Kia Ceed 2006 - 2012 Gasoline Diesel Factory Workshop Service Repair Manual

Contents
KIA CEED 2012 D 2.0 TCI-D Factory Workshop Service Repair Manual . . . . . . . . . . . . . . . . . . . . 2
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Body (Interior and Exterior) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Body Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
Clutch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
Driveshaft and axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
Engine Mechanical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
Heating,Ventilation, Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .953
Manual Transaxle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1048
Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1075
Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1128
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1409
Suspension System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1445
D 1.6 TCI-U2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1513
Automatic Transaxle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1513
Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1568
Engine Mechanical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1628
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1760
G 1.4 DOHC 1.6 DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1864
Emission Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2030
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2054
G 2.0 DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2127
Emission Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2283
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2297
2012 > D 2.0 TCID > General Information > General Information > General Information English
IDENTIFICATION NUMBER LOCATIONS
Identification Number Description
Vehicle Identification Number
English
1. World Manufacturer Identifier (WMI)
U5Y : Passenger vehicle
2. Vehicle line
H : Cee'd
3. Model & Series
A : Low grade (L)
B : MiddleLow grade (GL)
C : Middle grade (GLS, JSL, TAX)
D : MiddleHigh grade (HGS)
E : High grade (TOP)
4. Body/Cabin type, Gross Vehicle Weight Rating
U5Y
1 : Limousine
2 : Sedan 2 door
3 : Sedan 3 door
4 : Sedan 4 door
5 : Sedan 5 door
6 : Coupe
7 : Convertible
8 : Wagon
9 : Commercial Van
0 : PickUp
5. Restraint system, Brake system
U5Y
0 : Both side None
1 : Both side Active belt
2 : Both side Passive belt
6. Engine type
1 : Gasoline engine 1.4
5 : Diesel engine 2.0
6 : Diesel engine 1.6
7. Check digit or Driver’s side & Transmission
A : LHD & MT
B : LHD & AT
C : LHD & MT+Transfer
D : LHD & AT+Transfer
E : LHD & CVT
L : RHD & MT
M : RHD & AT
N : RHD & MT+Transfer
S : RHD & AT+Transfer
T : RHD & CVT
8. Production year
A : 2010, B : 2011, C : 2012, D : 2013 …
9. Plant of production
L: Zilina (Slovakia)
10. Vehicle production sequence number
000001 ~ 999999
Paint Code
Code Color
WD Cassa White
9S Machine Silver
5K Piston Gray
1K Black Pearl
8Q Pewter Beige
A6 Dakar Yellow
B6 Oil Blue
AA1 Infra Red
AA2 Solid Clyde Blue
5B Byte Blue
AA3 Sirius Silver
AA4 Phoenix Silver
Engine Number
1. Engine fuel
– G : Gasoline
– D : Diesel
2. Engine range
– 4 : 4 cycle 4 cylinder
– 6 : 4 cycle 6 cylinder
3 4. Engine development order and capacity
– FA : γ engine, 1396cc (Gasoline)
– FB : U engine, 1582cc (Diesel)
– FC : γ engine, 1592cc (Gasoline)
– GC : β engine, 1975cc (Gasoline)
– EA : D engine, 1991cc (Diesel)
5. Production year
– 9 : 2009, A : 2010, B : 2011, C : 2012, D : 2013 …
6. Plant of production
– A : Asan (Korea)
– B : Beijing (China)
– H : Hwasung (Korea)
– K : Montgomery (U.S.A)
– M : Chennai (India)
– P : Poseung (Korea)
– S : Sohari (Korea)
– T : Izmit (Turkey)
– U : Ulsan (Korea)
– W : Shandong (China)
– Z : Zilina (Slovakia)
– 1 : Yancheng (China)
7. Engine production sequence number
– 000001 ~ 999999
Transaxle Number
Manual
1. Model
R : M5CF1
P : M5CF2
S : M5CF3, M6GF2
2. Production year
9 : 2009, A : 2010, B : 2011, C : 2012, D : 2013 …
3. Gear ratio
1873 = 4.056
1767 = 3.941
C = 4.063
L = 4.533
4. Transaxle production sequence number
000001 ~ 999999
Automatic
1. Model
A : A4CF1
B : A4CF2
2. Production year
9 : 2009, : 2010, B : 2011, C : 2012, D : 2013 …
3. Gear ratio
A = 4.375
B = 3.532
4. Detailed chassification
AD : γ 1.6
CD : β 2.0
JD : U 1.6
5. Spare
6. Transaxle production sequence number
000001 ~ 999999
Warning / caution label locations
1. Coolant level caution 4. Battery caution
2. Fan caution 5. Air cleaner caution
3. Radiator cap caution
Battery Caution Label Describtion
Warning / Caution Label (Cont'd)
A.
Keep lighted cigarettes and all other flames or sparks away from the battery.
B.
Wear eye protection when charging or working near a battery. Always provide ventilation when working in an enclosed space.
• When lifting a plasticcased battery, excesive pressure on acid to leak resulting in personal injury. Lift with a battery
carrier or with your hands on opposite corners.
• Never attempt to change the battery when the battery cables are connected.
• The electrical ignition system works with high voltage.
Never touch these components with the engine running or the ignition switched on.
C.
Keep batteries out of the reach of children because batteries contain highly corrosive SULFURIC ACID. Do not allow battery
acid to contact your skin, eyes, clothing or paint finish.
D.
If any electrolyte gets into your eyes, flush your eyes with clean water for at least 15 minutes and get immediate medical
attention. If possible, continue to apply water with a sponge or cloth until medical attention is received.
If electrolyte gets on your skin, throughly wash the contacted area. If you feel a pain or a burning sensation, get medical
attention immediately.
E.
Always read the following instructions carefully when handing a battery.
F.
Hydrogen, which is a highly combustible gas, is always presents in battery cells and may explode if ignited.
G.
An improperly disposed battery can be harmful to the environment and human health.
Always confirm local regurations for battery disposal.
Handling And Storage The Battery
Battery Itself • Batteries should be stored in cool, dry (27 degrees Celsius) places and out of
direct sunlight.
• MF batteries are tightly sealed to prevent acid leakage.
However, tilting the battery to an angle of 45 degrees can cause acid to leak
through the vents on the sides. Therefore, batteries should always be stored in
their upright positions. Prevent placing any aqueous or solid (i.e. conductors)
bodies on top of the battery.
• It is extremely dangerous to use tools, such as hammers, on the battery terminals
when connecting cables to the mounted battery.
Battery on Vehicle • When storing the vehicle for long periods of time, make sure to remove the
memory fuse at junction box to prevent natural discharging.
• Also, run the engine for battery charging within 1 month if the memory fuse wasn't
removed from the start of vehicle storing.
If the memory fuse was removed, run the engine for battery charging within 3
months from the start of vehicle storing.

After reconnecting or recharging a discharged battery, the ESP OFF indicator may illuminate.
In this case, turn the handle half way to the left and right whilst the ignition switch is in the ON position.
Then, restart the engine after the ignition is OFF.
The ESP OFF indicator may turn OFF.
If the ESP OFF indicator does not turn OFF, have the system checked refering to DTC. (Refer to the BR group.)
Lift And Support Points

When heavy rear components such as suspension, fuel tank, spare tire, tailgate and trunk lid are to be removed, place
additional weight in the luggage area before hoisting. When substatial weight is removed from the rear of the vehicle, the
center of gravity may change and can cause the vehicle to tip forward on the hoist.

• Since each tire/wheel assembly weights approximately 30lbs (14kg), placing the front wheels in the luggage area
can assist with the weight distribution.
• Use the same support points to support the vehicle on safety stands.
1. Place the lift blocks under the support points as shown in the illustration.
2. Raise the hoist a few inches (centimeters) and rock the vehicle to be sure it is firmly supported.
3. Raise the hoist to full height to inspect the lift points for secure support.
Towing
If the vehicle needs to be towed, call a professional towing service. Never tow vehicle with just a rope or chain. It is very dangerous.
Emergency Towing
There are three popular methods of towing a vehicle :
– The operator loads the vehicle on the back of truck. This is best way of transporting the vehicle.
– The tow truck uses two pivoting arms that go under the tires of the driving axle and lift them off the ground. The other two
wheels remain on the ground.
– The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspension, and
the cables lift that end of the vehicle off the ground. The vehicle's suspension and body can be seriously damaged if this
method of towing is attempted.
If the vehicle cannot be transported by flatbed, should be towed with the wheels of the drivig axle off the ground and do the following :
Manual Transaxle
• Release the parking brake.
• Shift the Transaxle to neutral
Automatic Transaxle
• Release the parking brake.
• Start the engine.
• Shift to [D] position, then [N] position.
• Turn off the engine.

• The vehicle equipped with fulltime 4WD should be only transported on a flatbed.
• Improper towing preparation will damage the transaxle. follow the above procedure exactly. If you cannot shift the
transaxle or start the engine(automatic transaxle), your vehicle must be transported on a flatbed.
• It is the best to tow vehicle no farther than 30km (19miles), and keep the speed below 50km/h (30mph). (For the full
time 4WD vehicle, limit the towing to 1.5km (1mile) and 15km/h (10mph)
• Trying to lift or tow your vehicle by the bumpers will cause serious damage. The bumpers are not designed to
support the vehicle's weight.
General Service Information
Protection Of The Vehicle
Always be sure to cover fenders, seats, and floor areas before starting work.

The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine compartment
to prevent the hood from falling and causing possible injury.
Make sure that the support rod has been released prior to closing the hood. Always check to be sure the hood is firmly
latched before driving the vehicle.
Preparation Of Tools And Mesuring Equipment
Be sure that all necessary tools and measuring equipment are available starting work.
Special Tools
Use special tools when they are required.
Removal Of Parts
First find the cause of the problem and then determine whether removal or disassembly before starting the job.
Disassembly
If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will
not affect their performance or external appearance.
1) Inspection of parts
Each part, when removed, should be carefully on suspected for malfunction, deformation, damage, and other problems.
2) Arrangement of parts
All disassembled parts should be carefully arranged for effective reassembly.
Be sure to separate and correctly identify the parts to be replaced from those that will be used again.
3) Cleaning parts for reuse
All parts to be used again should be carefully and thoroughly cleaned by an appropriate method.
Parts
When replacing parts, use KIA genuine parts.
Replacement
Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
If removed, the following parts should always be replaced with new ones.
1) Oil seals
2) Gaskets
3) Orings
4) Lock washers
5) Cotter pins (split pins)
6) Plastic nuts
Depending on their location.
7) Sealant should be applied to gaskets.
8) Oil should be applied to the moving components of parts.
9) Specified oil or grease should be applied to the prescribed locations (oil seals, etc) before assembly.
Adjustment
Use gauges and testers to adjust correctly the parts to standard values correctly.
Electrical System
1. Be sure to disconnect the battery cable from the negative () terminal of the battery.
2. Never pull on the wires when disconnecting connectors.
3. Locking connectors will click when the connector is secure.
4. Handle sensors and relays carefully. Be careful not to drop them against other parts.
Ruber Parts And Tubes
Always prevent gasoline or from touching rubber parts or tubing.
Measuring Body Dimensiongs
1. Basically, all measurements in this manual are taken with a tracking gauge.
2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
3. For measuring dimensions, both projected dimensions and actual measurement dimensions are used in this manual.
Dimensions Projected
1. These are the dimensions measured when the measurement points are projected from the vehicle's surface, and are the
reference dimensions used for used for body alterations.
2. If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long as the
different value in height of the two surface.
Measuring Actual Dimensions
1. These dimensions indicate the actual linear distance between measurement points, and are used as the reference
dimensions when a tracking gauge is used for measurement.
2. First adjust both probes to the same length (A=A') before measurement.

Check the probes and gauge itself to make sure there is no free play.
Measurement Point
Measurements should be taken at the center of the hole.
Checking Cables And Wires
1. Check the terminal for tightness.
2. Check terminals and wires for corrosion from battery electrolyte, etc.
3. Check terminals and wires for open circuits.
4. Check wire insulation and coating for damage, cracks and degrading.
5. Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).
6. Check grounded parts to verify that there is complete continuity between their attaching bolt(s) and the vehicle's body.
7. Check for incorrect wiring.
8. Check that the wiring is so clamped to the prevent contact with sharp corners of the vehicle body, etc. or hot parts
(exhaust manifold, etc.)
9. Check that the wiring is clamped firmly to provide enough clearance from the fan pulley, fan belt and other rotating or
moving parts.
10. Check that the wiring has a little space so that it can vibrate between fixed and moving parts such as the vehicle body
and the engine.
Check Fuses
A blade type fuse test taps provided to allow checking the fuse itself without removing if from the fuse box. The fuse is good if the test
lamp lights up when one lead is connected to the test taps (one at a time) and the other lead is grounded. (Turn the ignition switch so that
the fuse circuit becomes operative)
Serivicing The Electrical System
1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable.

In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble code
retained by the computer will be cleared. There fore, if necessary, record the diagnostic data before removing the
battery cable.
2. Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the engine or
other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine vibrations to cause the
harness to come into contact with any of the surrounding parts and then secure the harness by using a clamp.
3. If any section of a wiring harness interferes with the edge of a parts, or a corner, wrap the section of the harness with tape
or something similar in order to protect if from damage.
4. When installing any parts, be careful not to pinch or damage any of the wiring harness.
5. Never throw relays, sensors or electrical parts, or expose them to strong shock.
6. The electronic parts used in the computer, relays, etc. are readily damaged by heat. If there is a need for service
operations that may cause the temperature to exceed 80°C (176°F), remove the electronic parts before hand.
7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.
8. When disconnecting a connector, be sure to grip only the connector, not the wires.
9. Disconnect connector which have catches by pressing in the direction of the arrows shown the illustration.
10. Connect connectors which have catches by inserting the connectors until they make a clicking sound.
11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the harness
side. If the connector is a sealed connector, insert the test probe through the hole in the rubber cap until contacts the
terminal, being careful not to damage the insulation of the wires.
12. To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and determine
the appropriate wire size.
Permissible current
Noeminal
SAE gauge No. In engine Other
size
compartment areas
0.3mm² AWG 22 5A
0.5mm² AWG 20 7A 13A
0.85mm² AWG 18 9A 17A
1.25mm² AWG 16 12A 22A
2.0mm² AWG 14 16A 30A
3.0mm² AWG 12 21A 40A
5.0mm² AWG 10 31A 54A
Precautions For Catalytic Converter

If a large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To prevent this
observe the following precations and explain them to your customer.
1. Use only unleaded gasoline.
2. Do not run the engine while the car is at rest for a long time. Avoid running the engine at fast idle for more than 10minutes
and idle speed for more than 20 minutes.
3. Do not measure engine compression for an extended time. Engine compression tests must be made as rapidly as possible.
Remove the fuel pump relay before performing a compression test.
4. Do not dispose of used catalytic converter together with parts contaminated with gasoline or oil.
2012 > D 2.0 TCID > Body (Interior and Exterior) > General Information > Specifications English
SPECIFICATIONS
HOOD Type Rear hinged, gas lifter type

Construction Front hinged, full door construction
FRONT DOOR Regulator system Wire drum type
Locking system Pinfork system
Construction Front hinged, full door construction
REAR DOOR Regulator system Wire drum type
Locking system Pinfork system
TAIL GATE Type Inner hinged, Gas lifter
Front 3 point type with Emergency Locking Retractor (E.L.R)
SEAT BELTS
Rear 3 point type with Emergency Locking Retractor (E.L.R)
TIGHTENING TORQUE
Items N·m kgf·m Lbf·ft

Door hinge to body 21.6~26.5 2.2~2.7 15.9~19.5
Door hinge to door 21.6~26.5 2.2~2.7 15.9~19.5
Foont and rear doors Door Striker 16.7~21.6 1.7~2.2 12.3~15.9
Checker to body 16.7~21.6 1.7~2.2 12.3~15.9
Checker to door 6.9~10.8 0.7~1.1 5.1~8.0
Hood hinge to body 21.6~26.5 2.2~2.7 15.9~19.5
Hood Hoodl hinge to hood 21.6~26.5 2.2~2.7 15.9~19.5
Hood latch to body 6.9~10.8 0.7~1.1 5.1~8.0
Front seat mounting bolts 34.3 ~ 53.9 3.5~5.5 25.3~39.8
Seat
Rear seat mounting bolts 16.7~25.5 1.7~2.6 12.3~18.8
Front seat belt height adjuster 39.2~53.9 4.0 ~ 5.5 28.9 ~ 39.8
Front seat belt buckle mounting bolt 39.2~53.9 4.0 ~ 5.5 28.9 ~ 39.8
Front seat belt anchor mounting bolt 39.2~53.9 4.0 ~ 5.5 28.9 ~ 39.8
Seat belt Front seat belt lower anchor 39.2~53.9 4.0 ~ 5.5 28.9 ~ 39.8
Front seat belt upper anchor 39.2~53.9 4.0 ~ 5.5 28.9 ~ 39.8
Rear seat belt anchor attaching bolt 39.2~53.9 4.0 ~ 5.5 28.9 ~ 39.8
Rear seat belt retractor mounting bolt 39.2~53.9 4.0 ~ 5.5 28.9 ~ 39.8
2012 > D 2.0 TCID > Body (Interior and Exterior) > General Information > Troubleshooting English
TROUBLESHOOTING
Symptom Suspect Area Remedy (Refer to page)

Dirt accumulated in drain tube Clear dirt inside of drain
Clogged drain tube Blow air into drain to remove dirt
Broken or dislocated drain tube, defective or Check tube installation and flange
Water leaks from sunroof cracked clip contact
Deteriorated roof lid weatherstrip Replace
Excessive roof lidtobody clearance and improperly
Adjust
fitted weatherstrip
Wind noise around sunroof Loose or deformed deflector, gaps in body work Retighten adjust or replace
Check drive cable and guide
Sunroof lid makes a noise when Foreign particles lodged in guide rail
rails for foreign particles
move
Loose guide rails and lid Retighten
Foreign particles lodged in guide rail
Incorrect engagement of motor pinion with drive
cable
Motor runs but sunroof Does not Decrease in motor`s clutch slipping force Adjust or replace
move or moves only partially
Increased sunroof sliding resistance
or interference of sunroof with drive
cables, weatherstrip, etc. due to
maladjustment of sunroof
Incorrect engagement of motor pinion with drive Check pinion installation and
Noise in motor (clutch slipping
cable retighten motor
noise from motor when sunroofIs
fully opened or closed is not an Worn out or damaged motor pinion bearing Replace motor assembly
unusual noise
Worn out or deformed drive cable Replace
Door glass fails to operate up and Incorrect window glass installation Adjust position

down Damaged or faulty regulator arm orregulator Correct or replace
Incorrect door installation Adjust position
Door does not open or close
Defective door check assembly Correct or replace
completely
Door hinge requires grease Apply grease
Striker and latch not properly aligned Adjust
Hood does not open or close
Incorrectly installed hood Adjust
completely
Incorrect hood bumper height Adjust
Water leak through windshield end Defective seal Fill with sealant

rear window Defective flange Correct
2012 > D 2.0 TCID > Body (Interior and Exterior) > General Information > Special Service Tools English
SPECIAL TOOLS
Tool (Number and name) Illustration Use
0979321000 Adjustment, removal and installationOf
Door hinge adjusting wrench the door hinge
0980021000
Trim removal
Ornament remover
0985331000
Removal of the headliner clips
Headliner clip remover
0986131100 Cutting the sealant of the windshield
Sealant cutout tool (Use with 0986131200)
0986131200 Cutting the sealant of the windshield
Sealant cutting blade (Use with 0986131100)
0986131000
Removal of the windshield molding
Windshield molding remover
098804F000
Installation of the hog ring clip
Hog ring clip installer
English
098401E100
Center fascia removal
Center fascia remover
2012 > D 2.0 TCID > Body (Interior and Exterior) > Exterior > Hood > Repair procedures English
REPLACEMENT
Hood Assembly Replacement

• When removing and installing the hood, an assistant is necessary.
• Take care not to damage the hood and body.
• When removing the clips, use a clip remover.
1. After loosening the hood hinge (E) mounting bolts,remove the hood (F).
2. Installation is the reverse of removal.

• Make sure the hood opens properly and locks securely.
• Adjust the hood alignment.
Hood Insulator Pad Replacement
1. Using a clip remover, detach the clips, and remove the hood insulator (A).

Take care not to scratch the hood panel.
2. Installation is the reverse of removal. English

Replace any damaged clips.
Hood Seal Weatherstrip Replacement
1. Detach the clips, then remove the hood weatherstrip (A). Take care not to scratch the hood.

• Replace any damaged clips.
Hood Weatherstrip Replacement
1. Remove the hood weatherstrip (A).

Replace any damaged clips.
Hood Release Handle Replacement
1. After loosening the mounting screw, then remove the hood release handle (A).

• Make sure the hood latch cable is connected properly.
• Make sure the hood locks securely.
Hood Latch Replacement
1. Remove the radiator grille upper cover (A).
2. Loosen the bolts, then remove the hood latch cover(A).
3. Remove the hood latch (A) mounting bolts.
4. Disconnect the hood latch cable (A) and remove the latch (B).

• Make sure the hood latch cable is connected properly.
• Make sure the hood locks securely.
ADJUSTMENT
Adjust Hood
1. After loosening the hinge (A) mounting bolt, adjust the hood (D) by moving it up or down, or right or left.
2. Adjust the hood height by turning the hood overslam bumpers (B).
3. After loosening the hood latch (C) mounting bolts,adjust the latch by moving it up or down, or right or left.
2012 > D 2.0 TCID > Body (Interior and Exterior) > Exterior > Tailgate > Repair procedures English
REPLACEMENT
Tailgate Trim Replacement (5Door)

• When prying with a flattipped screwdriver, wrap it with protective tape, and apply protective tape around the related
parts, to prevent damage.
• Put on gloves to protect your hands.
1. After loosening the screws the remove the tailgate trim (A).
2. Remove the upper trim (B) and side trim (C).

• Replace and damaged clips.
Tailgate Trim Replacement (3Door)

English

Tailgate Trim Replacement (Wagon)


Latch Assembly Replacement
1. Remove the tailgate trim.
2. After loosening the mounting nuts, then remove the latch assembly (A).
3. Disconnect the connector.

• Make sure the connector is connected properly and the connecting rod is connected properly.
• Make sure the tailgate opens properly and locks securely.
Outside Handle Replacement
2. After loosening the tail gate garnish mounting nuts, then tailgate garnish (A).
3. Remove the outside handle (A).

• Make sure the tailgate opens properly and locks securely.
Lifter Replacement
1. Using a screwdriver (A), lift up slightly the socket clips (B) of both ends on the lifer (D), and then remove the lifter from the
bracket (C).
2. Push the socket of the lifter into the bracket for installation.
ADJUSTMENT
1. After loosening the tailgate hinge (A) mounting bolt,adjust the tailgate by moving it up or down, or right or left.
2. Adjust the tailgate fit by turning the tailgate over slam bumper and side bumper (B).
3. Adjust the striker (C) by moving it up or down, or right or left.
2012 > D 2.0 TCID > Body (Interior and Exterior) > Exterior > Front Door > Repair procedures English
REPLACEMENTS
Door Trim Replacement

• Take care not to scratch the door trim and other parts.
1. Remove the quadrant inner cover (A).
2. Loosen the door trim (A) mounting screws. Release the clips that hold the door trim, then remove the door trim by pulling it
upward. Disconnect the power window switch connector, power mirror connector, and door courtesy lamp connector, trunk
lid connector.
3. Disconnect the cable (A).
English

• Make sure of connectors is plugged in properly and each rod is connected securely.
• Make sure the door lock and opens properly.
Inside Handle Replaement
1. Remove the door trim.
2. Loosen the door inside handle mounting screws, remove the door inside handle (A).
Glass Replacement
1. Remove the front door trim.
2. Remove the glass mounting hole plug (B).

• Using the door switch to align the mounting hole with the hole on the door glass.
• If it is impossible, align the hole with hands after removing the motor.
• Take care not to drop to glass and scratch the glass surface.
3. Carefully move the glass (A) until you can see thebolts, then loosen them. Separate the glass from the glass run and
carefully pull the glass out through the window slot.

• Roll the glass up down to see if it move freely without binding.
• Adjust the position of the glass as necessary.
Speaker Replacement
2. Drill out the rivets to remove the speaker (B) from the door module.
3. Disconnect the speaker connector (A).
Use sheet metal screws to secure the speaker.
Power Window Motor Replacement
1. Remove the door trim .
2. After disconnecting the connector (A), remove the power window motor (B).

• The area of rotational parts and springs should be applied with sufficient grease.
Door Module Assembly Replacement
1. Remove the following parts.
• Door trim.
• Glass.
• Outside handle.
1. Loosen the mounting screw (A).
2. Loosen the door module mounting bolts, then remove the door module (A).
3. Disconnect the connector (A).
4. Disconnect the door module wiring harness (B), then remove the module assembly (C).

• The area of whole parts should be applied with sufficient grease.
• Make sure the connector is plugged in properly and each rod is connected securely.
• Make sure the door lock and open properly.
Out Side Handle Replacement
1. After loosening the mounting bolt, then remove the key holder (A).
2. Remove the outside handle (A) by sliding it rearward.
3. Remove the outside handle pad (A).

• Make sure the door lock and open properly
Door Weatherstrip Replacement
1. Loosen the checker mounting bolts.
2. Detach the clips, then remove the weatherstrip(A).
ADJUSTMENT
Glass Adjustment

• Check the glass run channel for damage or deterioration, and replace them necessary.
• Quadrant inner cover.
• Door trim.
2. Carefully move the glass (A) until you can see theglass mounting bolts (B), then loosen them.
3. Check that the glass moves smoothly.
4. Raise the glass fully, and check for gaps.
Check that the glass contacts the glass run channel evenly.
5. Check for water leaks. Run water over the roof andon the sealing area as shown, and note these items:
– Use a 12mm (1/2Iin.) diameter hose.
– Adjust the rate of water flow as shown.
– Do not use a nozzle.
– Hold the hose about 300mm(12in.) away from the door.
Door Position Adjustment

• After installing the door, check for a flush fit with the body, then check for equal gaps between the front,Rear, and
bottom, door edges and the body. Check that the door and body edges are parallel. Before adjusting, replace the
mounting bolts.
1. Place the vehicle on a firm, level surface when adjusting the doors.
2. Adjust at the hinges (A):
– Loosen the door mounting bolts slightly, and move the door IN or OUT until it aligns flush withthe body.
– Loosen the hinge mounting bolts slightly, and move the door BACKWARD or FORWARD, UP or DOWN as necessary
to equalize the gaps.
– Place a shop towel on the jack to prevent damage to the door when adjusting the door.
3. Check that the door and body edges are parallel.
4. Grease the pivot portions of the hinges indicated by the arrows.
5. Check for water leaks.
Door Striker Adjustment
Make sure the door latches securely without slamming it.
If necessary adjust the striker (A): The striker nuts are fixed.
The striker can be fine adjusted up or down, and in or out.
1. Loosen the screws (B), then insert a shop towel between the body and striker.
2. Lightly tighten the screws.
3. Wrap the striker with a shop towel, then adjust the striker by tapping it with a plastic hammer.
Do not tap the striker too hard.
4. Loosen the screws and remove the shop towel.
6. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches
properly, tighten the screws and recheck.
2012 > D 2.0 TCID > Body (Interior and Exterior) > Exterior > Rear Door > Repair procedures English
REPLACEMENT
5Door, Wagon
Door Trim Replacement

• Take care not to scratch the door trim and other parts.
1. Remove the delta inner cover (A).
2. Loosen the door trim (A) mounting screws. release the clips that hold the door trim, then remove the door trim by pulling it
upward. disconnect the power window switch connector.
3. Disconnect the lock cable and (A) inside connect cable (B).
English

• Make sure of connectors is plugged in properly and each rod is connected securely.
• Make sure the door lock and opens properly.
Inside Handel Replacement
2. Loosen the door inside handle mounting screws, remove the door inside handle (A).
Glass Replacement

2. Remove the door belt weatherstrip.
3. Release the rear channel mounting bolt and nut.

• Take care not to drop to glass and scratch the glasssurface.
4. Carefully move the glass (A) until you can see thebolts, then loosen them. Separate the glass from the glass run and
carefully pull the glass out through the window slot.

• Adjust the position of the glass as necessary.
Speaker Replacement
2. Drill out the rivets to remove the speaker (B) from the door module.
3. Disconnect the speaker connector (A).
Use sheet metal screws to secure the speaker.
Power Window Motor Replacement
2. After disconnecting the connector (A), remove the power window motor (B).

• The area of rotational parts and springs should be applied with sufficient grease.
Out Side Handle Replacement
1. After loosening the mounting bolt, then remove the handle cover (A).
2. Remove the outside handle (A) by sliding it rearward.
3. Remove the outside handle pad (A).

Module Assembly Replacement
• Door trim.
• Window glass.
• Outside handle.
2. Loosen the mounting screw (A).
3. Remove the rear channel (A).
4. After loosening the door module mounting bolts, remove the door module (A).
5. Disconnect the connector (B).
6. Detach the clips, then remove the wiring harness(C).

• The area of whole parts should be applied with sufficient grease.
• Make sure the connector is plugged in properly and each rod is connected securely.
Door Weatherstrip Replacement
1. Loosen the checker mounting bolts.
2. Detach the clips, then remove the weatherstrip(A).
3. Installation is the reverse the removal.
ADJUSTMENT
Glass Adjustment

• Check the glass run channel for damage or deterioration, and replace them necessary.
• Door trim.
2. Carefully move the glass (A) until you can see theglass mounting bolts, then loosen them.
3. Push the glass against the channel, then tighten the glass mounting bolts.
4. Check that the glass moves smoothly.
5. Raise the glass fully, and check for gaps.
Check that the glass contacts the glass run channel evenly.
6. Check for water leaks. Run water over the roof andon the sealing area as shown, and note these items:
– Use a 12mm (1/2Iin.) diameter hose.
– Adjust the rate of water flow as shown.
– Do not use a nozzle.
– Hold the hose about 300mm(12in.) away from the door.
Door Position Adjustment

• After installing the door, check for a flush fit with the body, then check for equal gaps between the front,Rear, and
bottom, door edges and the body. Check that the door and body edges are parallel. Before adjusting, replace the
mounting bolts.
1. Place the vehicle on a firm, level surface when adjusting the doors.
2. Adjust at the hinges (A):
– Loosen the door mounting bolts slightly, and move the door IN or OUT until it aligns flush withthe body.
– Loosen the hinge mounting bolts slightly, and move the door BACKWARD or FORWARD, UP or DOWN as necessary
to equalize the gaps.
– Place a shop towel on the jack to prevent damage to the door when adjusting the door.
3. Check that the door and body edges are parallel.
4. Grease the pivot portions of the hinges indicated by the arrows.
5. Check for water leaks.
Door Striker Adjustment
Make sure the door latches securely without slamming it.
If necessary adjust the striker (A): The striker nuts are fixed.
The striker can be fine adjusted up or down, and in or out.
1. Loosen the screws (B), then insert a shop towel between the body and striker.
3. Wrap the striker with a shop towel, then adjust the striker by tapping it with a plastic hammer.
Do not tap the striker too hard.
4. Loosen the screws and remove the shop towel.
6. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches
properly, tighten the screws and recheck.
2012 > D 2.0 TCID > Body (Interior and Exterior) > Exterior > Body Side Moldings > Repair procedures
English
REPLACEMENT
Roof Rack Replacement (Wagon)

• When prying with a flattip screwdriver, wrap it with protective tape, and apply protective tape around the related
• Take care not to scratch the body surface.
1. Remove the roof rack cover (A).
2. Remove the roof rack (B).
Roof molding Replacement (Wagon)
1. Remove the roof molding (A).
Tailgate Garnish Replacement (5Door/Wagon)
2. Remove the tailgate garnish (A).
English
Roof molding Replacement (3Door)
1. Remove the roof molding (A).
Tailgate Garnish Replacement (3Door)
2. Remove the tailgate garnish (A).
2012 > D 2.0 TCID > Body (Interior and Exterior) > Exterior > Mirror > Repair procedures English
REPLACEMENT
Outside Rear View Mirror Relplacement

• When prying with a flatup screwdriver, wrap it with protective tape, and apply protective tape around the related
1. Remove the quadrant inner cover (A).
2. After disconnecting the connector (A), remove the outside rear view mirror (B).
Inside Rear View Mirror Replacement
1. Push the inside rear view mirror base (A) down to remove to inside rear view mirror assembly (B).
English
ECM Mirror Replacement
1. Gently detach the hook, then remove the ECM mirror cover (A).
3. Push the ECM mirror base down to remove the ECMmirror assembly (A).
2012 > D 2.0 TCID > Body (Interior and Exterior) > Exterior > Cowl Top Cover > Repair proceduresEnglish
REPLACEMENT
Cowl Top Cover Replacement
1. Remove the wiper (A).
2. Detach the clips, then remove the cowl top cover (A).
2012 > D 2.0 TCID > Body (Interior and Exterior) > Exterior > Fule Fill Door > Repair procedures English
REPLACEMENT

• When prying with a flattip screwdriver, wrap it with protective tape, and apply protective tape around the related
1. Open the fuel filler door.
2. Remove the fuel filler door cap (A).
3. Pull out the fuel filler door cable (A) by pushing the lock pin.
4. Remove the fuel filler door open switch (A) by pushing the both lock pins.
5. Remove the clips (A).
English
6. Remove the fuel filler door housing (B) by inserting the screwdriver (A) into the gap between the housing and body panel.

• Slightly pull out the packing part (C) inside of the housing before removing the fuel filler door housing.

• Be careful not to tear the housing.
7. Slightly pry up the lock pin (A) using a flat head screwdriver and remove the fuel filler door (B) by pulling it in the direction
of the arrow.

• Be careful not to damage the lock pin.
8. Reinstall all removed parts in the reverse order of removal.

• Make sure the fuel filler door locks/unlocks and opens/closes properly.
2012 > D 2.0 TCID > Body (Interior and Exterior) > Interior > Console > Components and Components
English
Location
COMPONENTS
1. Console assembly 4. Console upper cover
2. Floor console upper cover 5. Console upper bezel (AT)
3. Console switch assembly 6. Console upper bezel (MT)
2012 > D 2.0 TCID > Body (Interior and Exterior) > Interior > Console > Repair procedures English
REPLACEMENT
Floor Console Replacement

1. Remove the console upper cover (A).
2. After loosening mounting screws, then remove the floor console upper cover (A).
4. Gently detach the hook, remove the parking brake cover (A).
English
5. After loosening the console mounting screws, remove the floor console assembly (A).

• Make sure the connector is plugged in properly.
• Replace any damage clips.
Console Extenser Cover
1. Remove the console extenser cover (A).
Driver's
Passenger's
2012 > D 2.0 TCID > Body (Interior and Exterior) > Interior > Crash Pad > Components and Components
English
Location
COMPONENTS
1. Crash pad main panel 7. Crash pad centr tray 13. Air vent

2. Glove box housing 8. Audio assembly 14. Crash pad centr side cover
3. Glove box cover 9. Heater control unit 15. Crash pad lower panel
4. Airback module 10. Center facia panel 16. Shroud
5. Crash pad lower panel 11. Cluster panel 17. Crash pad side cover
6. Storage box 12. Cluster 18. Air vent
2012 > D 2.0 TCID > Body (Interior and Exterior) > Interior > Crash Pad > Repair procedures English
REPLACEMENT
Cluster Facia Replacement

1. Tilt the steering column down.
2. Separate the cluster facia panel (B) from the crash pad pulling the SST (098401E100) (A).
3. After loosening the mounting screws, then remove the cluster fascia (A).
English
5. Installation is the reverse the removal.

Center Facia Panel Replacement

1. Put the SST (098401E100) (A) into the space between the center fascia and crash pad.

• Be care not to damage the center facia and crash pad.
2. Separate the center facia panel from the crash pad pulling the SST (098401E100) (A) as shown on the photo.

• Pull the SST (098401E100) (A) slowly not to damage the center fascia panel.
3. Pull the other side of center facia panel with the SST (098401E100) in the way of "step 2)".
Center Facia Lower Tray Replacement
1. After loosening the mounting clips, then remove the center facia lower tray (A).
Lower Panel Replacement
1. Remove the crash pad side cover.
2. Disconnecting the connector (B).
3. After loosening the crash pad lower panel mounting screws, then remove the lower panel (A).
4. After loosening the mounting bolts, then remove the reinforcing panel (A).
Audio Assembly Replacement
1. Remove the center facia panel .
2. After loosening the mounting screws, then remove the audio assembly (A).

Glove Box Replacement
1. Disconnect the damper (B) from the glove box (A).
2. Remove the glove box (A) from the lift (B).
3. Disconnect the pine (A), then remove the glove box (B).
4. After loosening the mounting screws, then remove the glove box housing (A).
5. Disconnect teh connector (B).
Shroud Replacement
1. Loosen the screws.
2. Remove the shroud assembly (A).
Cover Replacement

1. Remove the crash pad side cover (A).
Driver's
Passenger's
Crash Pad Replacement

1. Remove the following items.
• Front seat.
• Cluster fascia panel, cluster.
• Audio assembly.
• Glove box.
• Crash pad side cover.
• Front pillar trim.
2. Remove the photo sensor.
3. Disconnect the passenger`s air bag connector (A).
Loosen the bolts and nuts, then remove the crash pad (B).

• Make sure the crash pad fits onto the guide pins correctly.
• Before tightening the bolts, make sure the crash pad wire harnesses are not pinched.
• Make sure the connectors are plugged in properly, and the antenna lead is connected properly.
• Enter the anti theft code for the radio, then enter the customer`s radio station presets.
2012 > D 2.0 TCID > Body (Interior and Exterior) > Interior > Roof Trim > Repair procedures English
REPLACEMENT
Sunvisor Replacement

• When prying with a flattip screwdriver, wrap it with protective tape to prevent damage.
1. Remove the cover (C).
2. Remove the sunvisor (A) and holder (B) from each side.
3. Disconnect the connector (D).
Assist Handle Replacement

1. Remove the covers (B), and remove the screws, then remove the assist handle (A).
English
Overhead Console Lamp Replacement

1. Remove the overhead console
• Remove the screw.
• Pull out the roof console (A).
• Disconnect the connector (B).
Room Lamp Replacement

1. Remove the room lamp.
• Remove the lens (A).
• Remove the screws.
• Pull out the room lamp (B).
• Disconnect the connector (C).
Headliner Replacement

• Take care not to bend or scratch the trim and panels.
• Front seat, rear seat assembly.
• Door scuff trim.
• Front pillar trim.
• Center pillar trim.
• Rear pillar trim.
• Overhead console.
• Room lamp.
• Sunvisor.
• Assist handle
2. Remove the roof trim (A).

2012 > D 2.0 TCID > Body (Interior and Exterior) > Interior > Interior Trim > Repair procedures English
REPLACEMENT
5Door

1. Remove the interior trim.
1. Cowl side trim 5. Front pillar upper trim
2. Front door scuff trim 6. Center pillar upper trim
3. Center pillar lower trim 7. Rear pillar trim
English
4. Rear door scuff trim
3Door

1. Remove the interior trim.
1. Rear guarter trim 4. Door scuff trim
2. Rear pillar trim 5. Front pillar trim
3. B pillar trim 6. Cowl side trim
Wagon

1. Cowl side trim 5. Front pillar trim
2. Front door scuff trim 6. Center pillar trim
3. Center pillar trim 7. Rear pillar trim
4. Rear door scuff
Luggage Side Trim Replacement
5Door

• When prying with a flattipped screwdriver, wrap it with protective tape to prevent damaged.
1. Remove the rear seat.
2. Remove the rear seat belt lower anchor.
3. After loosening the mounting screws, then remove the luggage side trim.
1. Front lord floor trim 6. Luggage covering m at
2. Luggage side shelf 7. Center luggage box
3. Luggage side trim 8. Luggage covering mat
4. Rear transverse trim 9. Rear pillar trim
5. Luggage center shelf 10. Luggage room lamp
3Door

1. Front lord floor trim 6. Luggage covering mat
2. Luggage side shelf 7. Center luggage box
3. Luggage side trim 8. Luggage covering mat
4. Rear transverse trim 9. Luggage room lamp
5. Luggage center shelf
Wagon

1. Side C/shelf trim 6. Front luggage box 11. Cargo screen

2. Luggage side trim 7. Rear luggage box 12. Luggage side box
3. Luggage room lamp 8. Front luggage covering 13. Luggage side box cover
4. Floor load trim 9. Luggage net 14. Rear pillar trim
5. Luggage side box 10. Rear transverse trim
2012 > D 2.0 TCID > Body (Interior and Exterior) > Interior > Windshield Glass > Components andEnglish
Components Location
COMPONENTS
2012 > D 2.0 TCID > Body (Interior and Exterior) > Interior > Windshield Glass > Repair procedures
English
REPLACEMENT
Removal

– Put on gloves to protect your hands.
– Use seat covers to avoid damaging any surfaces.
1. Remove the following items:
– Inside rear view mirror.
– Sunvisors and holders, both sides, overhead console, Grab handles, both sides.
– Front pillar trim, both sides.
– Windshield wiper arms and cowl cover. (See page BE "Windshield wiper")
2. Remove the molding (A) from the edge of the windshield (B). If necessary, cut the molding with a utility knife.
3. Pull down the front portion of the headliner. Take care not to bend the headliner excessively, or you may crease or break it.
4. Cut out the sealant using the sealant cutting tool [A(0986131100)].
English
5. Remove the winshield (B) carefully using the glass holder [A].
Installtion
1. With a knife, scrape the old adhesive smooth to a thickness of about 2mm (0.08 in.) on the bonding surface around the
entire windshield opening flange:
– Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
– Remove the rubber dam and fasteners from the body.
– Mask off surrounding surfaces before painting.
2. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting
on the clean surface.
3. Apply the glass primer (A) to the side of the windshield glass edge and stick the bothsided adhesive tape (B) on the inside
of molding (C).
4. When attaching the molding, make it in line (D) with the windshield glass and attach the windshield glass pad (E)to the
designated place.
5. Install the spacer (A) install the windshield glass (B) temperarily with making sure to position them on the center, and then
place the alignment mark (C).
6. Remove the windshield.
7. Apply a light coat of glass primer to the outside of the fasteners.

– Never touch the primed surface with your hand. If you do, the adhesive may not bond to the glass properly,
causing a leak after the windshield glass is installed.
– Do not apply body primer to the glass.
– Keep water, dust, and abrasive materials away from the primer.
8. With a sponge, apply a light coat of body primer to the original adhesive remaining around the windshield opening flange.
Let the body primer dry for at least 10 minutes:
– Do not apply glass primer to the body, and be careful not to mixup glass and body primer sponges.
– Never touch the primed surfaces with your hands.
– Mask off the dashboard before painting the flange.
9. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and
run a bead of sealant (A) around the edge of the windshield (B) between the fastener and molding as shown. Apply the
adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
10. Use glass holder (A) to hold the windshield over the opening, align it with the alignment marks (B) made in step 15, and
set it down on the adhesive. Lightly push on the windshield until its edges are fully seated on the adhesive all the way
around. Do not open or close the doors until the adhesive is dry.
11. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the
windshield, wipe with a soft shop towel dampened with alcohol.
12. Let the adhesive dry for at least one hour, then spray water over the windshield and check for leaks. Make leaking areas,
and let the windshield dry, then seal with sealant:
– Let the vehicle stand for at least four hours after windshield installation. If the vehicle has to be used within the first
four, it must be driven slowly.
– Keep the windshield dry for the first hour after installation.
13. Reinstall all remaining removed parts. Install the rearview mirror after the adhesive has dried thoroughly. Advise the
customer not to do the following things for two the three days:
– Slam the door with all the windows rolled up.
– Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven
roads).
2012 > D 2.0 TCID > Body (Interior and Exterior) > Bumper > Front Bumper > Components and English
Components Location
COMPONENTS
< 3 Door, 5 Door >
1. Front bumper cover 3. Front bumper lower stiffener
2. Front bumper energy absorber 4. Front bumper side bracket
< Sports Pack >
English
1. Front bumper cover 3. Front bumper lower stiffener
2. Front bumper energy absorber 4. Front bumper side bracket
2012 > D 2.0 TCID > Body (Interior and Exterior) > Bumper > Front Bumper > Repair procedures English
REPLACEMENT

• Put on gloves to protect your hands
• Take care not bend or scratch the cover and other parts.
1. Remove the mounting clips.
2. Loosen the radiator upper cover mounting screws and bolts.
3. After loosening the front bumper side's mounting screw, then disconnect the side's.
4. Disconnect the fog lamp connector (A).
English
5. Remove the front bumper cover.
2012 > D 2.0 TCID > Body (Interior and Exterior) > Bumper > Rear Bumper > Components and English
Components Location
COMPONENTS
< 3 Door, 5 Door >
1. Rear bumper cover 3. Rear bumper side bracket
2. Rear bumper energy absorber
< Sports Pack >
English
1. Rear bumper cover 3. Rear bumper side bracket
2. Rear bumper energy absorber
2012 > D 2.0 TCID > Body (Interior and Exterior) > Bumper > Rear Bumper > Repair procedures English
REPLACEMENT

• Put on gloves to protect your hands
• Take care not bend or scratch the cover and other parts.
1. Remove the mounting nuts.
2. Disconnect the connector (A), then remove the rear combination lamp (B).
3. Remove the rear bumper side’s screws.
4. Loosen the inside mounting bolts.
English
5. After loosening the mounting screws and clips, then remove the rear bumper cover (A).

2012 > D 2.0 TCID > Body (Interior and Exterior) > Seat & Power Seat > Front Seat > Components and
English
Components Location
COMPONENTS
2012 > D 2.0 TCID > Body (Interior and Exterior) > Seat & Power Seat > Front Seat > Repair procedures
English
REPLACEMENT
Seat Assembly Replacement
1. Remove the seat assembly mounting cover.
2. After loosening the seat assembly mounting bolts, remove the seat assembly (A).
3. Disconnect the connectors, and remove the seat assembly.
Driver`s
Passenger`s

English
SEAT MOUNTING BOLT INSTALLATION PROCEDURE (manual seat only)
– Set the into the most rearward position.Check then each slide is locked, and then
Tighten the front mounting bolt temporarily.
– Set the seat into most forward position.Check that each slide is locked, and thenTighten the rear mounting bolt
completely.
– Set the seat into the most rearward position.Check the front mounting bolt completely.
– Check that the seat operates to and fro smoothyand the locking portion locks properly.
Recliner Cover Replacement
1. After loosening the recliner mounting screw, then remove the recliner lever (A) and height lever (B).
2. After loosening the mounting screws, then remove the recliner cover (C).
3. Gently detach the hook, remove the recliner cover (A).
Seat Back Cover Replacement
1. Remove front seat assembly.
2. Remove the recliner cover .
3. After disconnecting the scuff band, remove the seat back panel.
4. Disconnect the protector (A) from the back frame.
5. Remove the lumber sport lever.
6. Pull out the headrest guides (A) while pinching the end of the guides, and remove them.
7. After removing the tape on the front of seat back remove the seat back cover (A).
Seat Cushion Cover Replacement
1. Remove front seat assembly.
2. Remove the recliner cover.
3. After disconnect the protector (A), then remove the seat cushion (B).
4. After removing the hogring clip on the front of seat cushion and remove the seat cushion cover (A).
Seat Frame Replacement
• Recliner cover
• Seat back panel
• Headrest guide
• Seat back cover
2. After loosening the mounting bolts, then disconnect the seat back frame (A) and seat cushion frame (B).

