure pipe
Low pressure pipe
Oil supply pipe

(High pressure)
Pipe mounting bolts
Sub frame
[Notice]
• If two oil pipes ( High, Low pressure ) are installed as

changed, abnormal vibration is detected through steering
handle and this damage to the power steering system.
(Smaller hole diameter for high pressure pipe)

AFFECTED VIN
32 4G
- Layout of high and low pressure pipe
Front
Rear

AFFECTED VIN
4G 33
TROUBLE DIAGNOSIS
Hard steering Lack of lubrication Rubricate & Replace
Abnormal wear or binding of steering ball joint Replace
Damaged or faulty steering gear Replace gear assembly
Improper preload of steering pinion Adjust
Faulty steering shaft joint Replace
Steering fluid leaks Repair or replace
Lack of fluid or air-in system Replenish or bleed
Faulty steering oil pump Replace
Steering pulls to one Damaged or loosened pump drive belt Adjust or replace
side Clogging oil line Repair or replace
Damaged wheel or tire Repair or replace
Faulty suspension system Repair or replace
Damaged steering linkage Repair
Damaged wheel and tire Repair or replace
Faulty brake system Repair or replace
Excessive wheel play Worn steering gear Replace gear assembly
Worn or damaged steering ball joint Replace
Loosened steering gearbox bolts Retighten
Poor return of steering Damaged or binding steering ball joint Replace
wheel Improper preload of steering pinion Replace gear assembly
Steering wheel vibration Damaged steering linkage Replace
(Shimmy) Loosened steering gearbox mounting bolt Retighten
Damaged or binding steering ball joint Replace
Worn or damaged front wheel bearing Replace
Abnormal noise from Loosened steering gearbox mounting bolt Retighten
steering system
Faulty steering gear Replace gear assembly
Steering column linterference Replace
Loosened steering linkage Retighten
Damaged or loosened oil pump drive belt Adjust or replace
Loosened oil pump bracket Retighten
Loosened oil pump mounting bolt Retighten
Air-in system Bleed
Faulty oil pump Replace

AFFECTED VIN
34 4G

Abnormal noise while Loosen steering column mounting nut or bad tightening Retighten
the operation
Worn or damage steering shaft bearing Replace steering column
Loosen inner shaft pinch bolt Retighten
Excessive steering force Worn or damaged steering shaft bearing Replace steering column
Ignition switch bad Defective lock cylinder Replace steering column
turning Defective ignition key Replace ignition key

AFFECTED VIN
4G 35

661 589 13 33 00 Removal of the upper and lower

Ball joint puller end assemblies of front
suspension

AFFECTED VIN
MEMO
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4H 1
4H - Wheels & Tire
Table of Contents
1. General information ..................................................... 4H-3
2. Specification ............................................................... 4H-5
3. Tire’s abnormal phenomena ........................................ 4H-5
4. Wheel alignment ......................................................... 4H-6
5. Removal and installation .............................................. 4H-8
6. Maintenance and replacement .................................. 4H-12
7. Inspection ................................................................. 4H-16
8. Trouble diagnosis ...................................................... 4H-21
WHEELS & TIRE CHANGED BY

AFFECTED VIN
4H 3
Tire And wheel Balancing 2. Breaker
A cord belt between tread and carcass prevents
There are two types of the tire and wheel balancing: static
damages of inner code due to outer shock and
and dynamic.
vibration.
Static balance is the equaldistribution of weight around
3. Carcass
the wheel. assemblies that are statically unbalanced cause
a bouncing action called wheel tramp. This condition may This major part made by pilling code papers of strong
eventually cause uneven tire wear. synthetic fiber forms a structure of tire. Since it
maintains tire pressure and endures applied load and
Dynamic balance is the equal distributio of weight on eeach
shock to tire, it should have a high anti-fatigue
side of the centerline so that when the assembly spins
characteristic.
there is no tendency for it to move frim side to side . As-
semblies that are dynamically unbalanced may cause 4. Side Wall
wheel shimmy. It is provided to improve the comfortable driving by
protecting carcass and cushion movement.
General Balance Precautions
5. Bead
Remove all deposits of foreign material from the inside of
the wheel. A steel wire winding the ending part of carcass code,
coated with rubber film and wrapped with nylon cord
[Caution] papers. It fixes tire to a rim.
Remove stones frim the gread in order to avoid operator

injury during spin balancing
Width
Inspect the tire for any damage. Balance the tire accord-
ing to the equipment manufacturer’s recommendations.
Structure of Tubeless Tube

Inside Outside
Diameter Diameter
Width
Height
The tire structure is different slightly according to the types

of the tire but a various type of the tire has the common
structure as following;
1. Tread
A part (that contacts) road surfaces directly is fixed
on the outsude of carcass and breaker.
It is a strong rubber coat made of high anti-abrasion
rubber. Its running performance depends on is surface
profile.

AFFECTED VIN
4 4H
Conventions for Radial Tire The Relations Between Inflation

P 225 / 65 R - 16 104 T Pressure and Tire
Max Speed :
190 km/h
Excessive Air-Pressure
Life
Load Index : (%)
900 kg Insufficient Air-Pressure
Rim Diameter : 16 inch.
Radial Tire
Air-Pressure to Standard air-Pressure (%)
Aspect Ratio = (Section Height ÷

Section Width) x 100 : 65 %
Section Width : 225 mm The Relations Between Load

and Tire
Passenger Car
Max Speed Symbol Load Index

Limit Speed Limit Speed Life
Symbol Symbol Index
(km/h) (km/h)
F 80 94 670
M 130 95 690
N 140 96 710
P 150 97 730
Load (Standard Ratei 100)
Q 160 98 750
R 170 99 775
S 180 100 800
T 190 101 825
U 200 102 850
H 210 103 875
V 240 104 900
Z Above 240 105 925
CHANGED BY WHEELS & TIRE

AFFECTED VIN
4H 5
2. SPECIFICATION
Wheel Size Aluminum type 6.5J x 16
Wheel nut tightening torque Aluminum wheel 13 ~ 16 kgf.m
Tire Type Radial tire Radial Tire
Inflation pressure (psi) P225/65R16 35 psi
Wheel alignment Toe-in Front 0 ~ 4 mm
Rear 0.4° ± 0.08° (5 mm ± 1 mm)
Camber Front 0° ± 30' (0° ± 0.5°)
Rear -1° ± 30' (-1° ± 0.5°)
Caster 4.5° ± 30'
3. TIRE’S ABNORMAL PHENOMENA

Standing Wave Hydroplaning
High speed Low speed

driving driving
During running the rotating tire repeats deformation and The condition of driving a vehicle fast on the road surface
restoring movement generated in tread. But when the wheel covered with water can cause tires to fail to rotate with a
rotating speed reaches high, the next deformation applied good contact on the surface, so results in remaining them
to tire before restoring last deformation so the trembling a float. This is so-called hydroplaning. It causes brake
wave appears in the tread portion. The lower the tire pres- failure, lower tractive force and losing the steering perfor-
sure the severe the trembling wave appears during the high mance so it is very vulnerable condition.
speed.

AFFECTED VIN
6 4H
4. WHEEL ALIGNMENT
The first responsibility of engineering is to design safe Camber
steering and suspension systems. Each component must
be strong enough to with stand and absorb extreme punish-
ment. Both the steering system and the front and the rear
suspension must function geometrically with the body
Tire center- Perpendicular- Perpendicular- Tire center-
mass. line line line line
The steering and suspension systems require that the front
wheels self-return and that the tire rolling effort and the
road friction be held to a negligible force in order to allow
the customer to direct the vehicle with the least effort and
the most comfort.
A complete wheel alignment check should include mea- Camver (+) Camver 0 Camver (-)
surements of the rear toe and camber.
Toe-in Camber is the tilting of the top of the tire from the vertical
when viewed from the front of the vehicle. When the tires
tilt outward, the camber is positive. When the tires tilt
inward, the camber is negative. The camber angle is mea-
sured in degrees from the vertical. Camber influnces both
directional control and tire wear.
Front side If the vehicle has too much positive camber, the outside
shoulder of the tire will wear. If the vehicle has too much
negative camber, the inside shoulder of the tire will wear.
Camber is measured in degrees and is not adjustable.
Toe-in is the turning in of the tires, while toe-out is the

turning out of the tires from the geometric centerline or
thrust line. The toe ensures parallel rolling of the wheels.
The toe serves to offset the small deflections of the wheel
support system which occur when the vehicle is rolling
forward.
The specified toe angle is the setting which achieves-de-
grees “0°” of toe when the vehicle is moving.
Incorrect toe-in or toe-out will cause tire wear and reduced
fuel economy. As the individual steering and suspension
components wear from vehicle mileage, additional toe will
be needed to compensate for the wear. Always correct
the toe dimension last.

AFFECTED VIN
4H 7
Caster
Front side
Center line Center line
Steering Steering
axle axle
Caster (+) Caster 0 Caster (-)
Caster is the tilting of the uppermost point of the steering

axis either forward or backward from the vertical when
viewed from the side of the vehicle. A backward tilt is posi-
tive and a forward tilt negative. Caster influences direc-
tional control of the steering but does not affect tire wear.
Weak springs or overloading a vehicle will affect caster.
One wheel with more positive caster will pull toward the
center of the car. This condition will cause the car to move
or lean toward the side with the least amount of positive
caster. Caster is measures in degrees and is not
adjustable.

AFFECTED VIN
8 4H
Tire
1. Remove the wheel cap.
2. Support the vehicle with safety jack.

Loosen the wheel nuts and raise the vehicle carefully.
3. Remove the wheel nuts.

AFFECTED VIN
4H 9
[Notice]
• Clean the mating surface of wheel and hub. Do not apply
grease or oil to bolts and nut. It may cause the looseness of
the fasteners.
• Lift up the vehicle until the tire is off approx. 3 mm from
ground.
• Tighten the wheel nuts by the order as shown in the figure
with several steps.
Tightening torque Aluminum wheel: 120 ~ 130 Nm

AFFECTED VIN
10 4H
Spare Tire
1. Prepare the spare tire handle and wheel nut wrench.
2. Install the handle through the hole at the rear side of the
vehicle.
3. Connect the wheel nut wrench at the end of the handle.
4. Turn the wheel nut wrench counterclockwise until the wire is loosened.

AFFECTED VIN
4H 11
5. Pull out the lift plate from spare tire.

6. Put the lift plate into the center of the wheel when
installing.
7. Turn the handle clockwise until it sounds “click”.
8. Remove the handle and the wheel nut wrench.
[Notice]
• Always keep the spare tire available.
• When reinstalling the spare tire, securely fasten it.
• If the lift plate is not in the center position or the spare tire
is not securely fastened, the spare tire may be out of position
during driving.
• If a movement of spare tire is found, check the system and
reinstall in needed.
• The wheel nut tightening surface of the spare tire should
be faced toward ground.
• This device is desined only for manual operation. Never
use the impact type tool to remove the spare tire.
• Store the flat and damaged tire in the trunk.

AFFECTED VIN
12 4H
6. MAINTENANCE AND REPLACEMENT

Separation
1. Fix the tire into the equipment and pull out the valve core
from the tire. Discharge the air inside the tire completely.
[Notice]
The assembly and disassembly of the tire is dangerous
working job. So, only the skillful worker must work this job
following the approved procedures.
2. Tighten the locker in the center of the equipment to

assemble the rim to the equipment.
3. Remove the balance weight on the rim.
4. Separate the tire’s bead from the rim flange using the
approved lubricant.
[Notice]
Do not use silicone, synthetic detergent and gasoline, etc.

AFFECTED VIN
4H 13
5. Apply the lubricant between the rim and the bead.
6. Insert the removal lever between the tire’s bead and the
rim and separate the rim from the tire.
[Notice]
Do not use the tool that may cause any damage such as pipe,
damaged bar.
7. Pull out the opposite bead upward using the lever and
then separate the bead from the rim.
Maintenance
1. Check any damage the rim and replace as needed.
[Notice]
• Do not repair the rim as welding or soldering.
• Replace the new valve as replaces new tire.

AFFECTED VIN
14 4H
Installation
1. Clean the rust, damaged rubber and dust, etc on the
rim’s surface with the brush.
2. Install the rim to the equipment with the valve upward.

3. Tighten the locker in the center of the equipment to
assemble the rim to the equipment.
4. Apply the lubricant at the both bead portions and both

rim’s flange of the tire.
5. Check any foreign material or liquid for the tire inside

and then install to push down the tire.

AFFECTED VIN
4H 15
6. Set the tire pressure to the specifications.
[Notice]
Do not remove the tire from the equipment before setting the
tire pressure.
Specification of the
30 psi (2.1 kg⋅cm2)
tire pressure

AFFECTED VIN
16 4H
7. INSPECTION
Visual Inspection
Condition Cause Action
Rapid wear at Under inflation or lack of rotation Adjust inflation pressure

shoulders
Rapid wear at center Over inflation or rotation
Tread damage Low the inflation pressure
Uneven wear Incorrect camber Adjust camber

Incorrect toe-in

AFFECTED VIN
4H 17

Feathered edge Incorrect toe-in Adjust toe-in
Bold spot Unbalanced wheel Adjust wheel balance
Sharply wear at the tread outside Unbalanced wheel Adjust
Wheel bearing play Check play
Check pre-load
Ball joint play Check
Faulty shock absorber Check

AFFECTED VIN
18 4H
General Inspection
Tread
Inspect the tread condition on the tire surface and various
damages resulting from the foreign material, crack, stone or
nail etc. If there is any damage in the tire, repair or replace it.
Tire Wear
• Measure the depth of the tire tread. If the depth of the tread
is below the specified value, replace the tire.
Limit of the Tread Wear 1.6 mm
• You can see the mark ‘ ’ in the groove, this is the indicator
of the tread wear limit.
• The limit of the tread wear for all season tires are 1.6 mm
as same as the general tires and the platform mark
indicates as ‘ ’.
Tire Inflation Pressure

1. Inflation pressure
Front / Rear 35 psi
2. Inspect the pressure of the tire surface and check the

inflation pressure.
[Notice]
• Lower than recommended pressure can cause tire squeal
on turns, hard steering, tire cord breakage and tire rim
bruises, etc.
• Higher than recommended pressure can cause hard ride,
tire bruising or damage and rapid tread wear at the center
of the tire.
Sufficient Insufficient Excessive

AFFECTED VIN
4H 19
Wheel Runout
Measure wheel runout with an accurate dial indicator. Mea-
surement may be taken with the wheels either on or off the
vehicle, using an accurate mounting surface such as a wheel
balancer. Measurements may be taken with or without the
tire mounted on the wheel.
1. Measure the dial runout and lateral runout on both the
inboard and outboard rim flanges.
Specification 2.66 mm
2. Measure free radial runout on the tire tread.
Specification 2.03 mm
[Notice]
If any measurement exceeds the above specifications, replace
the applicable tires or wheels.
Wheel Balance
Balance is the easiest procedure to perform and should be
done first if the vibration occurs at high speeds or if the tires or
the wheels are replaced.
When proceeding the wheel balancing procedure refer to the
following;
1. Do not the wheel weight over two at the inboard and the
outboard flanges.
2. The total weight ofthe wheel weight should not exceed
the 150 g (3.5 ounces)
3. Balancing the assemblies with the factory aluminum
wheels requires the use of the special nylon-coated, clip-
on wheel weights. Weight point
Balance weight
Balance weight
10 g 20 g 30 g 40 g 50 g 60 g
0.4 oz 0.7 oz 1.10 oz 1.40 oz 1.80 oz 2.10 oz
Balance weight
Weight point

AFFECTED VIN
20 4H
Rotation of Tires
Front and rear tires perform different jobs and can wear differ-
ently depending on the tires of road driven, driving condition,
etc.
The front tires will wear faster than the rear ones. To avoid
uneven wear of tires and to prolong tire life, inspect and rotate
the tires every 5,000 km (3,100 miles). After rotating the tires,
adjust the tire inflation pressures and be sure to check wheel
nuts tightness.
[Notice]
Do not mix different types of tires on the same vehicle such as
radial, bias and bias-belted tires except in emergencies,
because vehicle handling may be seriously affected and may
result in loss of control.

AFFECTED VIN
4H 21
Irregular tire wear Improper tire inflation pressure Adjust
Poor wheel balance Adjust
Improper tire rotation Rotation tires on the
maintenance schedule
Poor toe-in Adjust
Poor adjusting the pre-load of the wheel bearing Adjust
Poor braking performance Adjust
Driving noise, vibration Low tire inflation pressure Adjust
Poor balance of wheels, tires Adjust
Severe vibration due to wheels, tires Adjust or replacement
Irregular tires wear Check and adjust
Rapid wear Excessive tire inflation pressure Adjust
High speed driving with low tire pressure Adjust
Excessive vehicle weight Proper weight

AFFECTED VIN
MEMO
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4I 1
4I - Propeller Shaft
Table of Contents
1. General information ....................................................... 4I-3
2. Components and location .............................................. 4I-4
3. Removal and installation ................................................ 4I-5
4. Inspection ..................................................................... 4I-8
5. Trouble diagnosis ........................................................ 4I-11
6. Special tools and equipment ....................................... 4I-12
PROPELLER SHAFT CHANGED BY

AFFECTED VIN
4I 3
The propeller shaft transfers the power through the transmis-
sion and transfer case to the front/rear axle differential carrier
(final reduction gear). It is manufactured by a thin rounded
steel pipe to have the strong resisting force against the torsion
and bending.
Both ends of propeller shaft are connected to the spider and
the center of propeller shaft is connected to the spline to ac-
commodate the changes of the height and length. The rubber
bushing that covers the intermediate bearing keeps the bal-
ance of rear propeller shaft and absorbs its vibration.
Specification
Structure Yoke and spider type universal joint
Joint type Spider (Needle roller bearing)
Number of spiders Front TOD T/C 1
Rear 2
Outer diameter of spider (mm) φ 17.893
Tube run-out (after installation) below 0.4 mm
Unbalance Below 14.5 g.cm @ 4500 rpm (Front shaft + Full time T/C)
Below 18.0 g.cm @ 4500 rpm (Rear shaft + Full time T/C)
Front shaft dimension M/T(A/T) + 4426 TC (TOD) 495.8 (center position) x φ 50.8 (3.05t)
Length x Outer diameter (mm)
Rear shaft dimension DI engine + M/T(A/T) + 4426 TC (TOD) 606.1 (compressed) x φ72.2(2t)
Length x Outer diameter (mm) + 769.5 x φ 76.2 (2t)
DI engine + M/T + 2WD 923.5 x φ 63.5 (2t)
+ 750.4(compressed) x φ 63.5 (2t)
DI engine + A/T + 2WD 987.7 (compressed) x φ 63.5(2t)
+ 769.5 x φ 63.5 (2t)
Gasoline + M/T + 2WD 923.5 x φ 76.2(2t)
+ 750.4 (compressed) x φ 63.5 (2t)
Gasoline + A/T + 2WD 987.7 (compressed) x φ 76.2(2t)
+ 769.5 x φ 63.5 (2t)

AFFECTED VIN
4 4I
2. COMPONENTS AND LOCATION

Front Prepeller Shaft Assembly
Bolt Bolt
CV joint Front propeller shaft assembly Universial joint
Rear Prepeller Shaft Assembly
1st rear propeller shaft CV joint 2nd rear propeller shaft
Universial joint
Bolt/washer/nut
Center bearing assembly
Universial joint Bolt
CHANGED BY PROPELLER SHAFT

AFFECTED VIN
4I 5

Removal
Front Propeller Shaft (4WD)

1. Unscrew propeller shaft mounting bolts and remove the shaft from the vehicle. (T/C : 17 mm - 4EA, Axle : 14 mm
- 4EA)
* Leave a guide mark before

disassembly, and refer to
the mark when reinstall

AFFECTED VIN
6 4I
Rear Propeller Shaft

1. Unscrew propeller shaft mounting bolts. (T/C : 17 mm -
4EA, Axle : 14 mm - 4EA)
Center bearing
Axle side T/C side
2. Unscrew the rear propeller shaft center bearing

mounting bolts (17 mm - 2 EA)
* Leave a guide mark

before disassembly,
and refer to the mark
when reinstall.

AFFECTED VIN
4I 7
Installation
1. Installation in the reverse order of removal.
2. Keep the tigtening torque.
3. Keep the guide mark when install.
4. Check and replace parts if defective.
(1) Rear propeller shaft (T/C) (2) Center bearing bracket (3) Rear propeller shaft (Axle)
Tightening torque : 81 ~ 89 Nm Tightening torque : 80 ~ 90 Nm Tightening torque : 70 ~ 80 Nm
3. Rear axle 1. Rear - T/C
2. Center bearing 4. Front axle
5. Front - T/C
(4) Front propeller shaft (Axle) (5) Front propeller shaft (T/C)
Tightening torque : 70 ~ 80 Nm Tightening torque : 81 ~ 89 Nm

AFFECTED VIN
8 4I
4. INSPECTION
Disassembly
1. Place an alignment mark and remove the propeller shaft.
2. Place an alignment on the spiders before removing.
3. Remove the snap ring with snap ring pliers.
4. Tap the yoke shoulder on shaft with copper hammer to

remove the roller bearing. Remove the other bearings with
same manner.
5. If it cannot be removed, hold the welding area with vise
and remove the needle bearing by using a suitable drift
and hammer.
6. Disassemble the universal joint.

The universal joint compensates the angle changes due
to vertical movement of the axle shaft.
7. Remove the intermediate bearing bracket and remove

the bearing with special tool.