• Remove the side air bag for replacing side air bag installation seat.
• Be fore service, be fully aware of precautions and service procedure relevant to air bag (Refer to page RT
Airbag)
2012 > D 2.0 TCID > Body (Interior and Exterior) > Seat & Power Seat > Rear Seat > Components and
English
Components Location
COMPONENTS
2012 > D 2.0 TCID > Body (Interior and Exterior) > Seat & Power Seat > Rear Seat > Repair procedures
English
REPLACEMENT
Seat Assembly Replacement
1. Remove the seat cushion (A).
2. After loosening the mounting bolts, then remove the rear seat back (A).
2012 > D 2.0 TCID > Body (Interior and Exterior) > Seat Belt > Front Seat Belt > Repair procedures
English
REPLACEMENT
5Door/Wagon
Front Seat Belt Replacement

• When installing the belt, make sure not to damage the pretensioner.
1. Disconnect the battery negative cable, and wait for at least three minutes before beginning work.
2. After raise the lower anchor cover (A), loosen the lower anchor mounting bolt (B).
3. Remove the center pillar lower trim.
4. Remove the center pillar upper trim.
5. After disconnecting the pretensioner connector lock pin, remove the SIS connector (B), Loosen the mounting bolt, then
remove the pretensioner (C).
Hight Adjuster Replacement
1. Remove the following items first.
• Front seat assembly.
• Front seat belt.
2. After loosening the mounting bolt, then remove the height adjuster (A).
English
Front Seat Belt Buckle Replacement
2. Remove the wire harness of buckle from seat.
3. Remove the seat belt buckle (A).
3Door
Front Seat Belt Replacement

• When installing the belt, make sure not to damage the pretensioner.
2. After raise the lower anchor cover (A), loosen the lower anchor mounting bolt (B).
Tightening torque :
4.0~5.5kgf.m (39.2~53.9N.m, 28.9~39.8lbft)
3. Remove the door scuff trim (A).
4. Remove the rear guarter trim (A).
5. Remove the B pillar upper trim (A).
6. Remove the upper anchor (A).
7. After disconnecting the pretensioner connector lock pin, remove the SIS connector, Loosen the mounting bolt, then remove
the pretensioner (C).
Hight Adjuster Replacement
• Front seat belt.
2. After loosening the mounting bolt, then remove the height adjuster (A).
Tightening torque :
4.0~5.5kgf.m (39.2~53.9N.m, 28.9~39.8lbft)
Front Seat Belt Buckle Replacement
2. Remove the wire harness of buckle from seat.
2012 > D 2.0 TCID > Body (Interior and Exterior) > Seat Belt > Rear Seat Belt > Repair proceduresEnglish
REPLACEMENT
5Door
Rear Seat Belt Replacement

• When installing the belt, make sure not to damaged the pretensioner.
1. Remove the lower anchor (A).
2. After loosening retractor (C) mounting bolt, remove the rear seat belt (B).
Rear Seat Belt Buckle Replacement
1. Remove the rear seat cushion.
2. Remove the seat belt buckle and center seat belt (A).
Tightening torque :
4.0~5.5kgf.m (39.2~53.9N.m, 28.9~39.8lbft)
English
3Door
Rear Seat Belt Relacement

• Rear seat assembly.
• Rear door scuff trim.
3. Remove the side seat (A).
4. Remove the luggage side shelf (A).
5. After loosening the retractor (B) mounting bolt, remove the rear seat belt (C).
Tightening torque :
4.0~5.5kgf.m (39.2~53.9N.m, 28.9~39.8lbft)
1. Remove the sear seat cushion.
Tightening torque :
4.0~5.5kgf.m (39.2~53.9N.m, 28.9~39.8lbft)
4. Remove the center seat belt and buckle (A).
Tightening torque :
4.0~5.5kgf.m (39.2~53.9N.m, 28.9~39.8lbft)
Wagon
Rear Seat Belt Relacement

• Rear seat assembly.
• Rear door scuff trim.
Tightening torque :
4.0~5.5kgf.m (39.2~53.9N.m, 28.9~39.8lbft)
3. Remove the side shelf trim (A).
4. Remove the rear pillar trim (A).
5. Remove the luggage side trim.
6. After loosening the retractor (B) mounting bolt, remove the rear seat belt (C).
Tightening torque :
4.0~5.5kgf.m (39.2~53.9N.m, 28.9~39.8lbft)
1. Remove the sear seat cushion.
Tightening torque :
4.0~5.5kgf.m (39.2~53.9N.m, 28.9~39.8lbft)
4. Remove the center seat belt and buckle (A).
Tightening torque :
4.0~5.5kgf.m (39.2~53.9N.m, 28.9~39.8lbft)
2012 > D 2.0 TCID > Body Electrical System > General Information > General Information English
GENERAL TROUBLESHOOTING INFORMATION
Before Troubleshooting
1. Check applicable fuses in the appropriate fuse/relay box.
2. Using the battery checker (MCR570 KIT), check the battery for damage, state of charge, and clean and tight connections.
(Refer to the Engine Electrical System Battery)

• Do not quickcharge a battery unless the battery ground cable has been disconnected, otherwise you will
damage the alternator diodes.
• Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage
the wiring.
3. Check the alternator belt tension.
Handling Connectors
1. Make sure the connectors are clean and have no loose wire terminals.
2. Make sure multiple cavity connectors are packed with grease (except watertight connectors).
3. All connectors have pushdown release type locks (A).
4. Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component.
This clip has a pull type lock.
5. Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its
mount bracket (A).
English
6. Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead.
7. Always reinstall plastic covers.
8. Before connecting connectors, make sure the terminals (A) are in place and not bent.
9. Check for loose retainer (A) and rubber seals (B).
10. The backs of some connectors are packed with grease. Add grease if necessary. If the grease (A) is contaminated,
replace it.
11. Insert the connector all the way and make sure it is securely locked.
12. Position wires so that the open end of the cover faces down.
Handling Wires And Harnesses
1. Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations.
2. Remove clips carefully; don't damage their locks (A).
3. Slip pliers (A) under the clip base and through the hole at an angle, and then squeeze the expansion tabs to release the
clip.
4. After installing harness clips, make sure the harness doesn't interfere with any moving parts.
5. Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from
exposed screws and bolts.
6. Seat grommets in their grooves properly (A). Do not leave grommets distorted (B).
Testing And Repairs
1. Do not use wires or harnesses with broken insulation.
Replace them or repair them by wrapping the break with electrical tape.
2. After installing parts, make sure that no wires are pinched under them.
3. When using electrical test equipment, follow the manufacturer's instructions and those described in this manual.
4. If possible, insert the remover tool from the wire side (except waterproof connector).
5. Use a probe with a tapered tip.
Refer to the user's guide in the wiring repair kit (Pub No. : TRK 015.)
Fivestep Troubleshooting
1. Verify the complaint
Turn on all the components in the problem circuit to verify the customer complaint. Note the symptoms. Do not begin
disassembly or testing until you have narrowed down the problem area.
2. Analyze the schematic
Look up the schematic for the problem circuit.
Determine how the circuit is supposed to work by tracing the current paths from the power feed through the circuit
components to ground. If several circuits fail at the same time, the fuse or ground is a likely cause.
Based on the symptoms and your understanding of the circuit operation, identify one or more possible causes of the
problem.
3. Isolate the problem by testing the circuit.
Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to
efficient troubleshooting.
Test for the most likely cause of failure first. Try to make tests at points that are easily accessible.
4. Fix the problem
Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures.
5. Make sure the circuit works
Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was
a blown fuse, be sure to test all of the circuits on the fuse. Make sure no new problems turn up and the original problem
does not recur.
2012 > D 2.0 TCID > Body Electrical System > Audio > Specifications English
SPECIFICATION
Audio
Item Specification
Model RADIO/CD/MP3/RDS
Power supply DC 14.4V
Load Impedance 4 Ohm x 4
Dark Current 2mA Max (Head unit only)
Antenna 50 Ohm
Tuning type COURGAR TUNER
FM 87.5 ~ 108.0 MHz/100 KHz
Frequency range / Channel space
AM 531 ~ 1602 KHz/9 KHz
* RDS : Radio Data System.
Speaker
Item Specification
Front Max 40
Input Power
Rear Max 40
(W)
Tweeter Max 40
Front 4.0 ± 0.6
Speaker Impedance
Rear 4.0 ± 0.6
(Ω)
Tweeter 4.0 ± 0.6
Speaker Number 6
Antenna
Item Specification
Installation Position Roof
Input Voltage DC 10.5V~16.0V
Rated Voltage DC 12V (AM/FM) / DC 4.5V (GPS)
Output Impedance (Radio+GPS) 75Ω (AM/FM), 50Ω (GPS)
Output Impedance (Radio) 50Ω (AM/FM)
2012 > D 2.0 TCID > Body Electrical System > Audio > Components and Components Location English
COMPONENT LOCATION
1. Audio unit 5. Rear door speaker
2. Tweeter speaker 6. Antenna feeder cable
3. AUX Jack / USB Port / iPod 7. Roof antenna (Radio)
4. Front door speaker
2012 > D 2.0 TCID > Body Electrical System > Audio > Audio Unit > Components and Components
English
Location
COMPONENTS
2012 > D 2.0 TCID > Body Electrical System > Audio > Audio Unit > Repair procedures English
REMOVAL
1. Disconnect the negative () battery terminal.
2. Remove the crash pad center facia panel (A).
(Refer to the BD group "Crash pad")
3. Disconnect the connectors from the crash pad center facia panel.
4. Remove the mounting bolts then remove the audio unit (A).
5. Disconnect the audio connectors and cable (A).
INSTALLATION
1. Connect the audio unit connectors and cable.
2. Install the audio unit.
English
3. Install the crash pad center facia panel.
4. Check the audio system.
2012 > D 2.0 TCID > Body Electrical System > Audio > Speakers > Repair procedures English
REMOVAL
Front Speaker
(Refer to the BD group "Front door")
2. Remove the front speaker (A) after removing 4 rivets.
Rear Speaker
1. Remove the rear door trim.
(Refer to the BD group "Rear door")
2. Remove the rear speaker (A) after removing 4 rivets.
Tweeter Speaker
1. Remove the front door delta cover (A).
(Refer to the BD group "Front door")
2. Remove the tweeter speaker (A) after disconnecting the connector.
English
INSTALLATION
Front Speaker
1. Install the front speaker.
2. Install the front door trim.
Rear Speaker
1. Install the rear speaker.
2. Install the rear door trim.
Tweeter Speaker
1. Install the tweeter speaker after connecting the tweeter speaker connector.
2. Install the front door delta cover.
INSPECTION
1. Check the speaker with an ohmmeter. If an ohmmeter indicates the correct impedance of the speaker when checking
between the speaker (+) and speaker () of the same channel, the speaker is ok.
Specified impedance : 3.4 ~ 4.6Ω
2012 > D 2.0 TCID > Body Electrical System > Audio > Antenna > Components and Components Location
English
COMPONENTS
2012 > D 2.0 TCID > Body Electrical System > Audio > Antenna > Repair procedures English
INSPECTION
Antenna Cable
1. Remove the antenna jack from the audio unit and antenna.
2. Check for continuity between the center poles of antenna cable.
3. Check for continuity between the outer poles of antenna cable. There should be continuity.
4. If there is no continuity, replace the antenna cable.
5. Check for continuity between the center pole (A) and outer pole (B) of antenna cable. There should be no continuity.
English
6. If there is continuity, replace the antenna cable.
REPLACEMENT
1. Remove the rear roof trim.
(Refer to the BD group "Roof trim")
2. Disconnect the 1P power connector (A) from the roof antenna.
3. Remove the roof antenna(A) after removing a nut(B).
4. Disconnect the roof antenna feeder cable connector (A) on the quater inner panel.
2012 > D 2.0 TCID > Body Electrical System > Audio > Audio Remote control > Schematic Diagrams
English
CIRCUIT DIAGRAM
English
2012 > D 2.0 TCID > Body Electrical System > Audio > Audio Remote control > Repair procedures
English
REMOVAL
2. Remove the driver airbag module.
(Refer to the RT group "Airbag module and clock spring")
3. Remove the steering wheel after loosening the nut (B) and disconnecting the connector (A).
(Refer to the ST group "Steering column and shaft")
4. Remove the steering wheel lower cover (A) after loosening the 2 screws.
5. Loosen the screws (4EA) on the opposite side of the steering wheel.
6. Remove the audio remote control switch (A).
English
INSTALLATION
1. Install the audio remote control switch on the steering wheel.
2. Install the steering wheel.
3. Connect the audio remote control switch connector.
4. Install the driver airbag module.
INSPECTION
1. Check for resistance between No.6 and No.7 terminals in each switch position.
[Audio system + Auto cruise (Blue tooth switch + Trip/Voice switch)]
Switch Connector terminal Resistance (±5%)
Channel/Seek up 67 (Left) 430 Ω
Channel/Seek down 67 (Left) 1.1 kΩ
Mode 67 (Left) 2.11 Ω
Mute 67 (Left) 3.11 kΩ
Volume up 67 (Left) 4.61 kΩ
Volume down 67 (Left) 6.81 kΩ
[Audio system + Auto cruise/Limiter (Blue tooth switch + Trip switch)]
Channel/Seek up 67 (Left) 430 Ω
Channel/Seek down 67 (Left) 1.1 kΩ
Mode 67 (Left) 2.11 Ω
[Audio system (Blue tooth switch + Trip/Voice switch)]
Channel/Seek up 67 (Right) 430 Ω
Channel/Seek down 67 (Right) 1.1 kΩ
Mode 67 (Right) 2.11 Ω
[Audio system (Trip switch)]
Channel/Seek up 67 (Right) 430 Ω
Channel/Seek down 67 (Right) 1.1 kΩ
Mode 67 (Right) 2.11 Ω
2012 > D 2.0 TCID > Body Electrical System > Audio > AUX(Auxiliary) jack > Description and Operation
English
DESCRIPTION
The AUX, iPod and USB JACK on the center console is for customers who like to listen to external portable music players like the MP3,
iPod, earphone, USB memory stick, CD player and etc., through the vehicle's sound system when it is linked to this jack. The customer
has this added option.
In case of distortions from media connected to the AUX source, the audio unit may not be defect but the output level of the used media
does not match the specification of the AUX input.
2012 > D 2.0 TCID > Body Electrical System > Audio > AUX(Auxiliary) jack > Repair procedures English
REMOVAL
Multi Media Jack
1. Remove the upper cover (A) on the floor console.
(Refer to the BD group "Console")
2. Disconnect the power outlet connector (A) and multi media jack connector (B) from under cover.
3. Remove the multi media jack (A) after disconnecting the multi media jack connector.
English
INSTALLATION
Multi Media Jack
1. Install the multi media jack.
2. Connect the multi media jack connector.
3. Install the under cover to the floor console.
INSPECTION
1. Disconnect the negative() battery terminal.
2. Disconnect the multi media jack connector after removing the under cover.
3. To inspect USB / iPod port, check the voltage between NO.3 and 7 terminal of.
Standard value : 5V
4. To inspect AUX jack, check the voltage between NO. 6and 12 terminal of AUX jack / Audio jack input.
Standard value : 5V
5. Using an ohmmeter, check for continuity between the terminals of multi media jack connector.
2012 > D 2.0 TCID > Body Electrical System > Audio > Troubleshooting English
TROUBLESHOOTING
CUSTOMER COMPLAINT ANALYSIS CHECK SHEET
1. System Check Procedure
English
2. Radio Check Procedure
Chart 1
Chart 2
Chart 3
Chart 4
Chart 5
Chart 6
3. CD Check Procedure
Chart 1. CD Will Not Be Accepted
Chart 2. CD Sound Skips
Chart 3
4. USB Check Procedure
2012 > D 2.0 TCID > Body Electrical System > Multifunction switch > Specifications English
SPECIFICATIONS
Items Specifications
Rated voltage DC 12V
Operating temperature range 30°C ~ +80°C (22 ~ +176°F)
High : 0.2A (Relay load)
Dimmer & passing
Low : 0.2A (Relay load)
switch
Passing : 0.2A (Relay load)
Lighting switch Lighting : 0.2A (Relay load)
Turn signal switch 6.6 ± 0.5A (Lamp load)
High : 4.5A (Motor load)
Rated load Low : 4.5 A (Motor load)
Wiper & mist switch Intermittent : 0.22±0.05A(Relay Load)
Lock : Max. 28A (Motor load)
Mist : 4A (Motor load)
Front & Rear fog lamp
0.2A (Relay load)
switch
Wiper : 1A (Relay load)
Rear wiper & Washer
Washer : 4A (Motor load)
2012 > D 2.0 TCID > Body Electrical System > Multifunction switch > Components and Components
English
Location
COMPONENT
2012 > D 2.0 TCID > Body Electrical System > Multifunction switch > Repair procedures English
INSPECTION
Lighting Switch Inspection
1. With the multi function switch in each position, make sure that continuity exists between the terminals below.
If continuity is not as specified, replace the multifunction switch
Lighting Switch (Auto Light)
Lighting Switch
Dimmer And Passing Switch
Turn Signal Switch
English
Front Fog Lamp
Rear Fog Lamp
Wiper And Washer Switch Inspection
If continuity is not as specified, replace the multifunction switch.
Wiper Switch
Washer Switch
Rear Wiper & Washer Switch
REMOVAL
2. Remove the steering column upper and lower shrouds after removing 3 screws.

Remove the 2 screws (A,B) after turning the steering left and right.
3. Disconnect the light switch connector (A) and the wiper switch connector (B).
4. Remove the wiper switch (A) by releasing the lock (B).

when removing the wiper & washer switch only, release the lock of wiper switch without removing the steering wheel.
5. Remove the clock spring(A).
6. Loosen the screws from the multifunction switch assembly (A).
7. Remove the multifunction switch assembly after loosening the connectors.
INSTALLATION
1. Install the wiper switch then connect the lighting switch connector.
2. Install the lighting switch then connect the wiper switch connector.
3. Install the steering column upper and lower shrouds.
2012 > D 2.0 TCID > Body Electrical System > Horn > Components and Components Location English
COMPONENT LOCATION
2012 > D 2.0 TCID > Body Electrical System > Horn > Repair procedures English
REMOVAL
1. Remove the front bumper. (Refer to the BD group front bumper).
2. Remove the bolt and disconnect the horn connector, then remove the horn (A).
INSTALLATION
1. Install the horn after connecting the horn connector.
2. Install the front bumper.
(Refer to the BD group Front bumper).
INSPECTION
Test the horn by connecting battery voltage to the 1 terminal and ground the 2 terminal.
The horn should make a sound. If the horn fails to make a sound, replace it.
HORN RELAY Inspection
1. Remove the horn relay (A) from the engine room relay box.
2. There should be continuity between the No.30 and No.87 terminals when power and ground are connected to the No.85 and
No.86 terminals.
3. There should be no continuity between the No.30 and No.87 terminals when power is disconnected.
English
ADJUSTMENT
1. Operate the horn, and adjust the tone to a suitable level by turning the adjusting screw.

After adjustment, apply a small amount of paint around the screw head to keep it from loosening.
2012 > D 2.0 TCID > Body Electrical System > AVN System > Specifications English
SPECIFICATIONS
Item Specification
Power supply DC 14.4V () Negative ground
Load impedance 4 Ohm
Frequency range FM : 87.5~108.0MHz,
/ Channel space AM : 522~1620KHz
Tuning type PLL SYNTHESIZED TUNING
Antenna FM/AM : 75 Ohm / GPS : 50 Ohm
Dark current Max 2mA (Head unit)
FM : MIN 50 dB /
S/N
AM : MIN 40 dB
Operating : 4°F~ +158°F (20°C~ +70°C)
CD
Storage : 22°F~ +185°F (30°C~ +85°C)
Operating : 4°F~ +149°F (20°C~ +65°C)
Temperature range Radio
Storage : 22°F~ +176°F (30°C~ +80°C)
Esouthecon & button : 40°F~ +176°F (40°C~ +80°C)
SET
Storage : 40°F~ +176°F (40°C~ +80°C)
CD Deck
Item Specification
Power supply 8V (1800mA)
Distorion Max 0.3%
Speaker
Item Specification
Front 40
Input Power
Rear 40
(W)
Tweeter 40
Front 4.0 ± 0.6
Speaker Impedance
Rear 4.0 ± 0.6
(Ω)
Tweeter 4.0 ± 0.6
Speaker Number 6
2012 > D 2.0 TCID > Body Electrical System > AVN System > Components and Components Location
English
COMPONENT LOCATION
1. AVN (A/V & Navigation) head unit 5. Front door speaker
2. Tweeter speaker 6. Rear door speaker
3. AUX Jack / USB Port 7. Antenna feeder cable
4. Roof antenna (Radio/GPS)
COMPONENTS
AVN (A/V & Navigation) Head Unit
English
2012 > D 2.0 TCID > Body Electrical System > AVN System > Description and Operation English
LIMITATIONS OF THE NAVIGATION SYSTEM
GPS Signal Reception State
As the GPS satellite frequency is received/transmitted in straight lines, reception may not work if external devices are placed on or near
the GPS antenna or when travelling through the following locations.
• Tunnels
• Basement parking structures
• Underneath an overpass
• Roads within forested areas
• Areas near high rise buildings
• Roads within canyons
Vehicle Position Display
1. If multipass errors occur due to reflections from buildings or related causes, the current position mark on the navigation
may differ from the actual position of the vehicle.
2. The position of the vehicle on the navigation may be different from the actual position. If the vehicle is under the
occurrence, driving for a short period of time will allow vehicle to go through map matching or GPS information (several
minutes may be necessary in certain cases).
• When driving on a Yshaped road with a narrow angle, the current position may be displayed in the opposite direction.
• If the vehicle is loaded onto a car transport vehicle, the current position mark may be stalled on the last position prior
to loading.
• When driving on a spiralshaped road.
• When driving in mountain regions with sharp turns or sudden brakes.
• When entering a road after having been in an underground parking structure, building parking structure, or turnable with
many rotations.
• When the tires have recently been replaced (Especially upon use of spare or studless tires)
• If the battery terminal is removed.
• When driving in city streets, the current position may be displayed on the opposite side or on an offroad position.
• When changing the zoom level from the maximum zoom in level to a different zoom level, the current position mark
may be displayed on a different road.
• When driving in heavy traffic with frequent stop and go in traffic or intersections.
• When driving under slippery conditions, such as heavy sand, snow, etc.
• When driving with the tire chain in place.
• When using a tire with an incorrect size specification.
• When the tire pressure for the 4 tires are different.
• When the replacement tire is a worn or used tire (Especially studless tires having passed a 2nd seasons, etc.)
• When driving near highrise buildings
• If a roof carrier has been installed
• When driving under high speeds or having calculated a longdistance route.
Route Guidance
Suitable route guidance may not occur caused by search conditions or the driving position.
English
• Guidance to go straight may be given while driving on a straight road.
• Guidance may not be given even when having turned at an intersection.
• There are certain intersections in which guidance may not occur.
• A route guidance signaling entrance into a no enter zone may occur (No enter zone, road under construction, etc.)
• Guidance may be given to a position removed from the actual destination if roads to reach the actual destination do not
exist or are too narrow.
• Faulty voice guidance may be given if the vehicle breaks from the designated route (ex : if a turn is made at an
intersection while the navigation provided guidance to go straight).
• Map Data may be missing or incorrect causing route guidance to not be given.
Route Recalculation
The following phenomena may occur after conducting route recalculation.
• Guidance may be given to a position differing from the current position when turning at an intersection.
• Route recalculation may take a longer period of time when driving under high speeds.
• A route guidance signaling for a UTurn in a No UTurn location may occur.
• A route guidance signaling entrance into a no enter zone may occur (No enter zone, road under construction, etc).
• Guidance may be given to a position removed from the actual destination do not exist or are too narrow.
• Faulty voice guidance may be given if the vehicle breaks from the designated route (ex : if a turn is made at an
intersection while the navigation provided guidance to go straight)
2012 > D 2.0 TCID > Body Electrical System > AVN System > Repair procedures English
REMOVAL
2. Remove the crash pad center facia panel (A).
3. Disconnect the connectors from the crash pad center facia panel.
4. Remove the mounting bolts then remove the AVN head unit (A).
5. Disconnect the AVN head unit connectors and cable (A).
English

When the compact disc is not ejected, do not remove it forcibly.
INSTALLATION
1. Connect the AVN head unit connectors and cable.
2. Install the AVN head unit.
3. Install the crash pad center facia panel.
4. Connect the negative () battery terminal.

1) Make sure the connector are connected in properly.
2) Check the AVN system.
2012 > D 2.0 TCID > Body Electrical System > AVN System > GPS Antenna > Components and English
Components Location
COMPONENTS
2012 > D 2.0 TCID > Body Electrical System > AVN System > AUX/USB/iPod jack > Schematic Diagrams
English
CIRCUIT DIAGRAM
English
2012 > D 2.0 TCID > Body Electrical System > AVN System > AUX/USB/iPod jack > Description and
English
Operation
DESCRIPTION
The AUX, iPod and USB JACK on the center console is for customers who like to listen to external portable music players like the MP3,
iPod, earphone, USB memory stick, CD player and etc., through the vehicle's sound system when it is linked to this jack. The customer
has this added option.
In case of distortions from media connected to the AUX source, the audio unit may not be defect but the output level of the used media
does not match the specification of the AUX input.
2012 > D 2.0 TCID > Body Electrical System > AVN System > AUX/USB/iPod jack > Repair procedures
English
REMOVAL
Multi Media Jack
1. Remove the upper cover (A) on the floor console.
2. Disconnect the power outlet connector (A) and multi media jack connector (B) from under cover.
3. Remove the multi media jack (A) after disconnecting the multi media jack connector.
English
INSTALLATION
Multi Media Jack
1. Install the multi media jack.
2. Connect the multi media jack connector.
3. Install the under cover to the floor console.
INSPECTION
2. Disconnect the multi media jack connector after removing the under cover.
3. To inspect USB / iPod port, check the voltage between NO.1 and 4 terminal of.
Standard value : 5V
4. To inspect AUX jack, check the voltage between NO. 3 and 7 terminal of AUX jack / Audio jack input.
Standard value : 5V
5. Using an ohmmeter, check for continuity between the terminals of multi media jack connector.
2012 > D 2.0 TCID > Body Electrical System > AVN System > Troubleshooting English
TROUBLESHOOTING
Check Procedure
Status Cause How to check
• Audio/ MP3 rejected by 1) CD may be dirty 1) Clean CD with damp cloth.

the unit.
2) The CD does not comply with the CD player
specification.
3) See notes on Audio and MP3 CDs
• The operating panel 1) No error 1) Normal. The unit feels warm.

generates some heat.
• The volume decreases 1) An integrated safety circuit 1) Allow the unit to cool down (set low volume)

automatically. prevents the temperature in the
unit from exceeding a certain
value.
• Navigation radio not No power supply Check the fuse (unit and vehicle) and the connections

functioning, no function
of display
• No radio reception 1) Check if the antenna is completely and correctly
connected.
• Poor radio reception 1) Antenna (disc antenna) obscured, antenna rod
bent or antenna defective.
2) Please arrange for an authorized dealer to check
the antenna.
• The frequency instead of 1) The unit is tuned to a station that does not
the station name is transmit RDS signals or the transmitter is too
displayed. weak.
• The required station 1) The desired station is too 1) Set desired station manually (manu. tuning)

cannot be tuned to using weak.
2) Check whether the antenna is completely and
automatic search.
correctly connected.
• No traffic 1) Activate the traffic announcment by pressing the
announcements are TA button
switched through (during
CD playback)
• Distorted sound/skips 1) Player cannot read CD. CD is damaged or soiled.
during CD play.
• CD player does not work 1) In cold weather conditions, 1) With the set on, wait for 5 minutes until the

condensation may occur on the condensation evaporates.
laser.
• No sound during CD 1) Some CDs contain multimedia data which is not
playback recognized by the unit.
2) Advance the tracks until music is heard.
English
3) See notes on Audio and MP3 CDs.
• Problems with new 1) See notes on Audio and MP3 1) Some copy protection procedures are incompatible

copyprotected audio CDs. with acceptable standards for audio CDs. This is
CDs. not a fault on the unit.
Navigation Check Procedure
Status Cause How to check
• Display shows "Please The map CD is required for some Insert the CIQ map CD into the radio CDdrive with the

insert map CD" functions in naviation mode. label facing upwards.
• The direction advices Navi volume to low Set the navigation volume in the setup menu under

cannot be heard or are "Navigation → Navi volume"
very quiet.
• Guidance is not accurate An inaccuracy of appr. 30 m is 1) If greater inaccuracies ocur repeatedly, please

within the tolerance limits. contact your dealer.
2) The displayed distance to the turning point is
calculated to the centre of the junction (especially
for extended junctions and mainroad exits).
• Display position does not It is possible that the car's position The routing may have been changed and does not

correspond to the actual as calculated by the navigation correspond with the information stored on the map CD.
traffic conditions. system is not currently correct.
• Displayed time is Adjust the time zone using the "Clock/Date → Time
incorrect. Zone" option in the setup menu
Estimated time of arrival Check the time zone using the "Clock/Date → Time
displayed on the guidance Zone" option in the setup menu
screen is incorrect.
2012 > D 2.0 TCID > Body Electrical System > Keyless Entry And Burglar Alarm > Specifications English
SPECIFICATIONS
ITEM
Rated voltage DC 3V
Service voltage range DC 2.7V ~ 3.5V
Temperature range 4°F ~ 140°F (20°C ~ +60°C)
Storage temperature range 22°F ~ 176°F (30°C ~ +80°C)
DARK CURRENT MAX 0.1㎃
Modulation method FM(Frequency Modulation)
FREQUENCY 433.92MHz
CODE Rolling Code
Lifetime of a dry cell 20 years (20 times/day)
2012 > D 2.0 TCID > Body Electrical System > Keyless Entry And Burglar Alarm > Components and
English
Components Location
COMPONENT LOCATION
2012 > D 2.0 TCID > Body Electrical System > Keyless Entry And Burglar Alarm > Description andEnglish
Operation
DESCRIPTION
Burglar Alarm System
The burglar alarm system is armed automatically after the doors, hood, and tailgate are closed and locked.
The system is set off when any of these things occur :
• A door is forced open.
• The tailgate is opened.
• The hood is opened.
When the system is set off, the alarm sounds and the hazard lamp flash for about 30 seconds or until the system is disarmed by
unlocking the transmitter or door key.
For the system to arm, the ignition switch must be off and the key removed. Then, the body control module must receive signals that the
doors, hood, and tailgate are closed and locked. When everything is closed and locked, none of the control unit inputs are grounded.
The door switches, hood switch and tailgate switch are all close and lock the doors with the remote transmitter and then the system arms
immediately.
If anything is opened after the system is armed, the body control module gets a ground signal from that switch, and the system is set off.
If one of the switches is misadjusted or there is a short in the system, the system will not arm. As long as the body control module
continues to get a ground signal, it thinks the vehicle is not closed and locked and will not arm.
Keyless Entry System
The burglar alarm system is integrated with the keyless entry system. The keyless entry system allows you to lock and unlock the vehicle
with the remote transmitter. When you push the LOCK button, all doors lock. When you push the UNLOCK button again, all doors unlock.
The room lamp, if its switch is in the center position, will come on when you press the UNLOCK button. If you do not open a door, the light
will go off in about 30 seconds, the doors will automatically relock, and the burglar alarm system will rearm. If you relock the doors with
the remote transmitter within 30 seconds, the light will go off immediately.
You cannot lock or unlock the doors with the remote transmitter if the key is in the ignition switch.
The system will signal you when the doors lock and unlock by flashing the hazard lamp once when they lock, and twice when they
unlock.
FUNCTION
Keyless Entry Function
DOOR LOCK / UNLOCK and Tailgate (Folding key only) operation are performed with remocon
1. Keyless entry function is performed in a state that key in SW is eliminated from key cylinder
2. LOCK / UNLOCK and tailgate signals are received from the transmitter and DOOR LOCK / UNLOCK and Tailgate signals
are output.
Transmitter(tx) Spec
1. Transmission Distance : 30m or more from outside of the car
2. Registration procedure of the transmitter
(1) In registration mode, it shall be possible to register up to Max 4EA.
(2) At reregistration, data are registered newly after deleting the previous TX DATA
No. Saved CODE CODE to change Changed CODE
1 A A
2 A B B (A is deleted)
3 B C, D C, D (B is deleted)
English
4 C, D E, F, G E, F, G (C, D is deleted)
5 E, F, G H, I, J, K H, I, J, K (E, F, G are deleted)
6 A, B C, F, E, F, G C, F, E, F
7 A, B C, C, D, E, F C, D, E, F
8 A, B, C, D A A
9 A, B, C, D E E
(3) For the registration procedures by using Hiscan tool, refer to "TRANSMITTER CODE REGISTRATION".
3. Transmitter signal & Receiver Spec
(1) Transmission signal
– Transmit relevant transmission DATA (Transmission frame) twice by pushing TX SW.
– Only LOCK signal is output when pushing TX LOCK SW and UNLOCK SW at the same time.
DISARM
Condition 1
State Description
Initial Condition ALARM state
• IGN KEY ON during 30sec or ALT"L" = ON
• TX(Transmitter) Unlock & Any Door open(4Door SW ON)
• TX(Transmitter) Lock & Lock confirm failed
Event
• Driver door key unlock switch ON.
• Driver door key lock SW ON & Lock confirm failed
• TX tailgate ON (Folding key type only : 3 button).
• The state goes to DISARM state
• Hazard relay off, Horn relay off and start inhibit relay off.
Action • TX Unlock
– Unlock relay on for 0.5 sec.
– Hazard relay on (TWICE)
Condition 2
State Description
Initial Condition DISARM state & (IGN KEY OUT) & Any Door open
Event • TX Unlock
• No state change
• TX UNLOCK
Action
– Unlock relay on for 0.5 sec
– Hazard relay on (Twice)
Condition 3
State Description
Initial Condition ARMWAIT state
• At least one entrance opened
• Any door is unlocked
Event
• Key in SW ON
• Driver door key unlock SW ON
Action The state goes to DISARM state
Condition 4
State Description
Initial Condition AUTOLOCKTIMER1 state
• At least one entrance opened
• Key in SW ON
Event • Lock by AUTOLOCK, but Lock confirmation failure
• Tx Lock, but Lock confirmation failure
• Driver door key unlock SW ON, but Lock confirmation failure
Action • The state goes to DISARM state
Condition 5
State Description
• Any Door open
• Key in SW ON
Event • Lock by AUTOLOCK, but Lock confirmation failure
• Driver door key lock SW ON, but Lock confirmation failure
Condition 6
State Description
Initial Condition ARM state
• IGN KEY ON
Event
• Driver door key unlock SW ON
Condition 7
State Description
Initial Condition REARM state
• IGN KEY ON during 30sec or ALT"L" = ON
Event • Driver door key unlock SW ON
• Driver door key lock SW ON & Lock confirmation failure
• TX tailgate ON (Folding key type only : 3 button).
Action
• Start Inhibit relay OFF
Condition 8
State Description
Initial Condition PREARM state
• Key in SW ON
Event • All entrance closed & Any Door is unlocked
• Any Door open & Tx Unlock
• TX UNLOCK
Action – Unlock relay on for 0.5sec
– Hazard relay on (Twice)
Condition 9
State Description
Initial Condition AutoLockTimer3 state
• Key in SW ON
• Hood open
Event
• Any Door open
• Lock confirm failed
ARM
– LED is Blinking
Condition 1
State Description
Event • Tx Lock
• No state change
Action
• Hazard relay 1Time on(1sec)
Condition 2
State Description
Event • ARMWAITTIMER is expired
Action • The state goes to ARM state
ALARM
– LED is Blinking
Condition 1
State Description
Event • Any entrance open (DOORS, TAILGATE, or HOOD)
• The state goes to ALARM state
• The horn is ON one time for 27sec(±2sec)
Action
• The hazard is driven also (During Horn driving)
• Engine Start Inhibit is ON
T1 : 27s ± 2sec, T2 : 0.5s ± 0.1sec.

Horn Output : Period : 1sec(Can be calibrated Horn Period), 50% Duty
Condition 2
State Description
Event • Any door open or Hood open or tailgate open
• The state goes to ALARM state
Action • The horn is ON one time for 27sec (±2sec.)
• The hazard is driven also (During horn driven)
ARM WAIT MODE
– LED is turn on
Condition 1
State Description
Event • Tx Lock
• The state goes to State
Action • TX LOCK
– Hazard relay 1 Time on(1sec)
Condition 2
State Description
DISARM state & IGN KEY OUT & All entrances closed (DOORS, HOOD and
Initial Condition
TAILGATE)
• Tx Lock & locked confirmed
Event
• Driver door key lock SW ON & Locked confirmed
• The state goes to ARMWAIT State
• Start ARMWAITTIMER
Action
• TX LOCK & locked confirmed.
– Hazard relay 1 Time on (1 sec.)
Condition 3
State Description
Initial Condition ALARM state & All entrances closed(DOORS, HOOD and TAILGATE)
Event
• The state goes to ARMWAIT state
Action • Horn relay off
• Start inhibit relay off
Condition 4
State Description
• AUTO LOCK confirmed
Event • Tx Lock & locked confirmed
Action • Start ARMWAITTIMER
Condition 5
State Description
Initial Condition PREARM state
Event • Hood and 4door are closed & All doors locked & Tailgate closed.
Action • Hazard relay 1Time on(1sec)
• Dead lock
• Tailgate mark = set
Condition 6
State Description
Event
• Drive door key lock SW ON & locked confirmed
Action
Condition 7
State Description
Initial Condition Auto Lock Timer3 state
Event
• Drive door key lock SW ON & locked confirmed
Action
REARM MODE
– LED is Blinking
Condition 1
State Description
Initial Condition ALARM state
Event • All entrance is closed & Alarm Patten finished
Action • The state goes to REARM state
AUTOLOCKTIMER1 MODE
– LED is Blinking
Condition 1
State Description
Event • Tx Unlock
• The state goes to AUTOLOCKTIMER1 state
Action • Start AUTOLOCKTIMER1
• Hazard relay Twice on(0.5s ON/0.5s OFF)
Condition 2
State Description
• Timer is expired
Event
• Tx Unlock
• The state goes to State
• Tx Unlock
– Hazard relay Twice on(0.5s ON/0.5s OFF)
Action
– Restart AUTOLOCKTIMER1
• Expire AUTOLOCKTIMER1
– AUTOLOCK
Condition 3
State Description
Event • Tx Unlock
Condition 4
State Description
Initial Condition DISARM state & All entrances closed (DOORS, HOOD & TAILGATE) & IGN KEY OUT
Event • Tx Unlock
Condition 5
State Description
Initial Condition ALARM state & All entrances are closed (DOORS, HOOD & TAILGATE)
Event • Tx Unlock
• Start AUTOLOCKTIMER1
Action • Hazard relay Twice on(0.5s ON/0.5s OFF)
• Horn relay off
Condition 6
State Description
Event • Tx Unlock
Action
Condition 7
State Description
Initial Condition Auto Lock Timer3 state
Event • Tx Unlock
AUTOLOCKTIMER2 MODE
– LED is blinking
Condition 1
State Description
• Timer is expired
Event
• Tx Unlock
• No State change
• Tx Unlock
– Hazard relay Twice on(0.5s ON/0.5s OFF)
Action
– The timer restart
• Expire AUTOLOCKTIMER2
– AUTOLOCK
Condition 2
State Description
Initial Condition DISARM state & All Doors are closed & (HOOD is opened) & IGN KEY OUT
Event • Tx Unlock
Condition 3
State Description
Initial Condition ALARM state & All Door are closed & (HOOD is opened)
Event • Tx Unlock
• Horn relay off
Condition 4
State Description
PREARM state
Initial Condition
All Doors are closed & (HOOD is opened)
Event • Tx Unlock
Action
• Memorize Hood and Tailgate state
AUTO LOCK TIMER3 MODE
LED is blinking
Condition 1
State Description
Event • Tx TAILGATE Unlock
• The state goes to AUTO LOCK RELAY TIMER3 state
• Start AUTO LOCK RELAY TIMER3
• TAILGATE Mark=set
• Dead unlock
Condition 2
State Description
Initial Condition AutoLockTimer3 state
Action • Restart AUTO LOCK TIMER3 state
Condition 3
State Description
• The state goes to AUTO LOCK RELAY TIMER3 state
• Start AUTO LOCK RELAY TIMER3
Action • Dead Unlock
• TAILGATE Mark=set
PREARM MODE
– LED is blinking
Condition 1
State Description
• AUTOLOCK confirmed
Event • Tx Lock & locked confirmed
Action • The state goes to PREARM state
Condition 2
State Description
Initial Condition DISARM state & IGN KEY OUT
• ((4Door Not Closed = ON & Tailgate SW = OFF or (Hood SW = ON)) & Tx Lock &
Locked confirmed
Event
• ((4Door Not Closed = ON & Tailgate SW = OFF or (Hood SW = ON)) & driver door
key lock SW ON on & Locked confirmed
Action • The state goes to PREARM state
Condition 3
State Description
Initial Condition ALARM state & Hood SW = ON
• Tx Lock & Locked confirmed
Event
• The state goes to PREARM state
Action
• Horn relay off
• Hazard relay 1Time on (1sec.)
Condition 4
State Description
• Expire Auto Lock Timer3
Event
• Tailgate open
Action • The state goes to PREARM state.
RESET
1. In case of taking the battery out during the ALARM state
Condition 1
State Description
Initial Condition During ALARM, REARM
Event • TAKING THE BATTERY OUT (Cold or Warm RESET)
• The state goes to ALARM mode
Action • Horn relay 1 Times on (No remained time of warning signal)
• Hazard lamp is flashing during making horn
2. In case of taking the battery out during arm
Condition 2
State Description
Event • TAKING THE BATTERY OUT (Cold or Warm RESET)
• The state goes to ARM mode
Action
• Maintained ARM state
The Restricted Function Of Unlock By Centrol Door Lock Sw
1. In IGN Key OUT, UNLOCK is restricted by Central Door Lock SW if All DR LOCK & CLOSED when TX LOCK.
2. In IGN Key OUT, UNLOCK is restricted by Central Door Lock SW if All DR LOCK & CLOSED when DR LOCK by DRV DR
Key.
3. The restricted function of UNLOCK is canceled when TX UNLOCK signal output during the restricted function of Central
Door Lock SW.
4. The restricted function of UNLOCK is canceled when DR UNLOCK signal output during the restricted function of Central
Door Lock SW.
T1 : 0.5s ± 0.1s
Tailgate Release Function
Permissive Mode State
State Description
Initial Condition PROHIBITIONAL MODE STATE
Event Any Door Unlocked
Operating MOVE TO PERMISSIVE MODE STATE
State Description
Initial Condition 30s PERMISSIVE MODE STATE
Event Any Door Unlocked
Operating MOVE TO PERMISSIVE MODE STATE
State Description
Initial Condition PERMISSIVE MODE STATE
Event TAILGATE RELEASE SW = ON
• TAILGATE RELEASE RELAY 0.5SEC ON
Operating
• MOVE TO PERMISSIVE MODE STATE
30s Permissive Mode State
State Description
Initial Condition PROHIBITIONAL MODE STATE
Event TAILGATE UNLOCK
• START TAILGATE TIMER
Operating • HAZARD 2 FLASHING
• MOVE TO 30s PERMISSIVE MODE STATE
State Description
Event TAILGATE UNLOCK
• RESTART TGATE TIMER
Operating • HAZARD 2 times FLASHING
State Description
Event TAILGATE RELEASE SW = ON
• TAILGATE RELEASE RELAY OUTPUT FOR 0.5s
Operating
Prohibitional Mode State
State Description
• TAILGATE OPEN→CLOSE
Event
• 4Door Lock Confirm
Operating MOVE TO PROHIBITIONAL MODE STATE
State Description
Event TAILGATE TIMER IS EXPIRED
State Description
Initial Condition PERMISSIVE MODE STATE
Event 4Door Lock Confirm
2012 > D 2.0 TCID > Body Electrical System > Keyless Entry And Burglar Alarm > Repair procedures
English
INSPECTION
Burglar Alarm Horn Relay
Check for continuity between the terminals.
No.12 in the ICMA.
Front Door Lock Actuator
(Refer to the BD group Front door)
2. Remove the front door module.
(Refer to the BD group Front door).
3. Disconnect the connectors from the actuator.
[LHD]
[RHD]
English
4. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply
battery voltage only momentarily.
Rear Door Lock Actuator
(Refer to the BD group Rear door)
2. Remove the rear door module.
[LHD]
[RHD]
Tailgate Lock Actuator Inspection
1. Remove the tailgate trim. (Refer to the BD group tailgate)
2. Disconnect the 4P connector from the actuator.
Front Door Lock Switch
[LHD]
[RHD]
4. Check for continuity between the terminals in each switch position when inserting the key into the door according to the
table.
Rear Door Lock Switch
[LHD]
[RHD]
4. Check for continuity between the terminals in each switch position according to the table.
Tailgate Switch
1. Remove the tailgate trim. (Refer to the BD group Tailgate)
Door Switch
Remove the door switch and check for continuity between the terminals.
Hood Switch
1. Disconnect the connector from the hood switch (A).
2. Check for continuity between the terminals and ground according to the table.
Key Warning Switch
1. Remove the crash pad lower panel. (Refer to Body groupCrash pad)
2. Disconnect the 6P connector from the key warning switch.
3. Check for continuity between the terminals in each position according to the table.
Burglar Horn
1. Remove the burglar horn(A) after removing 1 bolt and disconnect the 2P connector from the burglar horn.
2. Test the burglar horn by connecting battery power to the terminal 1 and ground the terminal 2.
3. The burglar horn should make a sound. If the burglar horn fails to make a sound replace it.
2012 > D 2.0 TCID > Body Electrical System > Keyless Entry And Burglar Alarm > Transmitter > English
Specifications
SPECIFICATION
Items Specifications
Keyless entry transmitter
Lithium 3V battery (1EA)
Power source
Transmissible distance 30m or more
Life of battery 2 years or more (at 20 times per day)
2 Button Type 2 (Door lock, Door unlock)
Button
3 Button Type (Folding key) 3 (Door lock, Door unlock, Tailgat)
Transmission frequency 433.92 MHz
2012 > D 2.0 TCID > Body Electrical System > Keyless Entry And Burglar Alarm > Transmitter > Repair
English
procedures
INSPECTION
1. Check that the red light flickers when the door lock or unlock button is pressed on the transmitter.
2. Remove the battery and check voltage if the red light doesn't flicker.
Standard voltage : 3V
3. Replace the transmitter battery with a new one, if voltage is below 3V then try to lock and unlock the doors with the
transmitter by pressing the lock or unlock button five or six times.
4. If the doors lock and unlock, the transmitter is O.K, but if the doors don't lock and unlock, register the transmitter code,
then try to lock and unlock the doors.
5. If the transmitter is fails, replace only the transmitter (A).
TRANSMITTER CODE REGISTRATION
1. Connect the DLC cable of scan tool to the data link connector (16 pins) in driver side crash pad lower panel, turn the power
on scan tool.
2. Select the vehicle model and then do "CODE SAVING".
English
3. After selecting "CODE SAVING" menu, push "ENTER" key, then the screen will be shown as below.
4. After removing the ignition key from key cylinder, push "ENTER" key to proceed to the next mode for code saving. Follow
steps 1 to 4 and then code saving is completed.
2012 > D 2.0 TCID > Body Electrical System > Keyless Entry And Burglar Alarm > Troubleshooting
English
TROUBLESHOOTING
1. Alarm does not work. (Hazard lamps work)
2. When hood is opened in ARM mode, burglar horn does not work.
3. When door is opened, burglar horn does not work. (If tailgate and hood is opened, alarm works)
English
4. When tailgate is opened in ARM mode, burglar horn does not work.
5. When the vehicle is locked by the transmitter, central door lock function works but hazard lamp doesn't blink.
6. Central door lock function works, but keyless entry system does not work.
2012 > D 2.0 TCID > Body Electrical System > BCM (Body Control Module) > Body Control Module (BCM)
English
> Specifications
SPECIFICATIONS
Item Requirement Remark

Operating voltage range DC 9 ~ 16V
Shall activate normally in these range.
Operating temperature range 30°C ~ +80°C
storage temperature range 40°C ~ +85°C
Max humidity in use 95%
High voltage resistance 24V
100Mohm or more
Specify as well as parts that insulation like PCB, moisture
Insulation resistance (measured with 500V
proof COATING is required
MEGGER)
Max 5.5mA (KEYLESS)
Measure when the state, all output loads excepted security
(Included security IND Mean
Dark Current IND are OFF and there are no Input SW(including TX
value)
operation) changes, continues 2sec.
Max 3mA (NONKEYLESS)
Output terminals for TAIL LAMP RELAY, POWER WINDOW
Voltage drop 1.2V or less RELAY, SAFETY POWER WINDOW, BURGLAR ALARM
RELAY shall be 2.0V or less, DRL, Wiper, Relay
Rated Load
Item Rated load
Room lamp DC 12V 28W (LAMP load)
Key hole illumination DC 12V 2W (LAMP load)
Seat belt indicator DC 12V 1.2W (LED load)
Door lock relay DC 12V 200mA (Inductive load)
Door unlock relay DC 12V 200mA (Inductive load)
Dead lock relay DC 12V 200mA (Inductive load)
Hazard relay DC 12V 200mA (Inductive load)
Rear wiper relay DC 12V 200mA (Inductive load)
Power window relay DC 12V 200mA (Inductive load)
Wiper relay DC 12V 200mA (Inductive load)
Defogger relay DC 12V 200mA (Inductive load)
Tailgate relay DC 12V 200mA (Inductive load)
Tail lamp relay DC 12V 200mA (Inductive load)
Head lamp relay DC 12V 200mA (Inductive load)
Front deicer relay DC 12V 200mA (Inductive load)
Front fog relay DC 12V 200mA (Inductive load)
Rear fog relay DC 12V 200mA (Inductive load)
Horn relay DC 12V 200mA (Inductive load)
English
Security indicatior DC 12V 1W (LED load)
Central door lock indicator DC 12V 1W (LED load)
Door open indicator DC 12V 1W (LED load)
English
> Schematic Diagrams
CIRCUIT DIAGRAM
English
> Description and Operation
DESCRIPTION
Body control module (A) receives various input switch signals
controlling time and alarm functions for tail lamp, rear fog
lamp, wiper control, buzzer warning, front deicer timer, tail
lamp auto cut, central door lock, seat belt warning, key
operated warning, over speed warning, ignition key hole
illumination, room lamp control, power window timer, keyless
entry control, burgular alarm control, crash door unlock, key
reminder.
FUNCTION
Wiper control
1. WIPER Control coupled with Washer
(1) Under IGN2 SW ON, WIPER RELAY is turned ON after T2 from WASHER SW ON if WASHER SW is ON for T1 and
WIPER RELAY is turned OFF after T3.
T1 : 0.06s ~ 0.2s, T2 : 0.3s ± 0.1s,
T3 : 0.7s ± 0.1s
(2) Under IGN2 SW ON, WIPER RELAY is turned ON after T2 from WASHER SW ON if WASHER SW is ON for T1 or
more, and WIPER RELAY is turned OFF after T3 from the moment that WASHER SW is turned OFF.
English
T1 : 0.2s(MIN), T2 : 0.3s ± 0.1s,
T3 : 2.5s ~ 3.8s (2 ~ 3TURN)
(3) Operation in Item (2) is performed if WASHER SW is ON for at least T1 during WIPER operation with INT SW.
Operation in Item (1) is performed if WASHER SW is ON for T6.
T1 : 0.2s(MIN), T2 : 0.3s ± 0.1s,
T3 : 2.5s ~ 3.8s (2 ~ 3 times rotation),
T4 : T5 0.7s, T5 : INT TIME,
T6 : 0.2s ~ 0.59s, T7 : 0.7s ± 0.1s
(4) Operation is cancelled in case IGN is OFF during T3.
(5) Give priority to WASHER interlocking WIPER than Speed sensing INT WIPER function.
(6) WASHER SW signal input shall be ignored at startup (IGN1 ON & IGN2 OFF states).
2. VARIABLE INT WIPER
(1) Under IGN2 SW = ON & INT SW = ON states, and INT VOLUME value are acquired and intermittent time is
calculated. Then, WIPER intermittent time is automatically converted.
T1 : 0.3 sec Max.
T2 : 0.7 ± 0.1 sec.
T3 : INT TIME 2.2 ± 0.2sec (VR=0kΩ)Min ~ 10±1sec (VR 50kΩ)Max.
MF SW 0~1 Kohm 13 Kohm ± 10% 24 Kohm ± 10% 38 Kohm ± 10% 50 Kohm ± 10%

INT TIME (T3) 2.2 sec (± 0.2) 3.9 sec (± 0.4) 6.1 sec (± 0.6) 8.3 sec (± 0.8) 10.0 sec (± 1.0)
3. MIST Control coupled with WIPER
(1) Under IGN2 SW ON, WIPER RELAY is turned ON directly from MIST SW ON if MIST SW is ON for T1 and WIPER
RELAY is turned OFF after T2.
T1 : 0.7s (Max.), T2 : 0.7s ± 0.1s
(2) Under IGN2 SW ON, WIPER RELAY is turned ON directly from MIST SW ON if MIST SW is ON for at least T1, and
WIPER RELAY is turned OFF after T3 from the moment that MIST SW is turned OFF.
T1 : 0.7s(Min), T2 : 0.7s ± 0.1s
Rear Wiper & Washer Control (Non Variable)
1. Rear WIPER Control coupled with Rear Washer
(1) when Rr Washer SW Input is T2 or more at ) IGN2 ON Condition, Rr Wiper Rly is truned ON directly after T1 at the
time that Rr Washer SW ON and is turned OFF after operating 2.5s~3.8s(2~3 Times) from Rr Washer SW is turned
OFF.
T1：0.3s±0.1s, T2：0.2s(MIN)
T3：2.5s~3.8s (2~3 rotation)
(2) Rear WIPER Control coupled with Rear Washer is prior to at RR INT WIPER Function .
2. REAR INT WIPER
(1) REAR WIPER RELAY is turned ON by 1 CYCLE (0.7s ON / 7.5s OFF) when rear INT wiper SW ON.
T1 :0.7 ± 0.1sec,
T2 : 7.5 ± 1sec.
Buzzer Control
1. Buzzer Sound
Frequency Frequency(Duty) Cycle Sound Pressure Remark
Seat Beltreminder 800Hz 50% 1.0s 70±10dB Diminished sound
Speed Limit 800Hz 50% 1.0s 70±10dB Diminished sound
2. Output continues up to OFF cycle when output is OFF.
3. Sound pressure measurement distance: 1.0 m
Seat Belt Reminder Function
1. Driveriver & Passenger seat
(1) Waring lamp is turned ON when First is IGN1 ON seat belt is not fastened.
(2) In the above (1), Waring lamp is turned OFF when seat belt is fastened.
(But Warning lamp continues to light for 6sec if SEAT BELT is fastened within 6sec)
Warning lamp is turned ON continually If seat belt is not fastened Warning lamp output to pattern stop to light for 6sec
when Patten approach condition completion among Warning lamp continues to light for 6sec.
(3) In the above (2), Waring lamp is turned ON when above 9KPH and seat belt is not fastened.
(Warning lamp continues to flash for 6sec if SEAT BELT is refastened within 6sec)
(4) In the above (3), Waring lamp is turned ON when above 6KPH and seat belt is not fastened.
(5) In the above (3), The warning lamp continues to flash and BUZZER output follows the PATTERN once and seat belt is
not fastened.
(but, Warning lamp continues to light for 6sec if SEAT BELT is refastened within 6sec)
The warning lamp continues to flash and BUZZER is turned OFF after output completion.
PATTERN do not output when above 20KPH after PATTERN output once completion(Never entering Pattern)
(6) In the above (3),(4),(5), the warning lamp and BUZZER OFF are turned OFF when seat belt is fastened.
(7) 6) clause After Selt belt=belted,Driver Selt belt Switch Belt→Unbelted & above 9KPH case of spped, It outputs one
PATTERN. Between Pattern outputs Selt belt at the time of fastened A Pattern output stop is carried out.
Under a Driver Pattern output If the conditions of an Assist Pattern output are realized, it will be at the driver's seat
point. After a Pattern output end passenger seat remainder A Pattern output is performed.
(8) In the above (6), Selt/belt is fastened→unfastened and when vehicle speed becomes under 9KPH, warning lamp is
turn on.
(9) In the above (3),(4),(5), warning alarm is operated, warning lamp is turned off when IGN OFF.
• Chime Buzzer:1SEC Cycle, Seat belt Indicator : 1SEC Cycle
• Buzzer Operating Cycle & Seat Belt indicator Operating Cycle are synchronized.
• Speed recognition error
6KMPH : 5.6KMPH ±1.4Km/h
9KMPH : 8.5KMPH ±1.4Km/h
20KMPH: 19.6KMPH ±1.4Km/h
2. Seat Belt Reminder Logic
Speed Limited Warning
Speed Limit is On from, IGN1 On when conditions Buzzer On.
When the next condition is satisfied From IGN1 On condition, it executes Speed Limit Warning.
(1) When speed limit turn on, alarm start immediately.
(2) When speed limit turn off, remainder outputs alarm executes and ends after 1 second filtering time.
T1, T2：1s ± 0.1sec
Rear Defogger Timer
1. Defogger relay is turned for T1 if defogger SW is turned ON under ALT "L" ON.
2. Defogger relay is turned OFF if defogger SW is turned ON again under output ON or ALT"L" OFF.
T1 : 20MIN ± 1MIN
Front Deicer Timer
1. DEICER RELAY is turned for T1 if DEICER SW is turned ON under ALT "L" ON.
DEICER RELAY is turned OFF if DEICER SW is turned ON again under output ON or ALT"L" OFF.
T1 : 20MIN ± 1MIN
Delayed Room Lamp
1. ROOM LAMP lights 100% at DOOR OPEN.
(But, the lamp phases out lighting up to 0% in 2sec after lighting 100% for 20minute.)
2. Resolution is 32 STEP or more.
3. The lamp is immediately turned OFF at ALL DOOR LOCK or IGN SW is ON during T1(phasing out lighting for 2sec).
4. Should be no phasing out lighting if 4DOOR SW ON time is 0.08sec or less.
5. Should be no flashing.
6. Should be no flashing under 4DOOR OPEN and ROOM LAMP ON at IGN1 ON.
7. ROOM LAMP is turned ON for T3 when Tx UNLOCK signal is received under DOOR CLOSE.
ROOM LAMP signal output is extended for T3 if Tx UNLOCK signal is received under ON state.
The lamp lights continuously at DOOR OPEN under ON state. Operation in (1) is performed at DOOR CLOSE. ROOM
LAMP signal is turned OFF at ALL DOOR LOCK during ROOM LAMP ON.(phasing out for 2sec).
T1 : 30s ± 3s, T2 : 2 ± 0.2s,
T3 : 32 ± 3.2s
Tail Lamp Auto Cut
1. TAIL RELAY is turned ON when changing TAIL SW from OFF to ON.
2. TAIL RELAY is turned OFF when TAIL SW is OFF.
3. TAIL RELAY is turned OFF if the state is changed from KEY IN SW ON and TAIL SW ON to KEY IN SW OFF, TAIL SW
ON and Dr DOOR OPEN.(automatic light out)
4. TAIL RELAY is turned ON when KEY IN SW is turned ON after the operation in (3).
5. TAIL RELAY is not turned ON if Dr DOOR is closed after the operation in (3).
6. The previous MODE is held at BATTERY ON/OFF after the operation in (3).
IGN Key Hole Illumination
1. KEY ILLUMI LAMP is turned ON at IGN SW OFF and DOOR OPEN
2. KEY ILLUMI LAMP is turned ON for T1 at DOOR CLOSE after the operation in (1).
3. KEY ILLUMI LAMP is immediately turned OFF at IGN SW ON during output
4. KEY ILLUMI LAMP is immediately turned OFF at transition to warning MODE during output
T1 : 30s ± 3s
Rear Fog Lamp
1. Rear fog relay is turned ON if pushing rear fog Switch under head lamp Output ON and front fog SW ON after IGN ON and
Tail lamp Output ON.
2. Output is turned OFF if pushing rear Front fog lamp switch again under REAR FOG RELAY ON
3. REAR FOG RELAY is turned OFF unless the condition "IGN ON, TAIL Lamp Output ON & Head lamp Output ON (and front
fog SW ON)" is met.
4. Head Lamp Relay after Front fog lamp switch off Front Fog Lamp Relay=ON and Rear Fog Lamp Relay=ON it does from on
conditons and Rear Fog Lamp Relay off.
5. Rear FOG LAMP Switch is SelfReturn Type.
*1 ON : IGN1 = ON
OFF : IGN1 = OFF
Central Door Lock/unlock
1. All door lock relay signal is output for T1(0.5s) if Drver/Assist DOOR UNLOCK SW is locked within 3s, central door lock
indicator signal is output when All DOOR LOCKED.
2. All door unlock relay signal is output for T1(0.5s) if DR DOOR UNLOCK SW is unlocked within 3s, central door lock
indicator signal is not output when All DOOR UNLOCKED.
3. All door lock relay signal is output for T1(0.5s) when AS DR Key Lock SW is turned ON and if AS DOOR UNLOCK SW is
unlocked within 3s, Center DR Lock IND signal is not output when All DOOR LOCKED.
4. Change of UNLOCK(LOCK) → LOCK(UNLOCK) is ignored during LOCK(UNLOCK) signal ouput by other functions.
5. All door lock relay signal is output for T1 when TX LOCK signal is received, central door lock indicator siganal is output
when All DOOR LOCKED.
6. All Door Unlock Relay signal is output for T1 if TX UNLOCK signal is received, central door lock indicator siganal is not
output when any DOOR UNLOCKED or ALL DOOR UNLOCKED.
7. ALL DOOR UNLocked, All door lock relay signal is output for T1 if central door Lock/UNLOCK SW is turned ON, Central
door lock indicator signal is output when All DOOR LOCKED.
8. ALL DOOR Locked, All door unlock relay signal is output for T1 if central door Lock/UNLOCK SW is turned ON, Central
door lock indicator signal is not output when All DOOR UNLOCKED.
9. Any DOOR LOCKED, All door lock relay signal is output for T1 if central door Lock/UNLOCK SW is turned ON, Central
door lock indicator signal is output when All DOOR LOCKED.
10. At The condition Key In SW OFF(OUT) & central door Lock IND signal ouput is turned ON, central door Lock IND signal is
output for 1 minute then OFF.
11. Shall be no malfunction at BATTERY connection.(shall be no malfunction even at KEY IN position)
12. Inputs which are 40msec or less shall not be received.
(Door Key Lock/Unlock SW)
13. LOCK signal is not output by DOOR KEY LOCK SW when IGN turn ON.
14. Lock output is forbidden During IGN KEY REMINDER signal ouput by C/DOOR LOCK/UNLOCK SW or DOOR KEY.
T1 : 0.5 ± 0.1sec.
* The changes of NOBE by LOCK/UNLOCK output signal do not displayed.
Central Door Lock Indicator
1. KEY OUT, when All DOOR LOCK & TAILGATE CLOSED, LOCK & TAIL GATE CLOSE is turned OFF after lighting 100%
for 1 minute.
2. KEY IN, when All DOOR LOCK & TAILGATE CLOSED, CENTRAL DOOR LOCK INDICATOR lighting 100% continuously.
Under operation, Continuation blink is carried out by 1cycle.in ANY DOOR UNLOCK or ALL DOOR LOCK&TAIL GATE
OPEN. When ALL DOOR UNLOCK A output is turned off immediately.
3. Above 2), if KEY OUTED, CENTRAL DOOR LOCK INDICATOR is turned OFF after lighting for 1 minute. Under operation,
Continuation blink is carried out by 1cycle.in ANY DOOR UNLOCK or ALL DOOR LOCK&TAIL GATE OPEN. When ALL
DOOR UNLOCK A output is turned off immediately.
4. After above 3), when DR UNLOCK is changed and All DOOR LOCK & TAILGATE CLOSED, follow above 3).
5. When The changes of DOOR LOCK/UNLOCK state by AUTO DOOR LOCK function occure, follow above 2)~4).
The Reminder Unlock Function By Central Door Lock Sw Or Keyless Or Door Key
1. When Door UNLock SW LOCK by Key In SW OUT & Door SW OPEN & Central door LOCK/UNLOCK SW or KEYLESS or
DOOR KEY, Unlock relay output for 1sec after 0.5sec.
T1, T3 : 0.5±0.1sec, T2 : 1±0.1sec,
T4 : 0.5sec MAX.
*1 OPEN : Driver Door OPEN or Passenger side Door OPEN or Rear Right Door OPEN or Rear Left Door OPEN or Tailgate
OPEN
CLOSE : Driver Door Close and Passenger side Door Close and Rear Right Door Close and Rear Left Door Close
TAILGATE CLOSE
*2 Key In SW OUT, if door is closed within 0.5sec from the change that Door Unlock SW UNLOCK → LOCK by Central
door Lock/UNLOCK SW or KEYLESSor DOOR KEY, Unlock relay ouput for 1sec.(once)
*3 Key In SW OUT, if Door UNLOCK SW is LOCKED within 0.5sec from the change that DOOR OPEN → CLOSE by
Central door Lock/UNLOCK SW or KEYLESS or DOOR KEY, Unlock relay output for 1sec.(once)
* RETRY output is or is not which is decided RETRY output start point.(after 1.5sec from Unlock relay output at first time)
* Unlock relay output even if the condition is not maintained for 0.5sec after condition is valid.
* Above Time Chart, output by Door LOCK/UNLOCK Function is not displayed.
* The case LOCK & REMINDER UNLOCK by KEYLESS, HARZARD is not by ARM entry.
* This function is valid when enter LOCK mode by Central DR LOCK SW or KEYLESS or DOOR KEY.(When DOOR OPEN
& UNLOCK, REMINDER UNLOCK is not output by OVERRIDE.)
* REMINDER UNLOCK output once only, Monitoring of DOOR LOCK/UNLOCK state is not exercised additionally.
(NEED OF DIVISION WITH KEY REMINDER UNLOCK When DRV Or ASS Or RL Or RR DR OPEN & DR LOCK, if LOCK
state is maintained after ouput one time by above function, output three times additionally.)
IGN Key Reminder
1. This function is not performed when vehicle speed is 3km/h or more. Only, after AUTO DOOR LOCK operating the vehicle
speed from 3Km/h under hour KEY REMINDER conditions.
2. ALL DOOR UNLOCK signals are output for 1s after 0.5s from when the state becomes KEY IN SW IN & Driver DOOR
OPEN & Driver DOOR LOCK SW LOCK
3. ALL UNLOCK signal is output for 1s after 0.5s from when the state becomes KEY IN SW IN, Passenger side DOOR OPEN
and Passenger side DOOR LOCK SW LOCK
4. ALL UNLOCK signal is output for 1s after 0.5s from when the state becomes KEY IN SW IN, Rear right DOOR OPEN and
Rear right DOOR LOCK SW LOCK
5. ALL UNLOCK signal is output for 1s after 0.5s from when the state becomes KEY IN SW IN, Rear left DOOR OPEN and
Rear left DOOR LOCK SW LOCK
6. Even though UNLOCK output for 1sec by above (2)~(5), if the LOCK state is maintained Unlock relay ouput maximum
three times(except output for 1sec) ; (1sec cycle : 0.5sec ON/OFF)
7. If Key In SW IN, Tailgate SW OPEN and ALL DOOR Lock SW LOCK, Unlock relay ouput for 1sec after 0.5sec.
(Unlock relay is not output when ANY DOOR Lock SW UNLOCK)
*Even though UNLOCK output for 1sec by above (7), if the LOCK state is maintained Unlock relay ouput maximum three
times(except output for 1sec)
8. IGN KEY REMINDER outputting C/DOOR LOCK in compliance with LOCK/UNLOCK SW or DOOR KEY The output forbids.
T1, T3 : 0.5±0.1sec, T2 : 1±0.1sec,
T4 : 0.5sec MAX.
*1. OPEN : Dr DOOR OPEN or PASSENGER SIDE DOOR OPEN or RR DOOR OPEN or RL D00R OPEN
CLOSE : Dr DOOR CLOSE or PASSENGER SIDE DOOR CLOSE or RR DOOR CLOSE or RLDOOR CLOSE
*2. UNLOCK : Dr DOOR or PASSENGER SIDE DOOR or RR DOOR or RL DOOR Lock SW UNLOCK
LOCK : Dr DOOR or PASSENGER SIDE DOOR or RR DOOR or RL DOOR Lock SW LOCK
*3. UNLOCK signal is output (only once) within 1s if DOOR is closed within 0.5s from DOOR LOCK SW(DR or
PASSENGER or RR or RL) UNLOCK → LOCK under KEY IN SW IN.
*4. UNLOCK signal is output (only once) within 1s if DOOR LOCK SW is locked within 0.5s from DOOR (DR or
PASSENGER or RR or RL) OPEN → CLOSE under KEY IN SW IN. But, Performance followed above *9 when C/DOOR
LOCK,UNLOCK SW is turned ON within 0.5s.
*5. ALL DOOR UNLOCK signal is output at CTL DOOR LOCK after Dr DOOR & AsDOOR & RR DOOR & RL DOOR under
KEY IN.
*6. Judgment of the possibility of RETRY signal output is performed at RETRY signal output start.
(after 1.5s from the first UNLOCK signal output)
*7. After the condition if UNLOCK is met, UNLOCK signal is output if the condition is not held for 0.5s.
But, UNLOCK signal is not output if KEY IN SW is OUT at the moment that 0.5s passes after the condition is met by
DOOR LOCK SW change from UNLOCK to LOCK.
*8. Output by DOOR LOCK/UNLOCK functions is not displayed in the above TimeChart
*9. Signal is Output by Central door LOCK,UNLOCK or Driver DOOR KEY LOCK/UNLOCK Switch or Assist DOOR KEY
UNLOCK Switch input signal and IGN KEY REMINDER UNLOCK signal is not output(IGN KEY REMINDER function is
reseted) when Central DOOR LOCK,UNLOCK Switch or Driver DOOR KEY LOCK/UNLOCK Switch or Assist DOOR KEY
UNLOCK Switch is turned ON within 0.5s after IGN KEY REMINDER condition is valided.
*10. Central DOOR LOCK,UNLOCK Switch or Driver DOOR KEY LOCK/UNLOCK Switch or As DOOR KEY UNLOCK
Switch input signal is ignored during IGN KEY REMINDER UNLOCK output
Impact Sensing Door Unlock
1. UNLOCK signal is always output when Crash Input signal is input under IGN SW ON.
2. UNLOCK signal is output for the remaining time even when IGN SW ON is turned to OFF during UNLOCK output.
3. UNLOCK signal is not output when IGN SW OFF is turned to ON after Crash Input signal is input in advance.
4. UNLOCK signal is output for T3 when Driveriver or passenger or rear right or rear left DOOR LOCK SW is locked from
UNLOCK after UNLOCK signal is output.
5. AUTO DOOR LOCK function is not performed when CRASH UNLOCK condition is met.
6. CENTRAL DOOR LOCK function is not performed during or after CRASH UNLOCK signal output.
But, CENTRAL DOOR LOCK function is performed normally if CRASH UNLOCK function is reset after IGN OFF.
T1: 0.2s
T2: 40ms
T3: 5s ± 0.5s

a. Output at that time is immediately stopped and 100ms is extended when there is reverse direction output
request during output, then the reverse direction output is performed.
But, output is performed for the last received output request when there is output request during extending
100ms.
(200mS in DEAD LOCK Spec)
b. LOCK signal output is performed and UNLOCK signal output request is ignored when LOCK signal output and
UNLOCK signal output are performed at the same time.
c. CRASH DOOR UNLOCK function is given priority than LOCK/UNLOCK control by other functions.
d. LOCK/UNLOCK signal request by other functions is ignored during and after CRASH DOOR UNLOCK signal
output.
But, LOCK/UNLOCK signal control by other functions are performed in case of IGN1 SW OFF & IGN2 SW OFF.
e. LOCK (UNLOCK) signal request is not output again when All LOCK(UNLOCK) SW is LOCK (UNLOCK) state.
But, Driver DOOR UNLOCK signal request is not output again when Dr DOOR LOCK SW is UNLOCK state.
f. Dr DOOR UNLOCK signal is output as well as ALL DOOR UNLOCK signal when there is ALL DOOR UNLOCK
signal output request during Dr DOOR UNLOCK output.
g. TAILGATE LOCK/UNLOCK CONTROL CONDITION
TAILGATE LOCK COGNITIVE CONDITION : ALL DOOR LOCK & TAILGATE CLOSE
TAILGATE UNLOCK COGNITIVE CONDITION :
1) When one DOOR of All DOOR is UNLOCK
2) When TAILGATE OPEN
Speed Sensing Auto Door Lock (Unlock When Key Out)
1. This does not activate when vehicle speed is less than 15km/h.
2. LOCK signal is output if vehicle speed is 15km/h or more for at least 1s under ALT"L" ON, IGN SW = ON. But, LOCK
signal is not output if all DOORs are lockedor all DOORs are FAIL in advance.
3. LOCK signal is output 3 times as Max ((2) is ignored) if either one door is unlocked after LOCK signal output in (2).(1s
cycle) But, DOOR, which is locked from UNLOCK state during 3time output, is ignored.
4. Relevant DOOR is FAIL if the state is UNLOCK after 3time output.
5. After Lock relay output above (2), Lock relay output one time if LOCKED DR is changed Unlock. But After Lock relay
output, relevant Door Lock relay output three times if UNLOCK state is maintained.
6. FAIL DOOR is cleared at IGN SW = OFF or DOOR UNLOCK SW changed(UNLOCK→LOCK)
7. AUTO DOOR LOCK function is not performed when CRASH UNLOCK condition is met.
8. All DOOR UNLOCK signal is output when KEY OUT After IGN1 ON→OFF in LOCK condition.
But, when KEY OUT, UNLOCK function is relevant when AUTO DOOR LOCK function is performed.
T1 : 1 ± 0.1sec, T2 : 0.5 ± 0.1sec.
*1 ON : IGN1 ON, OFF : IGN1 OFF
*2 LOCK : Driver & Passenger & Rear Door Lock SW = LOCK
UNLOCK : Driver or Passenger or Rear Door LockSW = UNLOCK
Dead Lock / Unlock
1. Central Door LOCK signal is output for 0.5s if Central Door LOCK is performed with Driver/Passenger KEY or TX. Then,
DEAD LOCK signal is output for 0.5s after checking the state (after 200msec).
2. Not DEAD LOCK but only Central Door LOCK is perormed after Central Door LOCK output for 0.5s when Central Door is
LOCKED by Central Door LockSW.
3. Central Door UNLOCK ouput for 0.5s after DEAD UNLOCK output for 05.s and after 200ms when Central Door UNLOCK
SW is turned ON by Door KEY or TX after DEAD UNLOCK output for 05.s.
4. Not DEAD UNLOCK but only Central Door UNLOCK is perormed when Central Door UNLOCK is turned ON by Central Door
Lock SW.
(In DR, the relevant DOOR is performed Door UNLOCK & DEAD UNLOCK mechanically when UNLOCK by KEY)
5. DEAD LOCK/UNLOCK is performed when only DOOR CLOSED.
(But, except the state of DEAD LOCK by TX or Door Key. All DOOR Unlock signal is output when Door OPEN by
REMINDER function by TX or Dr Key.)
6. LOCK function is performed first when both LOCK/UNLOCK functions are performed at the same Time.
7. Priority is decided in order of TX>KEY>Door LOCK SW in case of simultaneous input with KEY/TX/Door LOCK SW.
If (7),(8) is happened simultaneously, priority is given to (8).
8. DEAD LOCK is canceled (DEAD UNLOCK signal output for 0.5SEC) at KEY IN & IGN ON after DEAD LOCK.
9. In the condition of IGN ON, DEAD LOCK is not output when DOOR KEY LOCK.
10. Door LOCK/UNLOCK signal output is ignored by TX, Central Door Lock/Unlock SW during DEAD LOCK/UNLOCK signal
output.
Functional Relay Output Condition
Relay 1 Relay 2 Relay 3
Central/Lock ON OFF OFF
Dead/Lock OFF OFF ON
Dead/Unlock ON ON OFF
Central/Unlock OFF ON ON
T1 : 0.5s±0.1s. T2 : 0.2s±0.05s.
Power Window Timer
1. POWER WINDOW RELAY it turned ON at IGN SW ON
2. POWER WINDOW RELAY is turned ON for T1 at IGN SW OFF
3. POWER WINDOW RELAY is immediately turned OFF if DOOR is opened under P/WINDOW RELAY ON for T1.
4. POWER WINDOW RELAY is immediately turned OFF at IGN SW ON→OFF under DOOR OPEN.
T1 : 30 ± 3sec.
Front Fog Lamp Control
1. IGN1 ON & TAIL Relay ON, if Front FOG SW is turned ON then Front FOG Relay is ON.
2. Above (1), Front FOG SW is turned ON then Front FOG Relay is OFF.
3. IGN1=ON & TAIL Relay ON & Front FOG SW ON when conditions are not formed, Front FOG Relay off.
Auto Light Control
1. AUTO LIGHT SENSOR value is always read at IGN1 ON.
2. LIGHT is turned ON after 2sec±0.2sec when AUTO LIGHT SENSOR value is same as LIGHT ON input value.
3. LIGHT is turned OFF after 2sec±0.2sec when AUTO LIGHT SENSOR value is same as LIGHT OFF input value.
4. LIGHT ON value of SENSOR is based on the below table.
5. Head Lamp signal is output when Head Lamp OUTPUT is ON.
6. After Head Lamp is turned OFF, Head Lamp signal output is kept if Head Lamp and Tail Lamp ON.
luminance condition is met at Auto Light SW ON.
7. After Head Lamp is turned OFF, Head Lamp signal output is immediately stopped if HEAD LAMP and Tail Lamp OFF
8. After Head Lamp is turned OFF, Head Lamp signal output is immediately stopped at TAIL SW signal input.
9. After Head Lamp is turned OFF, Head Lamp signal output is stopped if there is no input of Auto Light SW or TAIL SW.
(shall be no flashing of Head Lamp)
10. Head Lamp signal output is stopped when SW position is changed from AUTO to Head Lamp SW during Head Lamp ON
with Auto Light. (shall be no flashing of Head Lamp)
Light Sensor Reading
Head lamp & Tail lamp
ON 1.10 V
OFF 2.80 V
T1 : ON Filtering Time
T2 : OFF Filtering Time
T1 : ON Filtering Time
T2 : OFF Filtering Time
Head Lamp Escort
1. If Head Lamp is lighting by Head Lamp SW or AUTOLIGHT, Head Lamp lighting is maintained when IGN1 is changed ON to
OFF.
2. Following stste, Head Lamp lighting is truned off.
But, TAIL LAMP keep up lighting when KEY IN in the condition of lighting off after IGN ON→OFF and lighting.
(the condition of TAIL LAMP lighting off follows TAIL LAMP AUTOCUT function.)
• When Driver DOOR SW OPEN→CLOSE and after 30sec.
• When Head Lamp SW ON or not the case of AUTO LIGHT SW ON.
(ALC ; When Head Lamp ON, Head Lamp SW ON within Multifunction SW during ESCORT → Lighting keeping up
when SW is moned to AUTO LIGHT SW ON or reverse.)
• When Driver DOOR OPEN state is maintained after 5minute.
• When IGN1 ON→IGN OFF and sfter 5minute.
• When received TX LOCK signal two times during output.

– Head Lamp RELAY output of TIMING CHART contains the condition of TAIL LAMP ON.
– Head Lamp RELAY output by Head Lamp SW and HEAD LAMP RELAY output by AUTO LIGHT is regarded
identical condition.
That is, the explaining of HEAD LAMP RELAY ouput contains two cases.
– AUTO LIGHT SW ON : HEAD LAMP and TAIL LAMP signal by AUTO LIGHT is output.
– AUTO LIGHT SW OFF: HEAD LAMP and TAIL LAMP signal by AUTO LIGHT is not output.
Daytime Running Light
1. If IGN2 & ALT "L" ON & HEAD LAMP SW = OFF & TAIL LAMP SW=OFF, TAIL LAMP RELAY and HEAD LAMP RELAY is
output.
2. After above 1), HEAD LAMP RELAY output is OFF when TAIL LAMP SW=ON.
3. After above 2), HEAD LAMP RELAY output is ON when HEAD LAMP SW=ON again.
4. If TAIL LAMP Switch= ON and IGN2 & ALT "L" OFF→ON, only TAIL LAMP RELAY is ON.
5. HEAD LAMP ESCORT is performed when LAMP is turn on by HEAD LAMP Switch after IGN1 OFF, but HEAD LAMP
ESCORT is not performed when LAMP is turn on by DRL function after IGN1 OFF.
(HEAD LAMP SW=OFF)
6. DRL is not performed when DRL Deactivation INPUT=ON(GND).
7. During DRL operating, DRL function id stopped when DRL_Deactivation INPUT=ON(GND).
■ When DRL _ Deactivation INPUT = OFF (OPEN)
■ When DRL _ Deactivation INPUT = ON (GND)
Alternator Management System Control
1. HeadLamp in compliance with Switch ON/OFF or Auto light functions Head Lamp Relay at the time of ON/OFF percentage
AMS identically, ON/OFF it controls.
2. DRL in compliance with a functions Head Lamp Relay at the time of ON , It does not AMS ON.
Door Open Indicator
1. One more DOOR Open
Door Open IND is turned on when ("Driver Door SW OFF"or "Passenger side Door SW OFF" or "Rear Right Door SW OFF"
or "Rear left Door SW OFF")
2. Door Open IND is turned off when All DOOR CLOSE ("Driver Door SW ON" & "Passenger side Door SW ON" & "Rear Right
Door SW=ON" & "Rear Left DoorSW=ON")
● DOOR SW“ON” = DOOR CLOSE
● DOOR SW“OFF”= DOOR OPEN
CENTER FACIA PANEL SWITCH
Turn Signal And Hazard Control
1. Flashing function
(1) On the state of Tail Switch ON, Hazard symbol light ON.
(2) On the state of Tail Switch OFF, Hazard symbol light OFF.
(3) On the state of Hazard Switch ON, Micom sense the bulbs status that is normal, removed more than 3 bulbs , over
load or short to GND. At each state output signal is as follow.
• Normal : 85±10 C/M, DUTY RATIO 50%
• More than 3 Bulbs are removed : more than 120C/M, DUTY RATIO 50%
• Over Load or Short to GND: DO NOT OPERATE
(4) Hazard symbol light(LED;RED COLOR) is same as (3).
(5) SOUND R/Y output signal is same as (3).
(6) The state of GND Short is terminated by the input OFF signal signal for all Turn_Lamp
(7) RKE signal is prior to Hazard signal.
2. Turn Left/Right signal flashing function
(1) On the state of IGN1, TURN_SIGNAL switch is LOW ACTIVE .
(2) On the state of Turn_Signal Switch ON, Micom sense the bulbs state that is normal, removed more than 1 bulbs, over
load or short to GND. At each state output signal is as follow.
• Normal : 85±10 C/M,DUTY RATIO 50%
• More than 1 BULBs are removed : more than 120C/M, DUTY RATIO 50%
• Over Load or Short to GND: DO NOT OPERATE
(3) SOUND R/Y output signal is same as (3).
(4) The state of GND Short is terminated by the input OFF signal signal for all Turn_Lamp
(5) Hazard signal is prior to Turn_signal.
(6) RKE signal is prior to Turn_signal.
3. Lane change
(1) If Both IGN1 and Turn_signal SW are ON and then Turn_signal SW is under 1.8S,SW’s Turn_signal print out 3 time .
(2) Lane Change is stopped in case of as follows.
– The Opposite side T/Sig SW ON
– Hazard SW ON
(3) During Lane change is running through LH Turn signal SW, when RH Turn signal SW’s input is under 1.8s, cut output
of LH Turn signal and do output of RH Turn signal.
(4) During Lane change is running, when Lamp failure detection as follows.
– Before output the case lamp failure : Do normal output 1 time and Do output of Double blinking 3 time.
– During output the case lamp failure : After output completing Do output of Double blinking 3 time.
– During output and Turn signal lamp OFF the case lamp failure : Do normal output 1 time and Do output of Double
blinking 3 time.
(5) During Lane change is running, when short is happened, stop output at once.
English
> Repair procedures
REMOVAL
2. Remove the floor console assembly (A) after loosening the console mounting screws.
3. Remove the center facia lower try (A) after loosening the mounting screws.
4. Remove the body control module (A) after loosening 2 bolts and disconnecting connector.
INSTALLATION English
1. Install the body control module.
2. Install the center facia lower try.
3. Install the floor console assembly.
INSPECTION
BCM Connectors
Pin NO. Connector A Connector B Connector C

1 Battery Voltage Auto Light Signal Room Lamp
2 IGN1 Auto Light (Ground)
3 Alternator 'L' Rear Right Door Unlock Switch Defogger Relay
4 Key In Switch Rear Defogger Switch Tail Lamp Relay
5 Speed Limit Rear Fog Lamp Switch Wiper Relay
6 Rear Left Door Lock Switch Front Fog Lamp Switch DRL Lock Relay 1
7 Carsh Input Auto Light (Power) Dead Lock Relay 1
8 Driver Door Unlock Switch Horn Relay
9 Passenger Side Door Unlock Switch Hazard Relay
10 Rear Wiper Switch EMS Key Illumination Lamp
11 Safety Power Window ECU Driver Seat Belt Indicator
12 Ground Power Window Relay Ground(power)
13 IGN2 Front Deicer Relay Rear Fog Relay
14 Washer Switch Head Lamp Relay Diagnosis
15 INT Wiper Switch Door Lock Relay 2 Central Door Lock Indicator
16 Code Save Security Indicator Door Open Indicator
17 Rear Right Washer Switch Front Fog Lamp Relay
18 Tailgate Relay Rear Wiper Relay
19 Tailgate Handle Switch Head Lamp Escort
20 Driver Door Switch Passenger Seat Belt Indicator
21 Assist Door Switch
22 Rear Left Door Switch
23 Tailgate Door Switch
24 Hood Switch
25 Driver Door Key Lock Switch
26 Driver Door Key Unlock Switch
27
28 Tail Lamp Switch
29 INT Wiper Volume Switch
30 Speed Sensor
31 Auto Light Switch
32 Driver Seat Belt Switch
33 Head Lamp Switch
34 Assist Door Key Unlock Switch
35 Central Door Lock/unlock Switch
36 Assist Seat Belt Signal
37 Front Deicer Switch
38 MIST Switch
39 Rear Door Switch
40
Terminal Voltage
No Input signal name Logic state ON/OFF voltage recognition LEVEL(V) Remarks
1 B+ ON = BAT 9V~16V
ON = BAT
BAT=
2 IGN1 (IGN KEY is ON or START 7V or more/4V or less
BATTERY
position)
ON = BAT (IGN KEY is ON
3 IGN2 7V or more/4V or less
position)
4 Alt L ON = BAT(starting state) 7V or more/4V or less
IN = BAT (KEY insertion
5 Key In Switch 7V or more/4V or less
state)
1V or less/OPEN (Reference value: 4V or
6 Rear Left Door Switch OPEN = GND
more)
7 Driver door switch OPEN = GND
more)
8 Passenger side door Switch OPEN = GND
more)
LOCK = OPEN, UNLOCK = 1V or less/OPEN (Reference value: 4V or
9 Driver door unlock switch
GND more)
Passenger side door Unlock LOCK = OPEN, UNLOCK = 1V or less/OPEN (Reference value: 4V or
10
Switch GND more)
Center door lock/unlock 1V or less/OPEN (Reference value: 4V or
11 ON=GND
switch more)
12 Rear door switch OPEN = GND
more)
13 Tail gate switch OPEN = GND more)
14 Hood Switch OPEN = GND
more)
15 Driver door key lock switch ON = GND
more)
16 Driver door key unlock switch ON = GND
more)
Passenger door key unlock 1V or less/OPEN (Reference value: 4V or
17 ON = GND
switch more)
18 Front deicer switch ON = GND
more)
19 Washer switch ON = BAT 7V or more/4V or less
20 Wiper INT switch ON = BAT 7V or more/4V or less
21 Wiper INT volume switch 0V ~ 2.5V 0Ω~ 50KΩ
22 Rear washer switch ON = BAT 7V or more/4V or less
23 Rear wiper Int switch ON = BAT 7V or more/4V or less
24 Rear defogger switch ON = GND
more)
25 Tail switch ON = GND
more)
Fasten = OPEN, Unfasten = 1V or less/OPEN (Reference value: 4V or
26 L_Driver seat belt switch
GND more)
ON = GND(at crash 1V or less/OPEN (Reference value: 4V or
27 Crash Input (Impact sensor)
detection) more)
OPEN
28 Speed sensor Speed input = PULSE(0~5V) 1V or less/4V or more
COLLECTOR
29 Head lamp switch ON = GND
more)
30 Front fog switch ON = GND
more)
31 Rear fog switch ON = GND
more)
32 Tail gate handle switch ON = GND
more)
33 Code save unit ON = GND 1V or less/4V or more
34 Rear right door Unlock switch
GND more)
35 Rear left door Unlock switch
GND more)
36 Mist switch ON = BAT 7V or more/4V or less
37 Auto light sensor Signal
BCM Actuator Operation
SCAN tool can operates all actuators controlled by BCM by force.
NO. BCM DISPLAY
1 DOOR LOCK RELAY
2 DOOR UNLOCK RELAY
3 TAILGATE RELEASE RELAY
4 POWER WINDOW RELAY
5 WIPER RELAY
6 HAZARD RELAY (+RK)
7 BURGLAR HORN RELAY (+RK)
8 STARTER INHIBIT RELAY (+RK)
9 TAIL LAMP RELAY/DRL UNIT
10 HEAD LAMP RELAY
11 REAR FOG RELAY
12 FRONT DEICER RELAY
13 REAR DEFOGGER RELAY
14 DRIVER SEAT BELT INDICATOR
15 IGN KEY HOLE ILLUMINATION
16 ROOM LAMP
BCM Diagnosis With Scan Tool
1. It will be able to diagnose defects of BCM with scan tool quickly. Scan tool can operates actuator forcefully, input/output
value monitoring and self diagnosis.
2. Select model and menu.
3. Select "Current data", if you will check current data of BCM. It provides power supply status, multi function status, lamp
status, door status, lock system status, wiper, auto light status and so on.
4. If you will check BCM data operation forcefully, select "Actuation test".
5. You can turn ON/OFF as below option function with the user option program.
(1) LOCK / UNLOCK comfirming alarm: Alarm sound ON/OFF control when you LOCK/UNLOCK doors with transmitter.
(2) Mechanical LOCKING system: Arm/Disarm ON/OFF when you lock the door with the mechanical key.
(3) AUTO DOOR LOCK/UNLOCK system ON/OFF.
– Vehicle speed gearing AUTO DOOR LOCK (more than 20km/h)
– AUTO DOOR LOCK non application
– Shift lever gearing AUTO DOOR LOCK
– Driver seat AUTO DOOR LOCK
– AUTO DOOR UNLOCK non application
– All doors UNLOCK in the case of driver door UNLOCK
– All doors UNLOCK in the case of IGN key seperation.
(4) Riding & Getting off gearing
– Seat installation state ON/OFF
– Seat riding & getting off gearing ON/OFF
– Column installation state ON/OFF
– Column riding & getting off gearing ON/OFF
User Option Mode
The BCM offers 1 items user option mode for a user convenience (AUTO DOOR LOCK)
– It is able to set up the enable or disable of AUTO DOOR LOCK function or AUTO DOOR LOCK operation vehicle speed
when using it.
1. Select option "ED" and press ENTER.
2. Select option "BODY CONTROL MODULE" and press ENTER.
3. Select option "USER OPTION" and press ENTER.
4. Select option "AUTO DOOR LOCK STATUS by using the direction button(▲ / ▼).
5. Select the parameter by using the direction button(◀ / ▶) and press ENTER to save it.
(Disable / FIXING)
2012 > D 2.0 TCID > Body Electrical System > Seat Electrical > Components and Components Location
English
COMPONENT LOCATION
2012 > D 2.0 TCID > Body Electrical System > Seat Electrical > Schematic Diagrams English
CIRCUIT DIAGRAM
2012 > D 2.0 TCID > Body Electrical System > Seat Electrical > Seat Heater Switch > Repair procedures
English
INSPECTION
Front Seat Warmer Switch
2. Remove the center fascia panel(A) from the crash pad.
3. Disconnect the seat warmer switch connector.
4. Check that continuity exists between the terminals.
2012 > D 2.0 TCID > Body Electrical System > Seat Electrical > Seat Heater > Repair procedures English
INSPECTION
1. For cushion side of seat warmer, check for continuity and measure the resistance between No.2 terminal of control unit
harness connector and No.1 terminal of cushion connector.
2. For back side of seat warmer, check for continuity and measure the resistance between No.1 and No.2 terminal of back
connector.
Standard value
Cushion : 1.43Ω ± 10%, Back : 1.01Ω ± 10%
3. Operate the seat warmer after connecting the connectors, and then check the NTC(Negative Temperature Coefficient)
thermostat by measuring the temperature of seat surface.
Standard value
Item Cushion Back Remark
LOW 97°F (36°C) 104°F (40°C) ±36°F (±2°C)
MID 100°F (38°C) 109°F (43°C) ±36°F (±2°C)
HIGH 104°F (40°C) 115°F (46°C) ±36°F (±2°C)
2012 > D 2.0 TCID > Body Electrical System > Fuses And Relays > Components and Components
English
Location
COMPONENT LOCATION
English
2012 > D 2.0 TCID > Body Electrical System > Fuses And Relays > Relay Box (Engine Compartment) >
English
Components and Components Location
COMPONENT LOCATION
English
2012 > D 2.0 TCID > Body Electrical System > Fuses And Relays > Relay Box (Engine Compartment) >
English
Repair procedures
INSPECTION
2. Pull out the relay from the engine compartment relay box.
Power Relay (Type A)
A : Fuel pump relay
B : A/C relay
C : Head lamp relay (Low)
D : Horn relay
E : Head lamp relay (High)
F : Front fog lamp relay
G : Fuel filter heater relay
No.86 terminals.
English
Power Relay (Type B)
A : Wiper relay
No.86 terminals.
2. There should be continuity between the No.30 and No.87 terminals when power is disconnected.
Power Relay (Type C)
A : Condenser pan2 relay
B : Condenser pan 1 relay
C : Start relay
D : Glow relay
E : PTC heater relay #1
F : PTC heater relay #2
G : PTC heater relay #3
No.86 terminals.
Power Relay (Type D)
A : Main relay
No.86 terminals.
2. There should be continuity between the No.30 and No.87 terminals when power is disconnected.
Fuse
1. Be sure there is no play in the fuse holders, and that the fuses are held securely.
2. Are the fuse capacities for each circuit correct?
3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why the fuse blew first and
completely eliminate the problem before installing a new fuse.
REMOVAL
2. Remove the engine room junction box upper cover.
3. Loosen the ring terminal mounting 3 nuts(A) then remove the ring terminal cables.
4. Loosen the body and lower cover 2 bolts(B).
5. Loosen the connector 3 bolts(C).
6. Remove the fuse and relay box(A) from the lower cover.
7. Remove the lower cover and mating connectors after loosening the box mounting 2 bolts.
INSTALLATION
1. Install the lower cover.
TORQUE : 10 ~ 12Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbf.ft)
2. Install the fuse and relay box to the lower cover.
TORQUE :
Connector bolt : 10 ~ 12Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbf.ft)
Ring terminal mounting nut : 10 ~ 12Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbf.ft)
Body and lower cover bolt : 10 ~ 12Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbf.ft)
3. Install the junction box upper cover.
2012 > D 2.0 TCID > Body Electrical System > Fuses And Relays > Relay Box (Passenger Compartment) >
English
COMPONENT LOCATION
English
2012 > D 2.0 TCID > Body Electrical System > Fuses And Relays > Relay Box (Passenger Compartment) >
English
Repair procedures
INSPECTION
Fuse
1. Be sure there is no play in the fuse holders, and that the fuses are held securely.
2. Are the fuse capacities for each circuit correct?
3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why the fuse blew first and
completely eliminate the problem before installing a new fuse.
Passenger Compartment Relay
2. Remove the crash pad lower panel.
3. Remove the junction box.
Power Window
1. There should be continuity between the No.2 terminal in the I/PH and the No.16 or 17 terminal in the I/PF when power and
ground are connected to the No.2 terminal in the I/PH and the No.17 terminal in the I/PB.
2. There should be no continuity between the No.2 terminal in the I/PH and the No.16 or 17 terminal in the I/PF when power
and ground are connected to the No.2 terminal in the I/PH and the No.17 terminal in the I/PB.
Tail Lamp
1. There should be continuity between the No.2 terminal in the I/PH and the No.15(LH) or 4(RH) terminal in the I/PG when
power and ground are connected to the No.2 terminal in the I/PH and the No.6 terminal in the I/PD.
2. There should be no continuity between the No.2 terminal in the I/PH and the No.15(LH) or 4(RH) terminal in the I/PG when
power and ground are connected to the No.2 terminal in the I/PH and the No.6 terminal in the I/PD.
Tailgate Lid Open
1. There should be continuity between the No.3 terminal in the I/PH and the No.2 terminal in the I/PD when power and
ground are connected to the No.3 terminal in the I/PH and the No.28 terminal in the I/PF.
2. There should be no continuity between the No.3 terminal in the I/PH and the No.2 terminal in the I/PD when power and
English
Rear Heater
1. There should be continuity between the No.3 terminal in the I/PG and the No.2 or 4 terminal in the I/PF when power and
ground are connected to the No.3 terminal in the I/PG and the No.16 terminal in the I/PB.
2. There should be no continuity between the No.3 terminal in the I/PG and the No.2 or 4 terminal in the I/PF when power
and ground are connected to the No.3 terminal in the I/PG and the No.16 terminal in the I/PB.
2012 > D 2.0 TCID > Body Electrical System > Fuses And Relays > ICM (Integrated Circuit Module) Relay
English
Box > Components and Components Location
COMPONENT
English
Box > Description and Operation
DESCRIPTION
The ICM is united with many kinds of relays and installed over the instrument panel box.
English
Box > Repair procedures
INSPECTION
2. Remove the ICM relay box.
Door Lock
1. There should be continuity between the No.15 and No.6(or 16) terminals when power and ground are connected to the
No.15 and No.17 in the ICMB.
2. There should be no continuity between the No.15 and No.6(or 16) terminals when power is disconnected.
Door Unlock
1. There should be no continuity between the No.15 and No.4(or 14) terminals when power and ground are connected to the
No.12 and No.15 in the ICMB.
2. There should be continuity between the No.15 and No.4(or 14) terminals when power is disconnected.
Burglar Alarm Horn
No.11 in the ICMA.
Front Deicer
No.10 terminals in the ICMA.
Rear Fog Lamp
1. There should be continuity between the No.2(or 10) and No.11 terminals when power and ground are connected to the
No.9(or 10) and No.11 terminals in the ICMB.
2. There should be no continuity between the No.2(or 10) and No.11 terminals when power is disconnected.
Rain Sensor
Dead Lock
English
2012 > D 2.0 TCID > Body Electrical System > Indicators And Gauges > Components and Components
English
Location
COMPONENT LOCATION
1. Cluster assembly 7. Parking brake switch
2. Seat belt switch 8. Door switch
3. Vehicle speed sensor 9. Fuel gauge sender
4. Engine coolant temperature sender 10.Tailgate switch
5. Oil pressure switch 11. ISG OFF switch / ESP OFF switch
6. Brake fluid level warning switch
2012 > D 2.0 TCID > Body Electrical System > Indicators And Gauges > Instrument Cluster > Components
English
and Components Location
COMPONENTS
English
2012 > D 2.0 TCID > Body Electrical System > Indicators And Gauges > Instrument Cluster > Repair
English
procedures
REMOVAL
2. Remove the cluster fascia panel (A).
[LHD]
[RHD]
3. Remove the cluster fascia (A) from the housing after removing 4 screws.
[LHD]
[RHD]
English
4. Disconnect the cluster fascia connecters (A) and then remove the cluster.
INSTALLATION
1. Connect the cluster connector.
2. Install the cluster assembly.
3. Connect the trip switch connector.
4. Install the center facia panel.
INSPECTION
Speedometer
1. Adjust the pressure of the tires to the specified level.
2. Drive the vehicle onto a speedometer tester. Use wheel chocks(A) as appropriate.
3. Check if the speedometer indicator range is within the standard values.

Do not operate the clutch suddenly or increase/ decrease speed rapidly while testing.

Tire wear and tire over or under inflation will increase the indication error.
[km/h]
Velocity
20 40 60 80 100
(km/h)
Tolerance +3.6 +5.9 +7.0 +8.2 +8.9
(km/h) +0.6 +2.4 +3.5 +4.5 +5.9
Velocity
120 160 200 220 240
(km/h)
Tolerance +10.5 +12.7 +15.0 +16.1

(km/h) +6.5 +8.3 +10.0 +11.1
[MPH]
Velocity
10 20 40 60
(MPH)
Tolerance +3.2 +3.5 +4.5 +5.3
(MPH) +1.2 +1.6 +2.4 +3.3
Velocity
80 100 120 140
(MPH)
Tolerance +6.1 +7.3 +8.6

(MPH) +4.1 +4.5 +5.1
Vehicle Speed Sensor
1. Connect the positive (+) lead from battery to terminal 2 and negative () lead to terminal 1.
2. Connect the positive (+) lead from tester to terminal 3 and the negative () lead to terminal 1.
3. Rotate the shaft.
4. Check that there is voltage change from approx. 0V to 11V or more between terminals 3 and 1.
5. The voltage change should be 4 times for every revolution of the speed sensor shaft.
If operation is not as specified, replace the sensor.
Tachometer
1. Connect the scan tool to the diagnostic link connector or install a tachometer.
2. With the engine started, compare the readings of the tester with that of the tachometer. Replace the tachometer if the
tolerance is exceeded.

a. Reversing the connections of the tachometer will damage the transistor and diodes inside.
b. When removing or installing the tachometer, be careful not to drop it or subject it to severe shock.
Revolution
1,000 2,000 3,000 4,000 Remark
(rpm)
Tolerance
±100 ±100 ±100 ±100 Gasoline
(rpm)
Tolerance
±100 ±100 ±100 ±100 Diesel
(rpm)
Revolution
5,000 6,000 7,000 8,000 Remark
(rpm)
Tolerance
±100 ±100 ±100 ±100 Gasoline
(rpm)
Tolerance
±100 ±100 Diesel
(rpm)
Fuel Gauge
1. Disconnect the fuel sender connector from the fuel sender.
2. Connect a 3.4 wattages, 12V test bulb to terminals 1 and 3 on the wire harness side connector.
3. Turn the ignition switch to the ON, and then check that the bulb lights up and the fuel gauge needle moves to full.
Fuel Gauge Sender
1. Using an ohmmeter, measure the resistance between terminals 1 and 3 of sender connector (A) at each float level.
2. Also check that the resistance changes smoothly when the float is moved from "E" to "F".
Position Resistance(Ω)
E 184 ± 2.5Ω
Warning lamp 170 ± 2.5Ω
1/2 66 ± 2.4Ω
Sender (F) 15 ± 2.5Ω
3. If the height resistance is unsatisfied, replace the fuel sender as an assembly.

After completing this test, wipe the sender dry and reinstall it in the fuel tank.
Engine Coolant Temperature Gauge
1. Disconnect the wiring connector (A) from the engine coolant temperature sender in the engine compartment.
2. Connect a 12V, 3.4 wattages test bulb between the harness side connector 2 terminal and ground.
3. Turn the ignition switch ON.
4. Verify that the test bulb flashes and that the indicator moves to HOT position.
If operation is not as specified, replace the cluster (Engine coolant temperature gauge). Then recheck the system.
Engine Coolant Temperature Sender
1. Using an ohmmeter, measure the resistance between the terminal 2 and ground.
2. If the resistance value is not as shown in the table, replace the temperature sender.
[Super Vision]
Temperature 131 159.8 230 257
E/G
[°F(°C)] (55) (71) (110) (125)
0°±3° 35°±3° 35°±3° 75°±3° Gasoline
Deflection(°)
0°±3° 35°±3° 35°±3° 75°±3° Diesel
[General]
Temperature 122 185 230 257
E/G
[°F(°C)] (50) (85) (110) (125)
0°±3° 35°±3° 35°±3° 75°±3° Gasoline
Deflection(°)
0°±3° 35°±3° 35°±3° 75°±3° Diesel
Oil Pressure Switch
1. Check that there is continuity between the oil pressure switch terminal and ground with the engine off.
2. Check that there is no continuity between the terminal and ground with the engine running.
3. If operation is not as specified, replace the switch.
Oil Pressure Warning Lamp
1. Disconnect the connector from the warning switch and ground the terminal on the wire harness side connector.
2. Turn the ignition switch ON. Check that the warning lamp lights up. If the warning lamp doesn't light, test the bulb or inspect
the wire harness.
Brake Fluid Level Warning Switch
1. Remove the connector (A) from the switch located at the brake fluid reservoir.
2. Verify that continuity exists between switch terminals 1 and 2 while pressing the switch (float) down with a rod.
Brake Fluid Level Warning Lamp
1. Ignition "ON".
2. Release the parking brake.
3. Remove the connector from the brake fluid level warning switch.
4. Ground the connector at the harness side.
5. Verify that the warning lamp lights.
Parking Brake Switch
The parking brake switch is a pull type. It is located at the side of the parking brake lever.
1. Check that there is continuity between the terminal and switch body with the switch (A) ON.
2. Check that there is no continuity between the terminal and switch body with the switch OFF.
If continuity is not as specified, replace the switch or inspect its ground connection.
Door Switch
Remove the door switch and check for continuity between the terminals.
Seat Belt Switch
1. Remove the connector from the switch.
2. Check for continuity between terminals.
Seat belt condition Continuity
Fastened Nonconductive (∞Ω)
Not fastened Conductive (Ω)
Seat Belt Warning Lamp
With the ignition switch turned ON, verify that the lamp glows.
Seat belt condition Warning lamp
Fastened OFF
Not fastened ON
ISG OFF Switch
1. Remove the lower side crash pad switch assembly(A).
2. Disconnect the ISG off switch connector(A).
3. Check the continuity between switch terminals.
2012 > D 2.0 TCID > Body Electrical System > Indicators And Gauges > Troubleshooting English
TROUBLESHOOTING
Symptom Possible cause Remedy

Speedometer does not operate Cluster fuse (10A) blown Check for short and replace fuse
Speedometer faulty Check speedometer
Vehicle speed sensor faulty Check vehicle speed sensor
Wiring or ground faulty Repair if necessary
Tachometer does not operate Cluster fuse (10A) blown Check for short and replace fuse
Tachometer faulty Check tachometer
Fuel gauge does not operate Cluster fuse (10A) blown Check for short and replace fuse
Fuel gauge faulty Check gauge
Fuel sender faulty Check fuel sender
Low fuel warning lamp does not light up Cluster fuse (10A) blown Check for short and replace fuse
Bulb burned out Replace bulb
Fuel sender faulty Check fuel sender
Water temperature gauge does not Cluster fuse (10A) blown Check for short and replace fuse
operate
Water temperature gauge faulty Check gauge
Water temperature sender faulty Check sender
Oil pressure warning lamp does not light Cluster fuse (10A) blown Check for short and replace fuse
up
Oil pressure switch faulty Check switch
Parking brake warning lamp does not Cluster fuse (10A) blown Check for short and replace fuse
light up
Brake fluid level warning switch faulty Check switch
Parking brake switch faulty Check switch
Open door warning lamp and tailgate Memory fuse (15A) blown Check for short and replace fuse
warning lamp do not light up
Door switch faulty Check switch
Seat belt warning lamp does not light up Cluster fuse (10A) blown Check for short and replace fuse
Seat belt switch faulty Check switch
English
2012 > D 2.0 TCID > Body Electrical System > Power Door Locks > Components and Components
English
Location
COMPONENT LOCATION
2012 > D 2.0 TCID > Body Electrical System > Power Door Locks > Power Door Lock Actuators > Repair
English
procedures
INSPECTION
Front Door Lock Actuator
[LHD]
[RHD]
English
Rear Door Lock Actuator
[LHD]
[RHD]
Tailgate Lock Actuator Inspection
1. Remove the tailgate trim. (Refer to the BD group tailgate)
Front Door Lock Switch
[LHD]
[RHD]
4. Check for continuity between the terminals in each switch position when inserting the key into the door according to the
table.
Rear Door Lock Switch
[LHD]
[RHD]
Tailgate Switch
1. Remove the tailgate trim. (Refer to the BD group Tailgate)
2012 > D 2.0 TCID > Body Electrical System > Power Door Locks > Power Door Lock Relay > Repair
English
procedures
INSPECTION
Door Lock
3. Check for continuity between the terminals.
4. There should be continuity between the No.15 terminal and No.6(or 16) terminals in the ICMB when power and ground are
connected to the No.15 terminal and No.17 terminal in the ICMB.
5. There should be no continuity between the No.15 terminal and No.6(or 16) terminal in the I/PD when power is
disconnected.
Door Unlock
4. There should be continuity between the No.15 terminal and No.4(or 14) terminal in the ICMB when power and ground are
connected to the No.12 terminal and No.15 terminal in the ICMB.
5. There should be no continuity between the No.15 terminal and No.4(or 14) terminal in the ICMB when power is
disconnected.
Tailgate Open
English
2. Remove the passenger compartment junction box.
4. There should be continuity between the No.3 terminal in the I/PH and the No.2 terminal in the I/PD when power and
5. There should be no continuity between the No.3 terminal in the I/PH and the No.2 terminal in the I/PD when power and
2012 > D 2.0 TCID > Body Electrical System > Power Door Locks > Power Door Lock Switch > Repair
English
procedures
INSPECTION
Driver Door Lock Switch
2. Remove the center fascia panel from the crash pad. (Refer to the BD group "Crash pad")
3. Disconnect the connector from the center fascia panel.
2012 > D 2.0 TCID > Body Electrical System > Power Door Mirrors > Components and Components
English
Location
COMPONENT LOCATION
2012 > D 2.0 TCID > Body Electrical System > Power Door Mirrors > Power Out Side Mirror Switch >
English
COMPONENTS
2012 > D 2.0 TCID > Body Electrical System > Power Door Mirrors > Power Out Side Mirror Switch > Repair
English
procedures
INSPECTION
2. Remove the front door trim and power window switch module. (Refer to the BD groupfront door)
[LHD]
[RHD]
3. Check for the continuity between terminals of power door mirror switch according to the table.
English
2012 > D 2.0 TCID > Body Electrical System > Power Door Mirrors > Power Door Mirror Actuator > Repair
English
procedures
INSPECTION
1. Remove the front door quadrant inner cover (A). Take care not to damage fixing clips. (Refer to the BD group front door)
2. Disconnect the power door mirror connector from the harness.
3. Apply battery voltage to each terminal as shown in the table and verify that the mirror operates properly.
Mirror Heater
Folding Mirror
English
2012 > D 2.0 TCID > Body Electrical System > Power Windows > Components and Components Location
English
COMPONENT LOCATION
2012 > D 2.0 TCID > Body Electrical System > Power Windows > Description and Operation English
OPERATION
Function Of Safety Power Window
When all door (Front, Rear) power window autoup switch is operated, safety function is activated.
1. Safety function condition
When detect the force of 100N during the window rising, window is reversed.
2. Length of window reversing (except holding the autoup switch)
– When detect the jamming during the 4mm ~ 250mm from top of the door.
→ Window is reversed until 300mm from top of the door.
– When detect the jamming over the 250mm from top of the door.
→ Window is reversed until 50mm from jamming position.
→ Window is reversed 50mm or bottom position in case of 50mm reversing distance.
– When detect the jamming over 300mm from top of the door.
→ Window stops at reverse point.
3. Length of window reversing (holding the autoup switch)
– When detect the jamming during holding the autoup switch.
– Autoup function is not available during the 5 seconds from above condition.
→ When holding the autoup switch, window is operated as a manualup function. (Safety function is not activated.)
– When detect the jamming during holding the autoup switch again.
– When holding the autoup switch after 5 seconds from above condition.
→ Window is reverse until 25mm from jamming position.
English
4. Safety function is not available area
Safety function is not available during the 4mm from top of the door.
Initializing Method Of The Safety Power Window
1. Position counter and position initialization
(1) Position counter
Window position counting is implemented by use of one Hall Effect sensor (HEF) connected to timer capture unit of
the ?Controller with a resolution of 180° electrical.
Even the battery was separated from the car, it must keep the window position information.
(2) Position initialization
For position initialization, position counter detect the upper mechanical stop and lower mechanical Position. Motor
control unit (MCU) allow only Manual mode activity (without ASD AntiSqueeze Detection algorithm) feature) before to
be initialized.
Initialization means the condition to move the window system with full antipinch function and related functions by
detecting the window travel distance (Upper/Lower mechanical limits).
Conditions for initialization are
• deinitialized position counter
• Power window switch Up activated
• block condition detected
(no motor movement of more than 1 count during 1sec/ SW dependent)
Switch action with Deinitialized condition :
• Up direction : Manual & Auto P/WDW sw input → manual mode;
• Down direction : Manual P/WDW sw input → manual mode, + Auto s/w input → auto mode
(3) Reinitialization
During reinitialization, position counter is set to "zero" at upper block position to compensate counting errors by
software, mechanical tolerances or physics. Conditions for reinitialisation are
• initialized position counter.
• window at upper block position (capture range EEPROM programmable)
• block condition detected
(no motor movement of more than 1 count during 1 sec/ SW dependent)
(4) Deinitialization
The system initialization/calibration will be lost in the following cases:
• After parameter modification via diagnostic
• Wrong EEPROM checksum at ECU wakeup or poweron
• Movement outside predefined window stroke (above learned top position, below predefined bottom position)
• Deinitialisation after a defined number (EEPROM) of reversals without reinitialisation in the upper seal
(activation /deactivation controlled by EEPROM value). A window down movement or switching off the window
lifter permission resets the reversal counter value(activation by EEPROM bit).
• Deinitialisation after a defined number of movements (EEPROM) without reinitialisation in the upper seal
(activation /deactivation controlled by EEPROM value)
• Special deinitialization procedure :
The special window lifter deinitialization procedure works as follows:
– System is initialized
– Move window below softstop position (position EEPROM adjustable)
– Press MANUdown switch and keep it pressed
– Apply permission signal (seriallink = PIN 6) ON → OFF → ON within 2 seconds (time EEPROM adjustable)
(5) Soft stop function
In order to reduce noise and mechanical stress, the window movement is stopped under control of the ECU before the
bottom position is reached.
The clearance is 0 / +10 mm (at 11.5 V to 14.5 V).
To activate the soft bottom stop function, the top reference position and bottom reference position have to be
initialized. Therefore, the window is lifted into the top position until the block condition is detected. This position is
taken as top reference position.
Afterwards, the window is moved to the bottom position until the block condition is detected (mechanical stop). This
position is taken as bottom reference position.
The bottom reference position is reinitialized :
• When window is operated down starting from soft stop position
• Every "9" stops at soft stop position.
(6) Thermal protection
Thermal protection by software module is implemented to prevent from destruction of motor during overload condition.
Motor temperature is estimated by integrating squared motor current as an estimate for heating power integral. When
estimated motor temperature exceeds EEPROM programmable upper limit, motor is deactivated for fixed delay time
(default value = 30 sec.)
Thermal shutdown during a window operation will not interrupt the operation due to safety reasons.
(7) Operation time limiter
Maximal operation time of power window motor is limited to 15 sec (EEPROM programmable).
(8) Continuous reverse
Current Number of Continuous reverse of window is 5. With the below condition, this counter Will be initialized.
• IG OFF
• DOWN signal ON
• WINDOW CLOSE
2012 > D 2.0 TCID > Body Electrical System > Power Windows > Power Window Motor > Repair English
procedures
INSPECTION
Front Power Window Motor
1. Remove () negative battery terminal.
2. Remove the front door trim. (Refer to the BD groupfront door)
3. Disconnect the connector from the motor.
(A : Safety, B : Standard)
4. Connect the motor terminals directly to battery voltage (12V) and check that the motor operates smoothly. Next, reverse
the polarity and check that the motor operates smoothly in the reverse direction. If the operation is abnormal, replace the
motor.
Rear Power Window Motor
1. Remove () negative battery terminal.
2. Remove the rear door trim. (Refer to the BD grouprear door)
3. Disconnect the connector from the motor.
(A : Safety, B : Standard)
English
4. Connect the motor terminals directly to battery voltage (12V) and check that the motor operates smoothly. Next, reverse
the polarity and check that the motor operates smoothly in the reverse direction. If the operation is abnormal, replace the
motor.
2012 > D 2.0 TCID > Body Electrical System > Power Windows > Power Window Switch > Components
English
COMPONENTS
POWER WINDOW MAIN SWITCH
English
PASSENGER/REAR POWER WINDOW SWITCH
2012 > D 2.0 TCID > Body Electrical System > Power Windows > Power Window Switch > Repair English
procedures
INSPECTION
Power Window Main Switch Inspection
2. Remove the front door trim. (Refer to the BD group front door)
3. Disconnect the 16P connector from the switch.
[LHD]
[RHD]
4. Check for continuity between the terminals in each switch position according to the table. If the continuity condition is not
normal, replace the switch.
English
Passenger Power Window Switch Inspection
2. Remove the front door trim. (Refer to the BD group front door)
[Safety Window]
[Manual Power Window]
Rear Power Window Switch Inspection
2. Remove the rear door trim. (Refer to the BD group rear door)
[Safety Window]
[Manual Power Window]
2012 > D 2.0 TCID > Body Electrical System > Power Windows > Power Window Relay > Repair English
procedures
INSPECTION
(Refer to Body group "Crash pad")
5. There should be continuity between the No.2 in the I/PF and No.17 terminal in the I/PB when power and ground are
connected to the No.2 terminal in the I/PH and No.17 terminal in the I/PB.
6. There should be no continuity between the No.2 terminal in the I/PF and No.17 terminal in the I/PB when power is
disconnected.
2012 > D 2.0 TCID > Body Electrical System > Power Windows > Troubleshooting English
TROUBLESHOOTING
1. No windows operate from the main switch on the driver's door.
2. Driver's side window does not operate.
3. Passenger's side window does not operate.
English
2012 > D 2.0 TCID > Body Electrical System > Windshield Deicer > Components and Components
English
Location
COMPONENT LOCATION
2012 > D 2.0 TCID > Body Electrical System > Windshield Deicer > Description and Operation English
DESCRIPTION
Windshield deicer system prevent windshield wiper from freezing in the winter season. It consists of deicer in the lower part of
windshield, switch and relay. Body control module receives an input signal from the deicer switch, then controls relay.
Since the generator "L" is switched ON, if the deicer switch is ON, then deicer output is ON for 20 minutes.
2012 > D 2.0 TCID > Body Electrical System > Windshield Deicer > Windshield Deicer > Repair procedures
English
INSPECTION
1. Remove the cowl top cover.(Refer to the wiper)
2. Disconnect the windshield deicer connector (A) from the wiper motor linkage.
3. Check for continuity between the terminals of deicer lines.
4. Turn the ignition switch ON and the windshield deicer switch ON, then measure the voltage between the terminals of
harness side deicer connector.
O K : approx. Battery voltage (12V)
English
2012 > D 2.0 TCID > Body Electrical System > Windshield Deicer > Windshield Deicer Switch > Repair
English
procedures
INSPECTION
2. Remove the crash pad lower panel (A).
[LHD]
[RHD]
3. Disconnect deicer switch connectors.
[LHD]
[RHD]
English
4. Using an ohmmeter, inspect the continuity between the terminals.
[LHD]
[RHD]
2012 > D 2.0 TCID > Body Electrical System > Windshield Deicer > Windshield Deicer Relay > Repair
English
procedures
INSPECTION
2. Remove the ICM relay box to check the windshield deicer relay.
2012 > D 2.0 TCID > Body Electrical System > Rear Glass Defogger > Components and Components
English
Location
COMPONENT LOCATION
2012 > D 2.0 TCID > Body Electrical System > Rear Glass Defogger > Rear Glass Defogger Printed Heater
English
> Repair procedures
INSPECTION