AFFECTED VIN
4I 9
Inspection
1. Visual Check
Check the components for wear and crack and replace if
needed.
2. Outer diameter of spider journal
Specified value 17.893 mm

Limit 17.910 mm
3. Clearance between spider journal and bearing
Specified value 0.03 ~ 0.098 mm

Limit 0.25 mm
4. Run-out of propeller shaft

Set up the dial gauge on the center point of propeller
shaft and measure the run-out. If the run-out is out of the
specified range, correct it with press or replace it with
new one.
Limit 0.4 mm
5. Starting torque of universal joint
Specified value 3 ~ 8 kg.cm
6. Major causes of vibration

• Balance weights missing
• Excessive run-out of propeller shaft
• When using the general bolts
• Excessive wear of universal joint
• Stuck in sleeve joint
• Vibration is mainly caused by the angle changes in
front and rear universal joint. It normally occurs when
the vehicle speed is 60 ~ 100 km/h.
AFFECTED VIN
10 4I
Assembly
Clean the components and replace if damaged. Flange yoke
1. Align the alignment marks on the yoke and assemble
the spider, bearing and snap ring.
Spider
Bearing
Yoke Snap ring
2. Apply the grease to the inner lip of needle roller bearing

and assemble the needle roller.
Needle roller bearing
3. Install the yoke bearing shaft on the shaft and insert the
spider. Place the cap on the opposite side and tap it
with plastic hammer to seat it. Adjust the clearance of
Grease
spider below 0.1 mm and install the snap ring.
4. Apply the specified grease on the propeller shaft and

install it.

AFFECTED VIN
4I 11
Vibration Poor installation of sliding joint Adjust
Bending of propeller shaft replace
Incorrect symmetry of universal joint snap rings Adjust
Loose yoke bolt Tighten
Noise Worn or damaged universal joint bearing Replace
Missing universal joint snap ring Adjust and replace
Loose yoke connection Tighten
Worn sliding joint spline Replace
Lack of grease Add

AFFECTED VIN
12 4I

116 589 09 43 00 (P 99 48 003 0A) Centering the clutch disc

Remover and installer
129 589 00 34 00 (P 99 33 002 0B) Removal of bearing

Pulling arms

AFFECTED VIN
4J 1
4J - Brake - General
Table of Contents
BRAKE SYSTEM................................................ 4J-3
1. General information ...................................................... 4J-3
2. Specification ................................................................ 4J-5
3. Components................................................................. 4J-6
4. Master cylinder & booster ............................................ 4J-8
5. Inspection .................................................................... 4J-9
6. Removal and installation ............................................. 4J-11
7. Trouble diagnosis ....................................................... 4J-19
FRONT BRAKE ................................................ 4J-20

1. General information .................................................... 4J-20
2. Components............................................................... 4J-21
4. Special tools and equipment ...................................... 4J-25
REAR BRAKE .................................................. 4J-26

1. General information .................................................... 4J-26
2. Components............................................................... 4J-27
PARKING BRAKE ............................................ 4J-32

1. Components............................................................... 4J-32
BRAKE - GENERAL CHANGED BY

AFFECTED VIN
4J 3
BRAKE SYSTEM
Brake System Brake Pedal
Even though a driver cuts off the power, while driving, the
vehicle continues to move due to the law of inertia.
Therefore, a braking device is needed to stop the vehicle.
The brake system normally uses the frictional discs that
converts the kinetic energy to the thermal energy by fric-
tional operation.
The brake system consists of the brake disc (front wheel),
brake disc or drum (rear wheel), parking brake (mechanical
type), master cylinder, booster, pedal and supply lines
(pipes and hoses).
Hydraulic Brake
Brake pedal uses the leverage effect to apply bigger force
to the brake master cylinder.
Master Cylinder
This system uses the leverage effect and Pascal’s

principle. When depressing the brake pedal, the pedal
Rear Front
pressure is increased by booster and is delivered to mas-
ter cylinder to generate hydraulic pressure.
The hydraulic pressure generated by the master cylinder
is delivered to the brake caliper through the brake pipes or
The brake master cylinder is designed to convert the force
hoses.
from the brake master cylinder to the high hydraulic
This hydraulic pressure pushes the brake calipers, ac- pressure. The brake system uses the tandem type mas-
cordingly the caliper pads are contacted to brake disc to ter cylinder with in-line 2 pistons.
generate the braking force.
The in-line 2 pistons generate the hydraulic pressure. The
piston cup on the piston keeps the sealing conditions in
cylinder and prevents the oil leaks. The hydraulic pres-
sure generated by the primary piston is delivered to the
front wheels, and the hydraulic pressure generated by the
secondary piston is delivered to the rear wheels.

AFFECTED VIN
4 4J
Brake Booster
The brake booster is a power assist device for brake
system. It relieves the pedal depressing force by using
the pressure difference between the vacuum pressure gen-
erated by vacuum pump in intake manifold and the atmo-
spheric pressure.
1. Pressure distribution at working 2. Pressure distribution after working
Vacuum pump
When depressing the brake pedal, the push rod (1) in When releasing the brake pedal, the valve plunger (3) re-
booster pushes the poppet (2) and valve plunger (3). The turns back to the original position by return spring (4) and
poppet (2) pushes the power piston seat (5) resulting in the air valve (6) closes. At this time, the vacuum valve (9)
closing the vacuum valve (9). The chamber (A) and (B) in opens and the pressure difference between chamber (A)
power cylinder are isolated and the valve plunger (3) is and (B) in power cylinder is eliminated. Accordingly, the
separated from the poppet (2). And then the air valve (6) power piston (5) returns back to original position by the
opens and air flows into the chamber (B) through filter. reaction of master cylinder (10) and the diaphragm return
Then, the power piston (5) pushes the master cylinder spring (8).
push rod (7) to assist the brake operation.
CHANGED BY BRAKE - GENERAL

AFFECTED VIN
4J 5
2. SPECIFICATION
Item Type & Specification
Front brake type Ventilated disk
Rear brake type Solid disk
Master cylinder type Tendem type
Booster type Tendem booster (Foot control)
Brake fluid capacity, type, replacement period 0.6 (Liter), DOT4, by every 2 years
Brake pipe & hose replacement period Every 20,000 km or 12 months and change if needed
Brake pad, shoe, disk Checking by every 10,000 km

AFFECTED VIN
6 4J
3. COMPONENTS
Return spring
Vacuum pump
Pedal bracket
Gasket
Booster
Vacuum Booster
hose
Brake pedal Switch - Stop lamp

O-ring
Reservoir tank Pad
Pressure sensor Cable - RR
speed sensor Pad
M/T
A/T
Cable - FRT
speed sensor
Brake dust shield Knuckle

Brake dust shield
Hub flange
Hub flange
Knuckle Brake disk
Brake disk
Steering
knuckle assy

AFFECTED VIN
4J 7
Release lever
Parking brake assy
HECU
Cable
Brkt - HECU
Parking brake cable

Damper - rear RH
Parking brake cable
Pad - rear LH
Tension spring
Equalizer
Brake shoe
Adjuster
Return spring - Upper

Return spring - Lower
Knuckle
Operating lever
Brake dust shield
Hub flange
Brake disk

AFFECTED VIN
8 4J
4. MASTER CYLINDER & BOOSTER

ABS system is basically equipped to STAVIC.
Vehicle which adapted ESP system in option has two pressure sensors under master cylinder and these two sensor are
used for BAS (Brake Assist System) system.
Vehicle with ESP Vehicle with ABS
Vacuum Pump
Gasket
Booster
Vacuum hose
O-ring
Brake fluid
reservoir
tank
Master
cylinder
Pressure
sensor
<Vehicle with ESP>
Brake fluid reservoir tank Master cylinder
[Notice]
• Do not disassemble the brake oil pressure sensors These can not be reinstalled of disassembled.
• After reinstall the reserver tank perform a air bleeding of brake system

AFFECTED VIN
4J 9
5. INSPECTION
Air Bleeding (With ABS)
6. Repeat the step 4 through 5 until clear brake fluid
comes out of air bleed screw.
7. Perform the same procedures at each wheel.
[Notice]
Repeat the step 4 through 5 until clear brake fluid comes
out of air bleed screw.
After bleeding the air, make sure that the brake system is
properly operated.
[Notice]
Replace the brake oil at every 2 years.
[Notice]
Bleed air in the following order:
Right rear brake → Left rear brake → Right front brake
→ Left front brake
Check the fluid level repeatedly during air bleeding, and
add fluid if needed.
1. Apply the parking brake and start the engine when

the shift lever is at “P” position.
2. Connect the oil supply device (air bleeding device)
with air compressor to brake reservoir. The oil supply
device should be filled with sufficient oil.
3. Loosen the air bleed screw in caliper and place an
empty container under the screw. 8. Always start to bleed the air at the farthest wheel
4. Bleed the air in each wheel by using diagnostic device from the brake master cylinder. Observe the sequence
(Scanner). At this time, the modulator motor runs for number as shown in the above figure.
180 seconds.
5. Simultaneously, run the oil supply device to supply [Notice]
oil and depress the brake pedal repeatedly. • Always bleed the air after replacing the brake fluid or
This procedure needs at least 3 persons for doing master cylinder, caliper, brake hose and pipe.
below jobs: • Never reuse the used brake fluid.
1. Collect the bleeding oil into the container. • Do not pump the brake pedal too fast. It may cause
2. Depress the brake pedal repeatedly. some troubles for air bleeding operation.
3. Check the conditions of oil supply device. • Be careful not to splash the brake fluid on painted
area or body.
[Notice] • Check the connection areas for leaks after air bleeding.
Keep the brake pedal depressing until the bleed screw is

fully tightened.

AFFECTED VIN
10 4J
After Replacing Master Cylinder

1. Add oil after replacing the master cylinder.
2. Pump the brake pedal several times until the hydraulic
pressure is generated. Then, keep the pedal depressing.
3. Loosen the pipe screw at the outlet port in master cylinder
to bleed the air.
4. Repeat step 3 until clear brake fluid comes out of air
bleed screw.
5. If the hydraulic pressure is not properly generated during
pumping the brake pedal, bleed the at the outlet pipe in
hydraulic unit and wheel.
After Replacing Hydraulic Unit

1. Add oil after replacing the hydraulic unit.
2. Pump the brake pedal several times until the hydraulic
pressure is generated. Then, keep the pedal depressing.
3. Loosen the pipe screw at the outlet port in hydraulic unit
to bleed the air.
4. Repeat step 3 until clear brake fluid comes out of air
bleed screw.
5. If the hydraulic pressure is not properly generated during
pumping the brake pedal, bleed the at the wheel.

AFFECTED VIN
4J 11

Vacuum Hose - Brake Booster
1. Disconnect vacuum hose (A) from brake booster.

2. Remove vacuum hose mounting nut (B).
3. Disconnect vacuum hose (C - Vacuum modulator side).
4. Disconnect vacuum hose & bracket (D)

AFFECTED VIN
12 4J
Brake Fluid Reservoir Tank

1. Open the tank cap and drain the brake oil.
2. Disassemble brake fluid reservoir from master cylinder.
[Notice]
Do not apply excessive force to remore the reservoir.
[Notice]
• Use only specified brake fluid.
• After replacing the brake fluid reservoir be followed air-
breeding job moust.

AFFECTED VIN
4J 13
Master Cylinder (ESP Equipped Vehicle)

Preceding work : Drain the brake fluid
1. Disconnect the brake fluid level switch connector (A).

2. Disconnect brake pipes (B, C) from master cylinder.
3. Remove master cylinder with master cylinder mounting

nuts.
[Notice]
Be careful not to splash the brake fluid onto painted body. If
splashed, immediately clean the contaminated area.

5. Do the air bleeding job.

AFFECTED VIN
14 4J
Brake Booster
Preceding work : Drain the brake fluid
1. Disassembly the master cylinder assembly and remove

clevis pin on the booster push rod.
2. Remove the booster mounting nuts.

3. Disassemble the brake booster from vehicle.
[Notice]
Air-bleeding job must be done after repairing.

AFFECTED VIN
4J 15
Stop Lamp Switch

2. Disconnect the stop lamp switch connector.
3. Unscrew the lamp switch mounting nut and disassemble
the switch.
4. Install in the reverse of removal.
Stop Lamp Switch Check

1. Check if the electrical circuit is closed when the switch
plunger is pushed.

AFFECTED VIN
16 4J
Brake Pedal
1. Remove two stop lamp switch bracket bolts.
2. Remove brake pedal bracket bolts.
3. Disassemble the brake pedal assembly.
Nut
Pad
Stopper
Return spring
Washer
Brake pedal
Bolt
Bracket
5. After installation, hit the brake to check if its operation is

correct.

AFFECTED VIN
4J 17
Brake Pedal Check

Pedal Height / Maximum Stroke
Check the brake pedal with below procedures:
1. Start the engine.
2. Depress the brake pedal around 3 times.
3. Depress the brake pedal with approx. 30 kg and measure
the distance (A) between the upper surface of pedal pad
and the lower dash panel.
4. If the measured value is below the specified value, check
the following causes:
Pad wear, Shoe wear, Air in brake system, Defective
automatic clearance adjuster of rear brake shoe.
5. If the measured value is out of the specified range, adjust
the length of push rod by using lock nut in the brake
booster push rod.
Pedal height
Operating
Specified value (A) 177 mm (from carpet surface) rod
Stop lamp
[Notice]
switch
If the value is out of the specified range, adjust the pedal Operating rod
height by using lock nut of stop lamp switch. lock nut
Stop lamp
switch lock nut
Maximum stroke
Specified value (C) 138 mm
[Notice]
If the value is out of the specified range, adjust the maximum
stroke by using stop lamp and lock nut.

AFFECTED VIN
18 4J
Pedal Free Play

Depress the brake pedal several times to discharge the vacuum
pressure of the power booster. Measure the pedal free play
while pressing the brake pedal by hand.
Specified value 3 ~ 8 mm
If the free play is below the specified value, check if the clear-
ance between the outer case of the stop lamp and the brake
pedal is within the specified range.
If the clearance is out of the specified range, the clearance
between the clevis pin and the brake pedal arm is too large.
Check the components and repair if needed.
Brake Booster Check Normal
1. Let the engine run for 1 ~ 2 minutes and stop it. If the
brake pedal stroke is shortened as pumping the brake
pedal, the system is normal. If not, the system is Faulty
defective.
2. Depress the brake pedal several times with engine off. If
the brake goes down when starting engine with pedal
depressed, the system is normal. If not, the system is
defective.
3. Depress the brake pedal when the engine is running. If
the pedal height is not changed when stop the engine,
the system is normal. If not, the system is defective.
If the above 3 conditions are not satisfied, check the parts
Engine stop
concerned such as valve, vacuum hose, booster, etc.
Engine running

AFFECTED VIN
4J 19
Noise or vehicle vibra- Incorrectly mounted back plate or caliper Repair
tion when applied Loosened bolt of back plate or caliper Retighten
Crack or uneven wear of brake drum or disc Replace
Foreign material inside the brake drum Clean
Pad or lining sticking to contact surface Replace
Excessive clearance between caliper and pad Repair
Uneven contact of pad Repair
Lack of lubrication Lubrication
Loosened suspension Retighten
Pulls to one side when Incorrect tire pressure between left and right Adjust
braking Poor contact of pad or lining Repair
Oil or grease is applied to pad or lining Replace
Bent or uneven wear of drum Replace
Incorrectly mounted wheel cylinder Repair
Faulty auto adjuster Repair
Poor braking Dirty or lack of fluid Replenish or replace
Air in brake system Bleeding
Faulty brake booster Repair
Poor contact of pad or lining Repair
Oil or grease on pad Replace
Over heated rotor due to dragging pad or lining Repair
Clogging brake line Repair
Faulty proportioning valve Repair
Increasing pedal stroke Air in brake system Bleeding
(Pedal goes to floor) Fluid leaking Repair
Excessive clearance between push rod and m/cylinder Adjust
Brake dragging Parking brake is not fully released Repair
Incorrect adjustment of parking brake Adjust
Weak return spring of brake pedal Replace
Incorrect pedal free-play Repair
Broken rear drum brake shoe return spring Replace
Lack of lubrication Lubrication
Damaged master cylinder check valve or piston return spring Replace
Poor parking brake Insufficient clearance between push rod and master cylinder Adjust
Worn brake lining Replace
Dirty brake lining surface by grease or oil Replace
Binding parking brake cable Replace
Excessive lever stroke Adjust lever travel or
check the cable

AFFECTED VIN
20 4J
FRONT BRAKE
Caliper Adjustment of Clearance
The disc brake is normally used for front wheels, however, When the hydraulic pressure is applied to the piston, the
currently it is also used for rear wheels. The floating cali- piston moves to push the pad. The piston seal, which ex-
per type disc brake installed in this vehicle has only one tent considerable pressure against the piston, moves with
brake cylinder at one side of caliper. The hydraulic pres- cylinder.
sure generated by master cylinder pushes the piston to However, the piston seal shape is deformed since the pis-
contact the pad against the disc. The caliper is moved to ton seal is fixed at the cylinder groove as shown in below
contact to the opposite pad. figure.
The brake disc features: When the pressure is released from the piston, the piston
* Excellent radiation due to it is exposed to ambient air comes back to its original position by a restoring and elastic
* Less braking force changes force of the seal.
* No uneven braking When the pad wear is excessive, the piston seal cannot
* Simple structure and operation reach to the desired point because the seal’s deformation
is limited.
Accordingly, the piston always comes back by the de-
Piston
formed distance of piston seal, it keeps the initial clearance.
Pad
Disc
* General description
1. Piston 3. Pad
2. Piston seal a. Clearance
Specifications
Item Specification
Type Ventilated disc type
Inner diameter of caliper cylinder φ 42.9 x 2 mm
Pad thickness 10.5 mm
Disc thickness 26 mm

AFFECTED VIN
4J 21
2. COMPONENTS
For strong and safe brake force, ventilated disk and double piston type is adapted to front brakes.
Brake disk
Caliper
Brake hose
Disk
Caliper carrier
Pad spring Brake pad
Bolt - Caliper
Piston
Brake Caliper assembly

AFFECTED VIN
22 4J
Caliper / Brake Disk

Preceding work : Remove the tire
[Notice]
1. Disconnect brake hose from caliper.
Be careful not to splash the brake oil onto the painted
Tightening torque 20 ~ 30 Nm body.
2. Unscrew two caliper mounting bolts and disassemble the caliper assembly.
3. Unscrew two nuts and disassemble the brake disk.

AFFECTED VIN
4J 23
Brake Pad Change

1. Unscrew brake.
2. Swing up the callper cylinder assembly and hold it not

to damage the hose.
3. Remove the brake pads and replace them with new ones.
4. Compress the brake piston with special tool.
[Notice]
Insert the used pad to compress brake piston.
5. Install the caliper assembly.

AFFECTED VIN
24 4J
Inspection
Clean the dissembled components and visually check the
followings:
• Wear, rust and damage on the cylinder and piston
• Damage, crack and wear on cylinder body and guide pin
• Uneven wear and oil contamination on boot
• Damage and tear on boot
• Scratch and bending on disc plate
Pad Thickness
1. Remove the tire.
2. Measure the pad thickness and replace it if it is below
the wear limit.
New pad thickness Wear limit

10.5 mm 2 mm
Brake Disc Thickness

1. Measure the disc thickness at over four points.
2. If any of measured points is below the wear limit, replace
the brake disc with new one.

28 mm 25.4 mm
Brake Disc Run-out

1. Install the dial gauge on the side of brake disc and
measure the run-out while rotating the brake disc.
2. If the measured value exceeds the limit, replace the brake
disc with new one. Otherwise, it may cause the pedal
vibration and shimmy when braking.
0.03 mm (before installation)

Limit
0.07 mm (when installed)

AFFECTED VIN
4J 25

661 589 16 33 00 (W 99 48 002 0A) Removal of ABS front brake

Front ABS tooth wheel puller tooth wheel
661 589 17 33 00 (W 99 48 003 0A) Installation of ABS front brake

Front ABS tooth wheel installer tooth wheel
Piston Puller Compression of caliper piston

AFFECTED VIN
26 4J
REAR BRAKE
Disc Brake
1. Brake dust shield 5. Disc

2. Parking cable 6. Wheel
3. Parking cable lever 7. Air bleeder nipple
4. Caliper assembly 9. Shaft assembly
The disc brake is normally used for front wheels, however, The brake disc features:
currently it is also used for rear wheels. The floating cali- * Excellent radiation due to it is exposed to ambient air
per type disc brake installed in this vehicle has only one * Less braking force changes
brake cylinder at one side of caliper. The hydraulic pres-
* No uneven braking
sure generated by master cylinder pushes the piston to
* Simple structure and operation
contact the pad against the disc. The caliper is moved to
contact to the opposite pad.

AFFECTED VIN
4J 27
2. COMPONENTS
Brake Disk
Brake disk Caliper
Lock nut
Brake hose
Brake dust shield
Adjusting bolt
Brake shoe
Lock nut
Parking brake
operating lever

AFFECTED VIN
28 4J
Caliper Assembly
Caliper carrier Brake pad
Piston
Pad spring
Bolt-caliper
Caliper
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○

AFFECTED VIN
4J 29
Caliper / Brake Disk

1. Remove the rear tire.
[Notice]
• Park the vehicle on the flat and even ground and set the
blocks under the front tires.
• Release the parking brake.
• Place the shift lever to “N” (A/T) or “NEUTRAL” (M/T)
position.
2. Disconnect the brake hose from rear brake caliper.
[Notice]
Be careful not to splash the fluid.
3. Unscrew the bolts and remove the caliper assembly.
4. Disassemble the brake disk with two bolts.
[Notice]
Release the parking brake when disassemble the brake disk.