Wrap tin foil around the end of the voltmeter test lead to prevent damaging the heater line. Apply finger pressure on the
tin foil, moving the tin foil along the grid line to check for open circuits.
1. Turn on the defogger switch and use a voltmeter to measure the voltage of each heater line at the glass center point. If a
voltage of approximately 6V is indicated by the voltmeter, the heater line of the rear window is considered satisfactory.
2. If a heater line is burned out between the center point and (+) terminal, the voltmeter will indicate 12V.
3. If a heater line is burned out between the center point and () terminal, the voltmeter will indicate 0V.
English
4. To check for open circuits, slowly move the test lead in the direction that the open circuit seems to exist. Try to find a point
where a voltage is generated or changes to 0V. The point where the voltage has changed is the opencircuit point.
5. Use an ohmmeter to measure the resistance of each heater line between a terminal and the center of a grid line, and
between the same terminal and the center of one adjacent heater line. The section with a broken heater line will have a
resistance twice as that in other sections. In the affected section, move the test lead to a position where the resistance
sharply changes.
Repair Of Broken Heater Line
Prepare the following items :
1. Conductive paint.
2. Paint thinner.
3. Masking tape.
4. Silicone remover.
5. Using a thin brush :
Wipe the glass adjacent to the broken heater line, clean with silicone remover and attach the masking tape as shown.
Shake the conductive paint container well, and apply three coats with a brush at intervals of about 15 minutes apart.
Remove the tape and allow sufficient time for drying before applying power. For a better finish, scrape away excess
deposits with a knife after the paint has completely dried. (Allow 24 hours).
2012 > D 2.0 TCID > Body Electrical System > Rear Glass Defogger > Rear Glass Defogger Switch >
English
Repair procedures
INSPECTION
2. Remove the center facia panel(A). Take care not to damage fixing clips.
(Refer to the BD group Crash pad)
3. Disconnect connectors.
4. Using an ohmmeter, inspect the continuity between the terminals after removing controller.
English
2012 > D 2.0 TCID > Body Electrical System > Windshield Wiper/Washer > Components and Components
English
Location
COMPONENT LOCATION
2012 > D 2.0 TCID > Body Electrical System > Windshield Wiper/Washer > Windshield WiperWasher
English
Switch > Components and Components Location
COMPONENT LOCATION
2012 > D 2.0 TCID > Body Electrical System > Windshield Wiper/Washer > Windshield WiperWasher
English
Switch > Repair procedures
REMOVAL
2. Remove the steering column upper(A) and lower (B) shrouds after loosening 3 screws.
[LHD]
[RHD]
3. Remove the wiper switch (A) after disconnecting the connector(B) with pushing the lock pin (C) and loosening 2 screws.
[LHD]
English
[RHD]
INSTALLATION
1. Install the windshield wiper switch.
2. Connect the wiper switch connector.
INSPECTION
1. Multifunction switch operates head lamps and wiper by communicating with BCM through LIN communication.
2. Check BCM input/output value of each position of multifunction switch when you inspect the module whether faulty or not.
3. Select model and BCM menu.
4. Select "Current data" and wiper.
5. Check input/output value of washer & wiper switch.
2012 > D 2.0 TCID > Body Electrical System > Windshield Wiper/Washer > Front Wiper Motor > Repair
English
procedures
REMOVAL
1. Remove the windshield wiper arm and blade after removing a nut (A).
2. Remove the weather strip and the cowl top cover (A) after removing 5 retainers.
3. Remove the windshield wiper motor and linkage assembly(A) after removing 2 bolts and 1 nut. Disconnect the wiper motor
connector (B) from the wiper motor & linkage assembly.
INSTALLATION
1. Install the wiper motor and linkage assembly and then connect the wiper motor connector.
TORQUE : 711Nm (0.71.1, kgf.m, 5.07.9 lbf.ft)
2. Install the cowl top cover.
3. Install the windshield wiper arm and blade. English
TORQUE : 28~33 Nm (2.8~3.3 kgf.m, 20~23.1 lbf.ft)
INSPECTION
Speed Operation Check
1. Remove the connector(A) from the wiper motor.
2. Attach the positive (+) lead from the battery to terminal 4 and the negative () lead to terminal 2.
3. Check that the motor operates at low speed.
4. Connect the positive (+) lead from the battery to terminal 5 and the negative () lead to terminal 2.
5. Check that the motor operates at high speed.
Automatic Stop Operation Check
1. Operate the motor at low speed using the stalk control.
2. Stop the motor operation anywhere except at the off position by disconnecting terminal 4.
3. Connect terminals 4 and 2.
5. Check that the motor stops running at the off position.
2012 > D 2.0 TCID > Body Electrical System > Windshield Wiper/Washer > Front Washer Motor > Repair
English
procedures
REMOVAL
2. Remove the front bumper cover. (Refer to Body group Front bumper)
3. Remove the washer hose and the washer motor connector (A) and level sensor connector(B).
4. Remove the washer reservoir (A) after removing 3 bolts.
INSTALLATION
1. Install the washer reservoir.
2. Install the washer motor and connect the washer hose, the motor and level sensor connector.
3. Install the front bumper cover.
INSPECTION English
1. With the washer motor connected to the reservoir tank, fill the reservoir tank with water.
2. Connect positive (+) battery cables to terminal 2 and negative () battery cables to terminal 1 respectively.
3. Check that the motor operates normally and the washer motor runs and water sprays from the front nozzles.
4. If they are abnormal, replace the washer motor (A).
Washer Fluid Level Sensor Switch
2. Drain the washer fluid less than 700 cc.
3. Check for continuity between the No. 1 and No.2 terminal in each float position.
There should be continuity when the float is down.
There should be no continity when the folat is up.
4. If the continuity is not as specified, replace the washer fluid level switch
2012 > D 2.0 TCID > Body Electrical System > Windshield Wiper/Washer > Rain Sensor > Schematic
English
Diagrams
CIRCUIT DIAGRAM
2012 > D 2.0 TCID > Body Electrical System > Windshield Wiper/Washer > Rain Sensor > Description and
English
Operation
DESCRIPTION
The Rain sensing windshield wiper system is a wiper system that, in addition to providing normal wiper functions off, mist, manual low
speed, manual high speed, and wash, provides automatic control of automatic intermittent, automatic low, and automatic high speeds.
When the ignition key is in the ON position, the rain sensor (A) will be activated.
OPERATING MODES RAINSENSING WINDSHIELD WIPER SYSTEM
MULTIFunction SWITCH RAINSENSOR
SENSOR ACTION
POSITION OPERATING MODE
Mist is controlled by the column switch. The sensor has no
MIST MIST
affect on this function
If not already parked, wiper motor runs in low speed until
OFF OFF
blades are in the depressed park position.
AUTOMATIC
AUTOMATIC
Automatic INT/speed control.
Automatic mode has 5 AUTOMATIC
The sensitvity to raindrop accumulation on the windshield is
SENSITIVITY settings.
set by the MULTIFunction SWITCH sensitivity adjustment.
Wiper motor runs continuously in low speed, for example 45
LOW SPEED MANUAL wipes/minute.
The sensor has no affect on this function
Wiper motor runs continuously in high speed, for example 60
HI SPEED MANUAL wipes/minute.
The sensor has no affect on this function
If washer sw on after 0.6 sec then wipes during 2.5 to 3.8 sec.
WASH DEMAND
WASH The rain sensor enables the wipers and controls the after
WASHER SW ≥ 0.6 SEC
wipes.
WASH DEMAND
WASH If washer sw on less than 0.2 to 0.6 sec then once wipes
WASHER SW < 0.6 SEC
Off Mode
With the wipe switch in the OFF position and the ignition switch in the ON positions, the Rainsensor is considered to be in "OFF" mode. In
this mode, the sensor commands the wiper to be off.
The Rainsensor monitors the state of the windshield during OFF mode so that knowledge of the state of the windshield is present when
the MULTIFunction SWITCH is moved to any SENSITIVITY setting. This optimizes the performance of the sensor when moving from the
OFF condition to an AUTOMATIC mode. The algorithm assumes the nominal sensitivity setting when in the OFF mode.
English
Automatic Mode
When the MULTIFunction SWITCH is moved to AUTO position and the ignition switch is in the RUN or ACCESSORY positions, the
Rainsensor is considered to be in "AUTOMATIC" mode. Once a single "Instant wipe" has occurred, the wipers remain at "Innerwiper/park"
untill the Rainsensor determines that the dwell time at that position is appropriate for the amount of precipitation on the windshield,
considering the driver input from the switch SENSITIVITY setting. After the dwell time the Rainsensor provides input to the wiper motor to
activate the wipers to clear the preciptation from the windshield.
Automatic Int
For all AUTOMATIC INT operations the Rainsensor commands the wipers to operate in LOW SPEED for one wipe, followed by a variable
dwell period in the inner wipe position.
Automatic Low
AUTOMATIC LOW SPEED operation is utilized when the amount of precipitation imping on the windshield exceeds the AUTOMATIC INT
TO AUTOMATIC LOW threshold. This threshold includes sufficient hysterisis to prevent cycling between AUTOMATIC INT and
AUTOMATIC LOW SPEED operation with a steady amount of precipitation accumulation on the windshield.
Automatic High
AUTOMATIC HIGH SPEED operation is utilized when the amount of precipitation imping on the windshield exceeds the AUTOMATIC
LOW to AUTOMATIC HIGH threshold. This threshold includes sufficient hysterisis to prevent cycling between AUTOMATIC LOW to
AUTOMATIC HIGH operation with a steady amount of precipitation accumulation on the windshield.
Wash Mode
The Rainsensor monitors the MULTIFunction SWITCH to determine if the wash Function is selected. Rainsensor enables the wiper motor
to run in low speed during the wash mode and performs follow up wipes during 2.5 to 3.8 sec.
Manual Mode
The Rainsensor determines when a manual mode such as manual low, Mist, Off or manual high is selected. The column switch performs
these modes and the rain sensor has no affect.
2012 > D 2.0 TCID > Body Electrical System > Windshield Wiper/Washer > Rain Sensor > Repair English
procedures
INSPECTION
Rain Sensing Wiper
1. In IGN2 ON state, if auto switch input (LIN communication) is ON then both wiper low relay and wiper high relay outputs are
controlled by the rain sensor input signal.
2. If the wiper switch has been left in automatic mode with the vehicle ignition OFF, and then the vehicle ignition switch is
turned on, a single wipe will be performed.
3. A single wipe will be performed whenever rain has been detected (Rain Detected signal from Rain sensor) and the wiper
switch is moved to the AUTO position. But a single wipe will not be performed when the wiper switch is moved to the
AUTO position and OFF signal is being received from Rain sensor. But if the wiper switch is moved to AUTO position for
the first time since vehicle ignition switch is turned on then a single wipe will be performed regardless of Rain Detected or
OFF signal.
4. The drive may adjust the rain sensor performance by adjusting the sensitivity input. When in automatic mode, the BCM will
perform a single wipe each time the sensitivity is adjusted upward to a more sensitive setting (downward more then one
step). This single wipe will only be performed if Rain Detected signal is being received from the Rain sensor. If the
sensitivity adjustment is adjusted upward more than one sensitivity, the BCM will only perform a single wipe unless the
time between Increases is more than 2 seconds.
English
5. Fault strategy for the rain sensor
Rain Sensor Fault 1 Internal Fault Detected
This failure is detected when the wiper is in automatic mode and the input faulty rain sensor from the rain sensor has a duty
cycle corresponding to Fault 1. The confirmation delay for the failure is of 1 sec.
When this failure is detected, the wiper outputs are OFF and the wiper will also do a wipe in slow speed on the transition
from sensitivity 3 to sensitivity 2 (Step 2 to 3) in order to signal the presence of this fault. If another sensitivity is set, the
wiper won’t make any additional wipe.
Rain Sensor Fault 2 Glass Attachment Fault Detected
cycle corresponding to Fault 2. The confirmation delay for the failure is of 1 s.
When this failure is detected, the wiper outputs are OFF and the wiper will also do a wipe on the transition from sensitivity 4
to sensitivity 3 (Step 1 to 2) in order to signal the presence of this fault. If another sensitivity is set, the wiper won’t make
any additional wipe.
Rain Sensor Fault 3 No Input Signal Present
cycle corresponding to Fault 3 or in case the duty cycle of the input faulty rain sensor is 0% or 100%. The confirmation
delay for the failure is of 1 s.
When this failure is detected, the wiper outputs are OFF.
REMOVAL

The dust or foreign substance on the rain sensor have a bad effect upon the rain sensor capability,so protect the sensor
surface with protection cover until installing the rain sensor to bracket for accurate funtion.
The coupling pad on the rain sensor surface has adherive strength, so the coupling pad could stick to the windshield by
environment condition during the using time.
If separate it by force, it could be damaged. So make sure to separate the rain sensor from the windshield carefully.
1. Remove the rain sensor cover(A) first. Be careful not to damage the cover latch by applying excessive force. To remove
the latch, pull aside the latch using the cover hole (B) with the little () screwdriver (C).
2. Remove the wiring harness connector (D) from sensor.
3. Rain sensor module is attached to the front windshield by glue replacing the front windshield, remove the rain sensor
module from the existing front windshield and install on the new front windshield.
INSTALLATION

• In case of the windshield with reflection layer which reflects the infrared rays in sensing field, should install the rain
sensor into the field removed the reflection layer.
• Install the rain sensor after some time and be care not to be settled the dust after installation.
1. Install the rainsensor bracket to the windshield glass using the tape.

It is very important that the coupling pad pushes the windshield completely to stick to each other without bubbles.
2. Connect the rainsensor connector, and then install the sensor cover.
2012 > D 2.0 TCID > Body Electrical System > Windshield Wiper/Washer > Troubleshooting English
TROUBLESHOOTING
1. Wiper low and wiper high do not work.
2. When washer switch is on, wiper does not work.
2012 > D 2.0 TCID > Body Electrical System > Rear Wiper/Washer > Components and Components
English
Location
COMPONENT LOCATION
2012 > D 2.0 TCID > Body Electrical System > Rear Wiper/Washer > Rear Wiper Motor > Repair procedures
English
REPLACEMENT
1. Detach the wiper cap (A), then remove the rear wiper arm (C) after removing a nut (B).
Tightening torque Nut(B) :
10~14 Nm (1.0~1.4 kgf.m, 7~10 lbf.ft)
2. Remove the rear wiper cap & pad (B) after removing a nut (A).
Tightening torque Nut (A) :
10~14 Nm (1.0~1.4 kgf.m, 7~10 lbf.ft)
3. Open the tailgate then remove the tailgate trim.
4. Disconnect the rear wiper motor connector then remove the rear wiper motor (A) after removing 2 bolts.
Tightening torque Nut :
10~14 Nm (1.0~1.4 kgf.m, 7~10 lbf.ft)
English
INSPECTION
Rear Wiper And Nozzel Setting
1. Set the rear washer nozzle on the specified spray position.
2. Set the rear wiper blade and to the lowest defogger heat line and tailgate glass.
Rear Wiper Motor
1. Remove the 4P connector from the rear wiper motor.
2. Connect battery positive (+) and negative () cables to terminals 4 and 1 respectively.
3. Check that the motor operates normally. Replace the motor if it operates abnormally.
(1. GND, 2. Switch, 3. Parking, 4. B+)
Automatic Stop Operation Check
1. Operate the motor at low speed using the stalk control.
2. Stop the motor operation anywhere except at the off position by disconnecting terminal 2.
3. Connect terminals 2 and 3.
5. Check that the motor stops running at the off position.
2012 > D 2.0 TCID > Body Electrical System > Rear Wiper/Washer > Rear Washer Switch > Repair English
procedures
INSPECTION
1. With the rear wiper & washer switch in each position, make sure that continuity exists between the terminals below. If
continuity is not as specified, replace the multifunction switch.
Rear Wiper & Washer Switch
2012 > D 2.0 TCID > Body Electrical System > Rear Wiper/Washer > Rear Washer Motor > Repair English
procedures
INSPECTION
1. With the washer motor connected to the reservoir tank, fill the reservoir tank with water.
2. Remove the front bumper cover. (Refer to the BD group Front bumper)
3. Connect positive (+) and negative () battery cables to terminals 3 and 1 respectively to see that the washer motor runs and
water is pumped.
4. Check that the motor operates normally.
Replace the motor if it operates abnormally.
2012 > D 2.0 TCID > Body Electrical System > Electro chromic Inside Rear View Mirror > Description and
English
Operation
DESCRIPTION
The ECM (Electro Chromic inside rear view Mirror) is for dimming the reflecting light from a vehicle behind at night, in order the user not
to be dazzled by the light. The front looking sensor detects brightness of the surroundings, while the rearward looking sensor the strength
of the reflecting light so that adjusts the reflexibility of the mirror in the range of 10~70%. But, when the reverse gear is engaged, it stops
functioning.
(1. IGN(12V), 2. Reverse gear signal, 3. GND)
1. The front looking sensor sees if the brightness of the surroundings is low enough for the mirror to operate its function.
2. The rearward looking sensor detects glaring of the reflecting light from a vehicle behind.
3. The ECM is darkened to the level as determined by the rearward looking sensor. When the glaring is no longer detected,
the mirror stops functioning.
(1. Status indicator LED, 2. Buttom, 3. Rear indicator, 4. Front light sensor, 5. Front light sensor)
English
AUTOMATICDIMMING FUNCTION
To protect your vision during nighttime driving, your mirror will automatically dim upon detecting glare from the vehicles traveling behind
you. The autodimming function can be controlled by the Dimming ON/OFF Button :
1. Pressing and holding the Feature Control button for more than 3 but less than 6 seconds turns the autodimming function
OFF which is indicated by the green Status Indicator LED turning off.
2. Pressing and holding the Feature Control button again for more than 3 but less than 6 seconds turns the autodimming
function ON which is indicated by the green Status Indicator LED turning on.

The mirror defaults to the "ON" position each time the vehicle is started.
2012 > D 2.0 TCID > Body Electrical System > Electro chromic Inside Rear View Mirror > Repair English
procedures
INSPECTION
Check it by the procedure below to see if the function of the ECM is normal.
1. Turn the ignition key to the "ON" position.
2. Cover the foreward looking sensor to stop functioning.
3. Head a light to the rearward looking sensor.
4. The ECM should be darkened as soon as the rearward looking sensor detects the light.

If this test is performed in daytime, the ECM may be darkened as soon as the foreward looking sensor is covered.
5. When the reverse gear is engaged, the ECM should not be darkened.
When heading lights to both the foreward looking and rearward looking sensors, the ECM should not be darkened.
REMOVAL
1. Disconnect the inside rear view mirror connector(A).
2. Remove the mirror wire cover(A.
3. Remove the inside rear view mirror pulling it upside carefully after loosening the mirror base mounting screw.
English
INSTALLATION
1. Install the inside rear view mirror.
2. Install the mirror wire cover.
3. Connect the inside rear view mirror connector.
2012 > D 2.0 TCID > Body Electrical System > Hands Free System > Components and Components
English
Location
COMPONENTS
1. Hands free call switch 4. Front right speaker
2. Mic 5. Audio head unit (hands free control)
3. Front left speaker
※ There is no hands free jack. This system supports Bluetooth(wireless system).
2012 > D 2.0 TCID > Body Electrical System > Hands Free System > Description and Operation English
FUNCTION
Bluetooth
You can use a Bluetooth device in your car to make a handsfree phone call or to stream music onto your incar speakers (via this Head
Unit). This Head Unit supports HFP, A2DP and AVRCP connection.
Advanced Audio Distribution Profile (A2DP)
This profile defines how high quality audio(stereo or mono) can be streamed from onedevice to another over a Bluetooth connection.For
example: music streamed from amobile phone to a wireless headset or caraudio.
Audio/Video Remote Control Profile (AVRCP)
This profile is designed to provide a standardinterface to control TVs, Hifi equipment,etc. to allow a single remote control (or
otherdevice) to control all of the A/V equipment towhich a user has access. It may be used inconcert with A2DP or VDP.
HandsFree Profile (HFP)
This is commonly used to allow car handsfreekits to communicate with mobile phonesin the car.
Notes for mobile phones
Some functions (e.g. starting of speech recognition) are not supported by all mobile phones. We cannot guarantee that all functions
described will be supported by all mobile phones with Bluetooth.
New device
This function allows you to add a new phone to the Head Units Bluetooth Device List. Maximum of 5 devices can be added to the list. If
the list is full, the oldest device will be replaced by the newly added Bluetooth device, based on last pairing date.
Pairing
To pair your Bluetoothenabled device to this Head Unit, make sure that no device is currently streaming to this Head Unit first.
– Short press the SETUP button to enter the Setup menu.
– Short press the ▼ or ▲ button to access the Bluetooth submenu.
– Now select “New Device”.
– Press the ▼ or ▲ button to select the number of the first digit.
– Press the < or > button to select the next digit.
– Repeat the above steps for the other three digits.
– Press the OK button to confirm the 4digit PIN for authentication and activate the “Discoverable Mode“.
– In “Discoverable Mode” the Head Unit broadcasts a Bluetooth ID.
– Look for the “KIABLUETOOTH“ on your Bluetooth device.
– Enter identically the same PIN in your Bluetooth device and authenticate pairing on your Bluetooth device.
– When pairing is established, the ID of the Bluetooth device and the service list info will be stored in the Head Unit
Bluetooth Device List.
Device List
With this function you can browse through and select bluetooth devices that are stored in the Head Unit Bluetooth Device List.
– Press the > button to browse the Device List to select the required device.
– Press the OK button to start pairing between the selected device and the Head Unit.
English
Whenever there is at least one connecteddevice active, in the display the Bluetooth icon is visible.
Delete Device
This function allows you to delete a Bluetooth device ID from the Head Unit Bluetooth Device List.
– Press the > button to select Delete Device.
– Press the OK button to delete the selected device from the Head Unit Bluetooth Device List.
Phone Volume
– Select the option “Phone Volume”.
– Press the < or > button to decrease or increase the phone volume setting.
Default setting: 12
Setting range: 3 ... 25
– During an ongoing call, user is allowed toadjust the BT Phone volume. The adjustedvolume is memorized into Phone
Volumesetting.
Answering a Call
– Press the Call button on the Steering Wheel Remote Control to accept an incoming call.
Terminate / Reject Call
– Press the End Call button on the Steering Wheel Remote Control to terminate or reject a call.
Last Call Redial
– Short press the Call button on the Steering Wheel Remote Control to redial last dialled number (one attempt).
– Long press the Call button on the Steering Wheel Remote Control to redial last dialled number (two attempts).
Private Call
This function allows you to have a private call even if the phone is connected to the Head Unit.
– Press the Call button on your phone to start a private call.
OR
– Press the End Call button on your phone to end a private call.
Transferring a Call
This function allows you to transfer a call during an ongoing call.
– From the tuner to the phone
– From the phone to the tuner
– Long press the Call button on the Steering Wheel Remote Control to transfer the ongoing call back to the phone or back to
the tuner again.
Audio Streaming
Start Audio Streaming
This function allows the Head Unit to start streaming music from phone.
– The Bluetooth device must be connected with the Head Unit.
– Press the AUX button and select BT AUDIO.
– The Head Unit starts streaming the audio from the phone and will start playing the audio files.
– The Head Unit has no control on the sequence of track playback in phone.
Next/Previous Track
This function allows you to select the next/ previous track of phone‘s music player by using the next/previous track buttons on the Head
Unit or Steering Wheel Remote Control.
– Short press the < or > button on the Head Unit or the Steering Wheel Remote Control.
Suspend Audio Streaming
This function allows you to suspend streaming music from the phone to the Head Unit.
– Short press the Mute button on the Steering Wheel Remote Control.
– Press the AUX button and deselect BT AUDIO.
2012 > D 2.0 TCID > Body Electrical System > Hands Free System > Hands Free Switch > Schematic
English
Diagrams
CIRCUIT DIAGRAM
English
2012 > D 2.0 TCID > Body Electrical System > Hands Free System > Hands Free Switch > Repair English
procedures
INSPECTION
1. Check the hands free remote control switch for resistance between No.3 and No.4 terminals in each switch position.
Connector Resistance
Switch
terminal (±5%)
SEND 4 5 (LH) 10.71 kΩ
END 4 5 (LH) 18.91 kΩ
REMOVAL
2. Remove the driver airbag module (A).
(Refer to the RT group)
3. Remove the steering wheel lower cover after loosening the 2 screws.
English
4. Remove the hands free remote control switch (A) after removing the steering wheel remote control switch connector (B) and
2 screws.
INSTALLATION
1. Reassemble the steering wheel remote control switch after connecting the connector.
2. Reassemble the steering wheel.
3. Reassemble the driver airbag module.

Make sure the hands free remote control switch and the airbag module connectors are plugged in properly.
2012 > D 2.0 TCID > Body Electrical System > Hands Free System > Hands Free Mic > Repair procedures
English
INSPECTION
2. Remove the roof trim (A).
(Refer to the BD group "Roof trim")
3. Remove the hands free mic (A) after loosening the connector and screw (3EA) from loof top.
4. Check the continuity of Mic between terminals.
2012 > D 2.0 TCID > Body Electrical System > Sun Roof > Components and Components Location
English
COMPONENT LOCATION
2012 > D 2.0 TCID > Body Electrical System > Sun Roof > Schematic Diagrams English
CIRCUIT DIAGRAM
2012 > D 2.0 TCID > Body Electrical System > Sun Roof > Sunroof Switch > Repair procedures English
INSPECTION
2. Open the sunglass case cover from the overhead console then remove the 2 screws holding the overhead console.
Disconnect the switch connector(B) and then remove the overhead console lamp (A).
3. Check for continuity between the terminals. If the continuity is not as specified, replace the sunroof switch.
2012 > D 2.0 TCID > Body Electrical System > Sun Roof > Sunroof Motor > Repair procedures English
REPLACEMENT
2. Remove the overhead console then remove the sun roof motor mounting screws (3EA). And then remove the sunroof motor
after disconnecting the connector (10 Pin).
3. Ground the terminals as below table, and check that the sunroof unit operates as below table.
4. Make these input tests at the connector
if any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, the sunroof motor must be faulty; replace it.
Terminal Test condition Test : Desired result
Check for voltage to ground :
3 IG2 ON
There should be battery voltage
Check for continuity to ground :
1 Under all conditions
There should be continuity.
Check for voltage to ground :
6 Under all conditions
There should be battery voltage.
Resetting The Sunroof
Whenever the vehicle battery is disconnected or discharged, or you use the emergency handle to operate the sunroof, you have to reset
your sunroof system as follows :
1. Turn the ignition key to the ON position.
2. According to the position of the sunroof, do as follows.
(1) In case that the sunroof has closed completely or been tilted :
Press the TILT button until the sunroof has tilted upward completely.
(2) In case that the sunroof has slideopened :
English
Press and hold the CLOSE button for more than 5 seconds until the sunroof has closed completely.
Press and hold the CLOSE button for more than 5 seconds after the sunroof has closed completely. Press the TILT
button until the sunroof has tilted upward completely.
3. Release the TILT button.
4. Press and hold the TILT button once again until the sunroof has returned to the original position of TILT after it is raised a
little higher than the maximum TILT position.
When this is complete, the sunroof system is reset.
Protecting Motor From Overheating
In order to protect the sunroof motor from overheating from continuous motor operation, the sunroof ECU controls the Runtime and Cool
time of the motor as follows:
1. The Sunroof ECU detects the Run time of motor
2. Motor can be operated continuously for the 1st runtime(120 ± 10sec.).
3. The continuous operation of motor stops after the 1st Runtime(120 ± 10sec.).
4. Then Motor is not operated for the 1st Cooltime(18 ± 2sec.).
5. Motor is operated for the 2nd Runtime(10 ± 2sec.) at the continued motor operation after 1st Cooltime(18 ± 2sec.)
6. The continuous operation of motor stops operating after the 2nd Runtime(10 ± 2sec.)
7. Motor is not operated for the 2nd Cooltime(18 ± 2sec.).
8. Motor repeats the 2nd runtime and 2nd cooltime at the continued motor operation.
– In case that motor is not operated continuously, the runtime is increased.
– The RunTime of motor is initialized to "0" if the battery or fuse is reconnected after being disconnected, discharged or
blown.
T1 : 120 ± 10 sec., T2 : 18 ± 2 sec.,
T3 : 10 ± 2 sec., T4 : 18 ± 2 sec.
2012 > D 2.0 TCID > Body Electrical System > Lighting System > Specifications English
SPECIFICATION
Items Bulb Wattage (W)
Head lamp (High) 55
Head lamp (Low) 55
Front turn signal lamp 21
Front fog lamp 27
Rear stop/tail lamp (Outside) 21/5
Back up lamp 16
Rear turn signal lamp 21
Rear fog lamp Europe 21
License plate lamp 5
Side repeater 5
Room lamp 8
Overhead console lamp 10
High mounted stop lamp 1.6
Glove box lamp 5
Map lamp 10
2012 > D 2.0 TCID > Body Electrical System > Lighting System > Components and Components Location
English
COMPONENT LOCATION
1. Head lamp (Low) 10. Rear turn signal lamp
2. Head lamp (High) 11. Back up lamp
3. Position lamp 12. License plate lamp
4. Front fog lamp 13. Engine room junction box
5. Front turn signal lamp (Head lamp Low/High, Fog lamp relay)
6. Side repeater 14. Passinger compartment junction box (Tail lamp relay)
7. Over head lamp 15. ICM relay box (Hazard relay)
8. Room lamp(Center) 16. Vanity lamp
9. Tail/Stop lamp 17. Lugguage room lamp
18. Rear fog lamp & Rear reflector
2012 > D 2.0 TCID > Body Electrical System > Lighting System > Head Lamps > Repair procedures
English
INSPECTION
Head Lamp Relay / Front Lamp Relay
2. Pull out the relay from the engine compartment relay box.
A : Head lamp(Low) relay
B : Head lamp (High) relay
3. Check for continuity between terminals. There should be continuity between the No.87 and No.30 terminals when power and
ground are connected to the No.86 and No.85 terminals.
Tail Lamp
English
(1) There should be continuity between the No.2 terminal in the I/PH and the No.15(LH) or 4(RH) terminal in the I/PG
when power and ground are connected to the No.2 terminal in the I/PH and the No.6 terminal in the I/PD.
(2) There should be no continuity between the No.2 terminal in the I/PH and the No.15(LH) or 4(RH) terminal in the I/PG
when power and ground are connected to the No.2 terminal in the I/PH and the No.6 terminal in the I/PD.
Head Lamp Escort
1. If Head Lamp is lighting by Head Lamp SW or AUTOLIGHT, Head Lamp lighting is maintained when IGN1 is changed ON to
OFF.
2. Following stste, Head Lamp lighting is truned off.
But, TAIL LAMP keep up lighting when KEY IN in the condition of lighting off after IGN ON→OFF and lighting.
(the condition of TAIL LAMP lighting off follows TAIL LAMP AUTOCUT function.)
• When Driver DOOR SW OPEN→CLOSE and after 30sec.
• When Head Lamp SW ON or not the case of AUTO LIGHT SW ON.
(ALC ; When Head Lamp ON, Head Lamp SW ON within Multifunction SW during ESCORT → Lighting keeping up
when SW is moned to AUTO LIGHT SW ON or reverse.)
• When Driver DOOR OPEN state is maintained after 5minute.
• When IGN1 ON→IGN OFF and sfter 5minute.
• When received TX LOCK signal two times during output.

– Head Lamp RELAY output of TIMING CHART contains the condition of TAIL LAMP ON.
– Head Lamp RELAY output by Head Lamp SW and HEAD LAMP RELAY output by AUTO LIGHT is regarded
identical condition.
That is, the explaining of HEAD LAMP RELAY ouput contains two cases.
– AUTO LIGHT SW ON : HEAD LAMP&TAIL LAMP signal by AUTO LIGHT is output.
– AUTO LIGHT SW OFF: HEAD LAMP&TAIL LAMP signal by AUTO LIGHT is not output.
ADJUSTMENT
Head Lamp Aiming Instructions
The head lamps should be aimed with the proper beamsetting equipment, and in accordance with the equipment manufacturer's
instructions.

If there are any regulations pertinent to the aiming of head lamps in the area where the vehicle is to be used, adjust so as
to meet those requirements.
Alternately turn the adjusting gear to adjust the head lamp aiming. If beamsetting equipment is not available, proceed as follows :
1. Inflate the tires to the specified pressure and remove any loads from the vehicle except the driver, spare tire, and tools.
2. The vehicle should be placed on a flat floor.
3. Draw vertical lines (Vertical lines passing through respective head lamp centers) and a horizontal line (Horizontal line
passing through center of head lamps) on the screen.
4. With the head lamp and battery in normal condition, aim the head lamps so the brightest portion falls on the horizontal and
vertical lines.
Make vertical (A) and horizontal (B) adjustments to the lower beam using the adjusting wheel.
Front Fog Lamp Aiming
The front fog lamps should be aimed as the same manner of the head lamps aiming.
With the front fog lamps and battery normal condition, aim the front fog lamps by turning the adjusting gear (A).
[3Door]
[5Door/Wagon]
Head Lamp And Fog Lamp Aiming Point
1. Turn the low beam on with driver.
The cutoff line should be projected in the allowable range.
In case of equipping with the manual leveling device, set the leveling device switch on the "O" position.
In case of equipping with the auto leveling device, set the initialization by using the diagnostic tool before aiming.
2. Turn the front fog lamp on with driver.
The cutoff line should be projected in the allowable range
REMOVAL
2. Loosen the mounting bolts (3EA) of head lamp. Remove the head lamp assembly (A) after disconnecting the lamp
connectors.

Take care that retaining clip (A) is not to be damaged.
3. Remove the bulb caps from the head lamp assembly.
A : Head lamp high bulb & position bulb cab
B : Head lamp low bulb cab
C : Turn signal bulb cab
4. Remove the head lamp bulbs.
INSTALLATION
1. Install the head lamp bulbs.
2. Install the head lamp bulb caps.
3. Install the head lamp assembly after connecting the lamp connector.
2012 > D 2.0 TCID > Body Electrical System > Lighting System > Turn Signal Lamp > Repair procedures
English
REMOVAL
2. Remove the mirror (A) from mirror holder.
3. Remove the turn signal lamp fixing screw (A).
4. Remove the door mirror cover (A).
5. Remove the bulb and lens (A) from door mirror.
English
6. Remove the lens (A).
7. Replace the bulb (A).
INSTALLATION
1. Install the bulb and lens.
2. Install the door mirror cover.
3. Install the door mirror.
4. Connect the negative () battery terminal.
2012 > D 2.0 TCID > Body Electrical System > Lighting System > Room Lamp > Repair procedures
English
REMOVAL
2. Detach the lamp lens (A) from the room lamp with a flattip screwdriver then remove the bulb (B).
3. Loosen the fixing screw (2EA) and disconnect the 3P connector (C). And then remove the room lamp assembly.
INSTALLATION
1. Install the room lamp assembly after connecting the lamp connector.
2. Install the lamp lens after assembling the bulb.
INSPECTION
1. Remove the room lamp assembly then check for continuity between terminals.
2012 > D 2.0 TCID > Body Electrical System > Lighting System > Overhead Console Lamp > Repair
English
procedures
REMOVAL
2. Remove the overhead console lamp (A) after loosening the overhead console lamp screw (2EA).
3. Disconnect the sunroof switch and lamp connector (B) and then remove the overhead console (A) lamp (C).
INSTALLATION
1. Install the overhead console lamp after connecting the sunroof switch and lamp connector.
2. Install the lens after tightening 2 screws.
INSPECTION English
Remove the overhead console lamp assembly then check for continuity between terminals. If the continuity is not as specified, replace
the map lamp switch.
2012 > D 2.0 TCID > Body Electrical System > Lighting System > Hazard Lamp Switch > Repair English
procedures
INSPECTION
Hazard Lamp Switch
2. Remove the center facia panel (A).
3. Disconnect the hazard lamp switch conector.
4. Operate the switch and check for continuity between terminals with an ohmmeter.
2012 > D 2.0 TCID > Body Electrical System > Lighting System > Rheostat > Repair procedures English
INSPECTION
2. Remove the lower side crash pad switch assembly (A) by using the trim remover tool.
[LHD]
[RHD]
3. Disconnect the rheostat switch connector (A).
[LHD]
[RHD]
English
4. Check for intensity of new rheostat switch. If the light intensity of the lamps changes smoothly without any flickering when
the rheostat is turned, it can be assumed that the rheostat is normal.
2012 > D 2.0 TCID > Body Electrical System > Lighting System > Front Fog Lamps > Repair procedures
English
REMOVAL
2. Remove the front side cover screw.
3. Remove the front fog lamp assembly connector.
4. Remove the front fog lamp bulb (A).
[3Door]
[5Door/Wagon]
INSTALLATION
1. Install the front fog lamp bulb.
2. Connect the front fog lamp connector.
3. Install the front side cover.
INSPECTION
Front Fog Lamp Relay
2. Pull out the front fog lamp relay (A) from the engine compartment relay box.
3. Check for continuity between terminals. There should be continuity between the No.87 and No.30 terminals when power and
English
ground are connected to the No.85 and No.86 terminals.
2012 > D 2.0 TCID > Body Electrical System > Lighting System > Rear Fog Lamps > Repair procedures
English
REMOVAL
2. Remove the rear bumper.
(Refer to the BD group "Rear Bumper")
3. Remove the rear lamp (A) after loosening the cap.
4. Remove the rear lamp assembly after loosening the screws (4EA).
INSTALLATION
1. Install the rear lamp assembly.
2. Install the rear lamp
3. Install the rear bumper.
2012 > D 2.0 TCID > Body Electrical System > Lighting System > License Lamps > Repair procedures
English
REMOVAL
Licence Lamp
2. Remove the license lamp lens (A) from the panel after loosening a screw (2EA).
3. Replace the bulb (A).
Tailgate Room Lamp
2. Remove the tailgate room lamp len(A) from the luggage side trim.
3. Remove the bulb (A).
English
INSTALLATION
Licence Lamp
1. Install the bulb.
2. Install the license lamp lens.
Tailgate Room Lamp
1. Install the bulb.
2. Install the tailgate room lamp len.
2012 > D 2.0 TCID > Body Electrical System > Lighting System > Personal Lamp > Repair procedures
English
REMOVAL
2. Remove the vanity lamp lens (A) and then remove the bulb.
3. Remove the sunvisor (A) after loosening the screws (2EA).
4. Disconnect the sunvisor connector (A).
1. Install the vanity bulb.
2. Istall the vanity lamp lens.
3. Install the sunvisor assembly.
INSPECTION
Bulb
1. Disconnect the vanity lamp connector and check for continuity between terminals.
Sunvisor
1. Remove the sunvisor assembly and check for continuity between terminals. If the continuity is not as specified, replace the
vanity lamp or sunvisor.
(1) Condition A
– Power ON : When mirror frame in the sunvisor is opened over 1.97in(50mm)
(2) Condition B
– Lighting ON : When sunvisor is positioned within the vertical angle ±50° range.
2012 > D 2.0 TCID > Body Electrical System > Lighting System > Rear combination lamp > RepairEnglish
procedures
REMOVAL
[5Door]
2. Loose the nut (3EA) holding the rear combination lamp then disconnect the 4P connector (A) then remove the outside rear
combination lamp.
3. Replace the bulbs (3EA) turning in the counter clockwise direction after disconnecting the rear combination lamp assembly.
[3 Door]
2. Remove the trim cover (A).
3. Loose the nuts (3EA) holding the rear combination lamp then remove the rear combination lamp (A).
English
4. Replace the bulbs (3EA) (A) turning in the counter clockwise direction after disconnecting the rear combination lamp
assembly.
[Wagon]
2. Remove the screws (5EA).
3. Remove the rear combination upper lamp (A).

Be careful not to damage the fixing hook.
4. Remove the rear combination lower lamp (A).
5. Replace the bulbs (3EA) turning in the counter clockwise direction after disconnecting the rear combination lamp assembly.
INSTALLATION
1. Install the rear combination lamp assembly after assembling the bulb and connector.
2012 > D 2.0 TCID > Body Electrical System > Lighting System > Troubleshooting English
TROUBLESHOOTING
One lamp does not light Bulb burned out Replace bulb

(all exterior) Socket, wiring or ground faulty Repair if necessary
Head lamps do not light Bulb burned out Replace bulb
Head lamp fuse (LOW:10A, HIGH:20A)
Check for short and replace fuse
blown
Head lamp fuse (10A) blown Check for short and replace fuse
Head lamp relay faulty Check relay
Lighting switch faulty Check switch
Tail lamps and license plate lamps do Bulb burned out Replace bulb
not light
Tail lamp fuse (10A) blown Check for short and replace fuse
Tail lamp relay faulty Check relay
Lighting switch faulty Check switch
Stop lamps do not light Bulb burned out Replace bulb
Stop lamp fuse (15A) blown Check for short and replace fuse
Stop lamp switch faulty Adjust or replace switch
Stop lamps do not turn off Stop lamp switch faulty Repair or replace switch
Instrument lamps do not light Rheostat faulty Check rheostat

(Tail lamps light) Wiring or ground faulty Repair if necessary
Turn signal lamp does not flash on one
Turn signal switch faulty Check switch
side
Turn signal lamps do not light Bulb burned out Replace bulb
Turn signal lamp fuse (10A) blown Check for short and replace fuse
Flasher unit faulty Check flasher unit
Turn signal switch faulty Check switch
Hazard warning lamps do not light Bulb burned out Replace bulb
Hazard warning lamp fuse (15A) blown Check for short and replace fuse
Hazard switch faulty Check switch
Flasher rate too slow or too fast Lamps' wattages are smaller or larger
Replace lamps
than specified
English
Back up lamps do not light Bulb burned out Replace bulb
Back up lamp fuse (10A) blown Check for short and replace fuse
Back up lamp switch (M/T) faulty Check switch
Transaxle range switch (A/T) faulty Check switch
Room lamp does not light Bulb burned out Replace bulb
Room lamp fuse (15A) blown Check for short and replace fuse
Room lamp switch faulty Check switch
Front fog lamps do not light Bulb burned out Replace bulb
Front fog lamp fuse (15A) blown Check for short and replace fuse
Front fog lamp relay faulty Check relay
Front fog lamp switch faulty Check switch
Rear fog lamps do not light Bulb burned out Replace bulb
Rear fog lamp fuse (10A) blown Check for short and replace fuse
Rear fog lamp fuse (10A) blown Check for short and replace fuse
Rear fog lamp switch faulty Check switch
Rear fog lamp relay faulty Check relay
Room lamp does not light Bulb burned out Replace bulb
Map lamp switch faulty Check switch
Tailgate room lamp does not light Bulb burned out Replace bulb
Tailgate room lamp switch faulty Check switch
2012 > D 2.0 TCID > Body Electrical System > Auto Lighting Control System > Specifications English
SPECIFICATIONS
Item Specifications
Rated voltage 5V
Auto light Max. 2.62mA ± 10%
Operating current
Solar Max. 0.88mA ± 10%
ON 4.33V
Signal output Head lamp & Tail lamp
OFF 3.23V
2012 > D 2.0 TCID > Body Electrical System > Auto Lighting Control System > Components and English
Components Location
COMPONENT LOCATION
2012 > D 2.0 TCID > Body Electrical System > Auto Lighting Control System > Schematic Diagrams
English
CIRCUIT DIAGRAM
2012 > D 2.0 TCID > Body Electrical System > Auto Lighting Control System > Description and Operation
English
DESCRIPTION
The auto light control system operates by using the auto light switch.
If you set the multifunction switch to "AUTO" position, the tail lamp and head lamp will be turned automatically on or off according to
external illumination.
2012 > D 2.0 TCID > Body Electrical System > Auto Lighting Control System > Auto Light Switch > Repair
English
procedures
INSPECTION
If continuity is not as specified, replace the multifunction switch
[LHD]
[RHD]
Lighting Switch (Auto Light)
2012 > D 2.0 TCID > Body Electrical System > Auto Lighting Control System > Auto Light Sensor > Repair
English
procedures
INSPECTION
1. AUTO LIGHT SENSOR value is always read at IGN1 ON.
2. LIGHT is turned ON after 2sec±0.2sec when AUTO LIGHT SENSOR value is same as LIGHT ON input value.
3. LIGHT is turned OFF after 2sec±0.2sec when AUTO LIGHT SENSOR value is same as LIGHT OFF input value.
4. LIGHT ON value of SENSOR is based on the below table.
5. Head Lamp signal is output when Head Lamp OUTPUT is ON.
6. After Head Lamp is turned OFF, Head Lamp signal output is kept if Head Lamp&Tail Lamp ON.
7. After Head Lamp is turned OFF, Head Lamp signal output is immediately stopped if HEAD LAMP&Tail Lamp OFF
8. After Head Lamp is turned OFF, Head Lamp signal output is immediately stopped at TAIL SW signal input.
9. After Head Lamp is turned OFF, Head Lamp signal output is stopped if there is no input of Auto Light SW or TAIL SW.
(shall be no flashing of Head Lamp)
10. Head Lamp signal output is stopped when SW position is changed from AUTO to Head Lamp SW during Head Lamp ON
with Auto Light. (shall be no flashing of Head Lamp)
Light Sensor Reading
Head lamp & Tail lamp
ON 4.33V
OFF 3.23V
T1 : 2.5 ± 0.25sec.
REPLACEMENT
2. Remove the Photo & auto light sensor (A) using screw () driver.
English
3. Remove the auto light connector.
2012 > D 2.0 TCID > Body Electrical System > Daytime Running Lights > DRL Control Module > Repair
English
procedures
INSPECTION
1. The daytime running unit (A) is integrated in the I/P Junction box.
2. Check that the light operate according to the following timing chart.
(1) Operation condition
a. DRL ON
– ALT L signal and IGN2 signal input
b. DRL operation
– The head lamp low beam and tail lamp ON.
c. DRL OFF
– Tail lamp SW ON.
3. If the daytime running light is not operated well, Inspect the connector and terminals to be sure they are all making good
contact.
If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system.
If the terminals look OK, go to step 4.
4. Make these input tests at the connector by using ETM.
If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, the I/P (Instrument panel) junction box must be faulty; replace it.
2012 > D 2.0 TCID > Body Electrical System > Head lamp leveling Device > Components and Components
English
Location
COMPONENT LOCATION
2012 > D 2.0 TCID > Body Electrical System > Head lamp leveling Device > Schematic Diagrams English
CIRCUIT DIAGRAM
2012 > D 2.0 TCID > Body Electrical System > Head lamp leveling Device > Head lamp leveling Actuator >
English
Repair procedures
REMOVAL
2. Remove the head lamp assembly (Refer to the head lamp).
3. Remove the head lamp leveling actuator (A) by turning the adjusting gear in the hole(B) using the adjusting wheel or screw
driver.
INSTALLATION
1. Install the head lamp leveling actuator by turning the adjusting gear.
2. Install the head lamp assembly.
3. Adjust the head lamp in accordance with the head lamp aiming instructions.
2012 > D 2.0 TCID > Body Electrical System > Head lamp leveling Device > Head Lamp Leveling Switch >
English
Repair procedures
INSPECTION
2. Remove the side crash pad cover.
3. Remove the lower side crash pad switch (A) from the side crash pad cover by using the trim removal tool.
[LHD]
[RHD]
4. Remove the head lamp leveling switch connector from the lower crash pad switch.
[LHD]
English
[RHD]
5. Connect the battery voltage between terminals 3 and 4.
6. Measure the voltage between terminals 4 and 5 at each position.
Position No. Rotation Voltage (V) (±5%)

0 0° 11.55
1 20° 9.21
2 40° 7.52
3 60° 6.63
7. If the voltage is not as specified, replace the head lamp leveling switch.
2012 > D 2.0 TCID > Body Electrical System > Immobilizer System > Schematic Diagrams English
CIRCUIT DIAGRAM
2012 > D 2.0 TCID > Body Electrical System > Immobilizer System > Description and Operation English
DESCRIPTION
The immobilizer system will disable the vehicle unless the proper ignition key is used, in addition to the currently available antitheft
systems such as car alarms, the immobilizer system aims to drastically reduce the rate of auto theft.
1. Encrypted SMARTRA type immobilizer
– The SMARTRA system consists of a passivie challenge response (mutual authentication)transponder located in the
ignition key, an antenna coil, a encoded SMARTRA unit, an indicator light and the PCM(ECM).
– The SMARTRA communicates to the PCM(ECM) (Engine Control Module) via a dedicated communications line. Since
the vehicle engine management system is able to control engine mobilization, it is the most suitable unit to control the
SMARTRA.
– When the key is inserted in the ignition and turned to the ON position, the antenna coil sends power to the transponder
in the ignition key. The transponder then sends a coded signal back through the SMARTRA unit to the PCM(ECM).
– If the proper key has been used, the PCM(ECM) will energize the fuel supply system. The immobilizer indicator light
in the cluster will simultaneously come on for more than five seconds, indicating that the SMARTRA unit has
recognized the code sent by the transponder.
– If the wrong key has been used and the code was not received or recognized by the PCM(ECM) the indicator light will
continue blinking for about five seconds until the ignition switch is turned OFF.
– If it is necessary to rewrite the PCM(ECM) to learn a new key, the dealer needs the customer's vehicle, all its keys
and the Hiscan (pro) equipped with an immobilizer program card. Any key that is not learned during rewriting will no
longer start the engine.
– The immobilizer system can store up to eight key codes.
– If the customer has lost his key, and cannot start the engine, contact Hyundai motor service station.
COMPONENTS OPERATIONS
PCM (Power Train Control Module)
1. The PCM(ECM) (A) carries out a check of the ignition key using a special encryption algorithm, which is programmed into
the transponder as well as the PCM(ECM) simultaneously. Only if the results are equal, the engine can be started. The
data of all transponders, which are valid for the vehicle, are stored in the PCM(ECM).
ERN (Encrypted Randorn Number) value between EMS and encrypted smartra unit is checked and the validity of coded
key is decided by EMS.
English
Encrypted SMARTRA unit (A)
The SMARTRA carries out communication with the builtin transponder in the ignition key. This wireless communication runs on RF
(Radio frequency of 125 kHz). The SMARTRA is mounted behind of the crash pad close to center cross bar.
The RF signal from the transponder, received by the antenna coil, is converted into messages for serial communication by the SMARTRA
device. And, the received messages from the PCM(ECM) are converted into an RF signal, which is transmitted to the transponder by the
antenna.
The SMARTRA does not carry out the validity check of the transponder or the calculation of encryption algorithm. This device is only an
advanced interface, which converts the RF data flow of the transponder into serial communication to the PCM(ECM) and vice versa.
Transponder (Builtin keys)
The transponder (A) has an advanced encryption algorithm. During the key teaching procedure, the transponder will be programmed
with vehicle specific data. The vehicle specific data are written into the transponder memory. The write procedure is once only; therefore,
the contents of the transponder can never be modified or changed.
Antenna coil
The antenna coil (A) has the following functions.
– The antenna coil supplies energy to the transponder.
– The antenna coil receives signal from the transponder.
– The antenna coil sends transponder signal to the SMARTRA.
It is located directly in front of the steering handle lock.
2012 > D 2.0 TCID > Body Electrical System > Immobilizer System > Repair procedures English
TEACHING PROCEDURES
1. Key Teaching Procedure
Key teaching must be done after replacing a defective PCM(ECM) or when providing additional keys to the vehicle owner.
The procedure starts with an PCM(ECM) request for vehicle specific data (PIN code: 6digits) from the tester. The "virgin"
PCM(ECM) stores the vehicle specific data and the key teaching can be started. The "learnt" PCM(ECM) compares the
vehicle specific data from the tester with the stored data. If the data are correct, the teaching can proceed.
If incorrect vehicle specific data have been sent to the PCM(ECM) three times, the PCM(ECM) will reject the request of
key teaching for one hour. This time cannot be reduced by disconnecting the battery or any other manipulation. After
reconnecting the battery, the timer starts again for one hour.
The key teaching is done by ignition on with the key and additional tester commands. The PCM(ECM) stores the relevant
data in the EEPROM and in the transponder. Then the PCM(ECM) runs the authentication required for confirmation of the
teaching process. The successful programming is then confirmed by a message to the tester.
If the key is already known to the PCM(ECM) from a previous teaching, the authentication will be accepted and the
EEPROM data are updated. There is no changed transponder content (this is impossible for a learnt transponder).
The attempt to repeatedly teach a key, which has been taught already during the same teaching cycle, is recognized by the
PCM(ECM). This rejects the key and a message is sent to the tester.
The PCM(ECM) rejects invalid keys, which are presented for teaching. A message is sent to the tester. The key can be
invalid due to faults in the transponder or other reasons, which result from unsuccessful programming of data. If the
PCM(ECM) detects different authenticators of a transponder and an PCM(ECM), the key is considered to be invalid.
The maximum number of taught keys is 8
If an error occurs during the Immobilizer Service Menu, the PCM(ECM) status remains unchanged and a specific fault code
is stored.
If the PCM(ECM) status and the key status do not match for teaching of keys, the tester procedure will be stopped and a
specific fault code will be stored at PCM(ECM).

When teaching the 1st key, Smartra regists at the same time.
English
(1) PCM(ECM) learnt status.
(2) PCM(ECM) virgin status.
After replacing new "PCM(ECM)" scantool displays that PCM(ECM) is virgin status in Key Teaching mode.
"VIRGIN" status means that PCM(ECM) has not matched any PIN code before.
2. User Password Teaching Procedure
The user password for limp home is taught at the service station. The owner of the vehicle can select a number with four
digits.
User password teaching is only accepted by a "learnt" PCM(ECM). Before first teaching of user password to an
PCM(ECM), the status of the password is "virgin" No limp home function is possible.
The teaching is started by ignition on, with a valid key and sending the user password by tester. After successful teaching,
the status of the user password changes from "virgin" to "learnt"
The learnt user password can also be changed. This can be done if the user password status is "learnt" and the tester
sends authorization of access, either the old user password or the vehicle specific data. After correct authorization, the
PCM(ECM) requests the new user password. The status remains "learnt" and the new user password will be valid for the
next limp home mode.
If incorrect user passwords or wrong vehicle specific data have been sent to the PCM(ECM) three times, the PCM(ECM)
will reject the request to change the password for one hour. This time cannot be reduced by disconnecting the battery or
any other actions. After reconnecting the battery, the timer starts again for one hour.
(1) User password teaching
※ In case of putting wrong password, retry from first step after 10 seconds.
(2) User password changing
LIMP HOME FUNCTION
1. LIMP HOME BY TESTER
If the PCM(ECM) detects the fault of the SMARTRA or transponder, the PCM(ECM) will allow limp home function of the
immobilizer. Limp home is only possible if the user password (4 digits) has been given to the PCM(ECM) before. This
password can be selected by the vehicle owner and is programmed at the service station.
The user password can be sent to the PCM(ECM) via the special tester menu.
Only if the PCM(ECM) is in status "learnt" and the user password status is "learnt" and the user password is correct, the
PCM(ECM) will be unlocked for a period of time (30 sec.). The engine can only be started during this time. After the time
has elapsed, engine start is not possible.
If the wrong user password is sent, the PCM(ECM) will reject the request of limp home for one hour. Disconnecting the
battery or any other action cannot reduce this time. After connecting the battery to the PCM(ECM), the timer starts again
for one hour.
2. LIMP HOME BY IGNITION KEY
The limp home can be activated also by the ignition key. The user password can be input to the PCM(ECM) by a special
sequence of ignition on/off.
Only if the PCM(ECM) is in status "learnt" and the user password status is "learnt" and the user password is correct, the
PCM(ECM) will be unlocked for a period of time (30 sec.). The engine can be started during this time. After the time has
elapsed, engine start is not possible. After a new password has been input, the timer (30 sec.) will start again.
After ignition off, the PCM(ECM) is locked if the timer has elapsed 8 seconds. For the next start, the input of the user
password is requested again.
REPLACEMENT
Problems And Replacement Parts:
Problem Part set Scan tool required?
All keys have been lost Blank key (4) YES
Antenna coil unit does not work Antenna coil unit NO
ECM does not work PCM(ECM) YES
Ignition switch does not work Ignition switch with Antenna coil unit YES
Unidentified vehicle specific data occurs Key, PCM(ECM) YES
SMARTRA unit does not work SMARTRA unit YES
Replacement Of Ecm And Smartra
In case of a defective ECM, the unit has to be replaced with a "virgin" or "neutral" ECM. All keys have to be taught to the new ECM. Keys,
which are not taught to the ECM, are invalid for the new ECM (Refer to key teaching procedure). The vehicle specific data have to be left
unchanged due to the unique programming of transponder.
In case of a defective SMARTRA, it needs teaching the smartra. A new SMARTRA device replaces the old one and smartra need
teaching. There are no transponderrelated data stored in this device.
1. Things to remember before a replacement (PCM(ECM))
2. Things to remember before a replacement (Keys & Additional registration)

1) When there is only one key registered and you wish to register another key, you need to reregister the key
which was already registered.
2) When the key #1 is registered and master key #2 is not registered, Put the key #1 in the IG/ON or the start
position and remove it. The engine can be started with the unregistered key #2.
(Note that key #2 must be used within 10 seconds of removing key #1)
3) When the key #1 is registered and key #2 is not registered, put the unregistered master key #2 in the IG/ON or
the start position.
The engine cannot be started even with the registered key #1.
4) When you inspect the immobilizer system, refer to the above paragraphs 1, 2 and 3.
Always remember the 10 seconds zone.
5) If the pin code & password are entered incorrectly on three consecutive inputs, the system will be locked for one
hour.
6) Be cautious not to overlap the transponder areas.
7) Problems can occur at key registration or vehicle starting if the transponders should overlap.
Neutralising Of ECM
The PCM(ECM) can be set to the "neutral" status by a tester.
A valid ignition key is inserted and after ignition on is recorded, the PCM(ECM) requests the vehicle specific data from the tester. The
communication messages are described at "Neutral Mode" After successfully receiving the data, the PCM(ECM) is neutralized.
The ECM remains locked. Neither the limp home mode nor the "twice ignition on" function, is accepted by the PCM(ECM).
The teaching of keys follows the procedure described for the virgin PCM(ECM). The vehicle specific data have to be unchanged due to
the unique programming of the transponder. If data should be changed, new keys with a virgin transponder are requested.
This function is for neutralizing the PCM(ECM) and Key. Ex) when lost key, Neutralize the PCM(ECM) then teach keys.(Refer to the
Things to do when Key & PIN Code the PCM(ECM) can be set to the "neutral" status by a scanner.If wrong vehicle specific data have
been sent to SMATRA three times continuously or intermittently, the SMATRA will reject the request to enter neutral mode for one hour.
Disconnecting the battery or other manipulation cannot reduce this time. After connecting the battery the timer starts again for one hour.

• Neutralizing setting condition
– In case of PCM(ECM) status "Learnt" regardless of user password "Virgin or Learnt"
– Input correct PIN code by scanner.
– Neutralizing meaning .
: PIN code (6) & user password (4) deletion.
: Locking of ECM (except key teaching permission)
• Neutralizing meaning:
– PIN Code(6) & User P/Word(4) deletion
– Locking of EMS(except Key Learning permission)
Neutralising Of SMARTRA
The EMS can be set to the status "neutral" by tester
Ignition key (regardlss of key status) is inserted and after IGN ON.If receiving the correct vehicle password from GST, SMARTRA can be
neutralized.The neutralization of SMARTRA is possible if DPN is same as the value inputted by GST.
In case that the SMARTRA status is neutral, the EMS keeps the lock state. And the start is not possible by "twice ignition".
In case of changing the vehicle password, new virgin transponder must be only used. And in case of virgin key, after Learning the key of
vehicle password, it can be used.
If wrong vehicle specific data have been sent to SMATRA three times continuously or intermittently, the SMATRA will reject the request to
enter neutral mode for one hour. Disconnecting the battery or other manipulation cannot reduce this time. After connecting the battery the
timer starts again for one hour.

• Neutralizing Setting condition :
– In case of "SMARTRA status", "Learnt"
– Input correct Pin code by tester
• Neutralizing meaning :
– Vehicle password(DPN Code) & SEK Code deletion.
– Permission of New DPN Learning.
2012 > D 2.0 TCID > Body Electrical System > Immobilizer System > Immobilizer Control Unit > Repair
English
procedures
REMOVAL
2. Remove the crash pad lower panel (A) and disconnect the connectors (B). (Refer to the BD group "Crash pad").
3. Remove the reinforcing panel (A).
4. Insert a flatup screwdriver between immobilizer unit and mounting bracket located on the inside of crash pad.
5. Move a flatup screwdriver up and down slowly to loose the immobilizer unit (A) from bracket (B).
English
6. Remove the immobilizer unit (A) after disconnecting the connector.
INSTALLATION
1. Install the immobilizer control unit after connecting the unit connector.
2. Install the reinforcing panel.
3. Install the crash pad lower panel.
2012 > D 2.0 TCID > Body Electrical System > Immobilizer System > Antenna Coil > Repair procedures
English
REMOVAL
2. Remove the steering clumn upper(A) and lower(B) shrouds. (Refer to the ST group "Steering column and shaft").
[LHD]
[RHD]
3. Disconnect the 6P connector of the coil antenna and then remove the coil antenna (A) after loosening the screw.
INSTALLATION
1. Install the coil antenna and connect the 6P connector.
English
2012 > D 2.0 TCID > Body Electrical System > Immobilizer System > Troubleshooting English
DIAGNOSIS OF IMMOBILIZER FAULTS
– Communication between the ECM and the SMARTRA.
– Function of the SMARTRA and the transponder.
– Data (stored in the ECM related to the immobilizer function.
The following table shows the assignment of immobilizer related faults to each type:
Immobilizer Related Faults Fault types Diagnostic codes
PCM(ECM) fault 1) NonImmobilizerEMS connected to an Immobilizer P1610
1) Transponder not in password mode P1674
Transponder key fault
2) Transponder transport data has been changed. (Transponder status error)
P1675
Transponder key fault 1) Transponder programming error (Transponder programming
error)
P1676
SMARTRA fault 1) Invalid message from SMARTRA to PCM(ECM)
(SMARTRA message error)
1) Virgin SMARTRA at learnt EMS
2) Neutral SMARTRA at learnt EMS P169A
SMARTRA fault (SMARTRA Authentication
3) Incorect the Authentication of EMS and SMARTRA fail)
4) Locking of SMARTRA
1) No response from SMARTRA
2) Antenna coil error P1690
SMARTRA fault
3) Communication line error (Open/Short etc.) (SMARTRA no response)
4) Invalid message from SMARTRA to PCM(ECM)
P1691
Antenna coil fault 1) Antenna coil open/short circuit
(Antenna coil error)
Immobilizer indicator lamp P1692
1) Immobilizer indicator lamp error (Cluster)
fault (Immobilizer lamp error)
1) Corrupted data from transponder
2) More than one transponder in the magnetic field (Antenna P1693
Transponder key fault coil) (Transponder no response
error/invalid response)
3) No transponder (Key without transponder) in the
magnetic field (Antenna coil)
1) Request from PCM(ECM) is invalid
P1694
PCM(ECM) fault (Protocol layer violation Invalid request, check sum error
(PCM(ECM) message error)
etc.)
PCM(ECM) internal permanent 1) PCM(ECM) internal permanent memory (EEPROM) fault P1695

memory (EEPROM) fault 2) Invalid write operation to permanent memory (EEPROM) (PCM(ECM) memory error)
1) Virgin transponder at PCM(ECM) status "Learnt"Learnt
P1696
Invalid key fault (Invalid) Transponder at PCM(ECM) status "Learnt" (Authentication fail)
English
(Authentication fail)
HiScan fault 1) HiScan message error P1697
1) Exceeding the maximum limit of Twice IGN ON (⊇ 32 P1699
Locked by timer
times) (Twice IG ON over trial)
2012 > D 2.0 TCID > Body Electrical System > Rear Parking Assist System > General Safety Information
English
and Caution
WARNING
1. Range detected by back sensors is limited.
Watch back before reversing.
2. There is a blind spot below the bumper. Low objects (for example boundary barrier) may be detected from minimum 1.5m
away unable to detect at nearer.
3. Besides there are some materials unable to be detected even in detection range as follows.
(1) Needles, ropes, rods, or other thin objects.
(2) Cotton, snow and other material absorbing ultrasonic wave(for example, fire extinguisher device covered with snow)
4. Reversing toward the sloped walls.
5. Reversing toward the sloped terrain.
English
6. False alarm may operate in the following condition: irregular road surface, gravel road, sloped road and grass. Upon alarm
generation by grass the alarm may be generated by rock behind grass. Be sure to check for the safety.
Ultrasonic sensor cannot discriminate among glass, stake, and rock.
7. Sensors may not operate correctly in the below conditions.
Ensure sensors clean from mud or dirt.
(1) When spraying the bumper, the sensor opening is covered with something in order not to be contaminated. If sensor
opening is contaminated with mud, snow, or dirt, detection range will be reduced and alarm may not be generated
under the crash condition. Dirt accumulated on the sensor opening shall be removed with water.
Do not wipe or scrape sensor with a rod or a hard object.
(2) If the sensor is frozen, alarm may not operate until sensor thaws.
(3) If a vehicle stays under extremely hot or cold environment, the detection range may be reduced. It will be restored at
the normal temperature.
(4) When heavy cargo is loaded in tailgate, it changes the vehicle balance, which reduces the detection range.
(5) When other vehicle's horn, motor cycle engine noise, or other ultrasonic wave sources are near.
(6) Under heavy rain.
(7) When reversing towards a vertical wall and the gap between the vehicle and the wall is 15cm. (Alarm may sound
despite of no barrier)
(8) If radio antenna is installed at the rear.
(9) If the vehicle rear wiring is rerouted or electrical component is added at the rear part.
(10) Vehicle balance is changed due to the replacement of the rear spring.
(11) The unit will operate normally when the vehicle speed is 5km/h or less. Above the speed, the unit may not operate
normally.
8. Check the rear bumper for installation condition and deformation. If installed improperly or the sensor orientation is
deviated, it may cause malfunction.
9. Be careful not to apply shock during sensor installation on the transmission or reception unit.
10. When adding electrical devices or modifying harness at the rear body of the vehicle, ensure not the change the
transmission and reception unit wiring. Tagging the transmission side and reception side, it may cause malfunction.
11. High power radio transmitter (above 10W) may cause malfunction. Do not install it on the vehicle.
12. Be careful that heating or sharp objects shall not touch ultrasonic sensor surface.
Besides do not cover the sensor opening or press the sensor.
2012 > D 2.0 TCID > Body Electrical System > Rear Parking Assist System > Specifications English
SPECIFICATION
Item Specification
Rear parking assist system Voltage rating DC 12V
control unit
Operation voltage DC 9 ~ 16 V
Operation temperature 30°C ~ + 80°C
Operation current MAX 600 mA
Operation frequency 40 ± 5 KHz
Detective method Direct and indirect detection
Ultrasonic sensor Voltage rating DC 8 V
Detecting range 25 cm ~ 120 cm
Beam width Horizontal : 40±5°, Vertical : 60±5°
Number of sensors 4 (Right, Right center, Left center, Left)
Piezo buzzer Voltage rating DC 12 V
Oscillation frequency : 2.2±0.5 KHz
Sound, tone
Sound level : MIN 70 dB (DC 13V /m)
2012 > D 2.0 TCID > Body Electrical System > Rear Parking Assist System > Components and English
Components Location
COMPONENT LOCATION
2012 > D 2.0 TCID > Body Electrical System > Rear Parking Assist System > Schematic DiagramsEnglish
CIRCUIT DIAGRAM
2012 > D 2.0 TCID > Body Electrical System > Rear Parking Assist System > Description and Operation
English
DESCRIPTION
When reversing, the driver is not easy to find objects in the blind spots and to determine the distance from the object. In order to provide
the driver safety and convenience, rear parking assist system will operate upon shifting to "R" Ultrasonic sensor will emit ultrasonic wave
rearward and detect the reflected wave. Control unit will calculate distance to the object using the sensor signal input and output buzzer
alarm in three steps (first, second and third alarm).
ALARM RANGE
Upon detecting an object at each range out of 3 ranges as stated below within the operation range, it will generate alarm.
First alarm : Object comes near to the sensor located at the rear of vehicle, within 81120cm ± 15cm
Second alarm : Object comes near to the sensor located at the rear of vehicle, within 4180cm ± 10cm
Third alarm : Object comes near to the sensor located at the rear of vehicle, within 40cm ± 10cm

1) Time tolerance of the above waveform : Time ± 10%
2) At nearer distance than 40cm, detection may not occur.
3) Alarm will be generated with vehicle reversing speed 10km/h or less.
For moving target, maximum operation speed shall be target approach speed of 10km/h.
4) When the vehicle or the target is moving, sequential alarm generation or effective alarm may be failed.
5) Misalarm may occur in the following conditions.
– Irregular road surface, gravel road, reversing toward grass.
– Horn, motor cycle engine noise, large vehicle air brake, or other object generating ultrasonic wave is near.
– When a wireless transmitter is used near to the sensor.
– Dirt on the sensor.
– Sequential alarm may not occur due to the reversing speed or the target shape.
2012 > D 2.0 TCID > Body Electrical System > Rear Parking Assist System > Rear Parking Assist System
English
Control Unit > Repair procedures
REPLACEMENT
2. Remove the right side trim(A) of the trunk room.
(Refer to the BD group "Interior trim")
3. Loosen the mounting nuts and disconnect the connector.
4. Remove the rear parking assist system control unit (A).
5. Installation is the reverse of removal procedure.
2012 > D 2.0 TCID > Body Electrical System > Rear Parking Assist System > Parking Assist Sensor >
English
Description and Operation
OPERATION PRINCIPLE
The sensor emits ultrasonic wave to the objects, and it measures the time until reflected wave returns, and calculates the distance to the
object.
Distance Detection Type
Direct detection type and indirect detection type are used together for improving effectiveness of the detection.
1. Direct detection type: One sensor transmits and receives signals to measure the distance.
2. Indirect detection type: One sensor transmits signals and the other sensor receives the signals to measure the distance.
Measurement Principle
Rear parking assist system is a complementary device for reversing. Rear parking assist system detects objects behind vehicle and
provides the driver with buzzer alarm finding objects in a certain area, using ultrasonic wave propagation speed and time.
The propagation speed formula of ultrasonic wave in air is following :
v=331.5 + 0.6t (m/s)
v=ultrasonic wave propagation speed
t=ambient temperature
The basic principle of distance measurement using ultrasonic wave is :
English
Sensor detection range

1) 14cm (dia.) plastic rod is used for the test target.
2) The test result may differ by a different target object.
3) Detection range may be reduced by dirt accumulated on sensor, and extremely hot or cold weather.
4) The following object may not be detected.
– Sharp object or thin object like rope.
– Cotton sponge, snow or other materials absorbing sonic wave.
– Smaller objects than 14cm (dia.), 1m length.
2012 > D 2.0 TCID > Body Electrical System > Rear Parking Assist System > Parking Assist Sensor >
English
Repair procedures
REPLACEMENT
2. Remove the rear bumper ( Refer to the Body group "Rear bumper")
3. Disconnect the sensor connector (A) at the inside of the rear bumper, and then remove the sensor (B) from the housing.
4. Installation is the reverse of removal procedure.
2012 > D 2.0 TCID > Body Electrical System > Rear Parking Assist System > Buzzer > Repair procedures
English
INSPECTION
Test the buzzer by connecting battery voltage to the 1 terminal and ground the 2 terminal.
The buzzer should make a sound. If the buzzer fails to make a sound, replace it.
REPLACEMENT
2. Remove the crash pad side lower panel (A).
[LHD]
[RHD]
3. Remove the buzzer (A) after loosening the nut and disconnecting the 2P connector.
4. Installation is the reverse of removal procedure. English
2012 > D 2.0 TCID > Body Electrical System > Rear Parking Assist System > Troubleshooting English
DIAGNOSIS
1. Operate with ignition switch on and shift the lever to position "R"
2. Then it checks the system condition.
If no trouble, it generates buzzer alarm sound for 0.3 seconds after 0.8 seconds from power approval. In case of system
failure, then it indicates the failed point as follows.
– Left sensor failure : beepbeepbeep
– Left center sensor failure : beep beepbeep beepbeep beep
– Right center sensor failure: beep beep beepbeep beep beepbeep beep beep
– Right sensor failure : beep beep beep
3. Alarm is generated 3 times sequentially.
4. Effective operation range is 10km/h or less for the vehicle speed.
2012 > D 2.0 TCID > Body Electrical System > Ignition Switch Assembly > Repair procedures English
INSPECTION
1. Disconnect the ignition switch connector and key warning switch connector from under the steering column.
3. If continuity is not specified, replace the switch.
REMOVAL
2. Remove the crash pad lower panel (Refer to the BD group "Crash pad").
3. Remove the ignition switch (A) after loosening the screw (B) with IG ON and disconnecting the 6P connector (C).
English
4. Remove the steering column cover (Refer to the ST group steering column and shaft).
5. Remove the door warning switch and key illumination lamp (A) after loosening the screw and disconnecting the 6P
connector.
6. If it is necessary to remove the key lock cylinder (A), Remove the key lock cylinder after pushing lock pin (B) with key
ACC.
INSTALLATION
1. Install the key lock cylinder.
2. Install the door warning switch and key illumination lamp.
3. Install the steering column cover.
4. Install the ignition switch.
5. Install the crash pad lower panel.
2012 > D 2.0 TCID > Brake System > General Information > Specifications English
SPECIFICATIONS
Item Specification
Master cylinder
Type Tandem type
I.D. 22.22 mm (0.875 in)
Piston stroke 45 mm (1.77 in)
Fluid level warning sensor Provided
Brake booster
Type Vacuum
Boosting ratio 9 : 1
Front brake(Disc)
Type Floating type with ventilated disc
Disc O.D. 280 mm(11.02 in)
Disc I.D. 172 mm(6.77 in)
Disc thickness 26 mm(1.02 in)
Pad thickness 11 mm(0.43 in)
Cylinder type Single piston
Cylinder I.D. Ø57.15 mm(2.25 in)
Rear brake(Disc)
Type Floating type with solid disc
Disc O.D. 262 mm (10.31 in)
Disc I.D. 185 mm (7.28 in)
Disc thickness 10 mm (0.39 in)
Pad thickness 10 mm (0.39 in)
Cylinder type Single piston
Cylinder I.D. Ø34.0 mm (1.34 in)
Parking brake
Actuation DIH (Drum in hat)
Type Lever
Drum I.D. 168 mm(6.61 in)

ABS : Antilock Brake System
CBS : Conventional Brake System
Specification (ABS)
Part Item Standard value Remark
4 channel 4 sensor
System
(Solenoid)
HECU (Hydraulic and Type Motor, valve relay intergrated type ·ABS system: ABS &

Electronic Control Unit) Operating voltage 10 V ~ 16 V(DC) EBD control
40 ~ 110 °C
Operating temperature
(40 ~ 230 °F)
·ABS W/L: ABS failure
Operating voltage 12 V ·Brake W/L: Parking,
Warning lamp brake oil, EBD failure
English
Current consumption 80 mA
Supply voltage DC 4.5 ~ 20 V
40 ~ 150 °C
(40 ~ 302 °F)
Output current low 5.9 ~ 8.4 mA Typ.7 mA
Output current High 11.8 ~ 16.8 mA Typ.14 mA
Acitve wheel speed Frequency range 1 ~ 2500 HZ
sensor
0.4 ~ 1.0 mm
Front Typ.0.7 mm(0.03 in)
(0.02 ~ 0.04 in)
Air gap
0.2 ~ 0.8 mm
Rear Typ.0.7 mm(0.03 in)
(0.01 ~ 0.03 in)
Tone wheel 46 teeth
Output duty 30~70 %
Specification (ESP)
Part Item Standard Value Remark
System 4 channel 4 sensor (Solenoid)
Type Motor, valve relay intergrated type
HECU(Hydraulic and ·Total control (ABS,
Electronic Control Unit) Operating voltage 10 V ~ 16 V(DC) EBD, TCS, ESP)
40 ~ 110 °C
(40 ~ 230 °F)
Operating voltage 12 V ·ESP Operating Lamp
Warning lamp
Current consumption 80 mA ·ESP Warning Lamp
Supply voltage DC 4.5 ~ 20V
40 ~ 150 °C
(40 ~ 302 °F)
Output current low 5.9 ~ 8.4 mA
Output current high 11.8 ~ 16.8 mA
Active wheel speed
sensor Tone wheel 46 teeth
Frequency range 1 ~ 2500 HZ
0.2 ~ 0.8 mm
Front Typ.0.7 mm(0.03 in)
(0.01 ~ 0.03 in)
Airgap
0.4 ~ 1.0 mm
Rear Typ.0.7 mm(0.03 in)
(0.02 ~ 0.04 in)
Operating Voltage 8V ~ 16 V
Steering Wheel Angle
Current Consumption Max 150 mA
Sensor
Operating Angular velocity Max ± 780 °/sec
Operating Voltage 8 V ~ 16 V
Current Consumption Max. 120 mA
Output Voltage high 4.35 V~ 4.65 V Typ. 4.5 V
Yawrate & Lateral G Output Voltage low 0.35 ~ 0.65 V Typ. 0.5 V
sensor
Yaw Sensor Operating Range ±100 ° /s
G Sensor Operating Range ±1.8 G
Reference voltage output 2.464 ~ 2.536 V Typ. 2.5 V
Service Standard
Item Standard value
Standard value
Brake pedal height 174.3 mm (6.86 in) [LHD]
167.5 mm (6.59 in) [RHD]
Brake pedal stroke 135 mm (5.31 in)
Stop lamp switch outer case to pedal stopper clearance 1.0 ~ 2.0 mm (0.04 ~ 0.08 in)
Brake pedal free play 3 ~ 8 mm (0.11 ~ 0.31 in)
Booster push rod to master cylinder piston clearance 0.6 ~ 1.4mm (at 500 mmHg vacuum)
Parking brake lever stroke when lever assembly is pulled with 7 clicks
196N (20Kg, 44lb force)
Front disc brake pad thickness 11 mm (0.43 in.)
Front disc thickness 26 mm (1.02 in)
Rear disc brake pad thickness 10 mm (0.4 in)
Rear disc brake disc thickness 10 mm (0.4 in)
Rear brake lining thickness 3.3 mm (0.13 in)
Tightening Torque
Item Nm kgf.m lbft
Master cylinder to booster mounting nut 9.8 ~ 15.7 1.0 ~ 1.6 7.2 ~ 11.6
Brake booster mounting nut 12.7 ~ 15.7 1.3 ~ 1.6 9.4 ~ 11.6
Bleeder screw 6.9 ~ 12.7 0.7 ~ 1.3 5.1 ~ 9.4
Brake tube to HECU(M10 nut)ABS 12.7 ~ 16.7 1.3 ~ 1.7 9.4 ~ 12.3
Brake tube to HECU(M12 nut)ESP 18.6 ~ 22.6 1.9 ~ 2.3 13.7 ~ 16.6
Caliper guide rod bolt 21.6 ~ 31.4 2.2 ~ 3.2 15.9 ~ 23.1
Caliper mounting bolt (Front) 78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3
Caliper mounting bolt (Rear) 49.0 ~ 58.8 5.0 ~ 6.0 36.2 ~ 43.4
Brake hose to caliper 24.5 ~ 29.4 2.5 ~ 3.0 18.1 ~ 21.7
Brake pedal member assembly bracket mounting nut (cowl
16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
side upper mounting)
Brake pedal member bracket to booster mounting nut 12.7 ~ 15.7 1.3 ~ 1.6 9.4 ~ 11.6
Stop lamp switch mounting nut 7.9 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Wheel speed sensor mounting bolt 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8.0
HECU mounting bracket bolt 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
HECU bracket mounting nut 5.9 ~ 9.8 0.6 ~ 1.0 4.3 ~ 7.2
Yaw rate & Lateral G sensor mounting bolt 4.9 ~ 7.8 0.5 ~ 0.8 3.6 ~ 5.8
LUBRICANT
Item Recommended lubricant Quantity

Brake fluid DOT 3 or DOT 4 As required
Brake pedal bushing and brake pedal bolt Chassis grease As required
Parking brake shoe and backing plate contact
Bearing grease As required
surfaces
Front caliper guide rod bolt and boot AI11P or KL64Y 0.8 ~ 2.0g
Rear caliper guide rod and boot AI11P or KL64Y 0.8 ~ 2.0g
2012 > D 2.0 TCID > Brake System > General Information > Special Service Tools English
SPECIAL SERVICE TOOLS
Tool (Number and Name) Illustration Use
09581 11000 Pushing back of the front disc and rear disc
Piston expander brake piston
2012 > D 2.0 TCID > Brake System > General Information > Troubleshooting English
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the like cause of the problem. Check
each part in order. If necessary, replace these parts.
Symptom Suspect Area Remedy

Lower pedal or spongy 1) Brake system (Fluid leaks)
pedal Repair
2) Brake system (Air in) Air bleeding
3) Piston seals (Worn or damaged) Replace
Replace
4) Master cylinder (Faulty)
Brake drag 1) Brake pedal free play (Minimum)
2) Parking brake lever travel (Out of adjustment)
Adjust
3) Parking brake wire (Sticking) Adjust
Repair
4) Pad or lining (Cracked or distorted)
Replace
5) Piston (Stuck) Replace
Replace
6) Piston (Frozen)
Replace
7) Return spring (Faulty) Replace
Replace
8) Booster system (Vacuum leaks)
9) Master cylinder (Faulty)
Brake pull 1) Piston (sticking)
Replace
2) Pad or lining (Oily)
Replace
3) Piston (Frozen) Replace
Replace
4) Disc (Scored)
Replace
5) Pad or lining (Cracked or distorted)
Hard pedal but brake 1) Brake system (Fluid leaks)
inefficient
2) Brake system (Air in) Repair
3) Pad or lining (Worn) Air bleeding
Replace
4) Pad or lining (Cracked or distorted) Replace
5) Pad or lining (Oily) Replace
Replace
6) Pad or lining (Glazed) Replace
7) Disc (Scored) Replace
8) Booster system (Vacuum leaks)
Noise from brake 1) Pad or lining (Cracked or distorted)
2) Installation bolt (Loosen) Replace
3) Disc (Scored) Retighten
Replace
4) Sliding pin (Worn)
Replace
5) Pad or lining (Dirty) Clean
English
Replace
6) Pad or lining (Glazed)
Replace
7) Return spring (Faulty) Replace
Replace
8) Brake pad shim (Damage)
9) Shoe holddown spring (Damage)
Brake fades 1) Master cylinder Replace
Brake vibration, 1) Disc (Excessive thickness variation)
pulsation Replace
2) Disc (Faulty runout)
Replace
3) Disc (Uneven worn or crack) Replace
Replace
4) Pad or lining (Uneven worn and contact)
Replace
5) Caliper (Faulty pad sliding)
Brake chatter Brake chatter is usually caused by loose or worn components, or glazed or
burnt linings. Rotors with hard spots can also contribute to brake chatter.
Additional causes of chatter are outoftolerance rotors, brake lining not
securely attached to the shoes, loose wheel bearings and contaminated
brake lining.
2012 > D 2.0 TCID > Brake System > Brake System > Repair procedures English
OPERATION AND LEAKAGE CHECK
Check all of the following items:
Component Procedure
Brake Booster (A) Check brake operation by applying the brakes during a test drive. If the brakes do not work
properly, check the brake booster. Replace the brake booster as an assembly if it does not
work properly or if there are signs of leakage.
Piston cup and pressure cup Check brake operation by applying the brakes. Look for damage or signs of fluid leakage.
inspection (B) Replace the master cylinder as an assembly if the pedal does not work properly or if there is
damage or signs of fluid leakage.
Check for a difference in brake pedal stroke between quick and slow brake applications.
Replace the master cylinder if there is a difference in pedal stroke
Brake hoses (C ) Look for damage or signs of fluid leakage. Replace the brake hose with a new one if it is
damaged or leaking.
Caliper piston seal and piston Check brake operation by applying the brakes.
boots (D) Look for damage or signs of fluid leakage. If the pedal does not work properly, the brakes
drag, or there is damage or signs of fluid leakage, disassemble and inspect the brake caliper.
Replace the boots and seals with new ones whenever the brake caliper is disassembled.
BRAKE BOOSTER OPERATING TEST
For simple checking of the brake booster operation, carry out the following tests :
1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually becomes
higher when depressed succeeding times, the booster is operating properly, if the pedal height remains unchanged, the
booster is defective.
English
2. With the engine stopped, step on the brake pedal several times. Then step on the brake pedal and start the engine. If the
pedal moves downward slightly, the booster is in good condition. If there is no change, the booster is defective.
3. With the engine running, step on the brake pedal and then stop the engine. Hold the pedal depressed for 30 seconds. If the
pedal height does not change, the booster is in good condition, if the pedal rises, the booster is defective. If the above
three tests are okay, the booster performance can be determined as good. Even if one of the above three tests is not okay,
check the check valve, vacuum hose and booster for defect.
VACUUM HOSE (CHECK VALVE)
INSPECTION
1. Disconnect the brake booster vacuum hose (check valve built in) (A) at the booster .
2. Start the engine and let it idle. There should be vacuum available. If no vacuum is available, the check valve is not working
properly. Replace the brake booster vacuum hose and check valve and retest.
BRAKE PEDAL & BRAKE SWITCH ADJUSTMENT
PEDAL HEIGHT
1. Disconnect the brake switch connector, loosen the brake switch locknut (A), and brake off the brake switch (B) until it is no
longer touching the brake pedal.
2. Measure the pedal height (C) from the middle of the leftside center of the pedal pad (D).
Standard pedal height (on the carpet) :
174.3 mm (6.86 in) [LHD]
167.5 mm (6.59 in) [RHD]
3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from the floor is
reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod depressed.
BRAKE SWITCH CLEARANCE
Screw in the stop lamp switch until its switch rod is fully depressed (threded end (A) touching the pad (B) on the pedal arm) then brake off
the switch 3/4 turn to make 1.0~2.0 mm(0.04~0.08 in.) of clearance between the stop lamp switch pad. Make sure that the brake lights go
off when the pedal is released.
PEDAL FREE PLAY
1. With the engine stopped, depress the brake pedal two or three times. After eliminating the vacuum in the power brake
booster, press the pedal(B) down by hand, and confirm that the amount of movement(A) before resistance is met (the free
play) is within the standard value.
Standard value : 3 ~ 8 mm (0.117 0.312 in.)
2. If free play does not reach the standard value, check that clearance between the outer case of stop lamp switch(C) and
brake pedal is within the standard value. If free play exceeds the standard value, it is probably due to excessive clearance
between the clevis pin and brake pedal arm. Check for excessive clearance and replace faulty parts as required.
3. Start the engine, depress the brake pedal with approximately 120kg(1176.8N, 264.5 lb) of force, and check for oil leakage in
the master cylinder, brake line and each connecting part. Repair the faulty parts as required.
INSPECTION OF FRONT DISC BRAKE PAD
1. Check the brake pad thickness through the caliper body inspection hole.
Pad thickness
Standard value : 11.0 mm (0.43 in.)
Service limit : 2.0 mm (0.0787 in.)

– If the pad lining thickness is out of specification, left and right pads must be replaced as a complete set.
– When the thickness difference between the left pad and right pad is large, check the sliding condition of the
piston and the guide rod.
INSPECTION OF REAR DISC BRAKE PAD
1. Check the brake pad thickness through the caliper body inspection hole.
Pad thickness
Standard value : 10.0 mm (0.39 in.)
Service limit : 2.0 mm (0.0787 in.)

– If the pad thickness is out of specification, left and right pads must be replaced as a complete set.
– When the thickness difference between the left pad and right pad is large, check the sliding condition of the
piston and the guide rod.
2012 > D 2.0 TCID > Brake System > Brake System > Brake Booster > Components and Components
English
Location
COMPONENTS
1. Brake booster 5. Snap pin
2. Master cylinder 6. Clevis pin
3. Vaccum hose 7. Seal
4. Check valve 8. Brake booster vacuum pressure sensor
2012 > D 2.0 TCID > Brake System > Brake System > Brake Booster > Repair procedures English
REMOVAL
1. Remove air cleaner assembly.
2. Disconnect the vacuum hose from the brake booster.
3. Remove the master cylinder.
(Refer to "Master cylinder Removal")
4. Remove the brake booster vacuum pressure sensor connector.
5. Remove the clevis pin (A) and snap pin (B).
6. Remove the four booster mounting nuts (C).
7. Remove the brake booster (A) from the engine compartment.
English
INSTALLATION
1. Adjust push rod length of the booster, and then install the seal on the booster assembly.
Standard length(A) : 123 ± 0.5 mm (4.84 ± 0.02 in)
2. Insert the booster and tighten the nuts (C).
3. Connect the booster push rod and brake pedal with a clevis pin (A) and install a snap pin (B) to the clevis pin (A).

Grease the pin before installing the snap pin.
Always use a new snap pin.
4. Install the master cylinder, then install the brake tubes to the master cylinder.
5. Install the brake booster vacuum pressure sensor connector.
6. Connect the vacuum hose to the brake booster.
7. After filling the brake reservoir with brake fluid, bleed the system.
8. Check for fluid leakage.
9. Check and adjust the brake pedal for proper operation.
2012 > D 2.0 TCID > Brake System > Brake System > Master Cylinder > Components and Components
English
Location
COMPONENTS
1. Reservoir cap 5. Retainer
2. Reservoir 6. Primary piston assembly
3. Grommet 7. Secondary piston assembly
4. Cylinder pin 8. Master cylinder body
2012 > D 2.0 TCID > Brake System > Brake System > Master Cylinder > Repair procedures English
REMOVAL
1. Remove air cleaner assembly.
2. Disconnect the brake fluid level switch connector (A), and remove the reservoir cap (B).
3. Remove the brake fluid from the master cylinder reservoir with a syringe.

Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off
immediately with water.
4. Disconnect the brake lines (A) from the master cylinder. To prevent spills, cover the hose joints with rags or shop towels.
5. Remove the master cylinder mounting nuts (A) and washers.
6. Remove the master cylinder (B) from the brake booster. Be careful not to bend or damage the brake lines when removing
the master cylinder.
English
INSTALLATION
1. Install the master cylinder (B) to the brake booster.
2. Install the master cylinder mounting nuts (A) and washers.
Tightening torque :
9.8~15.7 N.m(1.0~1.6kgf.m, 7.2~11.6 lbft)
3. Connect the brake lines (A) to the master cylinder.
Tightening torque :
12.7~16.7 N.m (1.3~1.7kgf.m, 9.4~12.3lbft) M10
18.6~22.6 N.m (1.9~2.3kgf.m, 13.7~18.6lbft) M12
4. Connect the brake fluid level switch connector (A).
5. Install the air cleaner assembly.
6. Refill the master cylinder reservoir to the MAX line.
7. Bleed the brake system. (Refer to "Bleeding of brake system")
DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a suitable container.
2. Remove the reservoir (C) from the master cylinder (B) after remove the mounting screw (A).
3. Remove the retainer ring (A) by using the snap ring pliers.
4. Remove the primary piston assembly (B).
5. Remove the pin (D) with the secondary piston (C) pushed completely using a screwdriver. Remove the secondary piston
assembly (C).

Do not disassemble the primary and secondary piston assembly.
INSPECTION
1. Check the master cylinder bore for rust or scratch.
2. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.

1) If the cylinder bore is damaged, replace the master cylinder assembly.
2) Wash the contaminated parts in alcohol.
REASSEMBLY
1. Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.
2. Carefully insert the springs and pistons in the proper direction.
3. Press the secondary piston (C) with a screwdriver and install the cylinder pin (D).
4. Install the primary piston assembly (B) and the retainer ring (A).
5. Mount two grommets (D).
6. Install the reservoir (C) to the master cylinder (B) and tighten the screw (A).
2012 > D 2.0 TCID > Brake System > Brake System > Brake Line > Components and ComponentsEnglish
Location
COMPONENTS
2012 > D 2.0 TCID > Brake System > Brake System > Brake Line > Repair procedures English
REMOVAL
1. Disconnect the brake hose (C) from the brake line (A) using a flarenut wrench (B).
2. Remove the brake hose clip (B), and then remove the brake hose (A).
3. Remove the connector bolt (A) from the caliper, and disconnect the brake hose (B) from the caliper.
INSTALLATION
1. Install a brake hose (B) on the caliper with tightening brake hose bolt (A) and washer.
Tightening torque : N.m (kgf.m, lbft)
24.5 ~ 29.4 (2.5 ~ 3.0, 18.1 ~ 21.7)
English
2. Connect the brake hose (A) to the brake line (C) using a flarenut wrench (B).
3. Install the brake hose clip (A) to the brake hose bracket.
4. After installing the brake hose, bleed the brake system.

– Check the brake hoses for interference and twisting.
– Check the brake hose and line joint for leaks, and tighten if necessary.
INSPECTION
1. Check the brake tubes for cracks, crimps and corrosion.
2. Check the brake hoses for cracks, damaged and oil leakage.
3. Check the brake tube flare nuts for damage and oil leakage.
BRAKE SYSTEM BLEEDING

– Do not reuse the drained fluid.
– Always use Genuine DOT3/DOT4 or Brake Fluid. Using a nonGenuine DOT3/DOT4 or brake fluid can cause
corrosion and decrease the life of the system.
– Make sure no dirt of other foreign matter is allowed to contaminate the brake fluid.
– Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off
immediately with water.
– The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding procedure and
checked after bleeding each brake caliper. Add fluid as required.
1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line.
2. Have someone slowly pump the brake pedal several times, and then apply steady pressure.
3. Loosen the rightrear brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely.
4. Repeat the procedure for each wheel in the sequence shown below until air bubbles no longer appear in the fluid.
5. Refill the master cylinder reservoir to the MAX (upper) level line.
FRONT DISC BRAKE :
REAR DISC BRAKE
2012 > D 2.0 TCID > Brake System > Brake System > Brake Pedal > Components and Components
English
Location
COMPONENTS(1)
COMPONENTS(2)
English
2012 > D 2.0 TCID > Brake System > Brake System > Brake Pedal > Repair procedures English
REMOVAL
1. Remove the lower crash pad.(Refer to BD "crash pad")
2. Pull down steering column shaft after removing 4 bolts.
3. Remove the stop lamp switch connector (A).
4. Remove the clevis pin and snap pin.
5. Remove the brake pedal member assembly mounting nuts and then remove the brake pedal assembly.
INSTALLATION
Grease : LiG2

Coat the inner surface of the bushings with the specified grease.
2. Before inserting the pin, apply the specified grease to the joint pin.
3. Adjust the brake pedal height and free play.(Refer to "Brake pedal & stop lamp switch adjustment")
4. Install the stop lamp switch.
INSPECTION English
1. Check the bushing for wear.
2. Check the brake pedal for bending or twisting
3. Check all parts for crack and wear.
4. Check the stop lamp switch.
(1) Connect a circuit tester to the connector (12 terminals) of stop lamp switch, and check whether or not there is
continuity when the switch rod of the stop lamp switch is pushed in and when it is released.
(2) The stop lamp switch is in good condition if there is no continuity when the switch rod is pushed.
Pushed
Item Terminal Continuity
length(A)
2.3±0.25mm
Stop lamp switch 12 ON→OFF
(0.09±0.01in)
1.8±0.25mm
Cruise control switch 34 OFF→ON
(0.07±0.01in)
2012 > D 2.0 TCID > Brake System > Brake System > Front Disc Brake > Components and Components
English
Location
COMPONENTS(1)
COMPONENTS(2)
English
2012 > D 2.0 TCID > Brake System > Brake System > Front Disc Brake > Repair procedures English
REMOVAL
1. Remove the brake hose bolt (B) and the guide rod bolts (C) from the caliper assembly (A).
2. Remove the caliper assembly (A).
3. Remove the pads (B), the pad shims (C) and the pad springs (D) from the caliper carrier (A).
4. Remove the caliper carrier (B) and the caliper mounting bolts (A).
English
5. Remove the brake disc (A) and the screw (B).

Remove the brake disc from hub using M8 bolt (A) if the brake disc has been seized with the hub due to corrosion or
overheat.
Be careful not to use the hammer. The disc can be damaged if you remove the disc from the hub by hammer.
REPLACEMENT

Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
• Avoid breathing dust particles.
• Never use on air hose or brush to clean brake assemblies.
1. Remove guide rod bolt (B) and raise the caliper assembly (A).
INSTALLATION
1. Install the brake disc (A) and tighten the screw (B).
4.9~5.9 (0.5~0.6, 3.6~4.3)
2. Install the caliper carrier (B) and tighten the caliper mounting bolts (A).
78.5~98.1 (8.0~10.0, 57.9~72.3)
3. Install the pad springs (D) to the caliper carrier (A).
4. Install the brake pads (B) and pad shims (C) on the pad springs correctly. Install the pad with the wear indicator on the
inside. If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of
braking efficiency.

Check the foreign material at the pad shims (A) and the back of the pads (B).
Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
5. Push in the piston using the SST(0958111000) so that the caliper will fit over the pads. Make sure that the piston boot is in
position to prevent damaging it when installing the caliper.
6. Install the caliper assembly(A).

Be careful not to damage the piston pin boot.
7. Install the brake hose bolt (B) and the guide rod bolts (C) to the caliper assembly (A).
Bolt (B) : 24.5~29.4 (2.5~3.0, 18.1~21.7)
Bolt (C) : 21.6~31.4 (2.2~3.2, 15.9~23.1)
10. Depress the brake pedal several times to make sure the brakes work, then testdrive.

Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced
as a set. Several applications of the brake will restore the normal pedal stroke.
11. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
INSPECTION
FRONT BRAKE DISC THICKNESS CHECK
1. Remove all rust and contamination from the disc surface, and then measure the disc thickness at 8 positions at least.
Front brake disc thickness
Standard value : 26.0 mm (1.02 in)
Limit : 24.0 mm ( 0.94 in)
2. Thickness variation should not exceed 0.005 mm (0.0002in) (circumference) and 0.01 mm(0.0004 in) (radius) at any
directions.
3. If wear exceeds the limit, replace the discs and pad assemblies for left and right of the vehicle.
FRONT BRAKE PAD CHECK
1. Check the pad wear. Measure the pad thickness. replace it if it is less than the specified value.
Pad thickness
Service limit : 2.0 mm (0.0787 in)
2. Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
FRONT BRAKE DISC RUN OUT CHECK
1. Place a dial gauge about 5mm (0.2 in) from the outer circumference of the brake disc, and measure the run out of the disc.
Brake disc run out
Limit : 0.04 mm (0.0016 in.) or less
2. If the run out of the brake disc exceeds the limit specification, replace the disc, and then measure the run out again.
3. If the run out does not exceed the limit specification, install the brake disc after turning it and then check the run out of the
brake disc again.
4. If the run out cannot be corrected by changing the position of the brake disc, replace the brake disc.
2012 > D 2.0 TCID > Brake System > Brake System > Rear Disc Brake > Components and Components
English
Location
COMPONENT LOCATION
COMPONENTS
English
2012 > D 2.0 TCID > Brake System > Brake System > Rear Disc Brake > Repair procedures English
REMOVAL
1. Remove the brake hose bolt (B) and the guide rod bolts (C) from the caliper assembly (A).
2. Remove the caliper assembly (A).
4. Remove the rear upper arm (A).
English
5. Remove the caliper carrier (B) and the caliper mounting bolts (A).
6. Remove the brake disc (A) and the screw (B).

Remove the brake disc from hub using M8 bolt (A) if the brake disc has been seized with the hub due to corrosion or
overheat.
Be careful not to use the hammer. The disc can be damaged if you remove the disc from the hub by hammer.
REPLACEMENT

Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
• Avoid breathing dust particles.
• Never use on air hose or brush to clean brake assemblies.
1. Remove guide rod bolt (B) and raise the caliper assembly (A).
INSTALLATION
1. Install the brake disc (A) and tighten the screw (B).
4.9~5.9 (0.5~0.6, 3.6~4.3)
2. Install the caliper carrier (B) and tighten the caliper mounting bolts (A).
49.0~58.8 (5.0~6.0, 36.2~43.4)
3. Install the rear upper arm (A).
4. Install the pad springs (D) to the caliper carrier (A).
5. Install the brake pads (B) and pad shims (C) on the pad springs correctly. Install the pad with the wear indicator on the
inside. If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of
braking efficiency.

Check the foreign material at the pad shims (A) and the back of the pads (B).
Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
6. Push in the piston using the SST(0958111000) so that the caliper will fit over the pads. Make sure that the piston boot is in
position to prevent damaging it when installing the caliper.
7. Install the caliper assembly (A).

Be careful not to damage the piston pin boot.
8. Install the brake hose bolt (B) and the guide rod bolts (C) to the caliper assembly (A).
Bolt (B) : 24.5~29.4 (2.5~3.0, 18.1~21.7)
Bolt (C) : 21.6~31.4 (2.2~3.2, 15.9~23.1)
11. Depress the brake pedal several times to make sure the brakes work, then testdrive.

Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced
as a set. Several applications of the brake will restore the normal pedal stroke.
12. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
INSPECTION
REAR BRAKE DISC THICKNESS CHECK
1. Remove all rust and contamination from the disc surface, and then measure the disc thickness at 8 positions at least.
Rear brake disc thickness
Limit : 8.4 mm ( 0.33 in)
2. Thickness variation should not exceed 0.01 mm (0.0004in) (circumference) and 0.01 mm(0.0004 in) (radius) at any
directions.
3. If wear exceeds the limit, replace the discs and pad assemblies for left and right of the vehicle.
REAR BRAKE PAD CHECK
1. Check the pad wear. Measure the pad thickness. replace it if it is less than the specified value.
Pad thickness
2. Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
REAR BRAKE DISC RUN OUT CHECK
1. Place a dial gauge about 5mm (0.2 in) from the outer circumference of the brake disc, and measure the run out of the disc.
Brake disc run out
Limit : 0.05 mm (0.0020 in) or less
2. If the run out of the brake disc exceeds the limit specification, replace the disc, and then measure the run out again.
3. If the run out does not exceed the limit specification, install the brake disc after turning it and then check the run out of the
brake disc again.
4. If the run out cannot be corrected by changing the position of the brake disc, replace the brake disc.
2012 > D 2.0 TCID > Brake System > Parking Brake System > Parking Brake Assembly > Components and
English
Components Location
COMPONENT LOCATION
1. Rear parking brake 3. Parking brake switch
2. Parking brake lever 4. Parking brake cable
COMPONENT
Disc Brake Type
English
1. Backing plate 5. Adjuster
2. Operating lever 6. Shoe hold down spring
3. Upper spring 7. Shoe hold down pin
4. Lower spring
2012 > D 2.0 TCID > Brake System > Parking Brake System > Parking Brake Assembly > Repair English
procedures
REMOVAL
PARKING BRAKE LEVER

The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature failure.
1. Remove the floor console. (Refer to BD Gr. "Floor console")
2. Loosen the adjusting nut (A) and the parking brake cables.
3. Disconnect the connector (A) of parking brake switch.
4. Remove the parking brake lever assembly (A) with loosening the bolts.
PARKING BRAKE SHOE (DISC BRAKE TYPE)
1. Raise the vehicle, and make sure it is securely supported. English
2. Remove the rear tire and wheel, then remove the brake caliper. (Refer to "Rear disc brake removal")
3. Remove the parking brake cable (B), after remove the clip (A).
4. Remove the shoe hold down pin (A) and spring (B) by pressing and rotating the spring.
5. Remove the adjuster assembly (B) and the lower return spring (A).
6. Remove the upper return spring (C) and the brake shoes (D).
7. Remove the operating lever assembly (E).
INSTALLATION
PARKING BRAKE SHOE (DISC BRAKE TYPE)
1. Install the operating lever assembly (E).
2. Install the upper return spring (C) and the brake shoes (D).
3. Install the adjuster assembly (B) and the lower return spring (A).
4. Install the shoe hold down pin (A) and spring (B) by pressing and rotating the spring.
5. Install the parking brake cable (B), then install the clip (A).
6. Install the rear brake disc, then adjust the rear brake shoe clearance.
(1) Remove the plug from the disc.
(2) Rotate the toothed wheel of adjuster by a screw driver until the disc is not moving, and then return it by 5 notches in
the opposite direction.
7. Install the brake caliper. (Refer to "Rear brake installation")
8. Install the tire and wheel.
9. Adjust the parking brake lever.
10. If the parking brake shoe or the brake disc are replaced a newly one, perform the brake shoe bedin procedure.
(1) While operating the parking brake lever for 69 N(7 kgf, 15 lb) effort, drive the vehicle 500 meters (0.31 miles) at the
speed of 60 kph (37.3 mph).
(2) Repeat the above procedure more than two times.
(3) Must be held on at 30% grade.

After adjusting parking brake, verify the following;
1) Must be free from malfunction when the parking pedal is operated at 686N(70 kgf, 154 lb).
2) Check that all parts move smoothly.
3) The parking brake indicator lamp must be on after the parking lever is applied and must be off after the lever is
released.
PARKING BRAKE LEVER
1. Install the parking brake lever assembly, then tighten the mounting bolts.
8.8 ~ 13.7(0.9 ~ 1.4, 6.5 ~ 10.1)
2. Apply a coating of the specified grease to each sliding parts (A) of the ratchet plate or the ratchet pawl.
Specified grease :
Multi purpose grease RheoGel 429 (MS51154, LT2)
3. Install the parking brake cable adjuster, then adjust the parking brake lever stroke by turning adjusting nut (A).
Parking brake lever stroke :
7 cliks (Pull the lever with 20kg)

After repairing the parking brake shoe, adjust the brake shoe clearance, and then adjust the parking brake lever
stroke. (Refer to "Parking brake shoe installation")
4. Release the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are turned. Readjust
if necessary.
5. Make sure that the parking brakes are fully applied when the parking brake lever is pulled up fully.
6. Reconnect the connector (A) of parking brake switch.

Inspect the continuity of parking brake switch.
When the brake lever is pulled : continuity
When the brake lever is released : no continuity
7. Install the floor console.
(Refer to BD Gr. "Floor console")
ADJUSTMENT
Parking Brake Shoe Clearance Adjustment
Disc Brake Type
1. Raise the vehicle, and make sure it is securely supported.
2. Remove the rear tire and wheel.
3. Remove the plug from the disc.
4. Rotate the toothed wheel of adjuster by a screw driver until the disc is not moving, and then return it by 5 notches in the
opposite direction.
Parking Brake Lever Stroke Adjustment
1. Raise the vehicle, and make sure it is securely supported.
2. Remove the floor console cover. (Refer to Body Group "Console")
3. Adjust the parking brake lever (A) stroke by turning adjusting nut (B).
Parking brake lever stroke :
7 cliks (Pull the lever with 20kgf)

After repairing the parking brake shoe, adjust the brake shoe clearance, and then adjust the parking brake lever
stroke. (Refer to "Parking brake shoe installation")
4. Release the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are turned. Readjust
if necessary.
5. Make sure that the parking brakes are fully applied when the parking brake lever is pulled up fully.
6. Install the floor console cover. (Refer to Body Group "Console")
2012 > D 2.0 TCID > Brake System > ABS(AntiLock Brake System) > Components and Components
English
Location
COMPONENTS
1. Front left wheel speed sensor 4. Hydrauric line
2. ABS control module(HECU) 5. Rear right wheel speed sensor
3. Front right wheel speed sensor 6. Rear left wheel speed sensor
2012 > D 2.0 TCID > Brake System > ABS(AntiLock Brake System) > Description and Operation English
This specification applies to HCU(Hydraulic Control Unit) and ECU(Electronic Control Unit) of the HECU.(Hydraulic and Electronic
Control Unit)
This specification is for the wiring design and installation of ABS ECU.
This unit has the functions as follows.
– Input of signal from the wheel speed sensors attached to each wheel.
– Control of braking force.
– Failsafe function.
– Self diagnosis function.
– Interface with the external diagnosis tester.
Installation Position : Engine Compartment
– Brake tube length from Master cylinder port to HECU inlet port should be max. 1m
– The position should not be close to the engine block and not lower than the wheel.
Operation
The ECU shall be put into operation by switching on the operating voltage (IGN).
On completion of the initialization phase, the ECU shall be ready for operation.
In the operating condition, the ECU shall be ready, within the specified limits (voltage and temperature), to process the signals offered by
the various sensors and switches in accordance with the control algorithm defined by the software and to control the hydraulic and
electrical actuators.
Wheel Sensor Signal Processing
The ECU shall receive wheel speed signal from the four active wheel sensors.
The wheel signals are converted to voltage signal by the signal conditioning circuit after receiving current signal from active wheel
sensors and given as input to the MCU.
Solenoid Valve Control
When one side of the valve coil is connected to the positive voltage that is provided through the valve relay and the other side is
connected to the ground by the semiconductor circuit, the solenoid valve goes into operation.
The electrical function of the coils are always monitored by the valve test pulse under normal operation conditions.
Voltage Limits
– Overvoltage
When overvoltage is detected(above 16.8 V), the ECU switches off the valve relay and shuts down the system.
When voltage is returned to operating range, the system goes back to the normal condition after the initialization phase.
– Undervoltage
In the event of undervoltage(below 9.3 V), ABS control shall be inhibited and the warning lamp shall be turned on.
When voltage is returned to operating range, the warning lamp is switched off and ECU returns to normal operating mode.
Pump Motor Checking
The ECU performs a pump motor test at a speed of 30km/h once after IGN is switched on.
Diagnostic Interface
Failures detected by the ECU are encoded on the ECU, stored in a EEPROM and read out by diagnostic equipment when the ignition
switch is turned on.
The diagnosis interface can also be used for testing the ECU during production of the ECU and for actuating the HCU (Airbleeding line
or Roll and Brake Test line).
Warning Lamp Module
English
1. ABS Warning Lamp
The active ABS warning lamp indicates the selftest and failure status of the ABS.The ABS warning lamp shall be on:
– During the initialization phase after IGN ON. (continuously 3 seconds).
– In the event of inhibition of ABS functions by failure.
– During diagnostic mode.
– When the ECU Connector is separated from ECU.
2. Parking/EBD Warning Lamp
The active EBD warning lamp indicates the selftest and failure status of the EBD. However, in case the Parking Brake
Switch is turned on, the EBD warning lamp is always turned on regardless of EBD functions.The EBD warning lamp shall
be on:
– When the Parking Brake Switch is ON or brake fluid level is low.
– When the EBD function is out of order.
ABS CONTROL
1. Normal Braking without ABS
Inlet valve(IV) Outlet valve(OV) Return pump

Operation Open Close OFF

IV : Inlet Valve
OV : Outlet Valve
RL : Rear left wheel
FR : Front right wheel
FL : Front left wheel
RR : Rear right wheel
RP : Return pump
2. Decrease Mode
Operation Close Open ON(Motor speed control)

IV : Inlet Valve
OV : Outlet Valve
RP : Return pump
3. Hold Mode

Operation Close Close ON(Motor speed control)

IV : Inlet Valve
OV : Outlet Valve
RP : Return pump
4. Increase Mode
Operation Open Close ON(Motor speed control)

IV : Inlet Valve
OV : Outlet Valve
RP : Return pump
2012 > D 2.0 TCID > Brake System > ABS(AntiLock Brake System) > Schematic Diagrams English
ABS CIRCUIT DIAGRAM(1)
ABS CIRCUIT DIAGRAM(2)
English
ECU CONNECTOR INPUT/OUTPUT(ABS)
Current max.permissible
min.leakage
Wire No. Designation wire resistance
max min current A
R_L (mΩ)
100μA FET
13 Ground for recirculation pump 39 A 10 A 10
lexage
Ground for solenoid valves and
38 15 A 2 A 10 "
ECU
1 Voltage supply for pump motor 39 A 10 A 10 "
25 Voltage supply for solenoid valves 15 A 2 A 10 "
32 Voltage for hybrid ECU 1 A 500 mA 60 0
signal wheel speed sensor FL, FR,
22,6,20,31 16.8 mA 5.9 mA 250 0
RL,RR
Voltage supply for the active wheel
34,18,33,19 16.8 mA 5.9 mA 250 0
speed sensor FL,FR, RL, RR
30 brake light switch 10 mA 5 mA 250 0
14 CAN Low 30 mA 20 mA 250 250μA
26 CAN High 30 mA 20 mA 250 "
27 Wheel speed sensor output 20 mA 10 mA 250
17 Diagnostic K 6 mA 3 mA 250
ABS Hecu Connector
Connector terminal
Specification Condition
Number Description
Current range: Min.10A
13 Ground for recirculation pump Always
Max.39A
Ground for solenoid valves and Current range: Min.2A
38 Always
ECU Max.15A
1 Voltage supply for pump motor
Battery voltage Always
25 Voltage supply for solenoid valves
34
18 Voltage supply for the active wheel
Battery voltage IG On
33 speed sensor FL,FR, RL, RR
19
22
16 signal wheel speed sensor FL, FR, Voltage(High) : 0.89~1.26 V
On driving
20 RL,RR Voltage (Low) : 0.44~0.63 V
31
32 Voltage for hybrid ECU Battery voltage KEY ON/OFF
Voltage (High) : ≥ 4.5 * IG ON
30 Brake light switch Brake On/Off
Voltage (Low) : ≤ 2.0 * IG ON
27 Wheel speed sensor output
17 Diagnostic K Voltage (High) : ≥ 0.8 * IG ON
Voltage (Low) : ≤ 0.2 * IG ON
Sensor Output On GDS(ABS)
Description Abbreviation Unit Remarks
1 Vehicle speed sensor VEH. SPD Km/h
2 Battery voltage BATT. VOL V
3 FL Wheel speed sensor FL WHEEL Km/h
4 FR Wheel speed sensor FR WHEEL Km/h
5 RL Wheel speed sensor RL WHEEL Km/h
6 RR Wheel speed sensor RR WHEEL Km/h
7 ABS Warning lamp ABS LAMP
8 EBD Warning lamp EBD LAMP
9 Brake Lamp B/LAMP
10 Pump relay state PUMP RLY
11 Valve relay state VALVE RLY
12 Motor MOTOR
13 Front Left valve(IN) FL INLET
14 Front Right valve (IN) FR INLET
15 Rear Left valve (IN) RL INLET
16 Rear Right valve (IN) RR INLET
17 Front Left valve (OUT) FL OUTLET
18 Front Right valve (OUT) FR OUTLET
19 Rear Left valve(OUT) RL OUTLET
20 Rear Right valve (OUT) RR OUTLET
2012 > D 2.0 TCID > Brake System > ABS(AntiLock Brake System) > Troubleshooting English
Standard Flow Of Diagnostic Troubleshooting
Notes With Regard To Diagnosis
The phenomena listed in the following table are not abnormal.
Phenomenon Explanation
System check sound When starting the engine, a thudding sound can sometimes be heard coming from
inside the engine compartment. This is because the system operation check is being performed.
ABS operation sound 1) Sound of the motor inside the ABS hydraulic unit operation (whine).
2) Sound is generated along with vibration of the brake pedal (scraping).
3) When ABS operates, sound is generated from the vehicle chassis due to repeated brake
application and release
(Thump : suspension; squeak: tires)
ABS operation For road surfaces such as snowcovered and gravel roads, the braking distance for vehicles with ABS
(Long braking distance) can sometimes be longer than that for other vehicles. Accordingly, advise the customer to drive safely
on such roads by lowering the vehicle speed.
Diagnosis detection conditions can vary depending on the diagnosis code. When checking the trouble symptom after
the diagnosis code has been erased, ensure that the requirements listed in "Comment" are met.
ABS Check Sheet
English
Problem Symptoms Table
Symptom Suspect Area
ABS does not operate. Only when 1~4 are all normal and the problem is still occurring,
replace the HECU.
1) Check the DTC reconfirming that the normal code is output.
2) Power source circuit.
3) Speed sensor circuit.
4) Check the hydraulic circuit for leakage.
ABS does not operate intermittently. Only when 1~4 are all normal and the problem is still occurring,
replace the ABS actuator assembly.
1) Check the DTC reconfirming that the system is operating to
specifications.
2) Wheel speed sensor circuit.
3) Stop lamp switch circuit.
4) Check the hydraulic circuit for leakage.
Communication with GDS is not possible. 1) Power source circuit
(Communication with any system is not possible)
2) Diagnosis line
Communication with GDS is not possible. 1) Power source circuit
(Communication with ABS only is not possible) 2) Diagnosis line
3) HECU
When ignition key is turned ON (engine OFF), 1) ABS warning lamp circuit
the ABS warning lamp does not light up.
2) HECU
Even after the engine is started, the ABS 1) ABS warning lamp circuit
warning lamp remains ON.
2) HECU

During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such phenomena are due to intermittent changes in
hydraulic pressure inside the brake line to prevent the wheels from locking and is not an abnormality.
Detecting Condition
Trouble Symptoms Possible Cause
Brake operation varies depending on driving conditions and road surface conditions, so – Inoperative power source circuit
diagnosis can be difficult. However if a normal DTC is displayed, check the following
probable cause. When the problem is still occurring, replace the ABS control module. – Inoperative wheel speed sensor circuit
– Inoperative hydraulic circuit for leakage
– Inoperative HECU
Inspection procedures
DTC Inspection
1. Connect the GDS with the data link connector and turn the ignition switch ON.
2. Verify that the system is operating to specifications.
3. Is the system operating to specifications?
▶ Check the power source circuit.
▶ Erase the DTC and recheck using GDS.
Check the power source circuit
1. Disconnect the connector from the ABS control module.
2. Turn the ignition switch ON, measure the voltage between terminal 32 of the ABS control module harness side connector and body ground.
Specification: approximately B+
3. Is the voltage within specification?
▶ Check the ground circuit.
▶ Check the harness or connector between the fuse (10A) in the engine compartment junction block
and the ABS control module. Repair if necessary.
Check the ground circuit
2. Check for continuity between terminals 13, 38 of the ABS control module harness side connector and ground point.
3. Is there continuity?
▶ Check the wheel speed sensor circuit.
▶ Repair an open in the wire and ground point.
Check the wheel speed sensor circuit
1. Refer to the DTC troubleshooting procedures.
▶ Check the hydraulic circuit for leakage.
▶ Repair or replace the wheel speed sensor.
Check the hydraulic circuit for leakage
1. Refer to the hydraulic lines.
2. Inspect leakage of the hydraulic lines.
▶ The problem is still occurring, replace the ABS control module.
▶ Replace the leaking hydraulic lines.
Detecting Condition
Brake operation varies depending on driving conditions and road surface conditions, so – Inoperative power source circuit
diagnosis can be difficult. However if a normal DTC is displayed, check the following
probable cause. When the problem is still occurring, replace the ABS control module. – Inoperative wheel speed sensor circuit
– Inoperative hydraulic circuit for leakage
DTC Inspection
1. Connect the GDS with the data link connector and turn the ignition switch ON.
2. Verify that the system is operating to specifications.
▶ Check the wheel speed sensor circuit.
▶ Erase the DTC and recheck using GDS.
Check the wheel speed sensor circuit
1. Refer to the DTC troubleshooting procedures.
▶ Check the hydraulic circuit for leakge.
▶ Repair or replace the wheel speed sensor.
Check the hydraulic circuit for leakage
1. Refer to the hydraulic lines.
2. Inspect leakage of the hydraulic lines.
▶ The problem is still occurring, replace the ABS control module.
▶ Replace the leaking hydraulic lines.
Detecting Condition
Possible malfunction in the power supply system (including ground) for the diagnosis – An open in the wire
line.
– Poor ground
– Inoperative power source circuit
Check the power supply circuit for the diagnosis
1. Measure the voltage between terminal 9 of the data link connector and body ground.
2. Is voltage within specification?
▶ Check the ground circuit for the diagnosis.
▶ Repair an open in the wire. Check and replace fuse (15A) from the engine compartment junction
block.
Check the ground circuit for the diagnosis
1. Check for continuity between terminal 5 of the data link connector and body ground.
▶ Repair an open in the wire between terminal 5 of the data link connector and ground point.
Detecting Condition
When communication with GDS is not possible, the cause may be probably an open in – An open in the wire
the HECU power circuit or an open in the diagnosis output circuit.
– Inoperative power source circuit
Check for continuity in the KLine
2. Check for continuity between terminals 17 of the ABS control module connector and 1 of the data link connector.
▶ Check the power source of ABS control module.
▶ Repair an open in the wire.
Check the power source of ABS control module
2. Turn the ignition switch ON, measure the voltage between terminal 32 of the ABS control module harness side connector and body ground.
▶ Check for poor ground.
▶ Check the harness or connector between the fuse (10A) in the engine compartment junction block
and the ABS control module.Repair if necessary.
Check for poor ground
Check for continuity between terminal 5 of the data link connector and ground point.
▶ Replace the ABS control module and recheck.
▶ Repair an open in the wire or poor ground.
Detecting Condition
When current flows in the HECU the ABS warning lamp turns from ON – Faulty ABS warning lamp bulb
to OFF as the initial check. Therefore if the lamp does not light up, the
cause may be an open in the lamp power supply circuit, a blown bulb, – Blown fuse is related to ABS in the engine
an open in the both circuits between the ABS warning lamp and the compartment junction block
HECU, and the faulty HECU. – Faulty ABS warning lamp module
– Faulty HECU
Inspection Procedures
Problem Verification
1. Disconnect the connector from the ABS control module and turn the ignition switch ON.
2. Does the ABS warning lamp light up?
▶ Inspect again after replacing the ABS HECU.
▶ Check the power source for the ABS warning lamp.
Check the power source for the ABS warning lamp
1. Disconnect the instrument cluster connector (M01C) and turn the ignition switch ON.
2. Measure the voltage between terminal (M01C) 7 of the cluster harness side connector and body ground.
Specification : approximately B+
▶ Check the CAN circuit resistance for ABS warning lamp.
▶ Check for blown fuse.
Check the can circuit resistance for ABS warning lamp
1. Disconnect the instrument cluster connector (M01A) and turn the ignition switch OFF.
2. Measure the resistance between terminal (M01A) 2 and 3 of the cluster harness side connector.
Specification : 60Ω
3. Is resistance within specification?
▶ Repair ABS warning lamp bulb or instrument cluster assembly.
▶ Check the CAN circuit wiring for ABS warning lamp.
Check the Can Circuit Wiring for ABS Warning Lamp
1. Disconnect the instrument cluster connector (M01A) and ABS HECU connector, and then turn the ignition switch OFF.
2. Check for continuity between terminal (M01A) 3 of the cluster harness side connector and terminal 26 of ABS HECU harness side.
Check for continuity between terminal (M01A) 2 of the cluster harness side connector and terminal 14 of ABS HECU harness side.
Specification : Below 1Ω
▶ Repair short of wiring between terminal 26, 14 of ABS HECU harness connector and ABS warning
lamp module.
▶ Repair open of wiring between terminal 26, 14 of ABS HECU harness connector and ABS warning
lamp module.
Detecting Condition
If the HECU detects trouble, it lights the ABS warning lamp while at the same time – An open in the wire
prohibiting ABS control. At this time, the HECU records a DTC in memory. Even though
the normal code is output, the ABS warning lamp remains ON, then the cause may be – Faulty instrument cluster assembly
probably an open or short in the ABS warning lamp circuit. – Faulty ABS warning lamp module
– Faulty HECU
Inspection Procedures
Check DTC output
1. Connect the GDS to the 16P data link connector located behind the driver's side kick panel.
2. Check the DTC output using GDS.
3. Is DTC output?
▶ Perform the DTC troubleshooting procedure (Refer to DTC troubleshooting).
▶ Check the CAN circuit resistance for ABS warning lamp.
Check the can circuit resistance for ABS warning lamp
1. Disconnect the instrument cluster connector (M01A) and turn the ignition switch OFF.
2. Measure the resistance between terminal (M01A) 2 and 3 of the cluster harness side connector.
Specification : 60Ω
▶ Repair ABS warning lamp bulb or instrument cluster assembly.
▶ Check the CAN circuit wiring for ABS warning lamp.
Check the can circuit wiring for ABS warning lamp
1. Disconnect the instrument cluster connector (M01A) and ABS HECU connector, and then turn the ignition switch OFF.
2. Check for continuity between terminal (M01A) 3 of the cluster harness side connector and terminal 26 of ABS HECU harness side.
Check for continuity between terminal (M01A) 2 of the cluster harness side connector and terminal 14 of ABS HECU harness side.
Specification : Below 1Ω
lamp module. If no trouble in wiring, inspect again after replacing the ABS HECU.
lamp module. If no trouble in wiring, inspect again after replacing the ABS HECU.
Bleeding of Brake System
This procedure should be followed to ensure adequate bleeding of air and filling of the ABS unit, brake lines and master cylinder with brake fluid.
1. Remove the reservoir cap and fill the brake reservoir with brake fluid.

If there is any brake fluid on any painted surface, wash it off immediately.

When pressure bleeding, do not depress the brake pedal.
Recommended fluid........ DOT3 or DOT4
2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half filled clear plastic bottle.
3. Connect the GDS to the data link connector located underneath the dash panel.
4. Select and operate according to the instructions on the scan tool screen.

You must obey the maximum operating time of the ABS motor with the hiscan (Pro) to prevent the motor pump from burning.
(1) Select vehicle name.
(2) Select AntiLock Brake system.
(3) Select air bleeding mode.
(4) Press "OK" to operate motor pump and solenoid valve.
(5) Wait 60 sec. before operating the air bleeding. (If not, you may damage the motor.)
(6) Perform the air bleeding.
5. Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without bubbles. Then close the bleeder
screw(A).
Front
Rear
6. Repeat step 5 until there are no more bubbles in the fluid for each wheel.
7. Tighten the bleeder screw.
Bleed screw tightening torque:
6.9 ~ 12.7N.m (0.7 ~ 1.3kgf.m, 5.1 ~ 9.4lbft)
2012 > D 2.0 TCID > Brake System > ABS(AntiLock Brake System) > ABS Control Unit > Components and
English
Components Location
COMPONENTS
1. Front right tube 5. Master cylinder tube2
2. Rear left tube 6. Master cylinder tube1
3. Rear right tube 7. ABS control module connector
4. Front left tube 8. ABS control module (HECU)
2012 > D 2.0 TCID > Brake System > ABS(AntiLock Brake System) > ABS Control Unit > Repair English
procedures
REMOVAL
1. Disconnect the battery() terminal.
2. Disconnect the brake tubes from the HECU.
Tightening torque :
5.9 ~ 9.8 N.m(0.6 ~ 1.0 kgf.m, 4.3 ~ 7.2lbft)
3. Disconnect the HECU connector.
4. Remove the HECU by loosening the bracket mounting bolts.
Tightening torque :
16.7 ~ 25.5 N.m(1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8lbft)

• Never attempt to disassemble the HECU.
• The HECU must be protected during storage and transport, and must not be subjected to excessive shock.
INSTALLATION
2. After installation, bleed the brake system. (Refer to ABS bleeding)
2012 > D 2.0 TCID > Brake System > ABS(AntiLock Brake System) > Front Wheel Speed Sensor >
English
COMPONENTS
1. Front wheel speed sensor
2012 > D 2.0 TCID > Brake System > ABS(AntiLock Brake System) > Front Wheel Speed Sensor > Repair
English
procedures
INSPECTION
1. Measure the output voltage between the terminal of the wheel speed sensor and the body ground.

In order to protect the wheel speed sensor, when measuring output voltage, a 75Ω resistor must be used as shown.
2. Compare the change of the output voltage of the wheel speed sensor to the normal change of the output voltage as shown
below.
• V_low : 0.44 V ~ 0.63 V
• V_high : 0.885 V ~ 1.26 V
• Frequency range : 1~2,500 Hz
2012 > D 2.0 TCID > Brake System > ABS(AntiLock Brake System) > Rear Wheel Speed Sensor >English
COMPONENTS
1. Rear wheel speed sensor
2012 > D 2.0 TCID > Brake System > ABS(AntiLock Brake System) > Rear Wheel Speed Sensor > Repair
English
procedures
INSPECTION
1. Measure the output voltage between the terminal of the wheel speed sensor and the body ground.

In order to protect the wheel speed sensor, when measuring output voltage, a 75Ω resistor must be used as shown.
2. Compare the change of the output voltage of the wheel speed sensor to the normal change of the output voltage as shown
below.
• V_low : 0.44 V ~ 0.63 V
• V_high : 0.885 V ~ 1.26 V
• Frequency range : 1~2,500 Hz
2012 > D 2.0 TCID > Brake System > ABS(AntiLock Brake System) > EBD (Electronic BrakeforceEnglish
Distribution) > Description and Operation
DESCRIPTION
The EBD system (Electronic Brake force Distribution) as a subsystem of the ABS system is to control the effective adhesion utilization by
the rear wheels.
It further utilizes the efficiency of highly developed ABS equipment by controlling the slip of the rear wheels in the partial braking range.
The brake force is moved even closer to the optimum and controlled electronically, thus dispensing with the need for the proportioning
valve.
The proportioning valve, because of a mechanical device, has limitations to achieve an ideal brake force distribution tothe rear wheels
as well as to carry out the flexible brake force distribution proportioning to the vehicle load or weight increasing. And in the event of
malfunctioning, driver cannot notice whether it fails or not.
EBD controlled by the ABS Control Module, calculates the slip ratio of each wheel at all times and controls the brake pressure of the rear
wheels not to exceed that of the front wheels.
If the EBD fails, the EBD warning lamp (Parking brake lamp) lights up.
Advantages
– Function improvement of the basebrake system.
– Compensation for the different friction coefficients.
– Elimination of the proportioning valve.
– Failure recognition by the warning lamp.
Comparison between Proportioning valve and EBD
2012 > D 2.0 TCID > Brake System > ESP(Electronic Stability Program) System > Components and
English
Components Location
COMPONENTS
1. HECU module 6. ESP OFF lamp
2. Yaw rate & Lateral G sensor 7. Front wheel speed sensor
3. Parking brake/EBD warning lamp 8. Steering angle sensor
4. ABS Warning lamp 9. Rear wheel speed sensor
5. ESP lamp
2012 > D 2.0 TCID > Brake System > ESP(Electronic Stability Program) System > Description andEnglish
Operation
DESCRIPTION OF ESP
Optimum driving safety now has a name : ESP, the Electronic Stability Program.
ESP 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 needfor actuating the brake or the gas pedal.
ESP adds a further function known as Active Yaw Control (VDC) to the ABS, TCS, EBD and ESP functions. Whereas the ABS/TCS
function controls wheel slip during braking and acceleration and, thus, mainly intervenes in the longitudinal dynamics of the vehicle,
active yaw control stabilizes the vehicle about its vertical axis.
This is achieved by wheel individual brake intervention and adaptation of the momentary engine torque with no need for any action to be
taken by the driver.
ESC essentially consists of three assemblies : the sensors, the electronic control unit and the actuators.
Of course, the stability control feature works under all driving and operating conditions. Under certain driving conditions, the ABS/TCS
function can be activated simultaneously with the ESP function in response to a command by the driver.
In the event of a failure of the stability control function, the basic safety function, ABS, is still maintained.
Description of ESP Control
ESP system includes ABS/EBD, TCS and VDC (Vehicle Dynamic Control) function.
ABS/EBD function : The ECU changes the active sensor signal (current shift) coming from the four wheel sensors to the square
waveform.By using the input of above signals, the ECU calculates the vehicle speed and the acceleration & deceleration of the four
wheels.And, the ECU judges whether the ABS/EBD should be actuated or not.
TCS function prevents the wheel slip of drive direction by adding the brake pressure and engine torque reduction via CAN
communication. TCS function uses the wheel speed sensor signal to determine the wheel slip as far as ABS function.
VDC function prevents unstable maneuver of the vehicle. To determine the vehicle maneuver, VDC function uses the maneuver sensor
signals(Yaw Rate Sensor, Lateral Acceleration Sensor, Steering Wheel Angle Sensor).
If vehicle maneuver is unstable (Over Steer or Under Steer), VDC function applies the brake pressure on certain wheel, and send engine
torque reduction signal by CAN.
After the keyon, the ECU continually diagnoses the system failure. (selfdiagnosis)If the system failure is detected, the ECU informs
driver of the system failure through the BRAKE/ABS/ESP warning lamp. (failsafe warning)
English
Variant Coding
The HECU is programmed with a variant code based on the vehicle powertrain configuration. This variant code is used to determine the
appropriate ESP calculations. Variant code programming should be performed whenever an HECU is replaced.
Procedure of Variant Coding
1. Install a PCM(ECM & TCM)/ESP normally.
2. Connect the GDS to the data link connector located underneath the crash pad.
3. Select vehicle name.
4. Select ANTILOCK BRAKE SYSTEM.
5. Select the variant coding.
6. Ignition "ON" & Engine "OFF".
7. Perform variant coding.
8. Ignition "OFF" and then ignition "ON".
9. The variant coding is completed.

• If the warning lamp(ESP, EBD, ABS) is illuminated, follow the "Variant coding" again.
Input and Output Diagram
ESP OPERATION MODE
1. STEP 1
The ESP analyzes the intention of the driver.
2. STEP 2
It analyzes the movement of the ESP vehicle.
3. STEP 3
he HECU calculates the required strategy, then actuates the appropriate valves and sents torque control requests via CAN
to maintain vehicle stability.
ESP Operation Mode
1. ESP NonoperationNormal braking.
Traction Control High pressure
Valve(TCV) switch valve(HSV)
Normal braking Open Close Open Close OFF

IV : Inlet Valve
OV : Outlet Valve
RP : Return pump
TCV : Traction Control Valve
HSV : High pressure Switch Valve
2. ESP Increase Mode
ON(Motor speed
Normal braking Open Close Close(Partial) Open
control)

IV : Inlet Valve
OV : Outlet Valve
RP : Return pump
3. ESP Hold Mode ( FR is only controlled.)
Normal braking Close Close Close(Partial) Open OFF

IV : Inlet Valve
OV : Outlet Valve
RP : Return pump
4. ESP Decrease Mode (FR is only controlled)
ON(Motor speed
Normal braking Close Open Close(Partial) Open
low control)

IV : Inlet Valve
OV : Outlet Valve
RP : Return pump
ABS Warning lamp
The active ABS warning lamp indicates the selftest and failure status of the ABS .The ABS warning lamp shall be on:
– In the event of inhibition of ABS functions by failure.
EBD/parking brake warning lamp
The active EBD warning lamp indicates the selftest and failure status of the EBD. However, in case the Parking Brake Switch is turned
on, the EBD warning lamp is always turned on regardless of EBD functions. The EBD warning lamp shall be on:
– When the Parking Brake Switch is ON or brake fluid level is low.
– When the EBD function is out of order .
ESP OFF Lamp (ESP system)
The ESP OFF lamp indicates the selftest and ON/OFF status of the ESP.
The ESP OFF lamp operates under the following conditions :
– When driver turn off the ESP function by on/off switch.
ESP Lamp (ESP system)
The ESP lamp indicates the selftest and failure status of the ESP and operating status of the ESP.
The ESP lamp is turned on under the following conditions :
– In the event of inhibition of ESP functions by failure.
– When the ESP control is operating. (Blinking 2Hz)
– When the ECU connector is seperated from ECU.
ESP On/Off Switch (ESP system)
The ESP On/Off Switch shall be used to toggle the ESP function between On/Off states based upon driver input.
The On/Off switch shall be a normally open, momentary contact switch.
Initial status of the ESP function is on and the switch is used to request an ESC status change.
2012 > D 2.0 TCID > Brake System > ESP(Electronic Stability Program) System > Schematic Diagrams
English
CIRCUIT DIAGRAM ESP(1)
CIRCUIT DIAGRAM ESP(2)
English
ESP HECU CONNECTOR INPUT/OUTPUT
Connector Terminal
Specifications Conditions
No Description
Current range : Min10 A
13 Ground(Pump) Always
Max 39 A
Current range : Min2 A
38 Ground(Valve,ECU) Always
Max 15 A
1 Supply voltage(Pump)
Battery voltage Always
25 Supply voltage(Valve)
34 Wheel sensor voltage(FL)
18 Wheel sensor voltage(FR)
Battery voltage IG ON
33 Wheel sensor voltage(RL)
19 Wheel sensor voltage(RR)
22 Wheel sensor signal(FL)
6 Wheel sensor signal(FR) Voltage(High) : 1.34 ~ 2.02 V
RUNNING
20 Wheel sensor signal(RL) Voltage(Low) : 0.67 ~ 1.0 V
31 Wheel sensor signal(RR)
32 Ignition Battery voltage KEY ON/OFF
Voltage(High) : 0.6 * IG ON more
5 ESP Passive switch Switch ON/OFF
Voltage(Low) : 0.4 * IG ON lower
not communicating:2.5 ± 0.5 V
26 CAN High communication :
IG ON
14 CAN Low
voltage(High) : ≥ 4.5 V
30 Brake Light Switch BRAKE ON/OFF
voltage(Low) : ≤ 2.0 V
voltage(High) : ≥ 0.7 V * IG ON
12 Parking Brake Switch (Signal)
voltage(Low) : ≤ 0.35 V * IG ON
17 Diagnostic K
16 Clutch switch (M/T Only)
3 Reverse gear
2012 > D 2.0 TCID > Brake System > ESP(Electronic Stability Program) System > TroubleshootingEnglish
FAILURE DIAGNOSIS
1. In principle, ESP and TCS controls are prohibited in case of ABS failure.
2. When ESP or TCS fails, only the failed system control is prohibited.
3. However, when the solenoid valve relay should be turned off in case of ESP failure, refer to the ABS failsafe.
4. Information on ABS failsafe is identical to the failsafe in systems where ESP is not installed.
Memory of Fail Code
1. It keeps the code as far as the backup lamp power is connected. (O)
2. It keeps the code as far as the HCU power is on. (X)
Failure Checkup
1. Initial checkup is performed immediately after the HECU power on.
2. Valve relay checkup is performed immediately after the IG2 ON.
3. It executes the checkup all the time while the IG2 power is on.
Countermeasures In Fail
1. Turn the system down and perform the following actions and wait for HECU power OFF.
2. Turn the valve relay off.
3. Stop the control during the operation and do not execute any until the normal condition recovers.
Warning Lamp ON
1. ESP lamp turn on in case of
– ESP failure detect
– For 3sec after IGN ON
– During diagnostic mode
– When the ECU connector is separated from ECU
2. ESP lamp blinks when ESP Act.
3. ESP OFF lamp turn on in case of
– ESP OFF switch on
– For 3sec after IGN ON
2012 > D 2.0 TCID > Brake System > ESP(Electronic Stability Program) System > Yawrate and Lateral G
English
Sensor > Description and Operation
DESCRIPTION
When the vehicle is turning with respect to a vertical axis the yaw rate sensor detects the yaw rate electronically by the vibration change
of plate fork inside the yaw rate sensor.
If yaw velocity reaches the specific velocity after it detects the vehicle' yawing, the ESP control is reactivated.
The later G sensor senses vehicle's lateral G. A small element inside the sensor is attached to a deflectable lever arm by later G.
Direction and magnitude of lateral G loaded to vehicle can be known with electrostatic capacity changing according to lateral G.
Specifications
Description Specification Remarks
Operating voltage 10 ~ 16V
Output signal CAN Interface
Operating temperature 40 ~ 85°C(40 ~ 185°F)
Yawrate sensor Measurement range 100 ~ 100 deg/s
Lateral G sensor Measurement range 1.8 ~ 1.8g
External Diagram
2012 > D 2.0 TCID > Brake System > ESP(Electronic Stability Program) System > Yawrate and Lateral G
English
Sensor > Repair procedures
REMOVAL
1. Turn ignition switch OFF and disconnect the negative () battery cable.
2. Remove the console assembly. (Refer to the Body group Console)
3. Disconnect the yaw rate & lateral G sensor connector (B).
4. Remove the mounting bolts (A).
Tightening torque:
4.9 ~ 7.8 N.m (0.5 ~ 0.8 kgf.m, 3.6 ~ 5.8 Ibft)
Longitudinal G sensor Calibration
Register zero value of Longitudinal G sensor within the Yawrate for calibration to ESP to perform HAC (Hill Assist Control) function.
Calibration must be performed as following cases.
– Calibration failure.
– Yawrate and Lateral & Longitudinal G sensor replacement.
– HECU replacement.
– DTC codes (C1285 Longitudinal G sensor not calibrated) detection.
Calibration procedure
1. IG ON, ENG OFF.
2. Stand the vehicle on a flat ground without any inclination.
– Max. allowed inclination angle(A): ± 0,57° (1%)
3. Set the steering wheel at the center position.
4. Keep the vehicle under normal tire pressure condition and normal loading condition. English
5. Connect GDS to data link connector (DLC).
6. Perform Longitudinal Sensor Calibration.
2012 > D 2.0 TCID > Brake System > ESP(Electronic Stability Program) System > ESP OFF Switch >
English
DESCRIPTION
1. The ESP OFF switch is for the user to turn off the ESP system.
2. The ESP OFF lamp is on when ESP OFF switch is engaged.
2012 > D 2.0 TCID > Brake System > ESP(Electronic Stability Program) System > ESP OFF Switch > Repair
English
procedures
INSPECTION
2. Remove the lower crash pad switch assembly by using the scraper and then disconnect the connectors.
3. Check the continuity between the switch terminals as the ESP OFF switch is engaged.
2012 > D 2.0 TCID > Brake System > ESP(Electronic Stability Program) System > Steering Angle Sensor >
English
COMPONENT LOCATION
2012 > D 2.0 TCID > Brake System > ESP(Electronic Stability Program) System > Steering Angle Sensor >
English
DESCRIPTION
General data
The Steering Angle Sensor (SAS) is installed in EPS (Electric Power Steering) and it sends messages to HECU through CAN
communication line.
The SAS is used to determine turning direction and speed of the steering wheel.
The HECU uses the signals from the SAS when performing ESPrelated calculations.
Components (Steering Angle Sensor, Torque Sensor, Failsafe relay, etc.) of the EPS system are located inside the steering column &
EPS unit assembly and the steering column & EPS unit assembly must not be disassemble to inspect or replace them. (Refer to “ST
(Steering system) Gr.”)
2012 > D 2.0 TCID > Clutch System > General Information > Specifications English
SPECIFICATIONS
Item Specification
Clutch operation method Hydraulic type
Clutch cover assembly Type Diaphragm spring strap
Type Single dry with diaphragm
Gasoline 1.4 / 1.6 : Ø210 × Ø145
Clutch disc Facing diameter Gasoline 2.0 : Ø225 × Ø150
(outside x inside) mm(in) Diesel 1.6 : Ø235 × Ø155
Diesel 2.0 : Ø240 × Ø155
Clutch release cylinder Inside diameter 20.64 mm (0.81in)
Clutch master cylinder Inside diameter 15.87mm (0.62in)
Service Standard
Item Specification
Clutch disc thickness [When free] Gasoline 1.4 : 8.3 ± 0.3 mm
Gasoline 1.6 : 8.3 ± 0.3 mm
Gasoline 2.0 : 8.5 ± 0.3 mm
Diesel 1.6 : 8.3 ± 0.3 mm
Diesel 2.0 : 8.5 ± 0.3 mm
Clutch pedal height [Without carpet] 182.8 mm (7.19 in)
Clutch pedal free play 6 ~ 13 mm (0.24 ~ 0.51 in)
Clutch pedal stroke Gasoline : 140 ± 3mm(5.5 ± 0.12)
Diesel : 150 ± 3mm(5.9 ± 0.12)
Clutch disc rivet depth Gasoline 1.4 : Min 1.1 mm
Gasoline 1.6 : Min 1.1 mm
Gasoline 2.0 : Min 1.2 mm
Diesel 1.6 : Min 1.1 mm
Diesel 2.0 : 1.0 mm
Diaphragm spring end height difference Gasoline 1.4 : Max 0.5 mm
Gasoline 1.6 : Max 0.5 mm
Gasoline 2.0 : Max 0.5 mm
Diesel 1.6 : Max 0.5 mm
Diesel 2.0 : Max 0.8 mm
Clutch master cylinder clearance to piston 0.15 mm (0.006 in)
Tightening Torques
Item N.m kgf.m lbft

Clutch pedal installation bolt (to the pedal support member) 17 ~ 26 1.7 ~ 2.6 12.3 ~ 18.8
English
Clutch pedal installation nut (to the master cylinder) 6 ~ 8 0.6 ~ 0.8 4.3 ~ 5.8
Clutch tube flare nut 13 ~ 17 1.3 ~ 1.7 9.4 ~ 12.3
Clutch tube bracket installation bolt 8~ 10 0.8 ~ 1.0 5.8 ~ 7.2
Clutch release cylinder installation bolt 15 ~ 22 1.5 ~ 2.2 10.8 ~ 15.9
Clutch release cylinder union bolt 25 ~ 35 2.5 ~ 3.5 18.1 ~ 25.3
Clutch cover assembly Gasoline (6ea) 15 ~ 22 1.5 ~ 2.2 10.9 ~ 16.0
installation bolt
Diesel 1.6 (6ea) 12 ~ 15 1.2 ~ 1.5 8.7 ~ 10.9
Diesel 2.0 (6ea) 25 ~ 36 2.5 ~ 3.6 18.1 ~ 26.0
Ignition lock switch nut 8 ~ 10 0.8 ~ 1.0 5.8 ~ 7.2
LUBRICANTS
Items Specified lubricants Quantity

Contact surface of release bearing and fulcrum of clutch
CASMOLY L9508 As required
release fork
Inner surface of clutch release bearing CASMOLY L9508 As required
Inner surface of clutch release cylinder and outer
circumference of piston and cup
Inner surface of clutch disc spline CASMOLY L9508 As required
Inner surface of clutch master cylinder and outer
circumference of piston assembly
Wheel bearing grease SAE J310,
Clutch master cylinder push rod, clevis pin and washer As required
NLGI No.2V
Chassis grease SAE J310a, NLGI
Clutch pedal shaft and bushings As required
No.1
Contact portion of release fork to release cylinder push rod CASMOLY L9508 As required
Input shaft spline CASMOLY L9508 As required
2012 > D 2.0 TCID > Clutch System > General Information > Special Service Tools English

094111P000 Installation of the clutch disc.
Clutch disc guide
2012 > D 2.0 TCID > Clutch System > General Information > Troubleshooting English
TROUBLESHOOTING
Trouble symptom Suspect area Remedy (See page)

Clutch slipping Insufficient pedal free play Adjust
• Car will not respond to engine Clogged hydraulic system Correct or replace parts
speed during acceleration
Excessive wear of clutch disc facing Replace
• Insufficient vehicle speed
Hardened clutch disc facing, or oil on surface Replace
• Lack of power during uphill
Damaged pressure plate or flywheel Replace
driving
Weak or broken pressure spring Replace
Difficult gear shifting (gear noise Excessive pedal free play Adjust
during shifting)
Hydraulic system fluid leaks, air trapping or Repair or replace parts
clogging
Unusual wear or corrosion of the clutch disc Replace
spline
Excessive vibration (distortion) of the clutch disc Replace
Clutch When the clutch is not Insufficient play of the clutch pedal Adjust
noisy used
Excessive wear of the clutch disc facing Replace
A noise is heard after Unusual wear and/ or damage of the release Replace
the clutch is disengaged bearing
A noise is heard when Insufficient grease on the sliding surface of the Repair
the clutch is disengaged bearing sleeve
Improperly installed clutch assembly or bearing Repair
A noise is heard when Damaged pilot bushing Replace
the car suddenly rolled
up with the clutch
partially engaged
Hard pedal effort Insufficient lubrication of the clutch pedal Repair
Insufficient lubrication of the spline part of clutch Repair
disc
Insufficient lubrication of the clutch release lever Repair
shaft
Hard to shift or will not shift Excessive clutch pedal free play Adjust the pedal free play
Faulty of the clutch release cylinder Repair the release cylinder
Clutch disc out of place, runout is excessive or Inspect the clutch disc
lining broken
Spline on the input shaft or clutch disc dirty or Repair as necessary
burned
Faulty of the clutch pressure plate Replace the clutch cover
Clutch slips Insufficient clutch pedal free play Adjust the pedal free play
Clogged of the hydraulic system Repair or replace parts
Clutch disc lining oily or worn out Inspect the clutch disc
Faulty pressure plate Replace the clutch cover
Binding of the release fork Inspect the release fork English
Clutch grabs/chatters Clutch disc lining oily or worn out Inspect the clutch disc
Faulty the pressure plate Replace the clutch cover
Bent clutch diaphragm spring Replace the clutch cover
Worn or broken torsion spring Replace the clutch disc
Engine mounts loose Repair as necessary
Clutch noisy Damaged the clutch pedal bushing Replace the clutch pedal bushing
Loose part inside housing Repair as necessary
Worn or dirty release bearing Replace the replease bearing
Sticking release fork or linkage Repair as necessary
2012 > D 2.0 TCID > Clutch System > Clutch System > Description and Operation English
DESCRIPTION
Self Adjusting Clutch(S.A.C.) Cover
• As a clutch disc facing is worn away according to its durability, a cover weight is increasing and a clutch pedal pressure
can be more needed.
• To make up for this defect, the self adjusting clutch system makes the requsted pedal pressure minimized so that makes
the maintenance cycle longer.
Concentric Slave CylinderC.S.C.
It improves working efficiency and lowers the number and the weight of part by unifing clutch release control parts(clutch release bearing
~ clutch release cylinder) in a manual transaxle.
OPERATION
CONCENTRIC SLAVE CYLINDERC.S.C
When the clutch pedal is pressed, oil pressure is transmitted along the arrow directions shown below and that moves the clutch slave
cylinder and the diaphragm spring of the clutch cover.
English
2012 > D 2.0 TCID > Clutch System > Clutch System > Repair procedures English
SERVICE ADJUSTMENT PROCEDURE
Clutch Pedal Inspection And Adjustment
1. Measure the clutch pedal height (from the face of the pedal pad to the floorboard) and the clutch pedal clevis pin play
(measured at the face of the pedal pad.)
Standard value
(A) : 6 ~ 13 mm (0.24~0.51 in)
(B) : 182.8 mm (7.19 in)
2. If the clutch pedal freeplay and height is not within the standard value range, adjust as follows:
(1) Turn and adjust the bolt within the standard value, then secure by tightening the lock nut.

If the clutch pedal height is lower than the standard value, loosen the bolt and adjust the push rod.
After adjustment, tighten the bolt so that the clearance with pedal stopper becomes 0.5mm(0.02 in) to 1.0mm
(0.04 in) and secure with lock nut.
(2) Turn the push rod to agree with the standard value and then secure the push rod with the lock nut.

When adjusting the clutch pedal height or the clutch pedal play, be careful not to push the push rod toward the
master cylinder.
3. If the clutch pedal free play and the distance between the clutch pedal and the floor board when the clutch is disengaged,
do not meet with the standard values, it may be the result of either air in the hydraulic system or a faulty clutch master
cylinder. Bleed the air or disassemble and inspect the master cylinder or clutch.
English
Bleeding

Use the specified fluid. Avoid mixing different brands of fluid.
Specified fluid: SAE J1703 (DOT 3 or DOT 4)
[M5CF*,M6CF*]
1. Loosen the bleeder screw(A) at the clutch release cylinder.
2. Depress the clutch pedal slowly until all air is expelled.
3. Hold the clutch pedal down until the bleeder is retightened.
4. Refill the clutch master cylinder with the specified fluid.

The rapidlyrepeated operation of the clutch pedal in BC range may disrupt the release cylinder's position. During the
bleeding operation, press the clutch pedal to the floor after it returns to the "A" point.
[M6GF2]
Concentric Slave Cylinder Air Bleeding Procedure
1. After disconnecting a cap from the concentric slave cylinder air bleeder, insert a vinyl hose in the plug.
2. Loosening the plug screw, press and release the clutch pedal about 10 times.

Hold the air bleeder body not to rotate with a spanner(A). The holding is needed when the plug loosened or tightened.
3. Tighten the plug during the clutch pedal pressed. Afterwards, raise the pedal with a hand.
Tightening torque :
25~29N.m (2.5~2.9Kgf.m, 18~21lbft)
4. After pressing the clutch pedal 3 times more, loosen the plug and retighten it with the pedal pressed. Raise it again, then.
5. Repeat the step 4 two or three times. (until there is no bubble in the fluid)

1) Do not clamp the pipe of a concentric slave cylinder.
2) Be careful not to damage Orings.
2012 > D 2.0 TCID > Clutch System > Clutch System > Clutch Cover and Disc > Components andEnglish
Components Location
COMPONENTS
[M6GF2]
1. Concentric slave cylinder (Diesiel 2.0) 3. Clutch disc
2. Clutch disc cover
[M6CF*, M5CF*]
English
1. Clutch release fork 3. Clutch disc
2. Clutch disc cover 4. Clutch release bearing (Gasoline & Diesel U1.6)
2012 > D 2.0 TCID > Clutch System > Clutch System > Clutch Cover and Disc > Repair procedures
English
REMOVAL
1. Remove the transaxle assembly. (Refer to Manual transaxle's removal in MT group)
2. Loosen the bolts which attach the clutch cover to the flywheel in a star pattern. Loosen the bolts in succession, one or two
turns at a time, to avoid bending the cover.

Do not clean the clutch disc or the release bearing with cleaning solvent.
INSTALLATION
1. Apply multipurpose grease to the spline of the disc.
Grease: CASMOLY L 9508

When installing the clutch, apply grease to each part, but be careful not to apply excessive grease.
It can cause clutch slippage and vibration (shudder).
2. Temporarily install the clutch disc assembly to the flywheel using the special tool.
3. Tighten the bolts one or two steps at a time in a star pattern.
Tightening torque:
[Gasoline]
15 ~ 22 N.m (1.5 ~ 2.2 kgf.m, 10.9 ~ 16.0 lbft)
[Diesel 1.6]
English
12 ~ 15 N.m (1.2 ~ 1.5 kgf.m, 8.7 ~ 10.9 lbft)
[Diesel 2.0]
25 ~ 36 N.m (2.5 ~ 3.6 kgf.m, 18.1 ~ 26.0 lbft)
4. Remove the clutch disc guide.
5. Install the transaxle assembly to the engine. (Refer to Manual transaxle's installation in MT group)
INSPECTION
Clutch cover assembly
1. Check the diaphragm spring end for wear and uneven height.
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.
Clutch disc
1. Check the clutch facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil, or grease, and
replace the clutch disc if defective.
2. Measure the thickness of the disc when free.
Standard value
Clutch disc thickness(A)[when free]
Clutch disc rivet depth(B)
: refer to 'SERVICE STANDARD' in GENERAL section.
3. Check for the torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.
Clutch release bearing

The release bearing is packed with grease. Do not use cleaning solvent or oil.
Standard grease : CASMOLY L9508
1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.
Clutch release fork
If there is abnormal wear at the point of contact with the bearing, replace the release fork assembly.
2012 > D 2.0 TCID > Clutch System > Clutch System > Clutch Master Cylinder > Components andEnglish
Components Location
COMPONENTS
1. Washer 8. Spring seat
2. Snap pin 9. Spring
3. Rod assembly 10. Body assembly
4. Boot 11. Oring
5. Key 12. Nipple
6. Plate 13. Bolt
7. Piston assembly 14. Flexible hose
2012 > D 2.0 TCID > Clutch System > Clutch System > Clutch Master Cylinder > Repair procedures
English
REMOVAL
1. Drain the brake fluid through the bleeding plug (A).
2. Remove the flexible hose (A) connected to brake reserve tank from the master cylinder.
[LHD]
[RHD]
3. Disconnect the clutch tube (B) from the master cylinder.
4. Disconnect the two ignition lock switch connectors.
5. Remove the clutch pedal mounting nuts(A2ea) and the bracket mounting nut.
[LHD]
English
[RHD]
6. Disconnect the push rod from the master cylinder by removing the snap pin (A) and washer (B).
[LHD]
[RHD]
7. Remove the screws mounting the master cylinder to the clutch pedal assembly.
INSTALLATION
1. Apply the specified grease to the clutch pedal and bushings.
Chassis grease: SAE J310a, NLGI No.1
2. Install the screws or nut mounting the master cylinder to the clutch pedal assembly.
3. Apply the specified grease to the snap pin(A) and washer.
Wheel bearing grease: SAE J310, NLGI No.2
4. Connect the push rod to the clutch pedal by installing the snap pin (A) and washer (B).
[LHD]
[RHD]
5. Install the clutch pedal mounting nuts (A2ea).
Tightening torque :
17 ~ 26Nm (1.7 ~ 2.6kgf.m, 12.3 ~ 18.8Ibft)
[LHD]
[RHD]
6. Adjust the clutch pedal within the standard value, then secure by tightening the lock nut.
Standard value
Free play (A)
6~13mm (0.24~0.51 in)
Height (B)
182.8mm (7.19 in)
7. Connect the flexible hose of the brake reserve tank to the master cylinder.
[LHD]
[RHD]
8. Connect the clutch tube(B) to the master cylinder.
9. Refill the brake fluid.
10. Bleed the air in the clutch system.(refer to Bleeding in Serive Adjustment Procedure)
DISASSEMBLY
1. Remove the piston stop ring.
2. Pull out the push rod and piston assembly.
3. Remove the reserve tank band, reserve tank cap, and reserve tank.