AFFECTED VIN
30 4J
Inspection
1. Clean the dissembled components and visually check
the followings:
• Wear, rust and damage on the cylinder and piston
• Damage, crack and wear on cylinder body and guide
pin
• Uneven wear and oil contamination on boot
• Damage and tear on boot
2. Measure the pad thickness.

10 mm 2 mm
[Notice]
If any of pads is below the wear limit, replace both pads at a
time.
3. Measure the disc thickness.

20 mm 18 mm
4. Check the disc plate for scratch and bend.

AFFECTED VIN
4J 31
Brake Pad Change

1. Unscrew lower caliper bolt (14 mm).
Fastening torque 22 ~ 34 Nm
2. Swing up the caliper cylinder assembly and hold it not

to damage the hose.
3. Remove the brake pads and replace them with new ones.
4. Compress the brake piston with special tool.
[Notice]
Insert the used pad when compress the brake piston.
5. Install the brake cylinder assembly.

AFFECTED VIN
32 4J
PARKING BRAKE
1. COMPONENTS
Pedal assembly
Equalizer assembly
Return spring - upper

Adjusting bolt
Shoe holding spring
Return spring - lower
Operating lever

AFFECTED VIN
4J 33
Release lever
Release cable
Parking brake switch
Brake damper
Pedal assembly
Pedal
Equalizer assembly
Equalizer bolt
Tension spring
Rear brake cable - LH
Rear brake cable - RH

AFFECTED VIN
34 4J
Pedal Assembly
Preceding work : Remove lower cover - crash pad
1. Release the equalizer bolt.
[Notice]
Replace bolt when reinstall.
2. Remove the clamping ring from pedal assembly and disconnect the brake cable (1).
3. Disconnect the parking brake switch (2).

AFFECTED VIN
4J 35
4. Remove pedal assembly mounting bolts (12 mm) & nuts (12 mm).
Nut
Bolt

AFFECTED VIN
36 4J
Equalizer Assembly
1. Remove the equalizer adjustment bolt (1).

2. Unscrew the mounting bolt (2) in equalizer lever and disconnect front brake cable (3).
3. Disassemble equalizer lever (4) from frame floor mounting.
4. Disconnect rear brake cable (5) and disassemble the equalizer.
Adjustment
1. Park the vehicle on the car lift and set blocks under front
tires.
2. Place the shift lever to “N” (A/T) or “Neutral” (M/T).
3. Release the parking brake.
4. Lift the rear wheels with supplementary lift.
5. Check the brake force as rotating the wheels - specified
hand brake notch : 5
6. If the brake force is not made enough, adjust the parking
brake adjust nut in the brake drum.

AFFECTED VIN
4J 37
Parking Brake Shoe
Components
Adjusting bolt Return spring - upper
Shoe holding spring
Return spring - lower
Operating lever

1. Remove shoe holding spring (2 EA) with plier.
2. Remove upper return spring & adjust bolt.

AFFECTED VIN
38 4J
3. Remove lower return spring and disassemble sperating lever from brake cable.
Adjustment
1. Have the brake shoe contact the inner face of brake disk by winding the brake adjust bolt using a tool (screw
driver), and then, unscrew the bolt by 4 ~ 5 notch. (Clearance between brake disk and brake shoe : 0.2 mm)
2. Check if the wheel become locked when brake force is applied.

AFFECTED VIN
4K 1
4K - ABS/ESP System
Table of Contents
ABS SYSTEM .................................................... 4K-3
1. General information ..................................................... 4K-3
2. Components and location ............................................ 4K-8
3. Input and output diagram ............................................. 4K-9
4. Electrical circuit ........................................................ 4K-10
5. Hydraulic circuit diagram ............................................ 4K-11
6. Components description ............................................ 4K-14
7. Removal and installation ............................................ 4K-17
8. Special tools and equipment ..................................... 4K-22
ESP SYSTEM .................................................. 4K-23

1. General information ................................................... 4K-23
2. Components and locations ........................................ 4K-27
3. Input and output diagram ........................................... 4K-29
4. Electrical circuit diagram ........................................... 4K-30
5. Hydraulic circuit diagram ........................................... 4K-32
6. Components description ............................................ 4K-39
7. Removal and installation ............................................ 4K-56
8. ABS/ESP trouble diagnosis ...................................... 4K-61
9. Air bleeding ............................................................... 4K-69
ABS/ESP SYSTEM CHANGED BY

AFFECTED VIN
4K 3
ABS SYSTEM
The aim of the ABS is to mmaintain steerability and driving stability and to take the burden off the driver. If the stopping
distance is shorter on some road surfaces (carriageway conditions), this is a gift of physics and not a development aim.
ABS is a device which senses that one or more of the wheels are locking up during braking. It monitors the rotational
speeds of the wheels and reduces hydraulic pressure to any wheel it senses locking up. It is controlled by both
mechanical and electronic components. When you apply the brakes, the ABS will regulate the flow of brake fluid being
delivered to the brake calipers. By the use of electronic computers, the brakes rapidly alternate (at a rate of 30 times per
second) from full pressure to full release.
DRIVING PHYSICS
To give you a better understanding of the tasks and functions of ABS, we will first look at the physics principles.
The Stopping Distance

The stopping distance depends on the vehicle weight and initial speed when braking starts. This also applies for vehicle
with ABS, where ABS always tries to set an optimum brake force on each wheel. As great forces are exerted between
the tires and the carriageway when braking, even with ABS the wheels may scream and rubber is left on the road. With
an ABS skid mark one may be able to clearly recognize the tire profile. The skid mark of an ABS vehicle does not
however leave any hint of the speed of the vehicle in the case of an accident, as it can only be clearly drawn at the start
of braking.
Brake Force on a Wheel

The maximum possible brake force on a wheel depends on the wheel load and the adhesion coefficient between tire and
carriageway. With a low adhesion coefficient the brake force, which can be obtained is very low. You are bound to know
the result already from driving on winter roads. With a high adhesion coefficient on a dry road, the brake force, which can
be obtained, is considerably higher. The brake force, which can be obtained, can be calculated from below formula:
Maximum brake force
FBmax = Vehicle Weight x Adhesion coefficientmh
The braking process cannot be described sufficiently accu-

rately with the brake forces calculated. The values calculated
only apply if the wheel is not locked. In the case of a locking
wheel, the static friction turns into lower sliding friction, with
the result that the stopping distance is increased. This loss of
friction is termed “slip” in specialist literature.
Brake force on a wheel

AFFECTED VIN
4 4K
Slip
The brake slip is the difference between the vehicle speed and the wheel circumference speed. If the wheel locks, the
slip is greatest, that is 100 %. If the wheel is running freely and unbraked, the slip is the lowest, equal to 0 %. Slip can
be calculated from the vehicle speed Vveh and the wheel speed Vw. The equation for this is:
Vveh - Vw
S= X 100 %
Vveh
Vveh = 100 km/h, Vw = 70 km/h
100 - 70
S= X 100 %
100
The slip is 30 %.
Typical slip curves

For the various carriageway conditions the adhesion coeffi-
cients were plotted. The typical course of the curves is al- Dry concrete
ways the same. The only special feature is shown by the
Friction coefficient
curve for freshly fallen snow, for this curve increases at 100 % Wet concrete
slip. In a vehicle without ABS, the wheel locks on braking and
therefore pushes a wedge before it. This wedge of loose sur-
face or freshly fallen snow means and increased resistance
and as a result the stopping distance is shorter. This reduc- Snow
tion in stopping distance is not possible with a vehicle with Ice

ABS, as the wheel does not lock. On these surfaces the stop-
ping distance with ABS is longer than without ABS. The rea-
Slip
son for this is based in physics and not in the Anti-Lock
System. However, as mentioned before, ABS is not about the
stopping distance, but maneuverability and driving stability, <Typical slip curves>
for with ABS you can steer round an obstacle. A device with
locking wheels without ABS cannot be steered. So what use
then is the shorter stopping distance if the vehicle has already
hit the car in front, because you did not have a chance to
steer round the obstacle?
Kamm circle
Before we go into the Kamm circle, you should know that a
tire offers a maximum of 100 % transmissibility. It is all the
same for the tire whether we require 100 % in the direction of
braking or in the direction of the acting lateral force, e.g. when
driving round curves. If we drive into a curve too fast and the
tire requires 100 % transmissibility as cornering force, the tire
cannot transmit any additional brake force. In spite of the ABS Cornering
the car is carried out of the curve. The relationship between side force
brake force B and cornering force S is shown very clearly in
the Kamm circle. If we put a vehicle wheel in this circle, the
relationship becomes even clearer. In this relationship: as long KAMM circle
as the acting forces and the resulting force remain within the Braking force
circle, the vehicle is stable to drive. If a force exceeds the
circle, the vehicle leaves the road.
CHANGED BY ABS/ESP SYSTEM

AFFECTED VIN
4K 5
Brake and cornering force

- Brake force
ABS-Control range
When depressing the brake pedal the brake force increases
to the maximum, then the brake force decreases until the
wheel locks. Stable Unstable
- Cornering force Brake force
The cornering force is a maximum when the wheel is

turning freely with zero slip. When braking the cornering
force falls to zero if the wheel locks (slip 100 %).
- ABS operating range

The operating range starts just before the maximum brake
force and ends in maximum, for the unstable range then
begins, in which no further modulation is possible. The Cornering force
ABS controls the regulation of the brake pressure so that
the brake force only becomes great enough for a sufficient
proportion of cornering force to remain. With ABS we
remain in the Kamm circle as long as the car is driving
Slip
sensibly. We will leave driving physics with these
statements and turn to the braking systems with and
without ABS.
Basic ABS Controls

Brake pressure
Reference speed
Applications of the ABS control unit
Vehicle speed
The signals produced by the wheel sensors are evaluated in
Wheel speed
the electronic control unit. From the information received, the
control unit must first compute the following variables:
- Wheel speed
- Reference speed
- Deceleration
- Slip
Reference speed
The reference speed is the mean, I.e. average speed of all wheel speeds determined by simple approximation.
Simplified ABS control

If, during braking, one wheel speed deviates from the reference speed, the ABS control unit attempts to correct that
wheel speed by modulating the brake pressure until it again matches the reference speed. When all four wheels tend to
lock, all four wheels speeds suddenly deviate from the previously determined reference speed. In that case, the control
cycle is initiated again in order to again correct the wheel speed by modulating the brake pressure.
Selector low control

This control is used for regulating the brake pressure for rear axle during ABS operation. This control uses lower
adhesion coefficient to prevent the rear wheels from locking.

AFFECTED VIN
6 4K
EBD (ELECTRONIC BRAKE FORCE DISTRIBUTION) SYSTEM

System Description
As an add-on logic to the ABS base algorithm, EBD works in
Rearaxle braking force

a range in which the intervention thresholds for ABS control
can not be reached.
EBD ensures that the rear wheels are sensitively monitored
for slip with respect to the front axle. If slip is detected, the
inlet valves for the rear wheels are switched to pressure hold
to prevent a further increase in pressure at the rear-wheel
breaks, thus electronically reproducing a pressure-reduction
function at the rear-wheel brakes.
ABS features an enhanced algorithm which includes control Front axle braking force
of the brake force distribution between the front and rear axles.
This is called Electronic Brake Distribution. In an unloading
Service precautions
car condition the brake efficiency is comparable to the con-
ventional system but for a fully loaden vehicle the efficiency of Observe the following general precautions during any
the EBD system is higher due to the better use of rear axle ABS/TCS service. Failure to adhere to these precau-
braking capability. tions may result in ABS/TCS system damage.
1. Disconnect the EBCM harness connector before
performing the electric welding procedures.
The Benefits of EBD 2. Carefully note the routing of the ABS/TCS wiring
and wiring components during removal. The ABS/
• Elimination of conventional proportioning valve EBD utilizes TCS components are extremely sensitive to EMI
the existing rear axle wheel speed sensor to monitor rear (eletromagnetic interference). Proper mounting is
wheel slip. critical during component service.
• Based on many variables in algorithm a pressure hold, 3. Disconnect the EBCM connector with the ignition
increase and/or decrease pulsetrain may be triggered at OFF.
the rear wheels insuring vehicle stability.
4. Do not hang the suspension components from
• Vehicle approaches the ideal brake force distribution (front the wheel speed sensor cables. The cables may
to rear). be damaged.
• Constant brake force distribution during vehicle lifetime. 5. Do not use petroleum based fluids in the master
• EBD function is monitored via ABS safety logic cylinder. Do not use any containers previously
(conventional proportioning valves are not monitorable). used for petroleum based fluids. Petroleum
• “Keep alive” function. causes swelling and distortion of the rubber
components in the hydraulic brake system,
resulting in water entering the system and
lowering the fluid boiling point.

AFFECTED VIN
4K 7
ON-VEHICLE SERVICE
Service Precautions
[Notice] Electronic system service precautions
Take care to avoid electronic brake control module (HECU)
Brake Fluid may irritate eyes and skin. In case of contact,
take the following actions:
circuit overloading. In testing for opens or shorts, do not
ground or apply voltage to any circuit unless instructed to
• Eye contact - rinse thoroughly with water.
do so by the diagnostic procedure.
• Skin contact - wash with soap and water.
Test circuits only with a high-impedance multi-meter. Never
• Ingestion - consult a physician immediately.
remove or apply power to any control module with the igni-
tion switch in the ON position. Always turn the ignition to
[Notice] the OFF position before removing or connecting battery
cables, fuses or connectors.
To help avoid personal injury due to poor braking. DO
NOT Tap into the vehicle’s brake system to operate a General service precautions
trailer brake system. Disconnect the HECU connector before performing any
vehicle welding work using an electric arc welder.
Do not attempt to disassemble any component designated
[Notice]
as nonserviceable. The hydraulic modulator and the HECU
When fasteners are removed, always reinstall them at the can be seperated. (There is however no access to repair
same location from which they were removed. If a fastener the each components.)
needs to be replaced, use the correct part number fastener
for is not available, a fastener of equal size and strength Bleeding system
(or stronger) may be used. Fasteners that are not reused, Replacement modulators are shipped already filled and
and those requiring thread-locking compound will be bled. In normal procedures requiring removal of the
called out. The correct torque values must be used when modulator, such as to replace the HECU, air will not enter
installing fasteners that require them. If the above the modulator, and normal bleeding will be all that is
procedures are not followed, parts or system damage
needed.
could result.
If air enters the hydraulic modulator, or if an unfilled modu-
lator is installed, use the brake bleeding program in the
[Notice] scan tool to bleed the modulator. Manual bleeding of the
Use only DOT-3 equivalent hydraulic brake fluid. The use hydraulic modulator is not possible.
of DOT-5 (silicone) brake fluid is not recommended.
Reduced brake performance or durability may result.
[Notice]
Avoid spilling brake fluid on any the vehicle’s painted
surfaces, wiring, cables or electrical connectors. Brake
fluid will damage paint and electrical connections. If
any fluid is spilled on the vehicle, flush the area with
water to lessen the damage.

AFFECTED VIN
8 4K
2. COMPONENTS AND LOCATION

Newly introduced ABS has a different shape of integrated hydraulic modulator and HECU (Hydraulic and Electronic
Control Unit) compared to existing ABS. And, the wheel speed sensor uses different method to detect wheel speed. The
basic function of the ABS that maintains the vehicle stability by controlling the steerability of the vehicle when braking
has not been changed.
Wheel speed sensor - Front Wheel speed sensor - Rear
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ABS HECU
ABS & EBD warning lamp

AFFECTED VIN
4K 9
3. INPUT AND OUTPUT DIAGRAM
Battery + (hydraulic valve

and ECU power supply) CAN LO
Battery + CAN HI
(pump supply power)
IG1
H ABS warning lamp

(instrument panel)
Brake switch
E Diagnosis connector pin
Wheel speed sensor (FL)

C no.8
U
Wheel speed sensor (FR)
Ground (pump)
Wheel speed sensor (RL)
Ground (valve)
Wheel speed sensor (RR)

AFFECTED VIN
10 4K
4. ELECTRICAL CIRCUIT

AFFECTED VIN
4K 11
5. HYDRAULIC CIRCUIT DIAGRAM

Hydraulic Circuit of ABS
Master cylinder
Primary Secondary
circuit circuit
Damping
chamber
Pump
Low pressure Low pressure

accumulator accumulator
Inlet Inlet Inlet valve

valve valve (all rear
(FR) (FL) wheel)
Outlet valve Outlet valve Outlet valve

(FR) (FL) (all rear wheel)
Wheel (FR) Wheel (FL) Wheel (RR) Wheel (RL)
The vehicle equipped only with the ABS controls the wheel’s braking force using three 3-channel 4-sensor method. The
front wheels that are the primary circuit of the brake system is composed of two wheel speed sensors and two channel
valves system with two inlet valves and two outlet valves. The rear wheels that are the secondary circuit of the brake
system is composed of two wheel speed sensors, one inlet valve and one outlet valve. This system is similar to the one
from the previous model.

AFFECTED VIN
12 4K
ABS Circuit Per ABS Operation Range
Hydraulic Pressure Circuit when ABS is Not Operating
Low pressure
chamber
Pump
Inlet valve
Outlet valve
The hydraulic pressure in the master cylinder increases through the vacuum booster and it is delivered to the wheel via
the normal open inlet valve. At this moment, the normally-closed outlet valve is closed. The speed of the wheel that
hydraulic pressure is delivered reduces gradually .
No Hydraulic Pressure Circuit when ABS is Operating
Low pressure
chamber
Inlet valve
Pump
Outlet valve
Constant pressure
As hydraulic pressure on each wheel increases, the wheel tends to lock. In order to prevent the wheel from locking, the
hydraulic valve modulator operates the inlet valve control solenoid to close the inlet valve and stop the hydraulic pressure
increases. At this moment, the outlet valve is closed. This procedure helps the wheel to maintain a stable hydraulic
pressure.
AFFECTED VIN
4K 13
Pressure Decreases in the Circuit when ABS is Operating
Low pressure
chamber
Pump
Inlet valve
Outlet valve
Pressure decreases
Even when the hydraulic pressure on each circuit is stable, the wheel can be locked as the wheel speed decreases.
This is when the ABS ECU detects the wheel speed and the vehicle speed and gives the optimized braking without
locking the wheels. In order to prevent from hydraulic pressure increases, the inlet valve is closed and the outlet valve is
opened. Also, the oil is sent to the low pressure changer and the wheel speed increases again. The ABS ECU operates
the pump to circulate the oil in the low pressure chamber to the master cylinder. This may make the driver to feel the
brake pedal vibration and some noises.
Pressure Increases in the Circuit when ABS is Operating
Low pressure
chamber
Pump Inlet valve
Outlet valve
Pressure increases
As the wheel speed increases, the inlet valve opens and the wheel’s pressure increases due to the master cylinder
pressure. The oil in the low pressure chamber circulates to the wheel by the pump and the wheel speed decreases as
the hydraulic pressure at wheel increases. This operation continues repetitively until there are no signs that the ECU is
locking the wheels. When the ABS hydraulic pressure control takes place, there may be some vibration and noises at
the brake pedal.

AFFECTED VIN
14 4K
6. COMPONENTS DESCRIPTION
HECU (Hydraulic & Electronic
Control Unit)
HECU consists of motor pump (1), solenoid valve (2) and ECU
(3).
ECU connector has 47 pins and the number of valves in valve
body is 6 when equipped with only ABS and 12 when equipped
with ESP system.
Motor Pump
The motor is operated when ABS is activated. The cam-shaped
output shaft of the motor enables the brake system to receive
and supply the brake fluid during the motor operation.
Valve Body
The cam bushing is installed between plungers and it draws
and discharges the brake fluid.

AFFECTED VIN
4K 15
(Pumping)
When the cam pushes the left plunger during motor operation,
the system pressure is generated in the left cylinder. At this
time, the right plunger is expanded by spring force and the
expanded volume of the right cylinder draws the brake fluid.
ECU (Including Solenoid Valves –

ESP Equipped Model)
HECU controls the hydraulic valves by supplying or cutting off
the voltage to solenoid valves depending on the wheel speed
and other information from wheel speed sensors.
The figure shown in left side is for ESP ECU. There are two
channels for front wheels and one channel for rear wheels.
Each channel has one inlet and one outlet valve, therefore,
there are six solenoid valves.
(ECU lower cover)

The electrical components are weak to moisture. To protect
ECU, GoreTex-based plate is used at ECU lower cover. The
vent hall (arrow) allows air to ventilate but does not allow mois-
ture to penetrate.

AFFECTED VIN
16 4K
Active Wheel Speed Sensor

Function of Active Wheel Sensor
The speed sensor used in traditional ABS is made of permanent magnet and transmits the output voltage that changes
as the wheel rotor rotates to the HECU system. New wheel speed sensor detects the wheel speed through the current
value that depends on the resistance that changes according to the magnetic field by using four resisters and supplying
the 12 V power supply to the sensor.
< Front wheel speed sensor > < Rear wheel speed sensor >
< Active type > <Wheatstone bridge>
Active type wheel speed sensor generate square wave insteal of sine wave
Specifications
Item Specifications Reference
Supplying voltage DC 12V
Front: 0.335 ~ 0.945 mm
Air gap Cannot measure the air gap
Rear: 0.309 ~ 0.958 mm
Output current (vehicle speed: at 2.75 km/h) 7mA (Lo) ~ 14mA (Hi) +20 % / -16 %
Front: 19 ~ 25 Nm
Tightening torque 7.5 ~ 20 V
Rear: 6 ~ 10 Nm

AFFECTED VIN
4K 17

HECU Assembly
Preceding Work: Disassemble the battery negative
cable.
1. Unscrew battery mounting bracket bolts (12 mm - 2EA)
and remove battery assembly.
2. Unscrew preheating relay mounting bracket bolts (12 mm

- 2EA) and battery tray mounting bolts (12 mm - 4EA).
3. Disconnect the control unit connector.

AFFECTED VIN
18 4K
4. Disconnect the primary and secondary master cylinder

pipes from HECU.
5. Disconnect the front and rear wheel brake pipes.

Front Rear RH/LH
Secondary
FL: Front Left
Primary
FR: Front Right
[Notice]
Be careful not to damage the HECU pipe and nut thread when reinstall.
6. Unscrew the HECU mounting nuts (2EA), and remove it.
[Notice]
Do not attempt to disassemble the HECU assembly.

Wrap the end of pipes and HECU to prevent comtaminating.

8. After reinstallation, add some oil and perform the brake
air bleeding.
[Notice]
When you install a new HECU to the vehicle, Coding is excuted automatically.

AFFECTED VIN
4K 19
Front Wheel Speed Sensor

1. Disconnect the battery negative cable.
2. Disconnect the front wheel speed sensor connector.
3. Remove one of self-locking bolt.

Tightening torque
Front wheel speed sensor 19 ~ 25 mm

Airgap 0.369 ~ 1.213 mm
4. Remove wheel speed sensor.

5. When install, clean the sensing area and replace the
self-locking bolt with new one.
Rear Wheel Speed Sensor

2. Disconnect the speed sensor connector.
3. Remove one of self-locking bolt.

4. Remove rear wheel speed sensor.
Tightening torque
Rear wheel speed sensor 19 ~ 25 Nm

Airgap 0.3677 ~ 1.229 mm
5. When install, clean the sensing area and replace the

self-locking bolt with new one.

AFFECTED VIN
20 4K
System Fuse
The ABS/TCS system fuse and SB2 is located at the fuse
box in engine compartment.
Indicators
The ABS and TCS indicators are in instrument cluster.

AFFECTED VIN
4K 21
ABS FRONT TOOTH WHEEL
Removal
1. Remove the disc brake rotor. Refer to Front Disc Brakes
Section.
2. Remove the ABS front tooth wheel using the ABS tooth
wheel puller (1).
Installation
1. Install the ABS front tooth wheel using the ABS tooth
wheel installer (2).

AFFECTED VIN
22 4K

661 589 16 33 00
ABS tooth wheel puller
661 589 17 33 00
ABS tooth wheel installer

AFFECTED VIN
4K 23
ESP SYSTEM
Principle of ESP
ESP (Electronic Stability Program) recognizes critical driving conditions, such as panic reactions in dangerous situations,
and stabilizes the vehicle by wheel-individual braking and engine control intervention with no need for actuating the
brake. This system is developed to help the driver avoid the danger of losing the control of the vehicle stability due to
under-steering or over-steering during cornering.
The yaw rate sensor, lateral sensor and longitudinal sensor in the sensor cluster and the steering wheel angle sensor
under the steering column detect the spin present at any wheels during over-steering, under-steering or cornering. The
ESP ECU controls against over-steering or under-steering during cornering by controlling the vehicle stability using the
input values from the sensors and applying the brakes independently to the corresponding wheels.
The system also controls during cornering by detecting the moment right before the spin and automatically limiting the
engine output (coupled with the ASR system).
Under steering Over steering
Desired
course
With ESP
Desired Without
course ESP
With ESP
Braked
Braked wheel
wheel Without
ESP
Compen-
sating yaw
moment Compen-
Braking force
sating yaw
moment
Braking force
Understeering Oversteering
Understeering is when the steering wheel is steered to a Oversteering is when the steering wheel is steered to a
certain angle during driving and the front tires slip toward certain angle during driving and the rear tires slip outward
the reverse direction of the desired direction. Generally, losing traction. When compared with under steering
vehicles are designed to have under steering. The vehicle vehicles, the controlling of the vehicle is difficult during
can return back to inside of cornering line when the steer- cornering and the vehicle can spin due to rear wheel mo-
ing wheel is steered toward the inside even when the ve- ment when the rear tires lose traction and the vehicle speed
hicle front is slipped outward. As the centrifugal force increases.
increases, the tires can easily lose the traction and the
vehicle tends to slip outward when the curve angle gets
bigger and the speed increases.

AFFECTED VIN
24 4K
ESP controls during under steering ESP controls during oversteering

The ESP system recognizes the directional angle with the The ESP system recognizes the directional angle with
steering wheel angle sensor and senses the slipping route the steering wheel angle sensor and senses the slipping
that occurs reversely against the vehicle cornering direc- route that occurs towards the vehicle cornering direction
tion during understeering with the yaw rate sensor and the during oversteering with the yaw rate sensor and the lat-
lateral sensor. Then the ESP system applies the brake at eral sensor. Then the ESP system applies the brake at
the rear inner wheel to compensate the yaw moment value. the front outer wheel to compensate the yaw moment value.
In this way, the vehicle does not lose its driving direction In this way, the vehicle does not lose its driving direction
and the driver can steer the vehicle as driver intends. and the driver can steer the vehicle as he or she intends.
ESP Control
The ESP system includes the ABS/EBD and ASR systems allowing the system to be able to operate depending to the
vehicle driving conditions. For example, when the brakes are applied during cornering at the speed of 100 km/h, the ABS
system will operate at the same time the ASR or ABD systems operate to reduce the power from the slipping wheel. And
when yaw rate sensor detects the rate exceeding 4¡Æ/seconds, the ESP system is activated to apply the brake force
to the corresponding wheel to compensate the yaw moment with the vehicle stability control function. When various
systems operate simultaneously under a certain situation, there may be vehicle control problems due to internal mal-
function of a system or simultaneous operations. In order to compensate to this problem, the ESP system sets the
priority among systems. The system operates in the order of TCS (ASR or ABD), ESP and ABS. The order may be
changed depending on the vehicle driving situations and driving conditions. As the single-track vehicle model used for
the calculations is only valid for a vehicle moving forward, ESP intervention never takes place during backup.
ESP Operating ESP

range
Turning Turning

AFFECTED VIN
4K 25
Vehicle Control During Cornering

The figure below shows the vehicle controls by ESP system under various situations such as when the brake pedal is
pressed (or not pressed) during cornering and when the ABS is operating or when just the conventional brake is operat-
ing during braking. It also includes the vehicle conditions when the TCS that is included in the ESP system is operating.
Operations Understeering Control Oversteering Control

ESP auto brake
Only ESP operating Engine

No braking by driver control
ESP auto brake
: Service brake ESP auto brake

(none ABS)
ESP
+
Conventional
brake
(ABS not operating) ESP auto brake
: Service brake
1 : The slip occurs

2 : ABS operation under ESP operation
ESP
+
ABS brake
1 : The slip occurs
under ESP
operation
2 : ABS operation
2 : ASR operation 1 : The slip occurs

under ESP operation
ESP
+ Engine
control
ASR
1 : The slip occurs

under ESP
operation 2 : ASR operation

AFFECTED VIN
26 4K
HBA (Hydraulic Brake Assist System)

Experienced drivers
Deceleration
Inexperienced drivers
Elderly and physically

weak drivers
Time (s)
(1) Purpose
HBA (Hydraulic Brake Assist) system helps in an emergency braking situation when the driver applies the brake fast,
but not with sufficient pressure, which leads to dangerously long braking distance. ECU recognizes the attempt at full
braking and transmits the signal calling for full brake pressure from the hydraulic booster. An inexperienced, elderly or
physically weak driver may suffer from the accident by not fully pressing the brake pedal when hard braking is required
under emergency. The HBA System increases the braking force under urgent situations to enhance the inputted braking
force from the driver.
Based on the fact that some drivers depress the brake pedal too soft even under when hard braking is necessary, the
HECU system is a safety supplementary system that builds high braking force during initial braking according to
pressure value of the brake pressure sensor and the pressure changes of the pressure sensor intervals.
When the system is designed to apply high braking force when brake pedal is depressed softly by an elderly or
physically weak driver, the vehicle will make abrupt stopping under normal braking situation due to high braking pressure
at each wheels.
(2) Operation
The brake pressure value and the changed value of the pressure sensor are the conditions in which the HBA System
operates. There are 2 pressure sensors under the master cylinder. When the ESP ECU system determines that emer-
gency braking is present, the pump operates, the brake fluid in the master cylinder is sent to the pump and the braking
pressure is delivered to the wheels via the inlet valves.
If the drive depress the brake pedal slowly, the pressure change is not high. In this case, only the conventional brake
system with booster is activated.

AFFECTED VIN
4K 27
1. HECU: (Hydraulic & Engine 2. Pressure sensor 3. Wheel speed sensor

conrol unit)
ESP Warning lamp
4. Sensor cluster: 5. Steering wheel angle 6. ESP off switch (Electronic

(Yaw rate + lateral sensor + sensor Stability Program Switch)
longitudinal sensor)
2WD vehicle has the longitudinal sensor in the HECU.

AFFECTED VIN
28 4K
Comparison with ABS System

Specifications
Name Location
ABS ESP
HECU CPU: MCU60 (32 bit) CPU: MCU60 (32 bit)
(Hydraulic & Elec- Clock Frequency: 28 MHz Clock Frequency: 28 MHz Under battery
tronic Control Unit) Memory: 128 ~ 256 KB Memory: 256 ~ 512 KB
Each 4 wheels
Wheel speed sensor Active Type Active Type Front airgap: 0.335 ~ 0.945 mm
Rear airgap: 0.309 ~ 0.958 mm
Steering wheel Maximum angular velocity: 1500°/Sec

N/A Under steering wheel
angle sensor Working voltage: 9 ~ 16 V
2WD: Yaw rate sensor + Lateral sensor
Sensor cluster N/A
4WD: Yaw rate + Lateral sensor + Under front right seat
Longitudinal sensor Integrated in HECU Longitudinal sensor
Pressure sensor N/A Analog Output Under master cylinder

AFFECTED VIN
4K 29
3. INPUT AND OUTPUT DIAGRAM
Batt. + (voltage to hydraulic v/v) CAN LO
Battery + (voltage to pump) CAN HI
IG1
Brake switch
STICS (Vehicle speed)
ESP switch
A/V Head unit
Signal
A/V system is inoperative while driving
Wheel speed sensor (FL) Ground
Signal Cluster (Vehicle speed)

Wheel speed sensor (FR) Ground
E
Signal S ESP warning lamp
Wheel speed sensor (RL) Ground ESP lamp on while
Signal
P - ESP is in operation (Flicker)
- ESP, ABS system error
- ESP off switch is pushed
Wheel speed sensor (RR) Ground
ABS warning lamp
Power
source
Signal H ABS system error
Pressure sensor 1
Ground ESP buzzer
Power
E While ESP is in operation buzzer work by
source every 0.1sec
Pressure sensor 2
Signal C
Ground
U Diagnostic connector
IG1
ST1
ST2
SWAS
STN Ground (Pump)
Ground
Ground (Valve)
Power
source
CAN-H
Sensor cluster CAN-L
Ground

AFFECTED VIN
30 4K
4. ELECTRICAL CIRCUIT DIAGRAM

ABS/ESP
Wheel Speed Sensor, Stop Lamp, Diagnosis, Warnung Lamp (ABS/ESP)

AFFECTED VIN
4K 31
Brake Pressure Sensor, ESP Sensor, Sensor Cluster, ESP OFF Switch

AFFECTED VIN
32 4K
5. HYDRAULIC CIRCUIT DIAGRAM
Pressure
sensor
Damper Damper
(primary circuit) (secondary circuit)
Separation
valve (NO) Separation valve
(NO)
Damping chamber
Shuttle
Pump Shuttle valve
valve
Low pressure
accumulator
FR FL inlet RR RL
inlet valve valve inlet valve inlet valve
(NO) (NO) (NO) (NO)
FR FL RR RL
outlet outlet outlet outlet
valve(NC) valve(NC) valve(NC) valve(NC)
Wheel (FR) Wheel (FL) Wheel (RR) Wheel (RL)

AFFECTED VIN
4K 33
System Overview
When equipped with ABS, the braking force at each wheel will be controlled with 3-channel 4-sensor method. And when
equipped with ESP, 4 wheels will be controlled independently with 4-channel method. (When controlling ABS system
only, it will be operated with 3-channel method.) When compared to the vehicle equipped with ABS/EBD only, the
internal hydraulic circuit has a normally-open separation valve and a shuttle valve in primary circuit and in secondary
circuit. When the vehicle brakes are not applied during engine running or when applying the non-ABS operating brakes,
the normally-open separation valve and the inlet valve are open, whereas the normally-closed shuttle valve and the outlet
valve are closed. When the ESP system is operating, the normally-open separation valve will be closed by the solenoid
valve operation and the hydraulic circuit will be established by the shuttle valve. Then, the inlet and outlet valves will be
closed or open depending on the braking pressure increase, decrease or unchanged conditions.
The warning lamp comes on and warning beep sounds when the ESP is operating
When the ESP operates during vehicle movement, the ESP warning lamp on the instrument panel flickers and
beep comes on every 0.1 seconds. The ESP operation shows that the vehicle stability is extremely unstable
and it is used to warn the driver. The ESP system is just a supplementary system for the vehicle motion and it
cannot control the vehicle when it exceeds the physical limits. Do not solely rely on the system but be advised
to drive the vehicle safely.
Driving feeling when the ESP is operating

When the ESP system activates, the driving feeling can be different depending on vehicle driving conditions. For
example, you will feel differently when the ESP system is activated during when ABS is operating with the
brakes applied and when brakes are not applied on a curve. Thus, the ESP system would make the driver feel
more abruptly when the brakes are applied during the ESP system activation.
Noise and vibration that driver senses when the ESP is operating
The ESP system may transfer noise and vibration to the driver due to the pressure changes caused by the
motor and valve operations in a very short period of time. Extreme cornering will trigger the ESP operation and
this will make the driver feel noise and vibration due to sudden brake application. Also, the ESP system controls
the engine output. So, the driver may notice the engine output decrease even when the accelerator pedal is
being applied.

AFFECTED VIN
34 4K
(1) ESP Hydraulic unit in idling and normal braking position
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Outlet valve
Inlet valve
In this position, the separation valve and the inlet valve are open (normal open), the electrically operated shuttle valve and
the outlet valve are closed. When the brake is applied under these conditions, the brake fluid will be sent to each wheel
via the separation valve and inlet valve.

AFFECTED VIN
4K 35
(2) When applied ABS (decreased pressure)
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Inlet valve
Outlet valve
The pressure decreases just before the wheel speed drops and the wheels. The inlet valve closes and the outlet valve
opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied.
Then the pump operates to allow fast oil drainage.

AFFECTED VIN
36 4K
(3) When applied ABS (maintained pressure)
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Inlet valve Outlet valve
The Inlet valve and outlet valve will be closed to maintain the pressure in the hydraulic circuit applied at the wheels. By
closing the valves, the hydraulic pressure at the wheels will not be lost or supplied any more. During ESP operation, the
separation valve closes and only the shuttle valve at the pump opens.

AFFECTED VIN
4K 37
(4) When applied ABS (increased pressure)
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Outlet valve
Inlet valve
The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed. Then, the pump is
operated.
When ESP operates while the ABS is operating, the pressure will be increased continuously until just before the
corresponding wheel gets locked.

AFFECTED VIN
38 4K
(5) Hydraulic Diagram of HBA
Low pressure
chamber
Shuttle valve
Separation valve Outlet valve
Inlet valve
Pump
Rear wheel
Outlet valve
Inlet valve
Front wheel
The above figure shows one front and one rear wheel and the same hydraulic circuit forms as in the ESP operation.
When HECU recognizes that it is an emergency and it is required for hard braking, depending on the pressure value of
the brake pressure sensor and pressure changes caused by the pressure sensor timing, it operates the pump immedi-
ately to apply the brake pressure at the wheels.
Then, the pressure in the pump increases until just before the corresponding wheel gets locked. The motor still keeps
rotating and the outlet valve and the separation valve are will stay closed. When the wheel starts to lock, the HBA
function cancels and switches to ABS operation.

AFFECTED VIN
4K 39
6. COMPONENTS DESCRIPTION
HECU (Hydraulic and Electronic Control Unit)
HECU Installed in a Vehicle
RL: Rear left
Secondary
RR: Rear right
FL: Front left
Primary
FR: Front right
HECU consists of motor pump, solenoid valve and ECU.

ECU connector has 47 pins and the number of valves in valve body is 12 when equipped with ESP(6 valve for ABS/EBD),
and they cannot be disassembled.
Comparison between ESP HECU and ABS/EBD HECU
ABS/EBD HECU (2 ports 3 chnnels) ESP HECU (2 ports 4 chnnels)

AFFECTED VIN
40 4K
ECU (Electronic Control Unit)

The electronic control unit performs the following functions:
- controlling the ABS and ESP
- cotinuous monitoring of all electrical components
In the integrated control unit, the coils of the solenoid valves
are integrated into the control unit housing. The necessary
relays are mounted on the circuit board of the electronic con-
trol unit.
- yaw rate
- G sensor
- lateral/longitudinal acceleration
- pressure in hydraulic system
- wheel speed
- reference speed
- deceleration
- slip
# ABS control
If during braking, one wheel speed deviates from the reference Brake pressure
speed, the ABS control unit attempts to correct that wheel by Reference speed
modulating the brake pressure until it again matches the ref- Vehicle speed
erence speed. When all four wheels tend to lock, all four wheels Wheel speed
speeds suddenly deviate from the previously determined ref-
erence speed. In that case, the control cycle is initiated again
in order to again correct the wheel speed by modulating the
brake pressure.
Hydraulic Control Unit

The pump and the valve body are grouped together in one
housing, forming one compact unit with the electric motor.
Four pairs of valves (4 inlet valves, 4 outlet valves) are provided
for modulating the pressure at the wheels plus two isolating
valves and two electrically operated shuttle valves.
Mote pump Valve body

AFFECTED VIN
4K 41
Connector
Pin no. Name Current Tange Voltage Range ABS ECU

1 Battery (B+) Max. 30 A 0 ~ 18 V O
2 Self diagnosis (K-Line) Max.100 mA 0 ~ 18 V O
3 Steering wheel angle sensor (STN) Max. 10 mA 0 ~18 V -
4 IGN1 Max. 200 mA 0 ~ 18 V O
5 Steering wheel angle sensor ground Max. 100 mA 0V -
6 Sensor cluster power Max. 250 mA 0 ~ 18 V -
7 Steering wheel angle sensor power Max. 10 mA 0 ~ 18 V -
8 - - - -
9 - - - -
10 - - - -
11 CAN (High) Max. 100 mA 0 ~ 18 V O
12 - - - -
13 - - - -
14 - - - -
15 CAN (Low) Max. 100 mA 0 ~ 18 V O
16 Ground Max. 20 A 0V O
17 - - - -
18 Pressure sensor (No.1) power Max. 20 mA 5V -
19 Pressure sensor (No.1) ground Max. 20 mA 0V -
20 Pressure sensor (No.1) signal Max. 10 mA 5 V -
21 Pressure sensor (No.2) ground Max. 20 mA 0 V -
22 Pressure sensor (No.2) power Max. 20 mA 5 V -
23 Pressure sensor (No.2) signal Max. 10 mA 5 V -
24 - - - -
25 Sensor cluster CAN (Low) Max. 10 mA 0 ~ 18 V -
26 - - - -
27 - - - -
28 Steering wheel angle sensor (ST2) Max. 10 mA 1.3 ~ 4.1 V -
29 Sensor cluster CAN (HIGH) Max. 10 mA 0 ~ 18 V -
30 Steering wheel angle sensor (ST1) Max. 10 mA 1.3 ~ 4.1 V -
31 Sensor cluster ground Max. 250 mA 0V -
32 Battery (B+) Max. 20 A 0 ~ 18 V O
33 Wheel speed sensor ground (FR) 3 ~ 45 mA 0V O
34 Wheel speed sensor ground signal (FR) 3 ~ 45 mA 0 ~ 18 V O
35 - - - -
36 Wheel speed sensor ground signal (RL) 3 ~ 45 mA 0 ~ 18 V O
37 Wheel speed sensor ground ground (RL) 3 ~ 45 mA 0V O
38 - - - -
39 - - - -
40 ESP OFF switch Max. 10 mA 0 ~ 18 V -
41 Stop lamp switch Max. 10 mA 0 ~ 18 V O
42 Wheel speed sensor ground ground (RR) 3 ~ 45 mA 0V O
43 Wheel speed sensor ground signal (RR) 3 ~ 45 mA 0 ~ 18 V O
44 ABS warning lamp Max. 20 mA 0 ~ 18 V O
45 Wheel speed sensor ground signal (FL) 3 ~ 45 mA 0 ~ 18 V O
46 Wheel speed sensor ground ground (FL) 3 ~ 45 mA 0V O
47 Ground Max. 30 A 0V O

AFFECTED VIN
42 4K
Wheel Speed Sensor

Active Wheel Sensor
- Measuring bridge with four resisters
- Measuring the current
- Supplying the voltage (12 V)
- Amplifier/comparison measuring device
Function of Active Sensor System