1) Use care not to damage the master cylinder body and piston assembly.
2) Do not disassemble the piston assembly.
INSPECTION
1. Check the inside of the cylinder body for rust, pitting or scoring.
2. Check the piston cup for wear or distortion.
3. Check the piston for rust, pitting or scoring.
4. Check to make sure the clutch line tube is not clogged or restricted in any way.
5. Measure the master cylinder inside diameter and the piston outside diameter with a cylinder gauge micrometer.

Measure the inside diameter of the master cylinder at three places (bottom, middle, and top) in a perpendicular
direction.
6. If the master cylindertopiston clearance exceeds the limit, replace the master cylinder and/or piston assembly.
Limit : 0.15 mm (0.006 in)
REASSEMBLY
1. Apply the specified fluid to the inner surface of the master cylinder body (A) and to the entire periphery of the piston
assembly (B).
Specified fluid: Brake fluid DOT 3 or DOT 4
2. Install the piston assembly.
3. Install the piston snap ring.
4. Install the push rod assembly.
2012 > D 2.0 TCID > Clutch System > Clutch System > Clutch Pedal > Components and Components
English
Location
COMPONENTS
[LHD]
1. Pedal pad 5. Dust cover
2. Clutch arm assembly 6. Master cylinder assembly
3. Ignition lock switch 7. Washer
4. Clutch member assembly 8. Snap pin
[RHD]
English
1. Pedal pad 5. Dust cover
2. Clutch arm assembly 6. Master cylinder assembly
3. Ignition lock switch 7. Washer
4. Clutch member assembly 8. Snap pin
2012 > D 2.0 TCID > Clutch System > Clutch System > Clutch Pedal > Repair procedures English
REMOVAL
1. Drain the brake fluid through the bleeding plug (A).
2. Remove the flexible hose (A) connected to brake reserve tank from the master cylinder.
[LHD]
[RHD]
3. Disconnect the clutch tube (B) from the master cylinder.
4. Disconnect the two ignition lock switch connectors.
5. Remove the clutch pedal mounting nuts(A2ea) and the bracket mounting nut.
[LHD]
English
[RHD]
6. Disconnect the push rod from the master cylinder by removing the snap pin (A) and washer (B).
[LHD]
[RHD]
7. Remove the screws or nut mounting the master cylinder to the clutch pedal assembly.
INSTALLATION
1. Apply the specified grease to the clutch pedal and bushings.
Chassis grease: SAE J310a, NLGI No.1
2. Install the screws or nut mounting the master cylinder to the clutch pedal assembly.
3. Apply the specified grease to the snap pin(A) and washer.
Wheel bearing grease: SAE J310, NLGI No.2
4. Connect the push rod to the clutch pedal by installing the snap pin (A) and washer (B).
[LHD]
[RHD]
5. Install the clutch pedal mounting nuts (A2ea).
Tightening torque :
17 ~ 26Nm (1.7 ~ 2.6kgf.m, 12.3 ~ 18.8Ibft)
[LHD]
[RHD]
6. Adjust the clutch pedal within the standard value, then secure by tightening the lock nut.
Standard value
Free play (A)
6~13mm (0.24~0.51 in)
Height (B)
182.8mm (7.19 in)
7. Connect the flexible hose of the brake reserve tank to the master cylinder.
[LHD]
[RHD]
8. Connect the clutch tube(B) to the master cylinder.
10. Bleed the air in the clutch system.(refer to Bleeding in Serive Adjustment Procedure)
INSPECTION
1. Check the pedal shaft and bushing for wear.
2. Check the clutch pedal for bending or torsion.
3. Check the return spring for damage or deterioration.
4. Check the pedal pad for damage or wear.
Ignition lock switch inspection
Remove the ignition lock switch and check for continuity between the terminals. If the continuity is not as specified, replace the switch.
Standard value
Full stroke(A) : 12.0 ± 0.3mm (0.472 ± 0.012 in.)
ONOFF point (B) : 2.0 ± 0.3mm (0.078 ± 0.012 in)
2012 > D 2.0 TCID > Clutch System > Clutch System > Clutch Release Cylinder > Components and
English
Components Location
COMPONENTS
[M5CF*, M6CF*]
1. Union bolt 7. Bleeder screw
2. Gasket 8. Release cylinder
3. Tube joint 9. Return spring
4. Clutch tube 10. Piston
5. Valve plate 11. Boot
6. Valve spring 12. Push rod
2012 > D 2.0 TCID > Clutch System > Clutch System > Clutch Release Cylinder > Repair procedures
English
REMOVAL
1. Drain the brake fluid through the bleed plug(A).
2. Disconnect the clutch tube(A).
3. Remove the two clutch release cylinder mounting nuts(B2ea).
INSTALLATION
1. Coat the clutch clevis push rod specified grease.
Specified grease: CASMOLY L9508
2. Install the release cylinder mounting nuts(B2ea).
Tightening torque :
15 ~ 22Nm (150 ~220 kgf.cm, 11 ~ 16 lbft)
English
3. Install the clutch tube(A).
5. Bleed the air in the clutch system.
(refer to Bleeding in Service Adjustment Procedure)
INSPECTION
1. Check the release cylinder bore for rust and damage.
2. Measure the release cylinder bore at three locations (bottom, middle, and top) with a cylinder gauge and replace the release
cylinder assembly if the boretopiston clearance exceeds the limit.
Limit clearance to piston: 0.25mm (0.0098 in)
3. Check the clutch release cylinder for fluid leakage.
4. Check the clutch release cylinder boots for damage.
DISASSEMBLY
1. Remove the clutch hose, valve plate, spring, push rod, and boot.
2. Remove any dirt from the piston bore opening of the release cylinder.
3. Remove the piston from the release cylinder using compressed air.

• Use rags to prevent the piston from popping out and causing injury.
• Apply compressed air slowly. Keep the fluid from splashing in your eyes or on your skin.
REASSEMBLY
1. Apply specified brake fluid to the release cylinder bore and the outer surface of the piston and piston cup, and push the
piston cup assembly into the cylinder.
Specified fluid: Brake fluid DOT 3 or DOT 4
2. Install the valve plate(A), Spring(B), push rod(C) and boot(D).
2012 > D 2.0 TCID > Driveshaft and axle > General Information > Specifications English
SPECIFICATION
DRIVESHAFT
Joint type Max. permissible angle
Engine T/M
Outer Inner Outer Inner
Diesel 1.6 / 2.0 M/T AC3300i AAR3300i 45° 21°
M/T 45° 21°
Gasoline 2.0 AC2300i AAR2300i
A/T 45° 21°
M/T 45° 21°
Gasoline 1.4 / 1.6 AC2000i AAR2000i
A/T 45° 21°
Front wheel bearing
Bearing type Double row angular contact ball bearing
Starting torque 1.8 Nm (18 kgf.cm, 1.31 lbft) or below
Rear hub & bearing assembly
Bearing type Double row angular contact ball bearing
Starting torque 1.0 Nm (10 kgf.cm, 0.7 lbft) or below
ACi : Angular Contact Improved Joint
AARi : Angular Adjusted Roller Improved joint
Inner : On transaxle side
Outer : On tire side
TIGHTENING TORQUE
Items Nm Kgfm lbft
Wheel nut 88.3~107.9 9.0~11.0 65.1~79.6
Driveshaft nut (Castle nut) 240.3 ~ 269.7 24.5 ~ 27.5 177.2 ~ 198.9
Lower arm ball joint assembly to knuckle bolts 98.1~117.7 10.0~12.0 72.3~86.8
Wheel speed sensor bolt 6.9~9.8 0.7~1.1 5.1~7.2
Front caliper assembly to knuckle bolts 78.5~98.1 8.0~10.0 57.9~72.3
Tie rod end castle nut 23.5~33.3 2.4~3.4 17.4~24.6
Front strut assembly to knuckle bolts 137.3~156.9 14.0~16.0 101.3~115.7
Rear lower arm to carrier assembly bolts 137.3~156.9 14.0~16.0 101.3~115.7
Rear lower arm to cross member bolts 137.3~156.9 14.0~16.0 101.3~115.7
Rear upper arm to carrier assembly bolts 98.1~117.7 10.0~12.0 72.3~86.8
Rear caliper assembly to carrier assembly bolts 49.0~58.8 5.0~6.0 36.2~43.4
Rear shock absorber assembly to carrier assembly bolts 137.3~156.9 14.0~16.0 101.3~115.7
Assist arm to carrier assembly bolts 44.1~53.9 4.5~5.5 32.5~39.8
Trailing arm to carrier assembly bolts 34.3~53.9 3.5~5.5 25.3~39.8
Carrier assembly to rear hub assembly bolts 58.8~68.6 6.0~7.0 43.4~50.6
English
Replace selflocking nuts with new ones after removal.
2012 > D 2.0 TCID > Driveshaft and axle > General Information > Special Service Tools English
SPECIAL TOOLS
Tool(Number and Name) Illustration Use

0956834000 Remover of ball joint
Ball joint puller
094953K000 Installation of ear type boot band
Band installer
2012 > D 2.0 TCID > Driveshaft and axle > General Information > Troubleshooting English
TROUBLESHOOTING
Trouble Symptom Probable cause Remedy

Vehicle pulls to one Scoring of driveshaft ball joint Replace
side
Wear, rattle or scoring of wheel bearing Replace
Defective front suspension and steering Adjustment or Replace
Vibration Wear, damage or bending of driveshaft Replace
Driveshaft rattle and hub serration Replace
Wear, rattle or scratching of wheel bearing Replace
Shimmy Defective wheel balance Adjustment or Replace
Wear, damage or bending of driveshaft Replace
Rattle of driveshaft and worn hub splines Replace
Excessive noise Wear, rattle or scoring of wheel bearing Replace
Loose hub nut Adjustment or Replace
2012 > D 2.0 TCID > Driveshaft and axle > Driveshaft Assembly > Front Driveshaft > Components and
English
Components Location
COMPONENT
2012 > D 2.0 TCID > Driveshaft and axle > Driveshaft Assembly > Front Driveshaft > Repair procedures
English
REMOVAL
1. Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2. Remove the front wheel and tire from front hub.

Be careful not to damage to the hub bolts when removing the front wheel and tire.
3. Remove the split pin (A), then remove castle nut (B) and washer from the front hub under applying the break.
4. Remove the ball joint assembly mounting nut (A) from the knuckle.
5. Remove the split pin and castle nut and then disconnect the tie rod end (A) from the front knuckle by using a SST (09568
34000).
English
6. Using a plastic hammer, disconnect driveshaft (A) from the axle hub (B).
7. Insert a pry bar between the transaxle case and joint case, and separate the driveshaft (A) from the transaxle case.
[LH]
[RH]

• Use a pry bar being careful not to damage the transaxle and joint.
• Do not insert the pry bar too deep, as this may cause damage to the oil seal.
• Do not pull the driveshaft by excessive force it may cause components inside the joint kit to dislodge resulting
in a torn boot or a damaged bearing.
8. Pull out the driveshaft (A) from the transaxle case.

• Plug the hole of the transaxle case with the oil seal cap to prevent contamination.
• Support the driveshaft properly.
• Replace the retainer ring whenever the driveshaft is removed from the transaxle case.
• If the driveshaft is damaged, replace the driveshaft assembly.
INSTALLATION
1. Apply gear oil on the oil seal contacting surface (B) of transaxle case and the driveshaft splines (A).

• Replace circlip with new one.
• Be careful not to install a different kind, when replacing the circlip.
2. Before installing the driveshaft (C), set the opening side of the circlip (D) facing downward.
3. After installation, check that the driveshaft (C) cannot be removed by hand.
4. Install the driveshaft (A) to the axle hub (B).

• Be careful not to damage and dent the both boots.
• Keep clean without contamination on contacting point between the hubbearingand BJ.
5. Install the ball joint assembly mounting nut (A) to the knuckle.
Tightening torque Nm (kgf.m, lbft) :
98.1~117.7 (10~12, 72.3~86.8)
6. Install the washer (C), castle nut (B) and split pin (A) to the front hub assembly.
196.1~274.6 (20~28, 144.7~202.5)

The washer (C) should be assembled with convex surface outward when installing the castle nut (B) and split pin (A).
7. Install the wheel and the tire to the front hub.
88.3~107.9 (9~11, 65.1~79.6)

Be careful not to damage the hub bolts when installing the front wheel and tire.
INSPECTION
1. Check the driveshaft boots for damage and deterioration.
2. Check the boots for grease leak.
3. Check the ball joint for wear and damage.
4. Check the splines for wear and damage.
5. Check the dynamic damper for cracks, wear and position.
6. Check the driveshaft for cracks and wears.
7. If the driveshaft is damaged, replace the driveshaft assembly.
2012 > D 2.0 TCID > Driveshaft and axle > Front Axle Assembly > Front Hub Axle > Components and
English
Components Location
COMPONENTS
1. Split pin 6. Snap ring
2. Driveshaft nut (castle nut) 7. Dust cover
3. Brake disc 8. Knuckle
4. Hub 9. Driveshaft
5. Wheel bearing
2012 > D 2.0 TCID > Driveshaft and axle > Front Axle Assembly > Front Hub Axle > Repair procedures
English
REMOVAL
2. Remove the front wheel and tire from front hub.

Be careful not to damage to the hub bolts when removing the front wheel and tire.
3. Remove the wheel speed sensor (A) from the knuckle.
4. Remove the brake caliper mounting bolts (A), and then place the brake caliper assembly (B) with wire.
English
5. Remove the split pin (B), then remove castle nut (A) and washer (C) from the front hub under applying the break.
6. Remove the ball joint assembly mounting nut (A) from the knuckle.
34000).
8. Remove the brake disc (A) from the front hub assembly after remove the screws (B).
9. Remove the strut assembly mounting bolts (A) and nuts.
10. Remove the hub and knuckle assembly.

Be careful not to damage the boot and rotor teeth.
REPLACEMENT
Ball joint Rework instruction
1. Remove ball joint (A) with torque wrench.
2. Install ball joint (A) as tightening torque.
Tightening torque: 137.3 ~ 156.9 N.m (14.0 ~ 16.0 kgf.m, 101.3 ~ 115.7 lbft)

• Install as careing the direction of color above.
3. Make a calking with chisel.
4. Mark the position of ball joint (A) after repacement.
INSTALLATION
1. Install the hub and knuckle assembly to the drive shaft.
2. Install the knuckle to the strut assembly and tighten mounting bolts (A) and nuts.
Bolts(A): 137.3~156.9 (14.0~16.0, 101.3~115.7)
3. Install the brake disc (A) to the front hub assembly, and tighten the screws (B).
4. Install the tie rod end ball joint (A) to the knuckle.
5. Install the nut and split pin.
23.5~33.3 (2.4~3.4, 17.4~24.6)
6. Install the ball joint assembly mounting nut (A) to the knuckle.
Bolt(A) : 98.1~117.7 (10~12, 72.3~86.8)
7. Install the washer (C), castle nut (A) and split pin (B) to the front hub assembly.
274.4 ~ 294.3 N.m, (28.0 ~ 30.0 kgf.m, 202.4 ~ 217.0 lbft)

The washer (C) should be assembled with convex surface outward when installing the castle (B) nut and split pin (A).
8. Install the brake caliper and then tighten the mounting bolts(A).
78.5~98.1 (8~10, 57.9~72.3)
9. Install the wheel speed sensor (A) to the knuckle.
6.9~9.8 (0.7~1.1, 5.1~7.2)
10. Install the wheel and the tire to the front hub.
88.3~107.9 (9~11, 65.1~79.6)

Be careful not to damage the hub bolts when installing the front wheel and tire.
DISASSEMBLY
1. Remove the snap ring (A).
2. Remove the hub assembly from the knuckle assembly.
(1) Install the front knuckle assembly (A) on press.
(2) Lay a suitable adapter (B) upon the hub assembly shaft.
(3) Remove the hub assembly (B) from the knuckle assembly (A) by using press.
3. Remove the hub bearing inner race from the hub assembly.
(1) Install a suitable tool (A) for removing the hub bearing inner race on the hub assembly.
(2) Lay the hub assembly and tool (A) upon a suitable adapter (B).
(3) Lay a suitable adapter (C) upon the hub assembly shaft.
(4) Remove the hub bearing inner race (D) from the hub assembly by using press.
4. Remove the hub bearing outer race from the knuckle assembly.
(1) Lay the hub assembly (A) upon a suitable adapter (B).
(2) Lay a suitable adapter (C) upon the hub bearing outer race.
(3) Remove the hub bearing outer race from the knuckle assembly by using press.
5. Replace hub bearing with a new one.
INSPECTION
1. Check the hub for cracks and the splines for wear.
2. Check the brake disc for scoring and damage.
3. Check the knuckle for cracks.
4. Check the bearing for cracks or damage.
REASSEMBLY
1. Install the hub bearing to the knuckle assembly.
(1) Lay the knuckle assembly (A) on press.
(2) Lay a new hub bearing upon the knuckle assembly (A).
(3) Lay a suitable adapter (B) upon the hub bearing.
(4) Install the hub bearing to the knuckle assembly by using press.

• Do not press against the inner race of the hub bearing because that can cause damage to the bearing assembly.
• Always use a new wheel bearing assembly.
2. Install the hub assembly to the knuckle assembly.
(1) Lay the hub assembly (A) upon a suitable adapter (B).
(2) Lay the knuckle assembly (C) upon the hub assembly (A).
(3) Lay a suitable adapter (D) upon the hub bearing.
(4) Install the hub assembly (A) to the knuckle assembly (C) by using press.

• Do not press against the inner race of the hub bearing because that can cause damage to the bearing assembly.
3. Install the snap ring (A).
2012 > D 2.0 TCID > Driveshaft and axle > Rear Axle Assembly > Rear Hub Carrier > Components and
English
Components Location
COMPONENT
DISC BRAKE TYPE
2012 > D 2.0 TCID > Driveshaft and axle > Rear Axle Assembly > Rear Hub Carrier > Repair procedures
English
REMOVAL
DISC BRAKE TYPE
1. Release the parking brake.
3. Remove the rear wheel and tire from rear hub.

Be careful not to damage to the hub bolts when removing the rear wheel and tire.
4. Remove the mounting bolt (B) of the rear lower arm (A) and the rear carrier, while supporting the lower arm (A) with a jack
as shown in the illustration.

Be careful not to damage the deadener coating
5. Loosen the mounting nut (A) of the cross member and the rear lower arm, then remove the coil spring (B) by taking down
the jack.
English
6. Remove the wheel speed sensor (A) and parking brake cable (B).
7. Disconnect the upper arm (B) from the carrier assembly after loosen the nut (A).
8. Remove the brake caliper mounting bolts (A), and then place the brake caliper assembly (B) with wire as shown in the
illustration.
9. Remove the rear brake disc assembly (A) after loosen the screw (B).
10. Remove the rear shock absorber assembly (C) after loosen the bolt (A, B).
11. Remove the split pin and castle nut from the assist arm.
12. Using the SST (095684A000), disconnect the assist arm (A) from the carrier assembly.
13. Remove the carrier assembly (A) from the trailing arm after remove the mounting bolts.
14. Remove the rear hub assembly (C) and rear brake assembly (B) after remove mounting bolts (A).
INSTALLATION
DISC BRAKE TYPE
1. Install the rear hub assembly (C) and rear brake assembly (B) to the rear carrier, then tighten mounting bolts (A).
58.8~68.6 (6.0~7.0, 43.4~50.6)
2. Install the carrier assembly (A) to the trailing arm, then tighten the mounting bolts.
34.3~53.9 (3.5~5.5, 25.3~39.8)
3. Install the assist arm(B) to the carrier assembly (A) , then install the castle nut and split pin.
44.1~53.9 (4.5~5.5, 32.5~39.8)
4. Install the rear strut assembly (C), then tighten the bolt (A, B).
Bolt(A) : 49.0~63.7 (5.0~6.5, 36.2~47.0)
Bolt(B) : 137.3~156.9 (14.0~16.0, 101.3~115.7)
5. Install the rear brake disc assembly (A) and tighten screw (B).
6. Install the brake caliper, then tighten the brake caliper mounting bolts (A).
49.0~58.8 (5.0~6.0, 36.2~43.4)
7. Install the upper arm (B) from the carrier assembly , then tighten the nut (A).
Nut(A) : 98.1~117.7 (10~12, 72.3~86.8)
8. Install the wheel speed sensor (A) and parking brake cable (B).
9. Install the coil spring (A) on the rear lower arm (B), then slowly jackup the rear lower arm (B) by using jack.
10. Install the mounting bolt (B) of the rear lower arm (A) and the rear carrier with a specified torque, while supporting the lower
arm (A) with a jack as shown in the illustration. Tighten the mounting bolt (C) of the cross member and the rear lower arm
with a specified torque.
Bolt (B, C) :137.3~156.9 (14.0~16.0, 101.3~115.7)

11. Install the wheel and the tire to the rear hub.
88.3~107.9 (9~11, 65.1~79.6)

Be careful not to damage the hub bolts when installing the rear wheel and tire.
INSPECTION
1. Check the hub for cracks and the splines for wear.
2. Check the bearing for cracks or damage.
3. Check the brake disc for scoring and damage.
4. Check the rear axle carrier for cracks.
5. Check the rear tone wheel for chipped the teeth.
2012 > D 2.0 TCID > Engine Electrical System > Charging System > Description and Operation English
DESCRIPTION
The conventional internal voltage detection type alternator controls the charging voltage regardless of the battery condition and
according to the external load change so that it sometimes causes battery under or over charging or causes flickering of meters and
lamps due to ripples of generated voltage resulting from load fluctuation. The figure below show the internal circuits of the alternator and
voltage regulator.
2012 > D 2.0 TCID > Engine Electrical System > Charging System > Repair procedures English
ONVEHICLE INSPECTION

• Check that the battery cables are connected to the correct terminals.
• Disconnect the battery cables when the battery is given a quick charge.
• Do not perform tests with a high voltage insulation resistance tester.
• Never disconnect the battery while the engine is running.
CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES
1. Check that the battery terminals are not loose or corroded.
2. Check the fusible link and fuses for continuity.
INSPECT DRIVE BELT
1. Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be
replaced.
2. Using a belt tension gauge, measure the drive belt tension.
VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES
1. Check that the wiring is in good condition.
2. Check that there is no abnormal noise from the alternator while the engine is running.
CHECK DISCHARGE WARNING LIGHT CIRCUIT
1. Warm up the engine and then turn it off.
2. Turn off all accessories.
3. Turn the ignition switch "ON". Check that the discharge warning light is it.
4. Start the engine. Check that the light goes off.
INSPECT CHARGING SYSTEM
VOLTAGE DROP TEST OF ALTERNATOR OUTPUT WIRE English
This test determines whether or not the wiring between the alternator "B" terminal and the battery (+) terminal is good by the voltage drop
method.
PREPARATION
1. Turn the ignition switch to "OFF".

To find abnormal conditions of the connection, actions should not be taken on the two terminals and each connection
during the test.
2. Connect a digital voltmeter between the alternator "B" terminal and battery (+) lead wire to the battery (+) terminal. Connect
the (+) lead wire of the voltmeter to the "B" terminal and the () lead wire to the battery (+) terminal.
CONDITIONS FOR THE TEST
1. Start the engine.
2. Switch on the headlamps, blower motor and so on. And then, read the voltmeter under this condition.
RESULT
1. The voltmeter may indicate the standard value.
Standard value:0.2V max.
2. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case check the
wiring from the alternator "B" terminal to the fusible link to the battery (+) terminal. Check for loose connections, color
change due to an overheated harness, etc. Correct them before testing again.
3. Upon completion of the test, set the engine speed at idle. Turn off the head lamps, blower motor and the ignition switch.
OUTPUT CURRENT TEST
This test determines whether or not the alternator gives an output current that is equivalent to the nominal output.
PREPARATION
1. Prior to the test, check the following items and correct as necessary.
Check the battery installed in the vehicle to ensure that it is in good condition. The battery checking method is described in
"BATTERY".
The battery that is used to test the output current should be one that has been partially discharged. With a fully charged
battery, the test may not be conducted correctly due to an insufficient load.
Check the tension of the alternator drive belt.
2. Turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Disconnect the alternator output wire from the alternator "B" terminal.
5. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire. Be sure to
connect the () lead wire of the ammeter to the disconnected output wire.

Tighten each connection securely, as a heavy current will flow. Do not rely on clips.
6. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the alternator "B" terminal
and () lead wire to a good ground.
7. Attach an engine tachometer and connect the battery ground cable.
8. Leave the engine hood open.
TEST
1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the open
circuit in the wire between the alternator "B" terminal and battery (+) terminal, a blown fusible link or poor grounding is
suspected.
2. Start the engine and turn on the headlights.
3. Set the headlights to high beam and the heater blower switch to HIGH, quickly increase the engine speed to 2,500 rpm and
read the maximum output current value indicated by the ammeter.

After the engine starts up, the charging current quickly drops. Therefore, the above operation must be done quickly to
read the maximum current value correctly.
RESULT
1. The ammeter reading must be higher than the limit value. If it is lower but the alternator output wire is in good condition,
remove the alternator from the vehicle and test it.
Limit value (120Aalternator):50% of the rate voltage

• The nominal output current value is shown on the nameplate affixed to the alternator body.
• The output current value changes with the electrical load and the temperature of the alternator itself. Therefore,
the nominal output current may not be obtained. If such is the case, keep the headlights on the cause discharge
of the battery, or use the lights of another vehicle to increase the electrical load.The nominal output current may
not be obtained if the temperature of the alternator itself or ambient temperature is too high.In such a case,
reduce the temperature before testing again.
3. Remove the ammeter and voltmeter and the engine tachometer.
4. Connect the alternator output wire to the alternator "B" terminal.
5. Connect the battery ground cable.
REGULATED VOLTAGE TEST
The purpose of this test is to check that the electronic voltage regulator controls voltage correctly.
PREPARATION
1. Prior to the test, check the following items and correct if necessary.
Check that the battery installed on the vehicle is fully charged. For battery checking method, see "BATTERY".
Check the alternator drive belt tension.
2. Turn ignition switch to "OFF".
4. Connect a digital voltmeter between the "B" terminal of the alternator and ground. Connect the (+) lead of the voltmeter to
the "B" terminal of the alternator. Connect the () lead to good ground or the battery () terminal.
6. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire. Connect the ()
lead wire of the ammeter to the disconnected output wire.
7. Attach the engine tachometer and connect the battery ground cable.
TEST
1. Turn on the ignition switch and check to see that the voltmeter indicates the following value.
Voltage:Battery voltage
If it reads 0V, there is an open circuit in the wire between the alternator "B" terminal and the battery and the battery (), or
the fusible link is blown.
2. Start the engine. Keep all lights and accessories off.
3. Run the engine at a speed of about 2,500 rpm and read the voltmeter when the alternator output current drops to 10A or
less.
RESULT
1. If the voltmeter reading agrees with the value listed in the Regulating Voltage Table below, the voltage regulator is
functioning correctly. If the reading is other than the standard value, the voltage regulator or the alternator is faulty.
REGULATING VOLTAGE TABLE
Voltage regulator ambient temperature °C (°F) Regulating voltage (V)
30 (22) 14.1 ~ 15.2
20 (68) 14.1 ~ 14.7
120 (248) 13.3 ~ 14.7
2. Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.
4. Remove the voltmeter and ammeter and the engine tachometer.
2012 > D 2.0 TCID > Engine Electrical System > Charging System > Alternator > Components andEnglish
Components Location
COMPONENTS
2012 > D 2.0 TCID > Engine Electrical System > Charging System > Alternator > Repair procedures
English
REMOVAL
1) Disconnect the battery negative terminal frist, then the positive terminal.
2) Disconnect the alternator connector(A) and "B" terminal cable(B) from the alternator(C).
3) Disconnect the vacuum pump oil drain hose(D), vacuum pump oil feed hose(E) and vacuum hose(F).
4) Remove the mounting bolt and remove the alternator.
5) Installation is the reverse of removal.
INSTALLATION
Installation is the reverse of removal.
1. Befor install the rotor to the rear bracket, fix the brush(C) by inseting the wire(A) to the rear bracket(B) hole.
2. Remove the wire(A) after assembly the rotor.
English
DISASSEMBLY
DISASSEMBIY
1) Remove the pulley(A).
2) After loosening the three bolts(A). Remove the vacuum pump(B).
3) Remove the B terminal insulator(A) and loosen the five rear cover mounting nuts(B).
4) After loosening the four through bolts(A), remove the rear cover(B).
5) After removing the weld between the stator lead and diode lead(A), remove the regulator assembly(B).
6) Separate the rotor(A), stator(B), and front cover(C).
INSPECTION
INSPECT ROTOR
1. Check that there is continuity between the slip rings(A).
2. Check that there is no continuity between the slip rings and the rotor(B) or rotor shaft(C).
3. If the rotor fails either continuity check, replace the alternator.
INSPECT STATOR
1. Check that there is continuity between each pair of leads(A).
2. Check that there is no continuity between each lead and the coil core.
3. If the coil fails either continuity check, replace the generator.
2012 > D 2.0 TCID > Engine Electrical System > Charging System > Battery > Description and Operation
English
DESCRIPTION
1. The Closed Maintenance Free(CMF) battery is, as the name implies, totally mainfenance free and has no removable
battery cell cap.
2. The Closde Maintenance Free(CMF) battery is, water never needs to be added to the maintenance free battery.
3. The battery is completely sealde, except for small vent holes in the cover.
2012 > D 2.0 TCID > Engine Electrical System > Charging System > Battery > Components and English
Components Location
COMPONENTS
2012 > D 2.0 TCID > Engine Electrical System > Charging System > Battery > Repair procedures English
INSPECTION
Battery Diagnostic Flow
Vehicle parasitic current inspection
1. Turn the all electric devices OFF, and then turn the ignition switch OFF.
2. Close all doors except the engine hood, and then lock all doors.
(1) Disconnect the hood switch connector.
(2) Close the trunk lid. English
(3) Close the doors or remove the door switches.
3. Wait a few minutes until the vehicle’s electrical systems go to sleep mode.

For an accurate measurement of a vehicle parasitic current, all electriacl systems should go to sleep mode. (It takes
at least one hour or at most one day.) However, an approximate vehicle parasitic current can be measured after
10~20 minutes.
4. Connect an ammeter in series between the battery () terminal and the ground cable, and then disconnect the clamp from
the battery () terminal slowly.

Be careful that the lead wires of an ammeter do not come off from the battery () terminal and the ground cable to
prevent the battery from being reset. In case the battery is reset, connect the battery cable again, and then start the
engine or turn the ignition switch ON for more than 10 sec. Repeat the procedure from No. 1.
To prevent the battery from being reset during the inspection,
a. Connect a jump cable between the battery () terminal and the ground cable.
b. Disconnect the ground cable from the battery () terminal.
c. Connect an ammeter between the battery () terminal and the ground cable.
d. After disconnecting the jump cable, read the current value of the ammeter.
5. Read the current value of the ammeter.
• If the parasitic current is over the limit value, search for abnormal circuit by removing a fuse one by one and checking
the parasitic current.
• Check the parasitic current again, and search for suspected unit by removing a unit connected with the abnormal
circuit one by one.
Limit value (after 10~20 min.) : Below 50mA
CLEANING
1. Make sure the ignition switch and all accessories are in the OFF position.
2. Disconnect the battery cables (negative first).
3. Remove the battery from the vehicle.

Care should be taken in the event the battery case is cracked or leaking, to protect your skin from the electrolyte.
Heavy rubber gloves (not the household type) should be wore when removing the battery.
4. Inspect the battery tray for damage caused by the loss of electrolyte. If acid damage is present, it will be necessary to
clean the area with a solution of clean warm water and baking soda. Scrub the area with a stiff brush and wipe off with a
cloth moistened with baking soda and water.
5. Clean the top of the battery with the same solution as described above.
6. Inspect the battery case and cover for cracks. If cracks are present, the battery must be replaced.
7. Clean the battery posts with a suitable battery post tool.
8. Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged or frayed cables and
broken terminal clamps.
9. Install the battery in the vehicle.
10. Connect the cable terminals to the battery post, making sure tops of the terminals are flush with the tops of the posts.
11. Tighten the terminal nuts securely.
12. Coat all connections with light mineral grease after tightening.

When batteries are being charged, an explosive gas forms beneath the cover of each cell. Do not smoke near
batteries being charged or which have recently been charged. Do not break live circuit at the terminals of batteries
being charged.
A spark will occur when the circuit is broken. Keep open flames away form battery.
2012 > D 2.0 TCID > Engine Electrical System > Cruise Control System > Troubleshooting English
TROUBLESHOOTING
Before starting troubleshooting, inspect each of the following sections, and if there is an abnormality, carry out a repair.
1. Check that the actuator and pulley assembly are all normal.
2. Check if the pulley assembly and the movement of cables are working smoothly.
3. Check if there is no excessive play or tension in each cable.
TROUBLESHOOTING PROCEDURES
First, select the applicable malfunction symptom from the "TROUBLE SYMPTOM CHARTS" shown on nest pages.
Determine the condition of all function circuits.
1. Make the following preliminary inspections.
• Check that the installation of the actuator, accelerator cable are correct, and that the cables and links are securely
connected.
• Check that the accelerator pedal moves smootyly.
• Adjust the cable so there is not excessive tension or excessive play on the accelerator cable.
• Check that the actuator and unit assembly, cruise main, control switch and the connector of each cancel switch are
connected securely.
2. Check in the sequence indicated in the "TROUBLE SYMPTOM CHARTS".
3. If a normal condition is indicated, replace the cruise control module.
TROUBLE SYMPTOM CHARTS
TROUBLE SYMPTOM 1
English
TROUBLE SYMPTOM 2
Trouble symptom Probable cause Remedy
The set vehicle speed varies greatly Malfunction of the vehicle speed sensor
upward or downwqrd circuit Repair the vehicle speed sensor
"Surging" (repeated alternating system, or replace the part
Malfunction of the speedometer cable or
acceleration and deceleration) occurs
speedometer drive gear
after setting
Malfunction of the actuator and unit Replace the actuator and unit
TROUBLE SYMPTOM 3
The CC system is not canceled when Damaged or disconnected wiring of the Repair the harness or replace the stop
the brake pedal is deprssed stop lamp switch lamp switch
TROUBLE SYMPTOM 4
The CC system is not canceled when the Damaged or disconnected wiring of
Repair the harness or repair or replace
shift lever is moved to the "N" position (It inhibitor switch input circuit
the ingibitor switch
is canceled, however, when the brake
pedal is depressed Improper adjustment of inhibitor switch
TROUBLE SYMPTOM 5
Temporary damaged or disconnected Repair the harness or replace the SET
Cannot decelerate (coast) by using the wiring of SET switch input circuit switch
SET switch
Actuator circuit poor contact Repair the harness or replace the
actuator
Malfunction of the actuator
TROUBLE SYMPTOM 6
Damaged or disconnected wiring, or short
Repair the harness or RESUME switch
Cannot accelerate or resume speed by circuit, or RESUME switch input circuit
using the RESUME switch
actuator
TROUBLE SYMPTOM 7
CC system can be set while driving at a Malfunction of the vehiclespeed sensor
vehicle speed of less than 40km/h circuit Repair the vehicle speed sensor
(25mph), or there is no automatic system, or replace the part
cancellation at that speed
the speedometer drive gear
TROUBLE SYMPTOM 8
The cruise main switch indicator lamp Damaged or disconnected bulb of cruise
does not illuminate (But CC system is main switch indicator lamp Repair the harness or replace the part.
normal)
Harness damaged or disconnected
TROUBLE SYMPTOM 9
Malfunction of control function by Malfunction of circuit related to idle switch
function Repair the narness or replace the part
ON/OFF switching of idle switch
Malfunction of the actuator and unit
TROUBLE SYMPTOM 10
Overdrive is not canceled during fixed Malfunction of circuit related to overdrive
speed driving cancellation, or malfunction of actuator Repair the harness or replace the part
No shift to overdrive during manual and unit
driving
2012 > D 2.0 TCID > Engine Electrical System > Cruise Control System > Cruise Control Actuator >
English
Schematic Diagrams
CIRCUIT DIAGRAM
2012 > D 2.0 TCID > Engine Electrical System > Cruise Control System > Cruise Control Switch > Repair
English
procedures
REMOVAL
1. Remove the air bag module assembly. (Refer to 'RT','ST' group)
2. Disconnect the auto cruise control main switch connector.
3. Remove the auto cruise control main switch assembly.
4. To install, reverse the removal procedure.
INSPECTION
1. Operate the switchs and check for continuity between the terminals.
2. If continuity is not as specified, replace the switch.
2012 > D 2.0 TCID > Engine Electrical System > General Information > General Information English
THE MICRO 570 ANALYZER
The Micro 570 Analyzer provides the ability to test the charging and starting systems, including the battery, starter and alternator.

※ Because of the possibility of personal injury, always use extreme caution and appropriate eye protection when working
with batteries.
※ When charging battery by test result, Battery must be fully charged.
To get accurate test result, battery surface voltage must have subsided ahead before test when you test battery after
charged. (See following Battery Test Results)
Keypad
The Micro 570 button on the key pad provide the following functions :
Battery Test Procedure
1. Connect the tester to the battery.
– Red clamp to battery positive (+) terminal.
– Black clamp to battery negative () terminal.
English

Connect clamps securely. If "CHECK CONNECTION" message is displayed on the screen, reconnect clamps
securely.
2. The tester will ask if the battery is connected "INVEHICLE" or "OUTOFVEHICLE". Make your selection by pressing the
arrow buttons; then press ENTER.
3. Select CCA and press the ENTER button.

CCA : Cold cranking amps, is an SAE specification for cranking batteried at 0.4°F (18°C).
4. Set the CCA value displayed on the screen to the CCA value marked on the battery label by pressing up and down buttons
and press ENTER.

The battery ratings(CCA) displayed on the tester must be identical to the ratings marked on battery label.
5. The tester will conduct battery test.
6. The tester displays battery test results including voltage and battery ratings.
Refer to the following table and take the appropriate action as recommended by the Micro 570.
Battery Test Results
Result On Printer Remedy
GOOD BATTERY No action is required.
GOOD RECHARGE Battery is in a good state.
Recharge the battery and use.
※ You have to follow instruction below when you charge battery and retest, otherwise
test result can be inaccurate. (See ‘Charge and Retest method after battery charge’
below.)
CHARGE & RETEST Battery is not charged properly.
– Charge and test the battery again.
below.)
REPLACE BATTERY Replace battery and recheck the charging system.
– Improper connection between battery and vehicle cables may cause "REPLACE
BATTERY". Retest the battery after removing cables and connecting the tester to
the battery terminal directly prior to replacing the battery.
BAD CELLREPLACE Charge and retest the battery.
– If the Micro 570 recommends "REPLACE BATTERY", replace the battery and
recheck the charging system.
[Charge and Retest method after battery charge]
Battery charge
Set battery charger to ‘Auto Mode’ (The Mode that charging current drops as the battery charges.) and charge battery until
charging current down close to zero or the charger alerts you with an alarm when charge is complete.
(Minimum charging time recommended: More than 3 hours with Auto Mode that explained above)
• If battery is not fully charged, battery surface voltage will be high while the amount of current charged (CCA) in battery
is low. If you measure the battery under this condition, tester may misjudge that battery sulfation occurred because
the amount of current in battery is too low in comparison with battery voltage.
* Surface voltage: When battery is charged electrolyte temperature increases and chemical reaction become active
resulting in an excessive increase of battery voltage.
It is known that it takes approximate one day to subside this increased surface voltage completely.
Battery Test after charge
Do not test battery right after the charge. Test battery after battery surface voltage has subsided as instructed in the
following procedure.
(1) When battery charge is complete, install the battery in the vehicle.
(2) Put IG key to ON position and turn on head lamp with low beam, and wait 5 minutes. (Discharge for 5 minutes)
(3) Turn off the head lamp and IG key, and wait 5 minutes. (Waiting for 5 minutes)
(4) Remove +, cable from the battery and test battery.

Whenever filing a claim for battery, the print out of the battery test results must be attached.
Starter Test Procedure
7. After the battery test, press ENTER immediately for the starter test.
9. Cranking voltage and starter test results will be displayed on the screen.
Starter Test Results
CRANKING VOLTAGE System shows a normal starter draw.
NORMAL
CRANKING VOLTAGE LOW Cranking voltage is lower than normal level.
– Check starter.
CHARGE BATTERY The state of battery charge is too low to test.
– Charge the battery and retest.
REPLACE BATTERY Replace battery.
– If the vehicle is not started though the battery condition of "GOOD BATTERY" is
displayed, check wiring for open circuit, battery cable connection, starter and repair
or replace as necessary.
– If the engine does crank, check fuel system.

When testing the vehicle with old diesel engines, the test result will not be favorable if the glow plug is not heated.
Conduct the test after warming up the engine for 5 minutes.
Charging System Test Procedure
10. Press ENTER to begin charging system test.
11. The tester displays the actual voltage of alternator.
Press ENTER to continue.
12. Turn off all electrical load and rev engine for 5 seconds with pressing the accelerator pedal. (Follow the instructions on the
screen)
13. The message that engine RPM is detected will be displayed on the screen. Press ENTER to continue.
14. If the engine RPM is not detected, press ENTER after revving engine.
15. The tester will conduct charging system test during loads off.
16. Turn on electrical loads (air conditioner, lamps, audio and etc). Press ENTER to continue.
17. The tester will conduct charging system test during loads on.
18. Rev engine for 5 seconds with pressing the accelerator pedal. (Follow the instructions on the screen)
21. Turn off electrical loads (air conditioner, lamps, audio and etc). Turn the engine off.
22. Charging voltage and charging system test results will be displayed on the screen.
Shut off engine end disconnect the tester clamps from the battery. Refer to the following table and take the appropriate
action as recommended by the Micro 570.
Charging System Test Results
CHARGING SYSTEM Charging system is normal.
NORMAL / DIODE RIPPLE
NORMAL
NO CHARGING VOLTAGE Alternator does not supply charging current to battery.
– Check belts, connection between alternator and battery and replace belts or cable
or alternator as necessary.
LOW CHARGING VOLTAGE Alternator does not supply charging current to battery and electrical load to system fully.
– Check belts and alternator and replace as necessary.
HIGH CHARGING VOLTAGE The voltage from alternator to battery is higher than normal limit during voltage
regulating.
– Check connection and ground and replace regulator as necessary.
– Check electrolyte level in the battery.
EXCESS RIPPLE DETECTED One or more diodes in the alternator is not functioning properly.
– Check alternator mounting and belts and replace as necessary.
2012 > D 2.0 TCID > Engine Electrical System > General Information > Specifications English
SPECIFICATION
STARTING SYSTEM
Item Specifications
Type PRE.engaged drive
Rated voltage 12V, 2.0KW
No. of pinion teeth 12
Voltage 11V
Noload charasteristics Amperage 130A, MAX
Starter
Speed 3,600rpm, MIN
Standard
Commutator diameter 35 mm (1.378 in)
Limit
Standard
Undercut depth 0.7 mm (0.028 in)
Limit
CHARGING SYSTEM
Item Specifications
Rated voltage 12V, 120A
Speed 1,000 ~ 12,000 rpm
Alternator Voltage regulator I.C regulator builtin type
Regulator setting voltage 14.4 ± 0.3V(AT 20°C full chgreged battery)
Temperrature compensation 10 ± 3mV/°C
Type CMF 80AH
Cold cranking amperage at18°C (0°F) 720A
Battery
Reserve capacity 160min
Specific gravity at 20°C (77°F) 1.280 ± 0.01

– COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminal
voltage of 7.2V or greater at a specified temperature.
– REVERSE CAPACITY RATING is amount of time a battery can deliver 25A and maintain a minimum terminal
voltage of 10.5V at 25.7°C(77°F)
PREHEATING SYSTEM
Item Specifications
Glow plug 16A ± 1.5A after 4 seconds loading at rated
Current
voltage
English
Operating voltage range DC 9V ~ DC 16V
Glow plug relay
Operating temperature range 40°C ~ 120°C
Rated load current DC 12V, 70A
TIGHTENING TORQUE
Items Nm kgf.m lb·ft
Generator terminal (B+) 10.8 ~ 14.7 1.1 ~ 1.5 8.0 ~ 10.8
Generator mounting bolts 38.2 ~ 58.8 3.9 ~ 6.0 28.2 ~ 43.4
Starter motor terminal (B+) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Stater moter mounting bolts 58.8 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Battery terminal 0.4 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
Glow plug 9.8 ~ 13.7 1.0 ~ 1.4 7.2 ~ 10.1
Glow plug plate attaching nut 0.8 ~ 0.15 0.08 ~ 0.15 0.6 ~ 1.1
2012 > D 2.0 TCID > Engine Electrical System > General Information > Troubleshooting English
TROUBLESHOOTING
CHARGING SYSTEM
Charging warning indicator Fuse blown Check fuses
does not light with ignition Light burned out Replace light
switch "ON" and engine off Wiring connection loose Tighten loose connections
Electronic voltage regulator Replace voltage regulator
Charging warning indicator Drive belt loose or worn Adjust tension or replace drive belt
does not go out with engine Battery cables loose, corroded or worn Repair or replace cavles
running (Battery requires Fuse blown Check fuses
frequent recharging) Fusible link blown Replace fusible link
Electronic voltage regulator or generator Test generator
Wiring Repair wiring
Engine hesitates/poor Drive belt loose or worn Adjust tension or replace drive belt
acceleration Wiring connection loose or open circuit Tighten loose connection or repair wiring
Overcharge Replace fusible link
Fusible link blown Repair
Poor grounding Test generator, if faulty, repair or replace
Electronic voltage regulator or generator Replace battery
Worn battery Replace voltage regulator
Electronic voltage regulator Repair wire
Voltage sensing wire
STARTING SYSTEM
Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded or worn out Repair or replace cables
Transaxle range switch (Vehicle with automatic Adjust or replace switch
transaxle only)
Fusible link blown Replace fusible link
Starter motor faulty Repair starter motor
Ignition switch faulty Inspect
Engine cranks slowly Battery charge low Charge or replace battery
Starter motor Repair starter motor
Starter keeps running Starter motor Repair starter motor
Ignition switch Inspect
Starter spins but engine will Short in wiring Repair wiring
not crank Pinion gear teeth broken or starter motor Repair starter motor
Ring gear teeth broken Replace flywheel ring gear or torque
converter
2012 > D 2.0 TCID > Engine Electrical System > Preheating System > Components and Components
English
Location
COMPONENT LOCATION
2012 > D 2.0 TCID > Engine Electrical System > Preheating System > Repair procedures English
INSPECT PREHEATING SYSTEM
Conditions before inspection :
Battery voltage : 12V
1. Connect voltmeter between glow plug plate and plug body (ground).
2. Check indicated value on voltmeter with ignition switch ON.
3. Check that preheat indication lamp lights for about 6 seconds and indicates battery voltage (about 9V or over) for about 36
seconds immediately afterignitionswitch is turned on. [At cooling water temperature 20°C (68°F)]

Continuity time varies depending upon cooling water temperature.
4. After checking 3, set ignition switch at START position.
5. The system is normal if battery voltage (about 9V or over) is generatedforabout 6 seconds during engine cranking and after
start operation. [at coolingwater temperature 20°C (68°F)]
6. When the voltage or continuity time is not normal, check the terminal voltage in glow control unit, and single parts.
INSPECT GLOW PLUS
1. Check the continuity between the terminal and body as illustrated. Replaceif discontinuity or with large resistance.
Standard value : 0.25Ω

Remove oil from plug before measuring as glow plug resistance is verysmall.
2. Check for rust on glow plug plate.
3. Check glow plug for damage.
English
INSPECT GLOW PLUG RELAY
1. Remove the glow plug relay.
2. Inspect the relay continuity.
– Using an ohmmeter, check that there is continuity between terminals 85 and 86.
If there is no continuity, replace the relay.
– Check that there is no continuity between terminals 30 and 87.
If there is continuity, replace the relay.
3. Inspect the relay operation.
– Apply battery positive voltage across terminals 85 and 86.
4. Install the glow plug relay.
2012 > D 2.0 TCID > Engine Electrical System > Starting System > Description and Operation English
DESCRIPTION
The starting system includes the battery, starter motor, solenoid switch, ignition switch, inhibitor switch(A/T), ignition lock switch,
connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter motor's solenoid coil.
The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.
The contacts close and the starter motor cranks. In order to prevent damage caused by excessive rotation of the starter armature when
the engine starts, the clutch pinion gear overruns.
2012 > D 2.0 TCID > Engine Electrical System > Starting System > Repair procedures English
INSPECTION
STARTER CIRCUIT
The battery must be in good condition and fully charged.
1. Remove the fuel pump relay(A) from the fuse box.
2. With the shift lever in N or P (A/T) or clutch pedal pressed (M/T), turn the ignition switch to "START"
If the starter normally cranks the engine, starting system is OK.
If the starter will not crank the engine at all, go to next step.
If it won't disengage from the ring gear when you release key, check for the following until you find the cause.
• Solenoid plunger and switch malfunction.
• Dirty pinion gear or damaged overrunning clutch.
3. Check the battery condition. Check electrical connections at the battery, battery negative cable connected to the body,
engine ground cables, and the starter for looseness and corrosion. Then try starting the engine again.
If the starter cranks normally the engine, repairing the loose connection repaired the problem.
The starting system is now OK.
If the starter still does not crank the engine, go to next step.
4. Disconnect the connector from the Sterminal of solenoid. Connect a jumper wire from the Bterminal of solenoid to the S
terminal of solenoid.
If the starter cranks the engine, go to next step.
If the starter still does not crank the engine, remove the starter, and repair or replace as necessary.
5. Check the following items in the order listed until you find the open circuit.
• Check the wire and connectors between the driver's underdash fuse/relay box and the ignition switch, and between
the driver's underdash fuse/relay box and the starter.
• Check the ignition switch (Refer to BE group ignition system)
• Check the transaxle range switch connector or ignition lock switch connector.
• Inspect the starter relay.
STARTER SOLENOID TEST
1. Disconnect the wires from the Sterminal and the M terminal.
2. Connect the battery as shown. If the starter pinion pops out, it is working properly. To avoid damaging the starter, do not
leave the battery connected for more than 10 seconds.
English
3. Disconnect the battery from the M terminal.
If the pinion does not retract, the holdin coil is working properly. To avoid damaging the starter, do not leave the battery
connected for more than 10 seconds.
4. Disconnect the battery also from the body. If the pinion retracts immediately, it is working properly.
To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.
FREE RUNNING TEST
1. Place the starter motor in a vise equipped with soft jaws and connecta fullycharged 12volt battery to starter motor as
follows :
2. Connect a test ammeter (100ampere scale) and carbon pile rheostatas shown is the illustration.
3. Connect a voltmeter (15volt scale) across starter motor.
4. Rotate carbon pile to the off position.
5. Connect the battery cable from battery's negative post to the starter motor body.
6. Adjust until battery voltage shown on the voltmeter reads 11 volts.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely :
: Max. 130 Amps
: Min. 3,600 rpm
CLEANING
1. Do not immerse parts in cleaning solvent. Immersing the yoke assembly and/or armature will damage the insulation. Wipe
these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent. The overrun clutch is prelubricated at the factory and solvent will wash
lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.
2012 > D 2.0 TCID > Engine Electrical System > Starting System > Starter > Components and English
Components Location
COMPONENTS
2012 > D 2.0 TCID > Engine Electrical System > Starting System > Starter > Repair procedures English
REMOVAL
1. Disconnect the battery negative cable.
2. Disconnect the starter cable(A) from the B terminal on the solenoid, then disconnect the connector(B) from the S terminal.
3. Remove the 2 bolts holding the starter, then remove the starter.
Tightening torpue
42.2~53.9 N.m (4.3~5.5 kgf.m, 31.1~39.8 Ibft)
5. Connect the battery positive cable and negative cable to the battery.
INSPECTION
ARMATURE INSPECTION AND TEST
1. Remove the starter.
2. Disassemble the starter as shown at the beginning of this procedure.
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the
armature.
4. Measure the commutator (A) runout.
• If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the
segments.
• If the commutator runout is not within the service limit, replace the armature.
Commutator Runout
Standard (New) : 0.02mm (0.001 in.) max.
Service limit : 0.05mm (0.002 in.)
English
5. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the
armature.
6. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and between the
commutator and armature shaft (C). If continuity exists, replace the armature.
INSPECT STARTER BRUSH
STARTER BRUSH HOLDER TEST
INSPECT OVERRUNNING CLUTCH
1. Slide the overrunning clutch along the shaft.
Replace it if does not slide smoothly.
2. Rotate the overrunning clutch (A) both ways.
Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or it locks in both
directions, replace it.
3. If the starter driver gear (B) is worn or damaged, replace the overrunning clutch assembly: the gear is not available
separately.
Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.
DISASSEMBLY
1) Remove the nut(A) and disconnect the lead wire(B) from the magnetic switch terminal(C).
2) Remove the 2 bolts(A) and pull out the yoke assembly(B) with the armature(C) from the front bracket(D).
3) Remove the through bolts (A).
4) Remove the rear bracket (A) and brush holder assembly (B).
5) Remove the yoke (C) and armature (D).
6) Remove the mounting bolt (A) and the overrunning clutch (B), lever (C).
7) Reassembly is the reverse of disassembly.
2012 > D 2.0 TCID > Engine Mechanical System > General Information > Specifications English
SPECIFICATIONS
Description Specification 2.0(D4EA) Limit