The basic tone wheel and the magnetized encoder wheel to
activate the sensor. When the vehicle is moving, the sine wave
signal is changed in the magnetic field of wheatstone bridge
due to the rotation of tone wheel. This can be done directly by
ABS control unit.
Active Sensor Element of Encoder Wheel

This sensor has the measuring bridge integrated plastic hous-
ing and is fixed to small permanent magnet. Four lead wires Permanent
that receive electrical output value are connected to the IC magnet
integrated plastic housing. Two connecting pins are used for
signal output and voltage supply.
Sensor filament
Specifications
Description Specifications Reference

Supplying voltage DC 12 V
Front: 0.335 ~ 0.945 mm
Air gap Cannot measure the air gap
Rear: 0.309 ~ 0.958 mm
Output current
7 mA (Lo) ~ 14 mA (Hi) +20 % / -16 %
(vehicle speed at 2.75 Km/h)
Front: 19 ~ 25 Nm
Tightening torque 7.5 ~ 20 V
Rear: 6 ~ 10 Nm

AFFECTED VIN
4K 43
SWAS : Steering Wheel Angle Sensor

The steering wheel angle sensor is located between clock spring and multifunction switch. This sensor is used for
recognition of driver’s intends. If the sensor is replaced with new one, it can detect the neutral position after the vehicle
is moving over 20 km/h for more than 5 seconds.
1. Clock spring 2. Multi-function switch 3. SWAS (Steering Wheel Angle Sensor)
Specifications
Working voltage 9 ~ 16 V
Max. output current 10 mA
Detected max. angular velocity 1500°/S
Working temperature -30 ~ 75°C
Supplying voltage 9 ~ 16 V(battery voltage)
When short 0V
When short to sensor Power voltage - 0.7 V
Output voltage (HI) Approx. 3.50 V (3.0 ~ 4.1 V)
Output voltage (LO) Approx. 1.50 V (1.3 ~ 2.0 V)

AFFECTED VIN
44 4K
Steering wheel angle

sensor connector
LED Phototransistor
Steering column Slotted plate
Steering wheel angle
The steering wheel angle sensor is integrated with the phototransistor and the LED and there is a slotted plate between
them. When the inner slotted plate rotates with the steering column shaft when the steering wheel is turned, the voltage
occurs through the holes. The detected voltage will be transmitted to the ESP unit as a pulse from the 3 terminals.
Then, the two voltage pulses are used to get the average value for detecting the steering wheel position and its angle
speed. And the other pulse is used for checking the alignment of the steering wheel.
Steering
Wheel
ESP
Angle
unit
Sensor
(SWAS)
With ESP
Working voltage 9 ~16 V

Number of pulse
45 Pulses /1rev
per revolution
Duty Approx. 50 %
High - V 3.0 ~ 4.1 V
Low - V 1.3 ~ 2.0 V

Detects steering wheel
ST1 and ST2 angle and angular veloc-
ity as an average value
Detects the center value
STN Center line of steering wheel
of steering wheel

AFFECTED VIN
4K 45
Sensor Cluster
The lateral sensor, logitudinal sensor and the yaw rate sensor are important components of the Electronic Stability
Program. The cluster links these sensors to an on-board computer unit and to a CAN interface, incased in a sturdy
housing, that is mounted on the chassis. Its modular concept allows the integration of further sensor functions.
Location
Internal Electric Circuit of Sensor Cluster
Sensor cluster
Power supply Power supply

circuit
Yaw rate sensor
Micro controller
ECU A/D converter
(self diagnosis)
Lateral sensor
CAN Longitudinal sensor

CAN module

AFFECTED VIN
46 4K
Sensor Cluster Circuit
Power
Ground
Power
Sensor cluster ESP unit
Specification
(sensor cluster: yaw rate sensor + lateral acceleration sensor + Longitudinal acceleration sensor)
Supplying voltage Approx. 8 ~ 16 V
Output voltage when stop Approx. 2.5 V (Ignition switch “ON”)
Output range 0.2 ~ 4.8 V
Operation start speed -75°/s ~ +75°/s
Yaw Rate Sensor

The yaw rate sensor relies on the action of micro-scopic tun-
ing forks. The plane in which these forks vibrate shifts when
the car turns around its vertical axis. This shift is evaluated
electronically.
A faulty yaw rate sensor produces an output signal of 0 V.

AFFECTED VIN
4K 47
Installation position
• Tuning forks vertical
• Required accuracy of position: max. ± 3° tolerance to
maintain full comfort
• Failure to maintain the specified installation position will
result in asymmetrical control
Lateral/Longitudinal Acceleration
Sensor
These sensors sense the lateral/longitudinal acceleration of
the vehicle and located in sensor cluster. For 4WD vehicle,
the longitudinal sensor is located in sensor cluster and the
functions are same only except the direction. The lateral ac-
celeration sensor detects the movement of lateral direction
and the longitudinal acceleration sensor detects the move-
ment of longitudinal direction (driving direction).
Between two electrically charged stationary plates having the
same polarity, an electrically charged silicon element having
the opposite polarity is attached to the end of a cantilever
arm. Between these three plates, two electric fields are gen-
erated by the capacitors C1 and C2. The capacitances of C1
and C2 change in response to lateral acceleration. This change
can be used to calculate the direction and amount of lateral/
longitudinal acceleration acting on the vehicle. For 0 g lateral
acceleration, the sensor produces an output signal with a volt-
age of 2.5 V.
The signal of the lateral acceleration sensor alone cannot trig-

ger an ESP intervention.
The ESP sensor cluster can be considered as one module.
The measured value by lateral/longitudinal and yaw rate sen-
sors is transmitted to ESP unit via two CAN lines.
When a sensor is faulty, the sensor cluster produces an out-
put signal of 0 V (fail safe function).

AFFECTED VIN
48 4K
Pressure Sensor
Location
1. Master cylinder 4. Inside of pressure sensor

2. Primary pressure sensor 5. Connector
3. Second pressure sensor
Pressure Sensor Circuit
Ground
• HBA operating conditions with output value from
Power
pressure sensor:
- pressure: 20 bar
Signal output
- pressure deviation: over 1500 bar/sec
<Primary pressure sensor>
- vehicle speed: over 7 km/h
Ground
Power
Signal output
<Secondary pressure sensor> <ESP unit>
Specifications
Supplying voltage 4.75 ~ 5.25 V
Output range 0.25 ~ 4.75 V
Output voltage when stop 2.5 V

AFFECTED VIN
4K 49
Description
a. The pressure sensor senses the driver’s braking
intentions (braking while an ESP intervention is in
progress) and detects the precharging pressure.
b. The sensor consists of two ceramic disks, one of which

is stationary and the other movable. The distance
between these disks changes when pressure is applied.
c. The pressure sensors operate on the principle of changing

capacitance (a).
The distance (s) between the disks and, thus, the
capacitance changes when pressure is applied to the
movable disk by a braking intervention.
Brake not
applied
d. When brake pressure is applied from the master cylinder,

the ceramic disk moves towards the fixed ceramic disk
and the electric charge volume changes accordingly.
Brake
applied

AFFECTED VIN
50 4K
If two signals from pressure sensor deviates from the specified value, HECU determines the sensor is faulty. The sensor
output is analog signal that is proportional to voltage and the HECU recognized the pressure value as signal value
against supplying voltage.
Maximum measurable pressure: 170 bar

Linear changes of about 0.5 volts when the brake is not operating and 4.75 volts when the brake is operating.

AFFECTED VIN
4K 51
ESP OFF Switch

ESP OFF switch is located at center switch panel. When pressing the switch, the ESP warning lamp lights up and ESP
and TCS function is deactivated.
However, the ABS function is still activated.
Automatic coding
When replacing the HECU with new one, it is coded automatically. Therefore, additional coding operation is not needed.
When the existing ECU installed to another vehicle or a new HECU recognizes that the coded data is not matched with
the vehicle, the warning lamp lights up and ABS/ESP is not activated.
The HECU is coded when it is initially installed to the vehicle, and once coded data cannot be changed.
* If DTC C1170 (5170) is generated during automatic coding, clear it with a scan tool to resume automatic coding
process.

AFFECTED VIN
52 4K
WARNING LAMP AND INDICATOR

ESP Warning Lamp Blinking in Control
ESP warning lamp blinks when ESP control is activated. If the activation reaches a certain limitation, a beep sounds to
warn the driver. The ESP warning lamp goes off when ESP function is deactivated. Even when the ESP is operated for
a very short period of time, the ESP warning lamp blinks minimum of 4 times every 175 milliseconds and the buzzer
sounds for at least 1.4 seconds with 100 ms interval.
ON
ESP operation
(including ASR)
OFF
Min. 4 times
ON
ESP warning lamp

OFF
Min. 1.4 sec
ON
ESP buzzer
OFF
ESP System Cancellation Using the ESP OFF Switch

When the ESP switch at the center switch panel is pushed (for over approximately 150 ms), the ESP system will be
cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors. Then, the ESP
warning lamp on the instrument panel comes on.
The detailed operation procedures are as follows:
1) The ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms.
2) The switch returns to normal position when the OFF switch is released.
3) The ESP system will be cancelled after approximately 150 ms.
Based on the above procedures, we can see that the ESP system will be cancelled after a certain period (approx. 150
ms) from releasing the switch to the original position. The ESP system does not get canceled immediately when the
ESP warning lamp is turned on by pressing the ESP OFF switch.
When you turn the ESP system off by pressing the ESP switch for over 150 ms, the TCS system is turned off. And the
basic ABS system will operate.

AFFECTED VIN
4K 53
Resuming the ESP System by Using the ESP OFF Switch

The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESP switch at
the center switch panel is pushed (for over approximately 150 ms) while the ESP system is not operating.
The detailed operation procedures are as follows.
1) The ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms.
2) The switch returns to normal position when the OFF switch is released.
3) The ESP system will be resumed after approx. 150 ms.
RELEASE
PUSH
RELEASE
PUSH
HI
ESP operation Disabled range
LO
ESP function ON
(including ASR)
OFF
ON
ESP warning lamp
OFF
[Notice]
• When turning the ignition switch off while the ESP system is activated, the ESP system will be resumed when ignition
switch is turned on again.
• When the vehicle is controlled by ESP system during driving, the ESP OFF switch does not operate.
• The ESP OFF switch operates when it is pushed for over 150 ms. When it is pushed for less than 150 ms, the ESP OFF mode
and the ESP warning lamp will not be changed.
• When the ESP OFF switch is pushed within 350 ms of being turned off, the ESP warning lamp and ESP system will not be
turned on.

AFFECTED VIN
54 4K
ESP OFF Switch Monitoring

When the ESP unit recognizes that the ESP OFF switch is pushed for over 60 seconds, the ESP unit determines it as
a ESP OFF switch malfunction. When the ESP OFF switch is pushed, the ESP system is resumed after 60 seconds.
However, the ESP warning lamp comes on when the ESP OFF switch is pushed (for over 150 ms) and then goes out
when the ESP system is resumed. When the ESP OFF switch returns to normal position, the ESP unit resets the ESP
OFF switch for approx. 3.5 seconds.
Push Release
´
HI
ESP operation
LO
60 sec
3.5 sec
Return to switch signal Reset to normal condition
ON
ESP function
(including ASR) OFF
Cancellation of ESP OFF mode
Turning the ESP warning lamp off
ON
ESP warning lamp
OFF

AFFECTED VIN
4K 55
ESP Warning Lamp Operation Depending on System Conditions

The table shows ESP warning lamp operations when the ESP system is defective or ESP (including TCS function) is
working.
Warning Lamp Controls
EBD ABS ESP ESP Vehicle

EBD ABS ASR ABD yaw
W/L W/L W/L BUZZER control
Initial start ON ON ON OFF X X X X X
(for 1.8 sec) BLINKS INTERMITTENT BEEP
OFF OFF WHEN ESP SOUNDS WHEN ESP O O O O O
Normal mode OPERATION OPERATION
ESP fault OFF OFF ON OFF O O X X X
ABS fault OFF ON ON OFF O X X X X
System fault ON ON ON OFF X X X X X
Low batt. voltage 1 st
OFF ON ON OFF O X X X X
Low batt. voltage 2 nd
ON ON ON OFF X X X X X
High battery voltage ON ON ON OFF X X X X X
High brake pad temp. OFF OFF ON OFF O O **O X O
ESP-OFF mode OFF OFF ON OFF O O X X *O
Entering diag. mode ON ON ON OFF X X X X X
*) When the driver presses the brake pedal during the ESP OFF mode, the yaw control is performed to compensate
the vehicle stability (posture) during ESP operation.
* *) The ASR controls only engine control

AFFECTED VIN
56 4K

HECU Assembly
Preceding Work: Disassemble the battery negative
cable.
1. Unscrew battery mounting bracket bolts (12M - 2EA)
and remove battery assembly.
2. Unscrew preheating relay mounting bracket bolts (12M -

2EA) and battery tray mounting bolts (12M - 4EA).
3. Disconnect the control unit connector.

AFFECTED VIN
4K 57
4. Disconnect the primary and secondary master cylinder

pipes from HECU.
5. Disconnect the front and rear wheel brake pipes.
RL: Rear left
Secondary
RR: Rear right
FL: Front left
Primary
FR: Front right
[Notice]
Be careful not to damage the HECU pipe and nut thread
when reinstall.
6. Unscrew the HECU mounting nuts (2EA), and remove it.
[Notice]
Donot attempt to disassemble the HECU assembly.

Wrap the end of pipes and HECU to prevent comtaminating.

8. After reinstallation, add some oil and perform the brake
air bleeding.
[Notice]
When you install a new HECU to the vehicle, Coding is excuted

automatically.

AFFECTED VIN
58 4K
Steering Wheel Sensor

1. Disconnect the battery negative cable and align the tires straight forward.
2. Remove the airbag module.
3. Unscrew the steering wheel mounting nut and remove the wheel.
4. Remove the I/P panel lower cover.
[Notice]
• Leave marks on the column shaft(A) and on the wheel(B).

AFFECTED VIN
4K 59
5. Remove the steering column upper/lower cover.
6. Remove the contact coil.
7. Remove the steering wheel angle sensor frim the steering

wheel (combi switch).

AFFECTED VIN
60 4K
Sensor Cluster
1. Remove center panel and aircon controller.
2. Disconnect the sensor cluster connector and unscrew

the cluster mounting bolts (2EA).
3. Disassemble the sensor cluster.

AFFECTED VIN
4K 61
8. ABS/ESP TROUBLE DIAGNOSIS

DTC CODE
[O: Applied, X: N/A]
Trouble
Defective Components Descriptions ABS ESP
Code
Cause
- Defective front LH wheel speed sensor
- Short or poor contact wire to sensor
C1011 Wheel speed sensor
Action O O
(5011) front left-electrical
- Check the wheel speed sensor connector and HECU
connector
- Check the harness connection
Cause
- Defective front LH wheel speed sensor
- No signals from wheel speed sensor and tooth wheel
C1012 Wheel speed sensor - Different number of teeth in tooth wheel O O
(5012) front left-other Action
- Check air gap and tooth wheel mounting
- Check the number of teeth in tooth wheel: 48
Cause
- Defective front RH wheel speed sensor
C1021 Wheel speed sensor Action O O
(5021) front right-electrical - Check the wheel speed sensor connector and HECU
connector
Cause
- Defective front RH wheel speed sensor
- Too large air gap between wheel speed sensor and tooth
C1022 Wheel speed sensor wheel O O
(5022) front right-other
- Different number of teeth in tooth wheel
Action
Cause
- Defective rear RH wheel speed sensor
Action O O
(5031) rear right-electrical
- Check the wheel speed sensor connector
- Check the EBCM connector

AFFECTED VIN
62 4K
Trouble
Code
Cause
- Defective rear RH wheel speed sensor
C1032 Wheel speed sensor rear - Too large air gap between wheel speed sensor and
tooth wheel
O O
(5032) right-other
Action
Cause
- Defective rear LH wheel speed sensor
Action O O
(5041) rear left-electrical
- Check the HECU connector
Cause
- Defective rear LH wheel speed sensor
- Too large air gap between wheel speed sensor and
C1042 Wheel speed sensor tooth wheel O O
(5042) rear left-other
Action
Cause
- Abnormal signals from pressure sensor
- Defective pressure sensor or harness
C1051 Action
Pressure sensor X O
(5051)
- Check the pressure sensor connector
- Check the output voltage (stop): 0.5 V
- Check the output voltage (brake applied): 0.25 ~ 4.75 V
Cause
- Internally defective steering wheel angle sensor
- Abnormal signals from steering wheel angle sensor
- Short circuit between supplying voltage output and ground
- Abnormal signal voltage from steering wheel angle sensor
C1061 Steering wheel Angle - Poor installation of steering wheel angle sensor and
X O
(5061) sensor abnormal signal
Action
- Check the harness connection of steering wheel angle
sensor
- Check the working voltage : LOW – 1.3 ~ 2.0 V
HIGH – 3.0 ~ 4.1 V

AFFECTED VIN
4K 63
Trouble
Code
Cause
- Operating voltage exceeds specified range
(Hi: 18.0 ± 1.0 V / Lo: 6.5 ± 0.5 V)
C1073 Sensor cluster -electri- X
- Poor contact or installation of harness O
(5073) cal
Action
- Check the sensor cluster connector
- Others
Cause
- Internally defective HECU
- Abnormal A/D converter voltage: 5.0 ± 3 %
- Abnormal supplying voltage (4.580 ~ 4.960 V) to sensor
cluster
→ Short circuit between supplying voltage output of
sensor cluster and ground
- Poor ground of sensor cluster (0.0 ~ 0.5 V)
→ Short to ground on sensor cluster
C1074
Sensor cluster-internal - Abnormal signals from longitudinal acceleration sensor X O
(5074)
- Abnormal signals from lateral acceleration sensor
- Abnormal signals from yawing sensor
- Poor installation of sensor
- Defective sensor cluster
- Defective or short circuit of CAN communication line
Action
- Replace the sensor
- Initialize the sensor
Cause
C1101 - Low voltage out of specified range (9.7 ± 0.3 V)
Battery under voltage O O
(5101) Action
- Check the supplying voltage
Cause
C1102 - Over voltage out of specified range (18.0 ± 1.0 V)
Battery over voltage O O
(5102) Action
Cause
C1111 - Overheated brake disk due to braking force: over 500°C
Disk temperature is high Action O O
(5111)
- Stop driving for a period of time after turning off the ESP

AFFECTED VIN
64 4K
Trouble
Code
Cause
- Mechanical defective in brake switch
C1201
Brake lamp switch - Defective brake switch harness X O
(5201)
Action
- Check the harness and connector
Cause
- Mechanical defective in ESP OFF switch
C1202 - Defective ESP OFF switch harness (short to ground)
ESP OFF switch X O
(5202)
Action
- Check the harness and connector for ESP OFF switch
Cause
- Abnormal supplying voltage to valve solenoid
C1301
Valve, valve relay Action X X
(5301)
- Check the battery voltage
- Replace the HECU
Cause
- Too low (below 6.0 V) or no supplying voltage to pump
motor
- Over 0.93 V from pump motor voltage
C1311 - Poor contact in pump motor connector
Motor pump O O
(5302) - Poor ground
Action
- Replace the HECU
Cause
- Defective A/D converter, internal voltage regulator, and
C1401
HECU hardware controller O O
(5401)
- Defective sensor and short to supplying voltage line
Action
- Replace the HECU
Cause
- Abnormal signals from sensors
C1501 No calibration or SC
- Poor calibration for sensors X O
(5501) checksum error
Action
- Check and initialize the sensors

AFFECTED VIN
4K 65
Trouble
Code
Cause
- Coding error
- Defective CAN communication line
C1170
Variant coding error - Discrepancy between HECU coding and vehicle coding (O) O
(5170)
Action
- Check the HECU coding and vehicle coding
- Replace the HECU
Cause
C1601 - Defective CAN communication line
CAN bus off (O) O
(5601) Action
- Check CAN communication line
Cause
- Short to CAN communication line
CAN timeout EMS - Overload to CAN communication
C1602 (communication error Action X O
(5602) between engine ECU - Check the engine ECU
and CAN) - Check the CAN communication line
- Check the engine ECU connector
Cause
- Short to CAN communication line
CAN timeout TCU - Overload to CAN communication
C1603
(communication error Action X O
(5603)
between TCU and CAN) - Check the TCU
- Check the CAN communication line
- Check the engine TCU connector
Cause
- Defective communication with TCCU
C1604 CAN timeout 4WD Action
X O
(5604) (can signal error EMS) - Check the TCU
- Check the TCCU connector
- Check the CAN communication line
Cause
C1612 CAN timeout 4WD - Defective signal transmit of Engine ECU
X O
(5612) (can signal error EMS) Action
- Check the engine ECU varient coding

AFFECTED VIN
66 4K
ABS/ESP Sensor Value

No Contnet Unit ESP ABS
1 Wheel Speed Front RH 1 km/h O O
2 Wheel Speed Front LH 1 km/h O O
3 Wheel Speed Rear RH 1 km/h O O
4 Wheel Speed Rear LH 1 km/h O O
5 Battery Voltage 0.1 V O O
6 Longitudinal Acceleration Sensor 0.01 g O X
- : Straight ahead (Fixed Value: 0)
7 Lateral Aceleration Sensor 0.01 g O X
+ : Left Turn (Fixed Value: 0)
8 Yaw Rate Sensor 0.5 deg/s O X
9 Steering Wheel Angle Sensor 5 deg O X
10 Pressur Sensor (Primary) 1 bar O X
(Fixed Value: 0)
11 Pressur Sensor (Secondary) 1 bar O X
(Fixed Value: 0)
12 EBD Control Operation / Non-operation O O
13 BTCS Control Operation / Non-operation O X
14 Engine TCS Control Operation / Non-operation O X
15 ESP Control Operation / Non-operation O X
16 ESP / TCS OFF Switch ON / OFF O X
17 ABS Control Operation / Non-operation O O
18 Stop Lamp Switch ON / OFF O O
[O: Applied, X: N/A]

AFFECTED VIN
4K 67
ABS/ESP Forced Operation

No Name Operation
1 Front LH Inlet Operation / Non-operation
2 Front LH Outlet Valve Operation / Non-operation
3 Front RH Inlet Operation / Non-operation
4 Front RH Outlet Valve Operation / Non-operation
5 Rear (or RL) Inlet Valve (x1) Operation / Non-operation
6 Rear (or RL) Outlet Valve (x1) Operation / Non-operation
7 (Rear RH Inlet Valve (x2)) Operation / Non-operation
8 (Rear RH Outlet Valve (x2)) Operation / Non-operation
9 TCS Valve Primary (x3) Operation / Non-operation
10 TCS Valve Secondary (x3) Operation / Non-operation
11 ESV Valve Primary (x3) Operation / Non-operation
12 ESV Valve Secondary (x3) Operation / Non-operation
13 - -
14 - -
15 Motor Pump Operation / Non-operation

AFFECTED VIN
68 4K
Sensor Initialzation (SCAN 100)
INTIALIZE SENSOR(Only ESP)
INTIALIZE SENSOR
1] LONGITUDINAL ACCEL SENSOR(4WD only)
2] LATERAL ACCEL SENSOR
3] PRESSURE SENSOR
4] ABOVE 1, 2, 3 ALL SENSOR
Select one of the above items
INTIALIZE SENSOR
LONGITUAINAL ACCEL SENSOR(4WD only)

DO YOU START INITIALIZE ? (Yes/No)
CONDITION :
- ENGINE IS NOT RUNNING.
- VEHICLE STATUS IS FLAT.
- DO NOT PUT THE BRAKE PEDAL.
PROCEDURE :
MUST BE FOLLOW THE ABOVE CONDITION.
IF YOU START "INITIALZE SENSOR",
ADART TO AUTOMATIC.

AFFECTED VIN
4K 69
9. AIR BLEEDING
The vehicle equipped only with ABS can use the conventional air bleeding procedure, however, the vehicle equipped with
ESP should use the oil supply device with compressor to bleed the air.
Rear
Front
Oil supply
Oil return
Air bleeding should be done when:

1. After removal and installation of the brake master cylinder.
2. After removal and installation of the ABS HECU.
3. After removal and installation of the brake oil pipes and hoses.
4. After replacing the brake fluid.
5. Braking force is not made properly.

AFFECTED VIN
70 4K
Air bleeding procedures

1. Apply the parking brake and start the engine when the shift lever is at “P” position.
2. Connect the oil supply device (air bleeding device) with air compressor to brake reservoir. The oil supply device
should be filled with sufficient oil.
3. Loosen the air bleed screw in caliper and place an empty container under the screw.
4. Bleed the air in each wheel by using diagnostic device (SCAN 100). At this time, the modulator motor runs for 180
seconds.
5. Simultaneously, run the oil supply device to supply oil and depress the brake pedal repeatedly.
This procedure needs at least 3 persons for doing below jobs:
1) Collect the bleeding oil into the container.
2) Depress the brake pedal repeatedly.
3) Check the conditions of oil supply device.
6. Repeat the step 4 through 5 until clear brake fluid comes out of air bleed screw.
7. Perform the same procedures at each wheel.
Notice
Replace the brake oil at every 2 years.
Notice
• Always bleed the air after replacing the brake fluid or master cylinder, caliper, brake hose and pipe.
• Never reuse the used brake fluid.
• Do not pump the brake pedal too fast. It may cause some troubles for air bleeding operation.
• Be careful not to splash the brake fluid on painted area or body.
• Check the connection areas for leaks after air bleeding.

AFFECTED VIN
SECTION 05
BODY SYSTEM
CONTENTS
BODY INTERIOR ........................................................... 5A
BODY EXTERIOR .......................................................... 5B
BODY REPAIR ............................................................... 5C

5A 1
5A - Body Interior
Table of Contents
OVERVIEW ........................................................ 5A-2
AIRBAG ............................................................. 5A-4
1. Components ................................................................ 5A-4
2. Function description .................................................... 5A-6
3. Inflation of airbag ......................................................... 5A-9
4. Airbag unit (SDM) ...................................................... 5A-10
5. Wiring diagram ........................................................... 5A-11
6. Trouble diagnosis ...................................................... 5A-12
7. Special tools and equipment ..................................... 5A-15
8. Removal and installation ............................................ 5A-16
SEAT BELT ..................................................... 5A-21

1. Components .............................................................. 5A-21
2. Removal and installation - Seat belt .......................... 5A-24
SEAT ................................................................ 5A-32

1. Components .............................................................. 5A-32
2. Seat layout ............................................................... 5A-34
4. Operation of seat ....................................................... 5A-46
5. Seat rail .................................................................... 5A-55
ACCESSORIES ............................................... 5A-57

1. Storages ................................................................... 5A-57
2. Convinient devices ..................................................... 5A-64
3. ETC .......................................................................... 5A-71
INSTRUMENT PANEL ASSEMBLY ................ 5A-75

BODY INTERIOR CHANGED BY

AFFECTED VIN
2 5A
OVERVIEW
Height adjuster (Driver/passenger)
Front seat belt

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Passenger’s airbag
Passenger’s
Airbag unit (SDM)
Driver’s
Front seat
Fixed type buckle Belt type buckle Driver’s airbag
CHANGED BY BODY INTERIOR

AFFECTED VIN
5A 3
Pretensioner Retractor
Swivel seat (Rear 1st seat)
Rear 1st seat Rear 2nd seat Rear 3rd seat

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Rear 1st seat Rear 2nd seat Rear 3rd seat

AFFECTED VIN
4 5A
AIRBAG
1. COMPONENTS
Driver’s Airbag Module
Airbag module
Steering wheel
Contact coil

AFFECTED VIN
5A 5
Passenger’s Airbag Module
Cushion
Retainer
Housing
Inflator
Bracket

AFFECTED VIN
6 5A
2. FUNCTION DESCRIPTION
Bag (Cushion) Airbag Module
• The airbag system performance is influenced on the The driver airbag module is under the center pad of the
cushion size, shape and position. steering wheel.
• The cushion strength is a important parameter on the The passenger airbag module is installed in the instru-
impact absorb effect. ment panel at passenger side.
• Therefore, the control of the airbag performance The driver and passenger side airbag is inside each seat.
depends on cushion size, shape, inflator characteristic
and vent hole size for the gas discharge. [Notice]
• The cushion’s material and folding function to control Do not disassemble the airbag module because
the cushion deployment direction and the performance unintentional deployment of the airbags resulting from
to protect passenger’s face. any damage or interference of the module can cause
injury.
Module Cover/Housing
• It is a type of a container that includes the cushion
and the inflator.
• The module housing functions to deliver the reaction
force between the body structure and the airbag (The
airbag reaction is absorbed generally to the steering
wheel or instrument panel).
• The module cover must be considered in a viewpoint
of protection between exterior, internal units and
cushion. Also the module cover should be designed
not to cause any personal injury for deployment.
Inflator
• The inflator is a type of the direct gas generated device.
• The inflator with initial low pressure provides negative
SDM (Sensing and Diagnostic
restraint effect regarding passengers moving and time.
On the contrary, the inflator with initial high pressure
Module)
allows other components of the airbag to make a 1. The airbag system consists of the module section
excessive impact resulting in any personal injury. (driver, passenger and side), seat belt section and
Thus, the inflator output must be optimized according SDM.
to the characteristic of the vehicle and passenger 2. The SDM has no user-serviceable parts and monitors
moving. the system components continuously. The SDM also
• The discharge gas has no toxicity or inflammability records any faults which are discovered.
and also it is the important parameter to control the 3. The SDM allows the fault codes to be retrieved with a
high temperature for gas firing. scan tool and illuminates a warning lamp that alerts
the driver to any faults.
The SDM located on floor beneath the floor console
assembly. The SDM performs the following functions:
• Impact decision processor function.
• Determine the airbag deployment through the impact
signal of the accelerometer sensor and the safety
sensor.

AFFECTED VIN
5A 7
• Malfunction detection and recording any faults that Contact Coil

are detected.
The contact coil is installed between the steering wheel
Monitor the supplemental restrain system electrical
and the steering column and contains a coil that enables
components and set a diagnostic trouble code when
to contact electrically between the airbag wiring harness,
malfunction is detected.
the driver airbag module and the horn switch.
• Display airbag fault codes
Display airbag fault codes and system status [Notice]
information when connected to a scan tool.
Turning the steering wheel more than three and one-
• Self-diagnosis function quarter turns may damage the clock spring. The contact
Illuminate the AIRBAG indicator to alert the driver to coil should never be disassembled and must be replaced
any fault. if the airbag have been deployed.
• Power supply function

Provide a reserve power source to deploy the airbags
and pretensioners if an accident has disabled the
normal power source.
Accelometer Sensor
The accelerometer sensor electronically represents the
acceleration or deceleration of the vehicle during a frontal
impact.
In this electronic representation, the electrical signal is
proportional to the acceleration or deceleration of the
vehicle.
Safety Sensor
The safety sensor is safety device made up of a dual- [Notice]
contact, electro-mechanical switch that:
Turn the label of the clock spring clockwise to lock and
1. Acts independently of the electronic components. turn the label of the clock spring counterclockwise
2. Connects the acceleration sensor in series in order approximately 2.9 ± 0.2 turns to the neutral positions
to make up for the weak points in the current with the front wheels ahead.
electronic sensor. Align the pointed marks “43 ”.
Micro Controller
This device receives the impact signal from the sensor for
vehicle impact and identifies whether the current condi-
tion is necessary for airbag deployment or not. And then
the controller sends the specified currents to the airbag
ignition circuit as needed.
This device always monitors the airbag system in con-
duction with the diagnostic circuit. When it is detected
any problem, it illuminates the airbag warning indicator to
inform driver of the fault and stores the fault information.

AFFECTED VIN
8 5A
Airbag Warning Lamp Wiring Harness Connectors

The instrument cluster contains an airbag warning indica- If the sensing and diagnostic module (SDM) electrical con-
tor bulb to verify the operation of the AIRBAG indicator nector is not attached properly, a built in shorting bar will
and sensing and diagnostic module (SDM). connect the wire from airbag warning lamp with the SDM
The SDM performs a turn-on test when the ignition is turned ground wire. This turns on the AIRBAG indicator.
ON. The SDM flashes the AIRBAG indicator seven tomes To prevent deployment during servicing, additional short-
by supplying an intermittent ground to the indicator lamp ing bars are located in following locations:
circuit. After flashing seven times, the AIRBAG indicator • Driver airbag module connector
will turn off if no more malfunctions have been detected.
• Passenger airbag module connector
• Driver and passenger side airbag module connector
• SDM wiring harness connector
• Contact coil connector to airbag wiring harness
The shorting bar is only a backup safety device. Always
disable the supplemental restraints system (SRS) before
beginning any service procedure.
Belt Pretensioner
The belt pretensioner enables to retract the driver and the
passenger seat belt webbing to reduce any personal im-
pact when accounted a frontal collision.
Warning Lamp Status Fault Contents

Flash seven times within 7 System OK
seconds and then turn off
Warning lamp stays ON System fault
Internal SDM fault
No turn on Power supply circuit open

and fuse open
Warning lamp circuit open
SDM fault

AFFECTED VIN
5A 9
3. INFLATION OF AIRBAG
Front Airbag Operation (Driver’s and Passenger’s)

The air bag inflates when:
• Frontal impact against a solid concrete wall at over 25 km/h or near-frontal impact within 30 degrees from the center
of the vehicle at both corners
The air bag can inflate when:

• Underbody impact from the road surface; impact against the curb at a very high speed; dropping impact onto the
road surface with a large angle
The air bag does not inflate when:

• Rollover, side impact or rear impact
The air bag seldom inflates when:

• Oblique impact, rollover
• Weak impact in which the sensor is unable to detect (under the inflation requirements)
• Impact against narrow objects such as a telegraph pole or a tree
• The vehicle falls into a drainage or a puddle
• The front of the vehicle crashes into high impact point vehicle such as a truck
• Impact on the hood by falling stones
• The air bag warning lamp is on

AFFECTED VIN
10 5A
4. AIRBAG UNIT (SDM)

System Layout
Driver’s Passenger’s
airbag airbag
Airbag unit
Driver’s seat Passenger’s seat
SDM Specification
Item Specification
Voltage range 9 ~ 16V
Temperature range -30 ~ 85°C
Accelometer dynamic sensing range -50 ~ 50G
Impact record Diagnostic trouble code

AFFECTED VIN
5A 11
5. WIRING DIAGRAM

AFFECTED VIN
12 5A
Possible Cause Action
Ignition “ON” Does the warning lamp blink Yes System OK
Check warning at seven times for 7 sec- No Connect the scan tool to diagnostic connector (ALDL).
lamp on I/P onds and then turn off?
Select the fault code display menu and clear code menu.
Does the fault code display Yes Perform “Diagnostic System Check”.
on the scan tool display? No Check any fuse open.
Replace fuse.
Is there any open in fuse? Yes Disconnect wiring connector.
No Check any wiring short between fuse and wiring connector.
Is there any short in fuse? Yes Repair wiring.
No Disconnect SDM wiring connector.
Check wiring short between connector terminal and SDM
connector terminal.
Is there any short in wiring? Yes Replace airbag wiring.
No Check any open between ALDL connector No.4, No.5 ter-
minal and ground.
Is there any open in wiring? Yes Repair wiring
No Ignition “ON”
Measure voltage at the cigar lighter socket.
Does the voltage indicate 11 Yes Check any open or short between ALDL connector terminal
~ 14 V? and wiring connector terminal.
No Repair the wiring of the cigar lighter socket.
Is there any open or short Yes Repair wiring
in wiring?
No Check any open or short between SDM connector terminal
and wiring connector terminal.
Is there any open or short Yes Replace the airbag wiring.
in wiring?
No Replace the SDM.

AFFECTED VIN
5A 13
Diagnostic Trouble Code

Code Fault Contents Check
1101 High battery voltage Check the alternator voltage
Check the battery
Check the airbag unit terminal
1102 Low battery voltage Check the alternator voltage
Check the battery
Check the airbag unit terminal
1346 Driver’s air bag circuit resistance too low Check the connection of the driver airbag connector.
Check the wiring condition of the driver airbag.
(including clock spring)
Check the bending of the airbag terminal.
1347 Driver’s airbag circuit short to battery voltage Check the connection of the driver airbag connector.
1348 Driver’s airbag circuit short to ground Check the connection of the driver airbag connector.
1349 Driver’s airbag circuit short to battery voltage Check the connection of the driver airbag connector.
1352 Passenger’s airbag circuit resistance too high Check the connection of the passenger airbag connector.
Check the wiring condition of the passenger airbag.
1353 Passenger’s airbag circuit resistance too low Check the connection of the passenger airbag connector.
1354 Passenger’s airbag circuit short to ground Check the connection of the passenger airbag connector.
1355 Passenger’s airbag circuit short to battery Check the connection of the passenger airbag connector.
voltage Check the wiring condition of the passenger airbag.
1361 Driver’s pretensioner circuit resistance too Check the connection of the driver pretensioner connector.
high Check the wiring condition of the driver pretensioner.
1362 Driver’s pretensioner circuit resistance too low Check the connection of the driver pretensioner connector.
Check the wiring condition of the driver pretensioner.

AFFECTED VIN
14 5A
Code Fault Contents Check

1363 Driver’s pretensioner circuit short to ground Check the connection of the driver pretensioner connector.
Check the wiring condition of the driver pretensioner.
1364 Driver’s pretensioner circuit short to bat- Check the connection of the driver pretensioner connector.
tery voltage Check the wiring condition of the driver pretensioner.
1367 Passenger pretensioner circuit, resis- Check the connection of the passenger pretensioner connector.
tance too high Check the wiring condition of the passenger pretensioner.
1368 Passenger pretensioner circuit, resis- Check the connection of the passenger pretensioner connector.
tance too low Check the wiring condition of the passenger pretensioner.
1369 Passenger pretensioner circuit, short to Check the connection of the passenger pretensioner connector.
ground Check the wiring condition of the passenger pretensioner.
1370 Passenger pretensioner circuit, short to Check the connection of the passenger pretensioner connector.
battery voltage Check the wiring condition of the passenger pretensioner.
1620 SDM interal fault Replace the SDM
1650 Front impact memorid Replace the SDM
1651 Side impact (driver) memoried Replace the SDM
1652 Side impact (passenger) memoried Replace the SDM
1657 Belt pretensioner operation memoried Replace the SDM
1670 Secondary front impact memoried Replace the SDM
2500 Warning is faulty • Check the wiring to warning lamp

• Check the warning lamp bulb
• Check the SDM unit terminal
[Notice]
• Use only the scan tool to check the airbag module and the sensing and diagnostic module (SDM). Never measure the
resistance of an airbag module with an ohmmeter. An ohmmeter’s battery can deploy the airbag and cause injury.
• Before testing, disconnect the negative battery cable. Wait 1 minute for the SDM capacitor to discharge. The capacitor
supplies reserve power to deploy the airbags, even if the battery is disconnected. Unintentional deployment of the
airbags can cause injury.
• Do not attempt to repair the supplemental inflatable restraints (SIR) wiring harness. An SIR repair can create a high-
resistance connection which can keep the airbags from deploying when needed, resulting in injury.

AFFECTED VIN
5A 15

Name and Part Number
Scanner Wheel wrench

AFFECTED VIN
16 5A

Airbag Module(Driver’s Airbag)
Preceding Work: Disconnect the battery negative cable.
1. Align the steering wheel and remove airbag module mounting bolts.
2. Disconnect airbag module and horn connector, and then remove the module from steering wheel.
[Notice]
Pay attention to the connection of airbag module and its

mounting position.

AFFECTED VIN
5A 17
Contact Coil
1. Remove horn, airbag module, steering wheel(1), and lower
panel(2) from steering column.
2. Remove the steering column upper & lower cover.
3. Unscrew the contact coil mounting bolts and remove it from the steering column.

AFFECTED VIN
18 5A
[Notice]
Allgn the contact coil to the right direction. (Refer to the arroow mark in the following picture)
If thealignment of contact coil, is not precise. It could result in a accident due to bad steering condition.
Also, it can damage a contact coil and therefore, can be a reason of airbag failure.

AFFECTED VIN
5A 19
Passenger’s Airbag
2. Remove the I/P panel.
3. Remove the supplementary airbag module.


AFFECTED VIN
20 5A
Airbag Unit (SDM)

Preceding Work: Remove the center facia
1. Remove the center floor duct.
2. Disconnect the SDM and ground connectors.

3. Remove the SDM from the mounting deck.

AFFECTED VIN
5A 21
SEAT BELT
1. COMPONENTS
11 Passengers
Front Seat Belt (3 point)
Height adjuster
Buckle
Pretensioner
Lower anchor
Rear 1st row (3 point + 2 point)
Upper anchor
Retractor
Buckle
Lower anchor
Rear 2nd row (3 point + 2 point)
Upper anchor
Retractor
Buckle
Lower anchor
Rear 3rd row (3 point + 2 point)
Upper anchor
Retractor
Buckle
Lower anchor

AFFECTED VIN
22 5A
9 Passengers
Height adjuster
Buckle
Pretensioner
Lower anchor
Rear 1st row (3 point)
Upper anchor
Retractor
Buckle
Lower anchor
Rear 2nd row (3 point)
Upper anchor
Retractor
Buckle
Lower anchor
Rear 3rd row (3 point + 2 point)
Upper anchor
Retractor
Buckle
Lower anchor

AFFECTED VIN
5A 23
7 Passengers
Height adjuster
Buckle
Pretensioner
Lower anchor
Rear 1st row (3 point)
Upper anchor
Retractor
Buckle
Lower anchor
Rear 2nd row (3 point + 2 point)
Upper anchor
Retractor
Buckle
Lower anchor

AFFECTED VIN
24 5A
2. REMOVAL AND INSTALLATION - SEAT BELT

Seat Belt (3 point)
1) Front seat belt
1. Remove front & rear scarf trim. (screw - 6 EA)
Scarf trim
Front Rear
2. Unscrew seat belt upper / lower anchor bolts (17 mm - 2 EA) and remove the seat belt.
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Seat belt anchor (A) Upper anchor (B) Lower anchor

bolts bolt bolt
3. Disconnect the pretensioner connector and unscrew the mounting bolt
Pretensioner

AFFECTED VIN
5A 25
2) Rear 1st / 2nd / 3rd seat belt

1. Unscrew seat belt upper / lower mounting bolts.
Rear 2nd
Rear 3rd seat belt seat belt Rear 1st seat belt
[Notice]
To remove rear 3rd row seat belt, remove the seat from vehicle first.

AFFECTED VIN
26 5A
2. Unscrew the retractor mounting bolts to remove seat belt assembly.
Rear 1st row

seat belt
Rear 2nd row

seat belt
Rear 3rd row

seat belt

AFFECTED VIN
5A 27
Seat Belt (2 point)

1) Rear 1st seat belt
1. Unscrew seat mounting bolts and remove the seat.
[Reference]
• 2-point type seat belt are installed at the center seat of rear 1st / 2nd / 3rd row seat.
• Rear 1st seat have two types of seat belt. Normally it adapts 3 point type, however, it adapts 2 point type seat belt when
swivle.

AFFECTED VIN
28 5A
2. Unscrew the retractor mounting bolt to remove seat belt assembly.

AFFECTED VIN
5A 29
Center Seat Belt

1. Disassemble the seat mounting part on the seat under
cover.
2. Unscrew the seat mounting bolt and remove it.

AFFECTED VIN
30 5A
Buckle
1. Fixed type buckle
Preceding Work: Removal of the seat assembly
1. Remove seat cover.
2. Unscrew the mounting bolt and remove the buckle.

AFFECTED VIN
5A 31
2. Belt type buckle

Preceding Work: Removal of the seat assembly
1. Disconnect the seat connecting cable and unscrew the
seat back mounting bolt to remove it.
2. Remove screws on the seat and pull away the seat cloth.
3. Unscrew the buckle mounting bolt and remove the buckle.

AFFECTED VIN
32 5A
SEAT
1. COMPONENTS
Seat control switch
Sliding control Seat position control Seat height control Reclining control
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Sliding adjust lever
Seat warmer switch
Back flat adjust lever Back supporter (Driver’s seat)

AFFECTED VIN
5A 33
Head rest Back folding adjust lever
Rear 3rd seat back folding adjust lever
Seat sliding adjust lever Seat swivel control lever

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AFFECTED VIN
34 5A
2. SEAT LAYOUT
Layout - 11 Passengers
• Front seat : Move 36 mm from the far

end to the front
• Rear 1st seat : Movable
• Rear 2nd seat: Movable
• Rear 3rd seat : Fixed

AFFECTED VIN
5A 35

end to the front
• Rear 1st seat : Movable
• Rear 2nd seat: Movable

AFFECTED VIN
36 5A

AFFECTED VIN
5A 37
Various Seat Arrangement

• Front seat & rear 1st seat : Semi full flat
• Front seat : Move to the far front

Back semi full flat
• Rear 1st seat : Move to the far end
• Rear 2nd seat: Move to the far end
• Rear 1st & 2nd seat full flat

end to the front
• Rear 1st seat : Move to the far front
Remove head rest
Back full flat
Back semi full flat

AFFECTED VIN
38 5A
• Rear 1st seat (when swiveled)

Center seat jumping
Swiveled
• Rear 1st swiveled and rear 2nd seat back folding while driving

Center seat jumping
Swiveled
Back folding

AFFECTED VIN
5A 39
• Rear 1st seat swiveled and rear 2nd seat back folding (while parking)
• Front seat : Move to the far front

• Rear 1st seat : Middle
Center seat jumping
Swiveled
• Rear 2nd seat: Middle / Back folding
• 8 passengers with loading

end to the front
• Rear 1st seat : Middle
• Rear 2nd seat: Middle
• Rear 3rd seat : Double folding

AFFECTED VIN
40 5A

end to the front
• Rear 2nd seat: Middle
• Rear 3rd seat : Double folding
• Front seat : Move to the far end /

Back folding
• Rear 1st seat : Middle / Back folding
• Rear 2nd seat: Middle / Back folding
• Rear 3rd seat : Middle / Back folding

AFFECTED VIN
5A 41
Entry Way
Rear 1st seat : Folding center seat

Rear 2nd seat : Folding center seat
Rear 3rd seat : Fixed

AFFECTED VIN
42 5A
Sliding of Rear 1st and 2nd Seat
- 4 rail (1.610mm) for rear 1st and 2nd seat sliding

- Rail mounting : Floor bolt type
Seat Sliding distance Seat Sliding distance

Front 228 mm Rear 3rd Fixed
Rear 1st 280 mm Rail overlength 1,610 mm
Rear 2nd 400 mm

AFFECTED VIN
5A 43
Front
Seat
Rear 1st
seat
Rear 2nd
seat
Rear 3rd
seat

AFFECTED VIN
44 5A
Seat Mounting Point

AFFECTED VIN
5A 45
Removable Seat
1. Fold down the seatback of the third row seat while puling
up the seatback reclining lever ( ).
2. Remove the seat rail covers ( )
3. Slide the third row seat to its rear end (arrow direction)
while pulling up the seat sliding lever ( ).
4. Carefully remove the third row seat from the rail by using
the hand grips ( , ) on the seat as shown in the
figure.
5. Install the seat in the reverse order of removal.
[Caution]
• Be careful not to drop the seat when removing it. It may

cause a personal injury.
• Make sure that the seat is securely engaged on the rail
during installation.

AFFECTED VIN
46 5A
4. OPERATION OF SEAT
Front Seat (Driver’s Seat)
1) Components
Seat warmer
connector
Seat position
(up/down motor)
Seat position
(front up/down Seat position
rail) (up/down rail)
Sliding rail Seat position

(rear up/down
motor)
Sliding motor
Reclining motor

AFFECTED VIN
5A 47
2) Operation of seat
• Sliding
: Seat moves from front to rear controllde
by sliding control switch
• Seat position (front up/down)

: Front side of seat moves up/down
controlled by seat position control
switch
• Seat position (rear up/down)

: Rear side of seat moves up/down
controlled by seat position control
switch

AFFECTED VIN
48 5A
• Seat height (up/down)

: Seat moves up/down controlled
by seat height control switch
Seat reclining motor
• Reclining
: Seat back reclining controlled by
seat reclining control switch

AFFECTED VIN
5A 49
3) Seat electrical equipment check
• Disconnect the seat wiring connector and check if the power is supplied (Refer to the wiring diagram)
1) If the power supply has no problem, remove the seat.
2) Check the motor and wiring if damaged.
3) Connect the battery to the seat connector.
4) Control the seat switch and check the opration.
[Notice]
Electrical parts are not supplied by a part separately.

AFFECTED VIN
50 5A
4) Operation of center seat
When seating
When jumping
- Pull up the center seat when to jump

- Push down the center seat when to seat
5) Removal and installation of center seat (jumping seat)
- Unscrew 4 mounting nuts to remove the center seat

AFFECTED VIN
5A 51
Rear Seat
1) Rear 1st seat (swivel seat)
Seat back folding cable
Seat back flat cable
Jumping
mechanism
Sliding cable
Sliding lever
Swivel lever

AFFECTED VIN
52 5A
2) Operation of rear seat (Rear 1st and 2nd seat)
Seat sliding
Front
Rear

AFFECTED VIN
5A 53
3) Seat back flat

- When to recline or to flat fully
Rear 1st
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Rear 2nd
4) Seat back folding

- Fold the rear 1st or 2nd raw seat back to put something on or to utilize it as a table.
Rear
1st/2nd seat

AFFECTED VIN
54 5A
5) Seat swing (Rear 1st seat)

- Turn around seat as the swing lever is pulled.
6) Rear 3rd seat

- Pull the lever behind back seat to fold the back seat.
- Pull the lever under back seat to fold up the seat
- As the seat is folded, disconnect hook and spread out the board

AFFECTED VIN
5A 55
5. SEAT RAIL
Distance (cm)
A. Inner rail 50
B. Inner rail 74
- Outter rail
C. Outter rail 98

1. Remove all rear seats and then, unscrew the seat rail
guide screws.
2. Remove three screws under OVM tool storage.

AFFECTED VIN
56 5A
3. Unscrew the rear seat belt lower anchor bolt.
4. Remove the rear carpet and unscrew the seat rail

mounting bolts.

AFFECTED VIN
5A 57
ACCESSORIES
1. STORAGES
Overhead console
Front door map pocket Glove box
Passenger’s cabinet
Console box
Seat back pocket

AFFECTED VIN
58 5A
1) Console Box
- Foot lamp and a speaker are installed.
Console box - Fixed type

Standard
CD Changer (6 EA) DVD Changer (8 EA)
Components
1. Armrest
2. Console main rid & tray
3. Console rear facia
4. Console main rid cover
5. Rear foot lamp
6. Console main & tray
7. Console main bracket
8. CD Changer cover

AFFECTED VIN
5A 59
Console box - Portable type
When Installed
When used as table ○

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Console box - Portable type

AFFECTED VIN
60 5A

Console box assembly
- Unscrew bolts and nuts to remove console box.
Bolt 10 mm - 2 EA
Nut 10 mm - 2 EA
CD Changer & DVD Changer
- Unscrew the bracket bolts (10 mm - 4 EA) and remove the changer assembly.

AFFECTED VIN
5A 61
2) Glove Box
1. Disconnect the glove box clip (1) and wire.

2. Unscrew the box mounting bolts (4 EA).

AFFECTED VIN
62 5A
3) Overhead Console

1. Unscrew two mounting screws in the sun glass
cabinet and remove the overhead console by using a
tool.
2. Disconnect multi meter and room lamp connector.

And then, remove the console assemble.
3. Unscrew three screws behind the console assembly to remove multi meter.

AFFECTED VIN
5A 63
4) Passenger’s Cabinet
Above glove box

Preceding Work: Removal of glove box and I/P lower panel (passenger)
1. Open the cabinet and remove the mounting screws.
2. Unscrew the passenger’s cabinet mounting screws (LH / RH / center) at the back of lower panel.

AFFECTED VIN
64 5A
2. CONVINIENT DEVICES
Ticket holder Front cup holder
Front cigar lighter
Back table
Power outlet
Rear cigar lighter
A B
Rear cup holder Tea table
A B

AFFECTED VIN
5A 65
1) Front Cup Holder / Cigar Lighter / Power Outlet Assembly

Under I/P center panel
Cup holder Power outlet / cigar lighter

AFFECTED VIN
66 5A

1. Remove cup holder mounting screws (2 EA).
2. Disconnect power outlet and cigar lighter lighter connector and remove the assembly.

AFFECTED VIN
5A 67
2) Rear Cup Holder and Rear Cigar Lighter

Preceding Work: Removal of lower quarter trim and rear 2nd / 3rd seats.
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1. Remove the trim mounting screws shown in the above

picture.
2. Disconnect the cigar lighter and remove the cup holder
assembly.
[Reference]
When to remove rear cigar lighter only, remove the lower
quarter trim and remove the cigar lighter from inside of the
trim.

AFFECTED VIN
68 5A
3) Sunvisor
Driver’s Passenger’s
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- Unscrew the mounting screw and remove it.

- Remove the sunvisor.
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AFFECTED VIN
5A 69
4) Tea Table
[Notice]
• Don’t put a load heavier than 3.5kg on the tea table.

• Don’t use the table while driving to prevent body injury.
1. Remove two upper mounting screws.

2. Remove the tea table.

AFFECTED VIN
70 5A
5) Power Seat Switch Assembly (Driver’s Seat)

Preceding Work: Removal of driver’s seat
1. Remove the power seat nob with a proper tool.

2. Remove seat side cover and unscrew the power seat switch unit mounting screw on the rear.
3. Disconnect the connector.
6) Back Table & Folding Lever
- Unscrew table mounting screws (4 EA).

AFFECTED VIN
5A 71
3. ETC
1) ECM Room Mirror
1. Remove room mirror cover with a screw driver.
2. Disconnect the connector.

3. Pull the room mirror downward to disassemble.

AFFECTED VIN
72 5A
2) Rain Sensing Unit

Rain sensing unit detect the rain fall and control the speed of
wiper operation. This system is operated only when the wiper
switch is put on “Auto” mode.
[Refer th the electrical part] of this manual.

1. Remove the unit with a tool refering the picture below.
2. Disconnect the connector and disassemble the rain

sensing unit.

AFFECTED VIN
5A 73
3) Hand Grip
Passenger’s Overhead
“B” Piller
Rear 1st & 2nd Seat
Rear 1st seat Rear 2nd seat
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AFFECTED VIN
74 5A
4) Fire Extinguisher & OVM Tool

Fire Extinguisher
- Under rear 3rd seat
OVM Tool
- Under rear 3rd seat floor cover.
Components

AFFECTED VIN
5A 75
INSTRUMENT PANEL ASSEMBLY

Preceding Work:
2. Remove all the parts shown on the picture below.
“A” pillar Cluster and center cover “P” pillar
Door molding Center speaker

Center speaker
Door molding
Center console
assembly
Lower panel - passenger
Lower panel - Driver
3. Remove door molding and “A” pillar cover .

4. Remove the I/P panel side cover (LH/RH).
5. Remove the front center speaker , cluster and center
cover assembly .
6. Remove the center console assembly and AV head
unit.

AFFECTED VIN
76 5A
7. Remove the lower panel assembly.

1) Disconnect incar / humidity sensor, 4WD operation
switch, rear wiper switch (2).
8. Remove instrument lower panel assembly (passenger

side).
1) Remove the glove box.
2) Remove the lower inner panel.

AFFECTED VIN
5A 77

1. Disconnect all the connector at the I/P panel.
1) Driver 2) Passenger
1. Sun roof 3. Door connector, floor, seat belt pretensioner
2. Door connector, floor, seat belt pretensioner 7. GPS
16. Earth 8. Audio optic cable connector
17. Earth 9. Rear monitor
18. Earth
12. Brake connector
11. Parking connector

13. Accelator connector
14. Sensor cluster
9. Rear monitor
4. T/M controller & Earth
10. SDM connector
3. LH floor connector

AFFECTED VIN
78 5A
3) Center
5. T/M control connector
7. Earth
8. Earth 10. SDM connector
4) ETC 12. Accelator pedal connector (A)

Aircon module connector (3 point) 13. Brake pedal connector (B)
A B
11. Parking brake connector. 14. Sensor cluster

AFFECTED VIN
5A 79
2. Remove bolt and nut on the instrument panel.
* ICM Box assembly * Driver’s side I/P lower braket * To remove I/P panel, unscrew the steering wheel
(10 mm - 3 EA: Nut) (10 mm - 2 EA:Bolt) mounting bolts (12 mm - 2 EA) and remove the wheel.
1. I/P side mounting bolts 2. Driver’s side I/P inner bolts

(12 mm - 3 EA: LH/RH) (12 mm - 3 EA: LH/RH)
3. Center facia lower bolts 4. I/P inner side mounting bolts

(10 mm - 2 EA: LH/RH) (12 mm - 1 EA: LH/RH)

AFFECTED VIN
80 5A
3. Remove the following parts from the instrument panel.
1. Tweeter speaker 2. Auto light unit / 3. Sun sensor 4. GPS
5. Optical cable 6. Passenger’s airbag module 7. I/P wind blow nozzle housing

AFFECTED VIN
5A 81
4. Remove the panel bracket from the instrument panel.
5. Remove front dust from the instrument panel.

AFFECTED VIN
MEMO
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5B 1
5B - Body Exterior
Table of Contents
COMPONENTS AND LOCATION ..................... 5B-3
DOOR SYSTEM ................................................. 5B-5
1. Layout - Front door ...................................................... 5B-5
2. Layout - Rear door ...................................................... 5B-7
3. Operation - Window ..................................................... 5B-8
4. Operation - Door lock / Unlock .................................... 5B-9
HOOD / BUMPER & TAILGATE ..................... 5B-32

1. Operation - Tailgate .................................................. 5B-32
2. Layout - Tailgate ........................................................ 5B-33
3. Layout - Cowl assy / Hood ........................................ 5B-42
4. Layout - Front bumper ............................................... 5B-47
5. Layout - Rear bumper............................................... 5B-51
KEY CYLINDER .............................................. 5B-54

1. Components.............................................................. 5B-54
SUN ROOF ...................................................... 5B-58

1. Layout - Sun roof ....................................................... 5B-58
2. Components and locations ........................................ 5B-60
3. Operation .................................................................. 5B-61
ACESSORIES ................................................. 5B-64

1. Roof rack .................................................................. 5B-64
2. Fuel filler cap cable ................................................... 5B-65
3. Body jack point ......................................................... 5B-66
BODY EXTERIOR CHANGED BY

AFFECTED VIN
5B 3
COMPONENTS AND LOCATION

Hood
Roof rack
Front bumper assembly

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Front door Rear door Rear view mirror

AFFECTED VIN
4 5B
Rear view camera

Rear spoiler
Tailgate
Rear bumper assembly Sunroof assembly
Wide ganish assembly
CHANGED BY BODY EXTERIOR

AFFECTED VIN
5B 5
DOOR SYSTEM
1. LAYOUT - FRONT DOOR
B. Outside door handle A. Inside door handle
C. Power window switch
D. Folding switch & Adjustment

switch (Rear view mirrow)
E. Door courtesy lamp F. Door striker & contact switch

AFFECTED VIN
6 5B
Door connector Door hinge Check linkage
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Door latch & crank
Window regulator & motor

Rear view mirror folding unit
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AFFECTED VIN
5B 7
2. LAYOUT - REAR DOOR
Inside handle
Twitter speaker
Door courtesy lamp
Power window switch
Door latch & crank
Window regulator & Motor

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Door hinge Door striker Contact switch Door check linkage

AFFECTED VIN
8 5B
3. OPERATION - WINDOW
Window regulator
Guide rail
Regulator operating cable
Window motor
Operating Process
Power window motor (1) which is controlled by the window switch draws up and down the window regulator (2) and
operating cable. The window glass move up and down with the window regulator.
Window motor Operating cable
Window up/down Window regulator

AFFECTED VIN
5B 9
4. OPERATION - DOOR LOCK / UNLOCK

Front Door
Connecting rod - key cylinder
Door key cylinder

Outside door handle
Lock / Unlock cable
Connecting rod - outside handle
Operating cable - Inside handle
Door latch
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Lock / Unlock
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Inside door handle

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AFFECTED VIN
¢º Operating Process
10 5B
Operating Process
Lock / Unlock (Inside door handle)
→ →
Operation of lock button Operating cable Latch lock / Unlock
Inside handle
→ →
Operation of Inside handle Operating cable Latch open mode
Outside handle
→ →
Operation of outside handle Connecting rod - outside handle Latch open mode
Key cylinder
→ →
Insert key & operation Connecting rod - key cylinder Latch lock / Unlock

AFFECTED VIN
5B 11
Rear Door
Outside door handle
Rock / Unlock cable
Connecting rod - Outside handle
Operating cable - Inside handle
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
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Lock / Unlock
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Inside door handle

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CHILD / SAFETY mode

AFFECTED VIN
12 5B
Operating Process
Lock / Unlock (Inside door handle)
→ →
Lock button Operating cable Latch lock / Unlock
Inside handle
→ →
Operation of handle Operating cable Open mode - Latch
CHILD / SAFETY mode
Safety (FREE) mode Latch & Crank in operation

AFFECTED VIN
5B 13

Front Door Assembly
Preceding Work: Disassembly of battery cable (-)
1. Door connector 2. Door check link 3. Door hinge
1. Disconnect the door connector (1).

2. Unscrew the check linkage bolt (2) at body side.
3. Unscrew the upper and the lower door hinge bolts (3).
4. Remove the door assembly.

AFFECTED VIN
14 5B
Front Door Trim

Preceding Work: Disassembly of battery terminal (-)
1. Remove five screw rivets at the lower door trim.
2. Remove armrest grip cover and two screws.
3. Remove door handle cover.

4. Remove one screw (Refer to arrow mark).
[Notice]
Disconnect door handle cover with slim tool(driver) from

down side first otherwise, the grip holder can be damaged.

AFFECTED VIN
5B 15
5. After getting some space (1), disassemble door trim from the door panel as pushing up (2).
6. Remove door courtesy lamp connector & outside mirror connector at the inside of door trim.
7. Disconnect the power window switch.
8. Disassemble the front door trim.

AFFECTED VIN
16 5B
Front Door Trim Seal

Preceding Work: Removal of door trim
1. Remove door handle screw (1) and disconnect door handle

cable.
2. Unscrew 4-screws of two brackets.
3. Be careful not to damage the seal.

AFFECTED VIN
5B 17
Window Regulator Assembly

1. Unscrew two mounting bolts and disassemble door window
[Notice]
Be careful not to damage the body coating by window glass.
2. Be careful not to damage the body coating by window glass.

3. Disconnect door window regulator and motor mounting nuts (6 mm - 7 EA).
4. Disassemble window regulator assembly.

AFFECTED VIN
18 5B
Window Motor (Front / Rear)

Preceding Work: Disassemble of window regulator & motor assembly
- Disassemble power window motor mounting bolts (10 mm ~ 3 EA) from the requlator.
Door Latch & Crank Assembly

1. Disconnect key cylinder rod (1), outside handle rod (2) and rear view mirror folding unit connector.
2. Disconnect latch and crank assembly with mounting nuts (Hex - 3 EA).

AFFECTED VIN
5B 19
Rear Lock Striker (Front / Rear)

1. Removal :
1) Disassemble door lock striker with two bolts
2. Installation :
1) Temporarily install door lock striker.
2) Adjust the location of door lock striker and fully
tighten the bolts.
Door Lock Striker Adjustment

1. Removal :
1) Disassemble door lock striker with two bolts
2. Installation :
1) Temporarily install door lock striker.
2) Adjust the location of door lock striker and fully
tighten the bolts.
[Notice]
The door lock striker is an important attaching part that can affect the performance of vital components and systems and
can cause major repair expenses. If replacement becomes necessary, the door lock striker must be replaced by one with the
same part number or with an equivalent part. Do not use a replacement part of lesser quality or of a substitute design. The
specified torque values must be used during reassembly in order to ensure the proper retention of the part.
The door lock striker consists of a striker with two screws that are threaded into a tapped, floating cage plate located in
the appropriate body pillar. This floating cage plate allows the striker to be easily adjusted in or out and up or down. The
door is secured in the closed position when the door lock fork snaps over and engages the striker.

AFFECTED VIN
20 5B
Inside Door Handle

1. Disconnect connecting rod-key cylinder (1) and connecting rod - outside rod handle.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
2. Disassemble outside handle assembly (6 mm - 3 EA).
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

AFFECTED VIN
5B 21
Front Door Speaker

- Disconnect the door speaker connector (4 bolts)
Driver’s side
Passenger’s side

AFFECTED VIN
22 5B
Front Door Speaker

- Unscrew 6 bolts to remove door armest grip.
Rear View Mirror Folding Switch

Preceding Work: Removal of door armrest grip
Adjust switch - Rear view mirror
Folding switch - Rear view mirror
- Disassemble adjustment & folding switch assembly (Rear view mirrow)

AFFECTED VIN
5B 23
Door Courtesy Lamp

- Disconnect three clip behind lamp for disassembly (Use driver)
Power Window Switch Assembly

- Disconnect three clip behind lamp for disassembly (Use driver)

AFFECTED VIN
24 5B
Door Trim Molding

- Unscrew 7 - mounting screw to disassemble the molding.
Door Armrest Grip (II)
- Unscrew three mounting screws to disassemble door armrest grip
Door Contact Switch
- Remove a screw and disconnet door contact switch.

AFFECTED VIN
5B 25
Rear Door Assemble

Preceding Work: Disassemble the battery cable (-)
1. Door connector 2. Door check linkage 3. Door hinge
1. Disassemble “B” - pillar cover and disconnect door connector.

2. Remove check linkage mounting bolt from inside.
3. Remove door hinge mounting bolts.
4. Uninstall door assembly.
5. Install in the reverse of removal.

AFFECTED VIN
26 5B
Rear Window Regulator / Glass Run

1. Remove upper guide channel with two bolts, as weather strip is pulled.
2. Remove two screws in carrier plate and disassemble the window glass.

AFFECTED VIN
5B 27
3. Disassemble lower guide channel (two nuts).
4. Remove window regulator & motor mounting nuts (6 mm

- 7 EA)
5. Disconnect power window motor connector.
6. Disassemble power window regulator & window motor

assemble.

AFFECTED VIN
28 5B
Door Latch & Crank Assembly - Rear

1. Disconnect handle rod - outside door (B) and power window unit connector (A)
2. Remove three nuts (C) to disassemble latch & crank assembly.
○
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○
○
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○
○
○
○
○
○
○
○
○
○
○
○
○

AFFECTED VIN
5B 29
Outside Door Handle - Rear

1. Disconnect handle rod - outside handle.
2. Remove three nuts (6 mm - 3 EA).

AFFECTED VIN
30 5B
Rear View Mirror

General information
• Mirror adjustment
When switch-rear view mirror is operated, two motors which of one moves up and down and the other one moves left
and right are shifted to the direction the driver intended (Refer to the picture below).
• Folding
Motor is operated to fold the rear view mirrow when switch is pushed.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

AFFECTED VIN
5B 31
Removal and installation
1. Remove mirror cover and three mounting screws.
[Notice]
Pull out the mirror cover as lifted upward.
2. Disconnect the connector and disassemble the outside mirror assembly.
[Notice]
Be careful not to damage the mounting fastenr guided from inside of the door when handle the mirror.

AFFECTED VIN
32 5B
HOOD / BUMPER & TAILGATE

1. OPERATION - TAILGATE
Tailgate handle
Actuator
Connecting - tailgate handle
Key cylinder
Connecting rod - actuator handle
Connecting rod - key cylinder

Door latch

AFFECTED VIN
5B 33
2. LAYOUT - TAILGATE
Washer nozzle Rear view camera Rear spoiler
Wipre & motor Key cylinder

AFFECTED VIN
34 5B
Door latch Shock absorber
Door hinge
Door striker

AFFECTED VIN
5B 35

Tailgate Assembly
1. Remove tailgate upper & lower trim
2. Disconnect tailgate wiring & connector.
Tailgate main wiring Rear view camera / HMSL Heating wire & Ground

AFFECTED VIN
36 5B
3. Disconnect tailgate washer hose.

4. Disassemble tailgate assembly after remove shock absorber bolts & hinge.
5. Remove hinge cover mounting nut (M6).
6. Remove tailgate hinge mounting nut (M8) frominside.
7. Disassemble tailgate assembly.

AFFECTED VIN
5B 37
Rear Spoiler
1. Remove upper trim - tailgate.
2. Disconnect rear view camera & HMSL (High Mounted Stop Lamp) connector (B).
3. Unscrew spoiler mounting nut (4EA).
1.
3. "A" 2. "B"
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
4. Disasemble rear spoiler.

AFFECTED VIN
38 5B
HMSL (High Mounted Stop Lamp)

Preceding Work: Disassembly of rear spoiler
1. Disassembly HMSL cover carefully with slip driver (-).
2. Unscrew two bolts to disassemble HMSL.
Components - Rear Spoiler
Connector
Rear spoiler
Bulb Rear view carmera
HMSL
HMSL cover

AFFECTED VIN
5B 39
Tailgate Trim
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
* Inner side view
1. Unscrew two bolts to remove upper trim - tailgate.

2. Unscrew 6 screws to remove lower trim - tailgate.

AFFECTED VIN
40 5B
Wiper & Wiper Motor
Preceding Work: Removal of tailgate trim

1. Unscrew one nut (1) to remove wiper assembly (2) and unwind one mounting nut (3).
2. Disconnect motor connector and disassemble wiper motor assembly with two bolts.

AFFECTED VIN
5B 41
Latch
Latchand
andAcuator
Acuator- -Tailgate
Tailgate
• Latch - Tailgate
1. Disconnect latch wiring connector (1) and connecting rod
(2) at the inside of the door.
2. Unscrew latch mounting nut (6 mm - 3 EA).
• Actuator - Tailgate
1. Disconnect connecting rod at the inside of the tailgate.
2. Unscrew mounting nut (6 mm -2 EA).

AFFECTED VIN
42 5B
3. LAYOUT - COWL ASSY / HOOD
Cowl assembly
Hinge
Cap
Screw
Screw cap
Peace
Hood
Hood seal
- rear
Hinge
Bumper
Hood insulator
Hood over slam

Hood seal - sub
Hood latch handle
Hood seal - Front

Nut
Braket
Cable
Bolt
Hood latch
Key

AFFECTED VIN
5B 43

Hood
Preceding Work: Wrap the body with soft material to prevent from damage
1. Unscrew hood hinge bolts (8 mm - 4ea) and disassemble hood from thevehicle (A).
Adjustment
1. Release the hinge bolts.
2. Have the hood mounted properly. 3. Adjust the height of hood with overslam bumper.

AFFECTED VIN
44 5B
Hood Latch, Cable
Preceding Work: Removal of front bumper assem-

bly (Including head lamp)
1. Disconnect the hood cable from head latch handle.
2. Unscrew hood latch mounting bolts (6 mm - 4EA) and disconnect spring hood cable to disassemble hood latch.
3. Disassemble the hood cable.

AFFECTED VIN
5B 45
Cowl Grill & Insulator
Cowl Grill
1. Disconnect washer hoses at both wiper.
2. Unscrew wiper mounting nuts (14mm - 2EA) and
3. Remove cowl mounting clip (6EA) and screw (4EA).
4. Disassemble left / right cowl grill (Left side first, disassemble washer hose before take the cowl out)
Right
Left

AFFECTED VIN
46 5B
Replacement of Hood Insulation Pad

1. Disconnet the insulation pad with 14 screws.

AFFECTED VIN
5B 47
4. LAYOUT - FRONT BUMPER
Shock absorber - Energy
Upper cover
Bracket - side Bolt
Bumper facia assembly
Bracket - front guide bar Nut
Bolt
Bracket - side
Fog lamp cover

Front guide

AFFECTED VIN
48 5B

Preceding Work: Disconnect the battery negative cable
(1) Disassemble head lamp (2) Disconnect fog lamp connectors
(3) Remove guide bumper with mounting bolts

(8mm x 4ea)

AFFECTED VIN
5B 49
2. Uninstall the bumper assembly
(1) Bumper mounting bolts (Upper cover side - 4EA) (2) Bumper mounting bolts (Head lamp side)
(3) Bumper mounting bolts (Wheel arch side) (4) Upper cover grommet screws.

AFFECTED VIN
50 5B
3. Uninstall bumper facia end shock absorber - Energy

AFFECTED VIN
5B 51
5. LAYOUT - REAR BUMPER
Bracket - Rear bumper
Mounting screw
Mounting Grommet screw
Shock absorber - Energy
Guide cover - Rear bumper
Bumper facia assembly
Bolt
PAS (Parking Aid Sensor)

AFFECTED VIN
52 5B
Rear Bumper Assembly

1. Uninstall 4 items below.
(1) Uninstall rear combi lamp (2) Uninstall extension panel from inside to out side
carefully
(3) Remove mounting grommet screws (4) Remove mud guard / wheel arch mounting screws

AFFECTED VIN
5B 53
2. Disconnect parking aid sensor (3ea) inside of bumper assembly and unscrew mounting bolts to disassemble the
bumper assembly.
3. Disassemble bumper facia and shock absorber - Energy from bumper assembly.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

AFFECTED VIN
54 5B
KEY CYLINDER
1. COMPONENTS
Door handle - Front
Key cylinder
Starting key cylinder & key Key cylinder - Tailgate
Key cylinder
Door handle - Front

AFFECTED VIN
5B 55

Door Key - Front
Preceding Work: Removal of door trim / door handle - outside
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

AFFECTED VIN
56 5B
Tailgate Key
Preceding Work: Removal of failgate trim, seal
1. Disconnect connecting rod from key cylinder.
Connector
2. Unscrew center garnish mounting nuts.

3. Disconnect lamp-license plate connector.

AFFECTED VIN
5B 57
3. Remove the center garnish.
4. Remove two mounting bolts and key cylinder assembly.

AFFECTED VIN
58 5B
SUN ROOF
1. LAYOUT - SUN ROOF
Drain hose (Front)
Drain hose (Rear)

AFFECTED VIN
5B 59
Seal - glass panel
Glass
Glass panel
Wind deflector
Side cover - outter
Side cover - inner

Drain channel
support
Drain channel
support bar RH
Sunshade assembly Drain channel Panel
support bar pin curve on
Return spring Riret roll
Ventilation roof
Front lever Drain lever
spring Slider LH
Front
lever LH Drain lever LH
Main lever LH
Retraction
bar Pin
Breed nail
Prain channel
Frame assembly
Seal - drive tube
Tube cable guide
Frame assembly
Drive tube
Sunroof motor Sunroof control unit

AFFECTED VIN
60 5B
1. Drain hose 2. Control switch 3. Sun shade & glass
4. Control unit 5. Sun roof motor

AFFECTED VIN
5B 61
3. OPERATION
Tilting
Motor actuates the

operating cable
Push the front side of the button when the
glass is closed then, mtor actuate the op-
↓
erating cable to lift up the glass. Push the
rear side of the button to put down the glass.
Mechanical equip-
ment lifts up & down
the glass
Sliding
Motor actuates the

operating cable
push the rear side of the button ↓
to slide the door back.
Mechanical equip-
ment slides the
glass back and forth

AFFECTED VIN
62 5B

Preceding Work: Removal of head lining
1. Disassemble four sun roof drain hose (A).

2. Disconnect sun roof control unit connector (B).
3. Remove sun roof mounting bolts (Refer to arrow mark).

AFFECTED VIN
5B 63
Replacement of Sun Roof Glass
- Remove 6 screws to disassemble sun roof glass.

AFFECTED VIN
64 5B
ACESSORIES
1. ROOF RACK
Front / Rear mounting Center mounting

Preceding Work: Removal of head lining
1. Remove 10 bolts (left / right 5 each), and disassemble
roof rack assembly.
2. Installations reverse order of removal.

AFFECTED VIN
5B 65
2. FUEL FILLER CAP CABLE

Removal and installation
Preceding Work: Removal of front seat / 2nd, 3rd raw seat / scuff trim / lower trim - B pillar /
lower trim - quarter
1. Remove lever mounting screw and cover.
2. Disassemble rear speaker - LH.

3. Press the cable holder by both side key (Refer to arrow mark) and push.
4. Disconnect the cable from cable mounting bracket.

AFFECTED VIN
66 5B
3. BODY JACK POINT
* Rear * Front
[Notice]
Be sure to lift the vehicle only on the deginated jack point otherwise, the vehicle could be body damaged.

AFFECTED VIN
5C 1
5C - Body Repair
Table of Contents
BODY COMPONENTS & DISASSEMBLY ........ 5C-3
1. General overview ......................................................... 5C-3
2. Side garnish ................................................................ 5C-7
BODY DIMENSION ............................................ 5C-9

1. Exterior ....................................................................... 5C-9
2. Body structure .......................................................... 5C-10
3. Side structure ............................................................ 5C-11
4. Wind shield ............................................................... 5C-12
5. Tailgate ..................................................................... 5C-13
6. Under body I .............................................................. 5C-14
7. Under body II ............................................................. 5C-15
8. Floor member ............................................................ 5C-16
9. Front sub frame ......................................................... 5C-17
10. Body roof ................................................................ 5C-18
11. Frame mounting point .............................................. 5C-19
BODY GAP & ALLOWANCE ........................... 5C-21

1. Front ......................................................................... 5C-21
2. Rear .......................................................................... 5C-23
BODY REPAIR CHANGED BY

AFFECTED VIN
5C 3
BODY COMPONENTS & DISASSEMBLY

1. GENERAL OVERVIEW
Hood & Engine Room

AFFECTED VIN
4 5C
Floor Panel Assembly
CHANGED BY BODY REPAIR

AFFECTED VIN
5C 5
Side Panel & Rear Wheel House Panel

AFFECTED VIN
6 5C
Roof Panel/Tailgate/Door Panel

AFFECTED VIN
5C 7
2. SIDE GARNISH
A. Wide Garnish
<Wide garnish mounted>
Door wheel arch garnish Front wheel arch garnish
Rear door wide garnish Front door wide garnish
Rear step seal garnish Front step seal garnish

AFFECTED VIN
8 5C
B. Narrow Garnish

AFFECTED VIN
5C 9
BODY DIMENSION
1. EXTERIOR (unit: mm)

AFFECTED VIN
10 5C
2. BODY STRUCTURE (unit: mm)

AFFECTED VIN
5C 11
3. SIDE STRUCTURE (unit: mm)

AFFECTED VIN
12 5C
4. WIND SHIELD (unit: mm)
.2
1321
.2
63
1563.2
.6
15
1500

AFFECTED VIN
5C 13
5. TAILGATE (unit: mm)

AFFECTED VIN
14 5C
6. UNDER BODY I (unit: mm)
732
444
1099.28
2203
1200
930
300
850

AFFECTED VIN
5C 15
7. UNDER BODY II (unit: mm)

AFFECTED VIN
16 5C
8. FLOOR MEMBER (unit: mm)

AFFECTED VIN
5C 17
9. FRONT SUB FRAME (unit: mm)

AFFECTED VIN
18 5C
10. BODY ROOF (unit: mm)

AFFECTED VIN
5C 19
11. FRAME MOUNTING POINT

Front Sub Frame
Rear
Front
[Note]
Front/center/rear each washer is
incompatible. The other parts are
same.

AFFECTED VIN
20 5C
Rear Frame

AFFECTED VIN
5C 21
BODY GAP & ALLOWANCE

1. FRONT

AFFECTED VIN
22 5C
No Item Gap Allowance No Item Gap Allowance

1 40
Hood-outter
2 41 A pillar ~ Fander
~ Bumper-upper 4.6
3 42
Center accord (+1.0)
4 43
(Erro < 0.5)
5 44 Quad ~ Fender
6 HOOD to 6.7 -2 45
7 H/LAMP (+1.0) (0, -0.5) 46
8 47 4.5 0
Fender ~ Front door
9 48 (+1,0) (-1,0)
6.8
10 Fender ~ Head lamp -1.5 ± 1.0 49
(±1)
11 50
12 51 Quad ~ A pillar
13 52
14
15
16 Front bumper
6.8 ± 1.0 -1.5 ± 1.0
17 ~ Head lamp
18
19
20
21
22
23
Fender -0.5
24 4.5 ± 0.5
~ Hood-outter (0, -0.5)
25
26
27
28
29 Fender -2.0
2.4 ± 1.0
30 ~ Front bumper (+1.5, -1.0)
31
32
33
34
35
Glass & Panel
36
37
38
39

AFFECTED VIN
5C 23
2. REAR

AFFECTED VIN
24 5C
No Item Gap Allowance No Item Gap Allowance

1 40 Panel ~ Lamp 5.5 ± 0.5
2 41
Rear lamp 5
3 Roof rail 10 42 0.0
-2 ± 1.0 ~ Taillamp ± 0.5
4 ~ Spoiler-Rear (+1.0) 43
5 44
Tailgate gaenish
6 45 0.5
~ Panel
7 46
8 47 Extensior cover 8
Quarter glass-side 0.8
9 1.9 ± 1.0 48 ~ Tailgate panel ± 1.0
~ Quarter glass-rear
10 49
11 50
Tailgate panel 6
12 51
Quarter glass-rear -1 ~ Bumper ± 1.0
13 5 ± 1.0 52
~ Tailgate glass +1.5, -0.7
14 53
15 54 Garnish ~ Bumper 2.0 2.5
Quarter glass-side 0
16 5 ± 1.0 55 2.2 -2.0
~ Tailgate panel +0, -1 Panel ~ Bumper
17 56 ± 0.5
18 57 Cover ~ Bumper
19 58 Cover ~ Bumper
Tailgate panel
20 2.3 ± 1 59 Panel 3.2 0
~ Tailgate glass
21 60 ~ Fuel door ± 0.5 +0, -1
22 61
23 62 Quarter glass-front 5 -2.2
24 63 ~ Rear door frame +1, -0 +1, -0.5
25 64
26 Quarter glass-side 65
2.0
27 ~ Rear combi 66
Quarter glass-front
28 67 Compressed
~ Side panel
29 68
30 69
31
Combi lamp-rear 0
32 2.2 ± 1.0
~ extension cover ± 1.0
33
34
35 Combi lamp-tailgate
1.8
36 ~ Tailgate
37
38 Gap 1.0 -0.5
39 Panel ~ Lamp 2.0

AFFECTED VIN
STAVIC (2 OF 2)
CHASSIS SERVICE MANUAL
ISSUED BY
INTERNATIONAL A/S TEAM
SSANGYONG MOTOR CO., LTD.
150-3, CHILGOI-DONG, PYUNGTAEK-SI

GYEONGGI-DO, 459-711 KOREA
TELEPHONE : 82-31-610-2740
FACSIMILE : 82-31-610-3762
NOTE:All rights reserved. Printed in SSANGYONG Motor Co., Ltd.

No part of this book may be used or reproduced without the
written permission of International A/S Team.

STAVIC - Chassis Fal

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SECTION INDEX

MANUAL (vol. 2 of 2) ELECTRICAL SYSTEM 02

STAVIC AIRCONDITIONING SYSTEM 03

This manual includes procedure for maintenance,

ELECTRICAL SYSTEM................... SECTION 02

AIRCONDITIONING SYSTEM......... SECTION 03

CLUSTER/WARNING & INDICATOR PANEL .............. 2B

RAIN SENSING WIPER ................................................ 2D

PARKING ASSISTANCE SYSTEM ............................... 2H

ELECTRIC COMPONENTS AND LAYOUT .... 2A-10

FUSES AND RELAYS ..................................... 2A-12

ELECTRICAL SYSTEM CHANGED BY

ELECTRIC SYSTEM LAYOUT

Amplifier/Tuner/Navigation unit and PAS unit

DSP integrated amplifier

CHANGED BY ELECTRICAL SYSTEM

TV antenna Steering wheel angular

Sun roof unit and motor

Interior temperature and

Auto light sensor

TCU and TCCU

ELECTRICAL SYSTEM CHANGED BY

2. SWITCHES, UNITS AND SENSORS IN ENGINE COMPARTMENT

FFH (Fuel Fired Heater)

Ambient temperature sensor (FFH)

AQS/Ambient temperature sensor

CHANGED BY ELECTRICAL SYSTEM

Fuse and relay box in engine

ABS (ESP) HECU (under the battery)

PTC power supply relay (PTC system

beside battery positive

Theft deterrent horn (under the

ELECTRICAL SYSTEM CHANGED BY

3. SWITCHES IN PASSENGER COMPARTMENT

Audio remote control switch on the steering wheel

Volume button – Down

4WD switch and rear washer/

Outside rearview mirror

CHANGED BY ELECTRICAL SYSTEM

Room lamp and sun roof switch

Sun roof switch

Room lamp switch

Multifunction switch and

ELECTRICAL SYSTEM CHANGED BY

4. SYSTEM LAYOUT (BASED ON DVD SYSTEM EQUIPPED VEHICLE)

Front speaker (RH)

Front speaker (LH)

Amplifier integrated sub woofer

CHANGED BY ELECTRICAL SYSTEM

Rear tweeter speaker (RH)

Rear speaker (RH)

Rear speaker (LH)

TV antenna amplifier (LH)

ELECTRICAL SYSTEM CHANGED BY

ELECTRIC COMPONENTS AND LAYOUT

CHANGED BY ELECTRICAL SYSTEM

ELECTRICAL SYSTEM CHANGED BY

! " # $ % & '