General
Type Inline, Single Overhead Camshaft
Number of cylinders 4
Bore 83mm (3.27in.)
Stroke 92mm (3.62in.)
Total displacement 1991cc (121.5cu.in.)
Compression ratio 17.3 : 1
Firing order 1 3 4 2
Valve timing
Intake valve
Opens (BTDC) 7°
Closes (ABDC) 35°
Exhaust valve
Opens (BBDC) 52°
Closes (ATDC) 6°
Cylinder head
Faltness of gasket surface 0.03mm (0.0012in.) for width
0.09mm (0.0035in.) for length
0.012mm. (0.00047in.) / 51×51mm
Camshaft
Cam height
Intake 34.697mm (1.366in.) 34.197mm (1.346in.)
Exhaust 34.570mm (1.361in.) 34.070mm (1.341in.)
Journal O.D 28mm (1.10in.)
Bearing oil clearance 0.040 ~ 0.074mm (0.0020 ~ 0.0029in.)
End play 0.05 ~ 0.15mm (0.002 ~ 0.006in.)
Valve
Valve length
Intake 95.7mm (3.77in.)
Exhaust 95.4mm (3.76in.)
Stem O.D.
Face angle 45.5°
Thickness of valve head (margin)
English
Valve stem to valve guide clearance
Intake 0.022 ~ 0.067mm (0.00086 ~ 0.00263in.) 0.1mm (0.0039in.)
Exhaust 0.050 ~ 0.095mm (0.0020 ~ 0.0037in.) 0.15mm (0.0059in.)
Valve guide
Length
Valve seat
1.21 ~ 1.61mm (0.0477 ~ 0.6634in.)
Width of seat contact
(IN/EX)
Seat angle 44° ~ 44.5°
Valve spring
Free length 38.8mm (1.527in.)
Load 21.25kg/32mm (47.2lb/1.26in.)
at installed height
Cylinder block
Cylinder bore 83 + 0.03mm (3.27 + 0.0012in.)
Flatness of head gasket surface 0.042mm (0.00165in.) for width
0.096mm (0.00378in.) for length
0.012mm (0.00047in.) / 50×50mm
Piston
O.D 82.92 ~ 82.95mm (3.26 ~ 3.27in.)
Pistontocylinder clearance 0.07 ~ 0.09mm (0.0027 ~ 0.0036in.)
Ring groove width
No.1 1.915 ~ 1.945mm (0.075 ~ 0.076in.)
No.2 2.06 ~ 2.08mm (0.08 ~ 0.082in.)
Oil 3.02 ~ 3.04mm (0.119 ~ 0.1196in.)
Service size 0.25mm (0.010in.), 0.5mm (0.020in.)
oversize
Piston ring
Side clearance
No.1 0.064 ~ 0.114mm (0.00252 ~ 0.00449in.)
No.2 0.065 ~ 0.11mm (0.00256 ~ 0.00433in.)
Oil ring 0.03 ~ 0.07mm (0.00118 ~ 0.00275in.)
End gap
No.1 0.2 ~ 0.35mm (0.008 ~ 0.014in.)
No.2 0.40 ~ 0.50mm (0.016 ~ 0.024in.)
Oil ring side rail 0.2 ~ 0.45mm (0.0079 ~ 0.0177in.)
Connecting rod
Connecting rod pin O.D 28.022 ~ 28.034mm (1.103 ~ 1.104in.)
Connecting rod bearing oil clearance 0.024 ~ 0.042mm (0.0009 ~ 0.0016in.)
Crankshaft main bearing oil clearance 0.024 ~ 0.042mm (0.0009 ~ 0.0016in.)
Crankshaft
Journal O.D. 60.002 ~ 60.020mm (2.362 ~ 2.363in.)
Pin O.D. 50.008 ~ 50.026mm (1.9688 ~ 1.9695in.)
Outofround of journal and pin Less than 0.0035mm (0.0001in.)
Taper of journal and pin Less than 0.006mm (0.0002in.)
End play 0.09 ~ 0.32mm (0.0035 ~ 0.0126in.)
Flywheel
Runout 0.45mm/Ø200 0.45mm (0.0170in.)
Engine oil
When replacing a short engine or a
Total 7.4 L (7.81 US qt, 6.51 lmp qt)
block assembly
Oil quantity
Oil pan 6.2 L (6.55 US qt, 5.45 lmp qt)
Drain and refill 6.7 L (7.07 US qt, 5.89 lmp qt) Including oil filter
ACEA C3 (with CPF)
Classification
Oil grade ACEA B4 (without CPF)
SAE viscosity grade Recommended SAE viscosity number Refer to the "Lubrication System"
Oil temperature in oil pan : 80°C
Oil pressure (at idle) 78.45kPa (0.8kg/cm², 11.38psi) or above
(176°F)
Oil pump
Oil pump performance More than
[Oil temperature is 95 ~ 105°C (203 ~ 25ℓ/min (0.01471ft³/s)
221°F, SAE 10W 30)]&Eng rpm 1500 4.0kgf/cm²(8192lbf/ft²)
Tip clearance 0.28 ~ 0.36mm (0.01102 ~ 0.01417in.)
Radial clearance 0.13 ~ 0.23mm (0.0051 ~ 0.009in.)
Side clearance 0.02 ~ 0.07mm (0.00078 ~ 0.0027in.)
Relief spring
Freen length 47.5mm (1.835in.)
Opening pressure 570 ± 50kPa (82.67 ± 7.25psi)
Silent shaft
Front journal diameter 27.99 ~ 28.01mm (1.102 ~ 1.1027in.)
Rear journal diameter 41.99 ~ 42.01mm (1.6531 ~ 1.6539in.)
Oil clearacne
Front 0.050 ~ 0.09mm (0.0020 ~ 0.0036in.)
Rear 0.050 ~ 0.091mm (0.0020 ~ 0.0036in.)
Cooling method
Forced circulation with electrical fan
Cooling system quantity (Radiator)
7.3L (7.7U.S.qts, 6.42 lmp.qts)
Thermostat
Type Wax pellet type with jiggle valve
Normal opening temperature 85°C (185°F)
Opening temperature range 83.5 ~ 86.5°C (182 ~ 188°F)
Full opening temperature 100°C (212°F)
107.9 ± 14.7kPa
Radiator cap
(1.1±0.15kg/cm², 15.64±2.13psi)
Main valve openg pressure
Main valve closing pressure 83.4kPa (0.85kg/cm², 12.1psi )
Vacuum valve openting pressure 6.86kPa (0.07kg/cm², 1.00psi)
Air cleaner
Type Dry type
Element Unwoven cloth type
Exhaust
Muffler Expansion resonance type
Suspension system Rubber hangers
Coolant tempreature sensor
Type Thermister type
Resistance
20°C (68°F) 2.45 ± 0.14kΩ
80°C (176°F) 0.3222kΩ
SERVICE STANDARDS
Standard value
Coolant concentration
Tropical area 40%
Other area 50%
LUBRICANT
Engine oil ACEA : C3(CPF EQUIPPED SAE 15W40 (ABOVE 15°C)
VEHICLE
SAE 10W30 (20°C ~ 40°C)
ACEA : B4 or API CH4
ABOVE(NON CPF VEHICLE) SAE 5W30 (25°C ~ 40°C)
SAE 0W30 (BELOW 10°C)*1 *2
*1. Restricted to driving condition and area
*2. Not recommeded for sustained high speed
SEALANT
Engine coolant temperature sensor 3M No.1324 or equivalant
Oil pressure switch 3M ATD No. 8660 or Three bond TB 2403
Bed plate OMNI FIT FD20, DREIBOND 5105 or HYLOMAR 3000

O.D. = Outer Diameter
I.D. = Inner Diameter
O.S. = Oversize Diameter
U.S. = Undersize Diameter
TIGHTENING TORQUE
Items N.m kgf.m lbf.ft
Engine system
High fuel pipe(reil↔pump) mounting nut 24.5 ~ 28.4 2.5 ~ 2.9 18.1 ~ 21.0
Drive plate 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9
Damper pulley mounting bolt 29.4 ~ 33.3 3.0 ~ 3.4 21.7 ~ 24.6
Real roll stopper bracket sub frame bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Real roll mounting insulator bolts 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Relief plug 41.2 ~ 51.0 4.2 ~ 5.2 30.4 ~ 37.6
Balance shaft assembly mounting bolt 52.0 ~ 55.9 5.3 ~ 5.7 38.3 ~ 41.2
Engine support bracket bolt 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Starter motor mounting bolt 47.1 ~ 51.0 4.8 ~ 5.2 34.7 ~ 37.6
Cylinder head bolt 49.0 + 120° + 90° 5.0 + 120° + 90° 36.2 + 120° + 90°
Cylinder head cover mounting bolt(10mm) 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Cylinder head cover mounting bolt(12mm) 21.6 ~ 25.5 2.2 ~ 2.6 15.9 ~ 18.8
Air cleaner mounting bolt 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Air cleaner intake hose clamp 2.9 ~ 4.9 0.3 ~ 0.5 2.2 ~ 3.6
Engine mounting bracket bolt & nut 63.7 ~ 83.4 6.5 ~ 8.5 47.0 ~ 61.5
Injector holder bolt 7.8 ~ 10.8 0.8 ~ 1.1 5.8 ~ 8.0
A/T mounting bracket bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
A/T insulator bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Camshaft bearing cap bolt 26.5 ~ 29.4 2.7 ~ 3.0 19.5 ~ 21.7
Camshaft sprocket mounting bolt 122.6 ~ 140.2 12.5 ~ 14.3 90.4 ~ 103.4
Connecting rod cap bolt 24.5 + 90° 2.5 + 90° 18.1 + 90°
Crankshaft bed plate bolt(15mm) (27.5~31.4) + 120° (2.8~3.2) + 120° (20.3~23.1) + 120°
Crankshaft bed plate bolt(12mm) 33.3 ~ 37.3 3.4 ~ 3.8 24.6 ~ 27.5
Crankshaft pulley bolt 196.1 ~ 205.9 20.0 ~ 21.0 144.7 ~ 151.9
Crankshaft position mounting bolt 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
Front roll stopper bracket sub frame mounting bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Front roll stopper insulator bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Fly wheel 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.5
Timing system
Timing auto tensioner bolt 49.0 ~ 53.9 5.0 ~ 5.5 36.2 ~ 39.8
Upper cover mounting bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Rear cover mounting bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Idler mounting bolt 44.1 ~ 48.1 4.5 ~ 4.9 32.5 ~ 35.4
Auto tensiner adjustable bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Lower cover mounting bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Lubrication system
Oil lever gage mounting bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil screen mounting bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil jet mounting bolt 8.8 ~ 12.7 0.9 ~ 1.3 6.5 ~ 9.4
Oil pan drain plug 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Oil pan bolt 9.8 ~ 7.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pump mounting bolt 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil pump cover bolt 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Oil pressure switch 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Oil filter 22.6 ~ 24.5 2.3 ~ 2.5 16.6 ~ 18.1
Heater & oil cooler return pipe bracket mounting
7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
bolt(10mm)
Heater & oil cooler return pipe bracket mounting
19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
bolt(12mm)
Cooling system
Water pump mounting bolt(10mm) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump mounting bolt(14mm) 47.1 ~ 51.0 4.8 ~ 5.2 34.7 ~ 37.6
Radiator drain plug 7.8 ~ 15.7 0.8 ~ 1.6 5.8 ~ 11.6
Radiator shroud mounting bolt 8.8 ~ 10.8 0.9 ~ 1.1 6.5 ~ 8.0
Radiator upper bracket mounting bolt 8.8 ~ 10.8 0.9 ~ 1.1 6.5 ~ 8.0
Engine water coolant temperature sensor 19.6 ~ 23.5 2.0 ~ 2.4 14.5 ~ 17.4
Thermostat inlet mounting bolt, nut 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Intake & exhaust system
Main muffler and center exhaust pipe nuts 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Cylinder head and exhaust manifold nuts 24.5 ~ 37.3 2.5 ~ 3.8 18.1 ~ 27.5
Catalytic convert and center exhaust pipe nuts 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9
Turbo charger support bolt 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Intake manifold mounting nuts & bolt 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
2012 > D 2.0 TCID > Engine Mechanical System > General Information > Special Service Tools English
SPEICAL TOOLS

Camshaft oil seal installer Installation of the camshaft oil seal
(0921227100)
Valve spring compressor Removal and installation of intake and exhaust
(0922227300) valves
Valve stem oil seal installer Installation of valve stem oil seals
(0922227200)
Crankshaft rear oil seal Installation of the crankshaft real oil seal
installer
(0923127000)
Front case oil seal installer Installation of the front case oil seal
(0923127100)
Injector oil seal installer Installation of the injector oil seal
(0935127401)
Compression gauge & adapter Checking engine compression pressure
(0935127000)
(0935127500)
English
Oil filter wrench Removal and installation of oil filter
(0926327000) For the rest area except Europe LHD
Oil filter wrench Removal and installation of oil filter
(092632E000) For Europe LHD
Engine support fixture and Engine fixing
adapter
(0920038001, 092001C00)
2012 > D 2.0 TCID > Engine Mechanical System > General Information > Troubleshooting English
TROUBLESHOOTING
Symptom Suspect Remedy

Engine misfire with Loose or improperly installed engine flywheel. Repair or replace the flywheel as required.
abnormal internal lower
Worn piston rings Inspect the cylinder for a loss of compression.
engine noises.
(Oil consumption may or may not cause the Repair or replace as required.
engine to misfire.)
Worn crankshaft thrust bearings. Replace the crankshaft and bearings as required.
Engine misfire with Stuck valves Repair or replace as required
abnormal valve train (Carbon buildup on the valve stem can cause the
noise. valve not to close properly.)
Excessive worn or misaligned timing belt Replace the timing belt and sprocket as required.
Worn camshaft lobes. Replace the camshaft and valve lifters.
Engine misfire with • Faulty cylinder head gasket and/or cranking • Inspect the cylinder head and engine block
coolant consumption. or other damage to the cylinder head and for damage to the coolant passages and/or
engine block cooling system. a faulty head gasket.
• Coolant consumption may not cause the • Repair or replace as required.
engine to overheat.
Engine misfire with Worn valves, valve guides and/or valve stem oil Repair or replace as required.

excessive oil seals.
consumption.
Worn piston rings. • Inspect the cylinder for a loss of
(Oil consumption may or may not cause the compression.
engine to misfire) • Repair or replace as required.
Engine noise on start Incorrect oil viscosity. • Drain the oil

up, but only lasting a
few seconds. • Install the correct viscosity oil.
Worn crankshaft thrust bearing. • Inspect the thrust bearing and crankshaft.
• Repair or replace as required.
Upper engine noise, Low oil pressure. Repair or replace as required.

regardless of engine
Broken valve spring. Replace the valve spring
speed.
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing belt and/or damaged
Replace the timing belt and sprockets.
sprocket teeth.
Worn timing chain tensioner, if applicable. Replace the timing chain tensioner as required.
Worn camshaft lobes. • Inspect the camshaft lobes.
• Replace the timing camshaft and valve
lifters as required.
Inspect the valves and valve guides, then repair
Worn valve guides or valve stems.
as required.
Stuck valves. Inspect the vlaves and valve guides, then repair
(Carbon on the valve stem or valve seat may as required.
cause the valve to stay open.)
Lower engine noise, Repair or replace damaged components as
English
Low oil pressure.
regardless of engine required.
speed.
Loose or damaged flywheel. Repair or replace the flywheel.
Damaged oil pan, contacting the oil pump screen. • Inspect the oil pan.
• Inspect the oil pump screen.
Oil pump screen loose, damage or restired. • Inspect the oil pump screen.
Excessive pistontocylinder bore clearance. • Inspect the piston and cylinder bore.
• Repair as required.
Excessive piston pinto bore clearance. • Inspect the piston, piston pin and the
connecting rod.
Excessive connecting rod bearing clearance Inspect the following components and repair as
required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
• The crankshaft journal.
Excessive crankshaft bearing clearance Inspect the following components and repair as
required.
• The crankshaft bearings.
• The crankshaft journals.
Incorrect piston, piston pin and connecting rod • Verify the piston pins and connecting rods
installation are installed correctly.
Engine noise under load Low oil pressure Repair or replace as required.

Excessive connecting rod bearing clearance Inspect the following components and repair as
required.
• The crankshaft
Excessive crankshaft bearing clearnace Inspect the following components, and repair as
required.
• The cylinswe block crankshaft bearing bore.
Engine will not crank Hydraulically cylinder 1) Remove injectors and check for fluid.

crakshaft will not rotate • Coolant/antifreeze in cylinder.
2) Inspect for broken head gasket.
• Oil in cylinder.
3) Inspect for cranked engine black or cylinder
• Fuel in cylinder head.
4) Inspect for a sticking fuel injector and/or
leaking fuel regulator.
Broken timing chain and/or timing chain gears. 1) Inspect timing chain and gears.
2) Repair as required.
Material cylinder 1) Inspect cylinder for damaged components
• Broken valve and/or foreign materials.
• Piston material 2) Repair or replace as required.
• Foreign meterial
Seized crankshaft or connecting rod bearings. 1) Inspect crankshaft and connecting rod
bearing.
Bent or broken connecting rod. 1) Inspect connectong rods.
Broken crankshaft 1) Inspect crankshaft.
2012 > D 2.0 TCID > Engine Mechanical System > General Information > Repair procedures English
COMPRESSION PRESSURE INSPECTION
1. Check the engine oil, stater motor and the battery normal condition.
2. Warm up the engine until the normal operating temperature becoming 80~95°C(176~203°F).
3. Engine stop, remove the air cleaner assembly.
4. Remove the Electronic Control Module(ECM).
5. Remove the injector.(Refer to Injector in FLC Group).
6. While cranking the engine, remove impurity from the cylinder.
7. Install the pressure gauge(0935127000 , 0935127500) to the injector hall.
8. While cranking the engine, measure the compression pressure.
Compression pressure
Standard pressure :
2,549kPa (26.0kgf/cm², 369psi) 270rpm
Minimum pressure :
2,255kPa (23.0kgf/cm², 327psi)
9. Check the power balance between all cylinder are within limlt by repeating steps 7) through 8) for each cylinder.
Limit : each cylinder pressure 294kPa (3.0kgf/cm², 42psi)
10. If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinderthrough the
spark plug hole and repeat steps through for cylinders with low compression. Repeat steps 7) through 9) for each cylinder.
(1) If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.
(2) If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.
11. In case of remove the injection nozzle when measure cylinder compressed pressure replace gasket and holder with new
one and tighten them Tightening torque.
2012 > D 2.0 TCID > Engine Mechanical System > Engine And Transaxle Assembly > Repair procedures
English
REMOVAL

• Make sure jacks and safety stands are placed properly.
• Make sure the vehicle will not roll off stands and fall while you are working under it.
• Use fender covers to avoid damaging painted surface.
• Unplug the wiring connectors carefully while holding the connector portion to avoid damage.
• Mark all wiring and hoses to avoid misconnection.
Also, be sure that they do not contact other wiring or hoses or interfere with other parts.
1. Remove the engine cover(A).
2. Remove the front bumper upper cover (A) and the air duct (B).
Tightening torque :
7.8 ~ 10.8N.m (0.8 ~ 1.1kgf.m, 5.8 ~ 8.0lb.ft)
3. Disconnect the battery negative terminal(A) first, then the positive terminal(B) and remove the battery(C).
English
4. Remove the radiator cap to speed draining.
5. Loosen the radiator drain plug (A) and drain engine coolant.
6. Remove the air cleaner.
(1) Disconnect the air flow sensor (AFS) connect(A).
(2) Remove the air intake hose (B).
(3) Disconnect the electric control unit (ECU) connector (C).
(4) Remove the air clear assembly(D).
Tightening torque :
Hose clamp (B) : 2.9 ~ 4.9N.m (0.3~0.5kgf.m, 2.2 ~ 2.6lb.ft)
Mounting bolt : : 7.8 ~ 10.8N.m (0.8~1.1kgf.m, 5.8 ~ 8.0lb.ft)
7. Remove the battery tray (A) and disconnect the front connector (B).
8. Remove the intercooler hose (A) and disconnect the booster pressure sensor (BPS) connector (B).
9. Remove the fuse box cover.
10. Disconnect the terminals(A) from the fuse box.
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)

When connecting the alternator B+ cable, refer to the illustration below.
11. After removing the mounting bolts, remove the relay and fuse assembly(A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
12. Remove the connector wiring(A) and the engine wiring(B).
13. Remove the engine control side ground(A) and, the transaxle control side one(B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
14. Remove the solenoid valve vacuum hose(A).
15. Disconnect the fuel hoses(A) and fuel temperature sensor connector(B).
16. Disconnect the brake booster vacuum hose(A) and heater hose(B).
17. Remove the heater hose(A) and EGR cooler hose(B).
18. Remove the radiator upper hoses(A) and the coolant bleed hose(B).
19. Remove the radiator lower hose(A).
20. Disconnect the transaxle wire harness and the control cable.
(Refer to Transaxle control system in MTC Group).
21. Remove the high & low pressure pipe. (Refer to Air conditioner compressor in HA Group).
22. Remove the steering column mounting bolt(A), (Refer to Steering column in ST Group).
23. Remove the front wheels and tires.
24. Disconnect the stabilizer bar link and remove the mounting bolts from the lower arm and the front axles.
(Refer to front suspension system in SS Group)
25. Remove the front muffle (A).
26. Install the SST (0920038001, 092001C000), the engine support fixture and the adapter, on the engine and transaxle
assembly.
27. Remove the engine mounting bracket (A) and the ground line (B).
Tightening torque :
63.7 ~ 83.4N.m (6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb.ft)
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb.ft)
28. Remove the transaxle mounting bracket (A) and the ground line (B).
29. Remove the sub frame mounting bolts and nut.
Tightening torque :
49.0 ~ 63.7N.m (5.0~6.5kgf.m, 36.2 ~ 47.0lb.ft)
30. Remove the engine and transaxle assembly by lifting vehicle.

When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body
components.
INSTALLATION
Install the engine in the reverse order of removal.
Reinstall the mount bolts/nuts in the following sequence.
Failure to follow these procedures may cause excessive noise and vibration, and reduce bushing life.
1. Install the sub frame installation bolt.
2. Tighten the engine and transmission mounting bolts.
3. Connect the power steering oil hoses.
4. Install the front muffler.
5. Install the front tires/wheels and splash shield.
6. Connect the air condition hoses.
7. Install the transmission links.
8. Connect the fuel hoses.
9. Connect the engine wire harness connectors.
10. Connect the radiator upper and lower hoses.
11. Connect the heater hoses.
12. Connect the hose to the reservoir tank.
13. Connect the intercooler hoses.
14. Install the air cleaner and the battery.
15. Perform the following :
• Clean the areas where the driveshaft contact the transmission thoroughly with solvent or carburetor cleaner, and dry
with compressed air.
• Check that the snap rings on the ends of the driveshaft click into place.
2012 > D 2.0 TCID > Engine Mechanical System > Timing System > Timing Belt > Components and
English
Components Location
COMPONENTS
2012 > D 2.0 TCID > Engine Mechanical System > Timing System > Timing Belt > Repair procedures
English
REMOVAL
1. Remove the front tires.(RH)
2. Remove the side cover.
3. The tensioner should be lifted up to remove the drive belt(A).
4. Remove the engine mounting bracket(A) and the groud cable(B).
5. Remove the crankshaft pulley(A).
6. Remove the timing belt lower cover(A).
English
7. Remove the timing belt upper cover(A).
8. Remove the engine support bracket(A).
9. Align the timing marks(A, B) on the camshaft sprocket(C) and the crankshaft sprocket(D) with the marks(E, F) on the
cylinder head(G) and the oil pump hausing(H) with rotating the engine.
10. Insert a pin(A) into the aligned holes in the autotensioner(B).
11. Using a hexagonal wrench (5mm)(A), loosen the stop bolt(B). And then, turning the autotensioner(C) clockwise fully with
the boss bolt(D) and 12mm spanner(E), retighten the stop bolt(B).
12. Remove the timing belt.

To be prepared in case the removed belt is used, mark an arrow on the timing belt in the direction of rotation before
removing it.
INSPECTION
1. Remove the upper cover.
2. Inspect the timing belt(A) for cracks and oil or coolant soaking.

• Replace the belt if oil or coolant soaked.
• Remove any oil or solvent that gets on the belt.
SPROCKETS, TENSIONER, IDLER
1. Check the camshaft sprocket.
Camshaft sprocket, crankshaft, tensioner pulley and idler pulley for abnormal wear, cracks or damage. Replace as
ecessary.
2. Inspect the tensioner pulley and the idler pulley for easy and smooth rotation and check for play or noise. Replace as
necessary.
3. Replace the pulley if there is a grease leak from its bearing.
INSTALLATION
1. Align the timing mark(A) on the camshaft sprocket(B) with the mark(C) on the cylinder head(D).
2. Align the timing mark(A) on the crankshaft sprocket(B) with the pin(C) press fitted in the oil pump housing(D).
3. Install the timing belt.
(1) Install the timing belt(A) tightly in the sequence shown.
① Timing belt drive pulley(B) (crankshaft) → ② Water pump pulley(C) ③ Timing belt idler(D) →① ④ Camshaft
sprocket(E) → ⑤ Timing belt tensioner(F).
(2) Turn the autotensioner(C) counterclockwise fully to install the timing belt using the boss bolt(D) and spanner(E).
(3) Rotate the crankshaft by hand 2 complete revolutions (clockwise) to take up any slack and set to TDC(Top Dead
Center).
(4) Using a hexagonal wrench, install the stop bolt.
Tightening torque :
10 ~ 12N.m (1.0 ~ 1.2 kgf.m, 7 ~ 9lbft)
(5) Remove the fixing pin(A)
4. Install the engine support backet(A).
Tightening torque :
43 ~ 55N.m (4.3 ~ 5.5kgf.m, 31.72 ~ 40.57lbft)
5. Install the timing belt upper cover(A) and lower cover(B).
Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.75 ~ 8.70lbft)
6. Install the crankshaft pulley(A).
Tightening torque :
30 ~ 34N.m (3.0 ~ 3.4kgf.m, 22 ~ 25lbft)
7. Install the engine mounting bracket(A) and the groud cable(B).
Tightening torque :
Nut(C) : 63.7 ~ 83.4N.m(6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lbft)
Bolt, nuts(D) : 49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lbft)
Bolt(E) : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbft)
8. Install the drive belt(A), following the sequence below.
1.Alternator → 2.Idler → 3.Air compressor → 4.Crankshaft pulley → 5.Tensioner.
The tensioner should be lifted up to install the drive belt(A).
9. Install the side cover.
10. Install the front tires.(RH)
2012 > D 2.0 TCID > Engine Mechanical System > Cylinder Head Assembly > Components and English
Components Location
COMPONENTS
English
2012 > D 2.0 TCID > Engine Mechanical System > Cylinder Head Assembly > Repair procedures English
REMOVAL
1. Before removing the cylinder head, the timing belt should be removed first. Refer to the timing belt 'removal' step.
2. Remove injector connector.
3. Disconnect the fuel return hose after removing the clips(A).
4. Remove the fuel tube. (Refer to Fuel pump in FLC group)
5. Remove the plugs(A).
a. Pull the plug up slightly. (more than 1mm)
b. Rotate the plug 90° clockwise.
c. Remove the plug with inserting a ()driver between the plug assy(B) and the cylinder head cover(C).
6. Remove the injector hoder bolt using the torx wrench.
English
7. Pull the injector holders with the bolts.
8. Remove the injectors(A).
a. Disconnector the position sensor.
b. Remover the wiring bracket.
c. Remove the pipe between the oil pan.
d. Remove the fuelline hose bolt.
9. Remove the cylinder head cover mounting bolts(A,B).
10. Remove the cylinder head cover.
11. Remove the injector holders(A) with the bolts(B).
12. Remove the metal tube(A) between the fuel pump(B) and the common rail(C).
13. Remove the fuel pump(A) after removing the three bolts(B).
14. Remove the exhaust manifold.
15. Remove the intake manifold.
16. Remove the cylinder head bolts(A), then remove the cylinder head(B).

To prevent warpage, unscrew the bolts in sqience 1/3 turn at a time:repeat the sequence until all bolts are loosened.
DISASSEMBLY

• Identify parts as they are removed to ensure reinstallation in original locations.
• Inspect camshafts.
1. Remove the engine hangers, the knock bushes and the studs.
2. Remove the camshaft bearing caps(A).
3. Remove the camshaft(A) with the oil seal(B).
4. Remove the Intake/Exhaust cam followers(A, B).
5. Remove the lash adjusters(C).
6. Remove the valve caps(D).
7. Using an appropriatesized socket and plastic mallet, lightly tap the valve retainer to loosen the valve retainer locks before
installing the valve spring compressor.

Identify valves and valve springs as they are removed so that each item can be reinstalled in its original position.
8. Using the SST(0922227300), compress the valve spring(A) in order to remove the valve spring retainer locks(B).
9. Remove the valve stem seals(A).
Intake Valve Dimensions
A Standard (New) :
28.5 ~ 28.7mm (1.1220 ~ 1.1299in.)
B Standard (New) :
94.0 ~ 94.2mm (3.7008 ~ 3.7087in.)
C Standard (New) :
5.933~5.953mm (0.2336~0.0669in.)
D Standard (New) :
1.5 ~ 1.7mm (0.0591 ~ 0.0669in.
Exhaust Valve Dimensions
A Standard (New) :
24.3 ~ 24.5mm (0.9567 ~ 0.9646in.)
B Standard (New) :
94.0 ~ 94.2mm (3.7008 ~ 3.7087in.)
C Standard (New) :
5.905~5.925mm (0.2325~0.2333in.)
D Standard (New) :
1.2 ~ 1.4mm (0.0472 ~ 0.0551in.)
INSPECTION
CAMSHAFT

Do not rotate the camshaft during inspection.
1. Put the camshaft(A) and the camshaft bearing caps(B) on the cylinder head(C), then tighten the bolts to the specified
torque with the following sequence below.
Specified torque
26.5 ~ 29.4N.m (2.7 ~ 3.0kgf.m, 19.5 ~ 21.7lbft)
2. Seat the camshaft by pushing it toward the rear of the cylinder head.
3. Zero the dial indicator(A) against the end of the camshaft(B).
Push the camshaft(B) back and forth, and read the end play.
Camshaft End Play
Standard (New) : 0.05 ~ 0.15mm (0.002 ~ 0.006in.)
4. Remove the bolts, then remove the camshaft bearing caps from the cylinder head(A).
• Lift the camshaft(B) out of the cylinder head(A), wipe it clean. Replace the camshaft if any lobes are pitted, scored, or
excessively worn.
• Clean the camshaft bearing surfaces in the cylinder head, then set the camshaft back in place.
• Place a plastigauge strip(C) across each journal.
5. Install the camshaft bearing caps and tighten the bolts to the specified torque.
6. Remove the camshaft bearing caps, then measure the widest portion of the plastigage(C) on each journal.
CamshafttoCamshaft bearing cap oil clearance
Standard (New)
0.040 ~ 0.074mm (0.0020 ~ 0.0029in.)
7. If the camshafttocamshaft bearing cap oil clearance is out of tolerance :
• And the camshaft(A) has already been replaced, you must replace the cylinder head.
• If the camshaft has not been replaced, first check the total runout with the camshaft supported on Vblocks.
Camshaft Total Runout
Standard (New)
0.035mm (0.0014in.) for No.2 and4
0.050mm (0.0019in.) for No.3
• If the total runout of the camshaft is within tolerance, replace the cylinder head.
• If the total runout is out of tolerance, replace the camshaft and recheck the camshafttocamshaft bearing cap oil
clearance. If the oil clearance is still out of tolerance, replace the cylinder head.
8. Check the cam height wear.
[Standard]
Intake : 34.697mm (1.366in.)
Exhaust : 34.570mm (1.361in.)
[Limit]
Intake : 34.197mm (1.346in.)
Exhaust : 34.070mm (1.341in.)
CYLINDER HEAD
Check the cylinder head(A) for warpage.
• If warpage is less than 0.03mm (0.0012in.) for width, 0.09mm (0.0035in.) for length and 0.012mm (0.0035in) for 51mm
×51mm, cylinder head is in good condition.
• If warpage is over the standard value, replace the cylinder head.
Measure along edges, and three ways across center.
REASSEMBLY

Prior to reassembling, cylinder head assembly shall be cleaned sufficiently to remove scrap and clust. (Clean holes with
special care.)
1. Using the SST(0922227200) insert the valve stem seals(A).
2. Insert the valves through the valve stem seals.

Make sure the valves move up and down smoothly.
3. Install the valve spring(A) and valve spring retainer(B), then install the SST (0922227300, the valve spring compressor).
Compress the spring(A) and install the valve spring retainer lock(C).
4. Lightly tap the end of each valve stem two or three times with a plastic mallet to ensure proper seating of the valve and
valve spring retainer locks.

Tap the valve stem only along its axis so you do not bend the stem.
5. Assembly of lash adjuster.
(1) Until installing, lash adjuster shall be held upright so that gas oil in lash adjuster should not spill and assured that dust
does not adhere to adjuster.
(2) Lash adjust shall be inserted tenderly to the cylinder head not to spill gas oil from lash adjuster. In case of spilling air
bent shall be done in accordance with the air bent procedure below.

Air bent procedure
1) In case of lash adjuster alone.
Stroke lash adjuster in gas oil 4~5 times by pushing its cap while pushing the ball down slightly by hard
steel wire.
Take care not to severely push hard steel wire down since ball is several grams.
2) After installed on engine
Lash adjuster might give out unusual noise if air is mingled. Apply slow racing from idle to 3,000rpm
(Approximately one minute per one racing) and the air shall be removed from adjuster.
Therefore noise can be extinguished.
6. Install the valvecaps.
7. Put the cam followers on the lash adjusters and valve caps.
8. After wiping down the camshaft and camshaft seal in the cylinder head, lubricate both surfaces and install the camshaft
with engine oil.
9. Confirm that cam followers are located on lash adjusters and their rollers are in touch with camshaft.
10. In assembly camshaft bearing cap, to the cylinder head with the cylinder block, all pistons should be in the middle position
between TDC(Top Dead Center) and BDC(Bottom ead Center) because valves come out of the bottom surface of the
cylinder head.
11. Install the bolts loosely.
12. Tighten each bolt two turns at a time in the sequence shown below to ensure that the cam followers do not bind on the
valves.
Tightening torque
26.5 ~ 29.4N.m (2.7 ~ 3.0kgf.m, 19.5 ~ 21.7lbft)
INSTALLATION
Install the cylinder head in the reverse order of removal :

• Always use a new head gasket.
• Cylinder head and cylinder block surface must be clean.
• Turn the crankshaft so the No.1 piston is at TDC(Top Dead Center).
1. Cylinder head dowel pins must be aligned.
2. Select the cylinder head gasket.
(1) Measure the piston protrusion from the upper cylinder block face (I) on 8 places (A ~ H) at T.D.C. Measure on the
crankshaft center line considering the piston migration.
(2) Install the gasket so that the identification mark faces toward the flywheel side.
(3) Select the gasket in the table below using the average value of piston protrusions.
Although even the only 1 point is over than the each rank limit, use 1 rank upper gasket than specified in the table
below.
Displacement 2.0 L
0.194 ~ 0.337mm (0.0079 ~ 0.337 ~ 0.440mm (0.013 ~ 0.440 ~ 0.542mm (0.017 ~
Average of pisston protrusion
0.013in.) 0.017in.) 0.021in.)
1.13 ± 0.05mm (0.0445 ± 1.23 ± 0.05mm (0.0484 ± 1.33 ± 0.05mm (0.0523 ±
Gasket thickness
0.0019in.) 0.0019in.) 0.0019in.)
Limit of each rank extant 0.43mm (0.0169in.) 0.53mm (0.0208in.)
Identification code
3. Position the cylinder head assembly over the gasket.
4. Tighten the cylinder head bolts slightly.
5. Install the camshaft sprocket, aligning the timing mark.
Tightening torque
124.5 ~ 144.2N.m (12.7 ~ 14.7kgf.m, 91.9 ~ 106.3lbft)
6. Tighten the bolts to the specified torque
Tightening torque
49.0Nm (5.0kgf.m, 36.2lbft) + 120° + 90°

• Tightening sequence of cylinder head bolt should be confirmed to the upper drawing.
• Cylinder head bolt must be replaced.
7. Install the fuel pump assembly.
8. Install the intake/exhaust manifold assemblies.
9. Install the hose between the vacuum pump and the cylinder head.
10. If it is necessary to replace the oil seals on the cylinder head cover for injectors, use the SST(0935127401).
11. Install the camshaft oil seal with use the SST(09212 27100)
12. Install the injector holder(A).
13. Install the head cover gasket in the groove of the cylinder head cover.

• Cylinder head cover gasket must be replaced.
• Before installing the head cover gasket, throughly clean the seal and the groove.
14. Apply liquid gasket to the head cover gasket at the four corners of the recesses.

• Use liquid gasket LOCTITE 5699 or TH1212D.
• Check that the mating surface are clean and dry before applying liquid gasket.
• Do not install the parts if five minutes or more have elapsed since applying liquid gasket.
Instead, reapply liquid gasket after removing old residue.
• After assembly, wait at least 30 minutes before filling the engine with oil.
15. Install the sylinder head cover bolts(A, B).
Tighten torque
(A) : 21 ~ 25N.m (2.2 ~ 2.6kgf.m, 15.9 ~ 18.8lbft)
(B) : 8 ~ 10N.m (0.8 ~ 1.0kgf.m, 5.9 ~ 7.38lbft)

After assembly, wait at least 30 minutes before filling the engine with oil.
16. Insert the injectors(C), moving back the injector holders(A) with the bolts(B).
Tighten torque :
24.5 ~ 28.4N.m (2.5 ~ 2.9kgf.m, 18.1 ~ 21.0lbft)
17. Install the injector holder bolts(A) useing the torx wrench(B).
18. Install the injector plug(A).
a. Make sure that the stopper of the plug faces 'OPEN' side. Otherwise pull and rotate the plug clockwise so the
stopper should face 'OPEN' side.
b. Apply the engine oil on the head cover mating surface or the gasket of the plug.
c. Insert the plugs in the head cover.
d. Rotate the plug inserted counterclockwise 90°.
e. After installation, rotate the plug clockwise. If it is rotated, repeat the step a ~ d.

Plug gasket must be replaced.
19. Install the fuel tube.(Refer to Injector in FLC group)
2012 > D 2.0 TCID > Engine Mechanical System > Cylinder Block > Components and Components
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Location
COMPONENTS
English
2012 > D 2.0 TCID > Engine Mechanical System > Cylinder Block > Repair procedures English
REPLACEMENT
MAIN BEARING SELECTION
Crankshaft Bore Code Location
1. Letters have been stamped on the end of the block as a code for the size of each of the 5 main journal bores. Write down
the crank bore codes.
If you can't read the codes because of accumulated dirt and dust, do not scrub them with a wire brush or scraper. Clean
them only with solvent or detergent.
Discrimination of cylinder block
Discrimination SIZE
Class Mark (Inside diameter of crank bore)
Ø64mm(2.5197in)
A A
(0 ~ +0.006in)(0 ~ +0.0002in)
Ø64mm(2.5197in)
B B
(+0.006 ~ +0.012in)(+0.0002~0.0005in)
Ø64mm(2.5197in)
C C
(+0.012 ~ +0.018in)(+0.0005~0.0007in)
Main Journal Code Locations
1. The main Journal Codes are stamped on the No.1 web.
Discrimination of crank shaft
Discrimination SIZE
Class Mark (Outside diameter of main journal)
Ø60mm(2.3622in)
I A
(+0.014 ~ +0.020in)(+0.0006~+0.0008in)
English
Ø60mm(2.3622in)
II B
(+0.008 ~ +0.014in)(+0.0003~0.0006in)
Ø60mm(2.3622in)
III C
(+0.002 ~ +0.008in)(+0.0001~+0.0003in)
2. Use the crank bore codes and crank journal codes to select the appropriate replacement bearings from the following table.

• Color code is on the edge of the bearing. Refer to the table in the step 6 of the main bearing clearance
inspection.
• When using bearing halves of different colors, it dose not matter which color is used in the top or bottom.
Installing procedure of bearing
Shaft bore combination
Bearing mark Oil clearance
Shaft mark Bore mark
A (A) A (BLUE)
I (A) B (B) B (BLACK)
C (C) C ( )
A (A) B (BLACK)
0.024 ~ 0.042mm
II (B) B (B) C ( )
(0.0009 ~ 0.0017in)
C (C) D (GREEN)
A (A) C ( )
III (C) B (B) D (GREEN)
C (C) E (YELLOW)
Rod Bearing Selection
1. Inspect each connecting rod for cracks and heat damage.
Connecting Rod Big End Bore Code Locations
1. Each rod has tolernance range from 0 to 0.018mm (0.0007in.), in 0.006mm (0.0002in.) increments, depending on the size of
its big end bore. It's then stamped with a letter (A, B or C) indicating the range. You may find any combination of letters in
any engine.

Discrimination connecting rod
Discrimination SIZE
Class Mark (Inside diameter of connecting rod big end bore)
Ø 53mm(2.0866in)
A A
(0 ~ +0.006in)(0~+0.0002in)
Ø 53mm(2.0866in)
B B
(+0.006 ~ +0.012in)(+0.0002~0.0005in)
Ø 53mm(2.0866in)
C C
(+0.012 ~ +0.018in)(0.0005~0.0007in)
Connecting Rod Journal Code Locations
1. The connecting Rod Journal Codes are stamped on the No. 1 web.
)

Discrimination of crank shaft pin
Discrimination SIZE
Class Mark (Outside diameter of pin)
Ø50mm(1.9685in)
I A
(+0.020 ~ +0.026in)(+0.0008~0.0010in)
Ø50mm(1.9685in)
II B
(+0.014 ~ +0.020in)(+0.0006~0.0008in)
Ø50mm(1.9685in)
III C
(+0.008 ~ +0.014in)(+0.0003~0.0006in)
2. Use the big end bore codes and rod journal codes to select appropriate replacement bearings from the following table.

Color code is on the edge of the bearing.
Refer to the table in the step 5 of rod bearing clearance inspection.
Shaft bore combination
Bearing mark Oil clearance
Sahft mark Bore mark
A (A) A (BLUE)
I
B (B) B (BLACK)
C (C) C (WHITE)
A (A) B (BLACK)
0.024 ~ 0.042mm
II B (B) C (WHITE) (0.0009~0.0017in)
C (C) D (GREEN)
A (A) C (WHITE)
III B (B) D (GREEN)
C (C) E (YELLOW)
Piston, Pin and Connecting Rod
1. Apply engine oil to the piston pin snap rings and turn them in the ring grooves.

Take care not to damage the ring grooves.
2. Remove both snap rings(A) carefully so they do not go flying or get lost. Wear eye protection.
3. Remove the piston pin and the conecting rod assembly.
4. Measure the diameter of the piston pin.
Piston Pin Diameter
Standard (New)
27.995 ~ 28.000mm (1.1022 ~ 1.1024in.)

Inspect the piston, piston pin and connecting rod when they are at room temperature.
5. Zero the dial indicator to the piston pin diameter.
6. Check the difference between the piston pin diameter and piston pin hole diameter in the piston.
Piston PintoPiston Clearanace
Standard (New)
0.015 ~ 0.030mm (0.00059 ~ 0.00118in.)
7. Measure the piston pintoconnecting rod clearance.
Piston PintoConnecting Rod Clearance
Standard (New)
0.022 ~ 0.039mm (0.00087 ~ 0.00154in.)
8. Set a snap ring in one side of piston pin hole.
9. Before inserting the piston pin, apply a sufficient amount of the lubricant oil to the outer surface of the piston, the inner
surface of the piston pin hole and the small end bore of the connecting rod.
10. Insert the piston pin(A). Assembly the piston and connecting rod with the embossed front marks on the same side.

The front mark of the piston is embossed on the piston whereas some letters are located on a side surface of the
connecting rod as the front mark.

• Be sure to keep the small end bore, piston pin hole and piston pin undamaged and unscratched when inserting
the piston pin.
• Set the snap rings to be sure for contacting with the groove of the piston pin hole.
Piston Ring
1. Using a piston, push a new ring into the cylinder bore.
2. Measure the piston ring endgap(B) with a feeler gauge :
• If the gap is too small, check to see if you have the proper rings for your engine.
• If the gap is too large, recheck the cylinder bore diameter against the wear limits.
If the bore is over the service limit, the cylinder block must be rebored.
Piston Ring EndGap
Top ring
Second Ring
Oil Ring
3. Using a ring expander, remove the old piston rings.
4. Clearance all ring grooves thoroughly with a squaredoff broken ring or ring groove cleaner with a blade to fit the piston
grooves.
Top ring groove
1.915 ~ 1.945mm (0.07539 ~ 0.07657in.)
2nd ring groove
2.060 ~ 2.080mm (0.08110 ~ 0.08189in.)
Oil ring groove
3.020 ~ 3.040mm (0.11889 ~ 0.00968in.)
File down a blade if necessary.
Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with cleaning tools.

If the piston is to be separated from the connecting rod, do not install new rings yet.
5. Install the piston rings.
Piston Ring Dimensions
Top Ring (Standard)
Width : 2.95 ~ 3.25mm (0.116 ~ 0.128in.)
Thickness : 2mm (0.079in.)
Second Ring (Standard)
Width : 3.60 ~ 3.90mm (0.142 ~ 0.154in.)
Thickness : 1.970 ~ 1.995mm (0.078 ~ 0.079in.)
6. After installing a new set of rings, measure the ringtogroove clearances :
Top Ring Clearance
Standard (New)
0.083 ~ 0.137mm (0.00327 ~ 0.00529in.)
Second Ring Clearance
Standard (New)
0.065 ~ 0.110mm (0.00256 ~ 0.00433in.)
Oil Ring Clearance
Standard (New)
0.03 ~ 0.07mm (0.00118 ~ 0.00275in.)
REMOVAL
1. Remove the engine and transaxle assembly from the vehicle.(Refer to Engine and transaxle assembly in this Group)
2. Remove the timing belt assembly.(Refer to Timing system in this Group)
3. Remove the intake and the exhaust manifold.(Refer to Cylinder head assembly in this Group)
4. Remove the cylinder head assembly.
5. Remove the alternator. (Refer to Alternator in EEC Group)
6. Remove the engine oil level gauge(A).
7. Remove the Crankshaft Position Sensor(CKP)(A) and the oil pressure switch(B).
8. Remove the heater and oil cooler return pipe assembly(A) after loosening the hose clamps(B) and the bolts(C, D, E).
9. Remove the tube(A) between the vacuum pump and the cylinder head.
10. Remove alternator lower bracket.
11. Remove the water inlet pipe assembly(A) by loosening a bolt(B) and clamps.
12. Remove the air compressor(A). (See HA group compressor)
13. Remove the autotensioner(A) by loosening the bolt(B).
14. Remove the timing belt rear cover(A).
15. Remove the water pump assembly(A) with the gasket(B).
16. Remove the oil pan(A).

• Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of
① arrow.
• After tapping the SST with a plastic hammer along the direction of ② arrow around more than 2/3 edge of the
oil pan, remove it from the ladder frame.
• Do not turn over the SST abruptly without tapping. It is result in damage of the SST.
17. Remove oil screen for removal of oil pump assembly(B).
18. Remove the crankshaft bolt(A), then seperate the crankshaft sprocket(B).
19. Remove the oilpump assembly(B) by loosening the bolts(A).
20. Remove the crankshaft key(A).
DISASSEMBLY
1. Remove the bed plate assembly.
• Remove the bolts(A).
To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time : repeat the sequence until all bolts are
loosened.
• Remove the bolts(B).
2. Remove the connecting rod bearing caps(A) and bearings(B).
• After removing No. 1 and 4 connecting rod bearing caps and turn the crankshaft No. 2 and 3 crankpins are at the top.
• Remove the rest bearing caps and bearings.
• Keep all caps/bearings in order.
3. If you can feel a ridge of metal or hard cabon around the top of each cylinder, remove it with a ridge reamer. Follow the
reamer manufacturer's instructions. If the ridge is not removed, it may damage the pistons as they are pushed out.
4. Drive out the piston assembly from the engine block.
a. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.
b. To avoid mixup on reassembly, mark each piston/connecting rod assembly with its cylinder number.
5. Lift the crankshaft(A) out of the cylinder block(B), being careful not to damage the journals.
6. Remove the piston oil jet(A) by loosening the hexagonal bolt(B) with a hexagonal wrench.
INSPECTION
FLYWHEEL
1. Inspect ring gear teeth for wear or damage.
2. Flywheel bolts should be free from detrimental flaws.
Connecting Rod and Crankshaft End Play
1. Measure the connecting rod end play with a feeler gauge(A) between the connecting rod(B) and crankshaft(C).
Connecting Rod End play
Service Limit : 0.40mm (0.016in.)
2. If the connecting rod end play is outoftolerance, install a new connecting rod, and recheck. If it is still outoftolerance,
replace the crankshaft.
3. If the end play is excessive. Replace parts as necessary.
Main Bearing Clearance
1. To check main bearingtojournal oil clearance, remove the bed plate, the crankshaft and the bearing halves.
2. Clean each main journal and bearing half with a clean shop towel.
3. Cut plastigauge to the same length as the width of the bearing.
4. Place one strip of plastigauge across each main journal on the cylinder block and the bed plate, avoiding the oil holes.
5. Reinstall the bearings, crankshaft and bed plate then torque the bolts to the specified valve.

Do not rotate the crankshaft during inspection.
6. Remove the bed plate and bearings again and measure the widest part of the plastigauges with a calibrated scale on which
an arrow of marks has beeen printed.
Main bearingtojournal Oil Clearance
Standard (valve)
0.024 ~ 0.042mm (0.0009 ~ 0.0017in.)

Discrimination of crankshaft main bearing
Discrimination SIZE
Place of identification mark
Class Mark (Thickness of bearing)
1.987~1.990mm
E YELLOW
(0.0782~0.0783in)
1.984~1.987mm
D GREEN
(0.0781~0.0782in)
1.981~1.984mm
C
(0.0780~0.0781in)
1.978~1.981mm
B BLACK
(0.0779~0.0780in)
1.975~1.978mm
A BLUE
(0.0778~0.0779in)
7. If the plastigauge mesaure too wide or too narrow, remove the crankshaft, and remove the upper half of the bearing. Install
a new, complete bearing with the same color code(s), and recheck the clearance. Do not file, shim, or scrape the bearings
to adjust clearance.
8. If the plastigauge shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or
below that one), and check again. If the proper clearance cannot be obtained by using the appropriate larger or smaller
bearings, replace the crankshaft and start over.
Rod bearing Clearance
1. Remove the connecting rod cap and bearing half.
2. Clean the crankshaft rod journal bearing half with a clean shop towel.
3. Place pastigauge across the rod journal.
4. Reinstall the bearing half and cap, and torque the bolt.

Do not rotate the crankshaft during inspecition.
5. Remove the rod cap and bearing half and measure the widest part of the plastigauge.
Connectinng Rod BearingtoJournal Oil
Clearance : 0.024 ~ 0.042mm (0.0009 ~ 0.0017in.)
6. If the plastigauge measure too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with
the same color code(s), and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust
clearance.

Discrimination of connecting rod bearing
Discrimination Size
Place of Identification
Class Mark (Thickness of bearing)
1.484 ~ 1.487mm
E YELLOW
(0.0584~0.0585in)
1.481 ~ 1.484mm
D GREEN
(0.0583~0.0584in)
1.478 ~ 1.481mm
C WHITE (0.0582~0.0583in)
1.475 ~ 1.478mm
B BLACK
(0.0581~0.0582in)
1.472 ~ 1.475mm
A BLUE
(0.0580~0.0581in)
7. If the plastigauge shows the clearance is still incorrect, try the next larger or smaller bearins (the color listed above or
below that one), and check clearance again. If the proper clearance cannot be obtained by using the appropriate larger or
smaller bearing, replace the crankshaft and start over.
Balancer Shafts
1. Measure runout on the journals of each balance shaft(A) to make sure the balancer shafts are not bent.
Balancer Shaft Total Indicated Runout
Standard (New) : 0.025mm (0.00098in.)
2. Measure the diameters of the journals on the balance shafts(A).
Journal Diameter
Standard (New)
No. 1 journal :
19.980 ~ 19.993mm (0.7866 ~ 0.7871in.)
No. 2 journal :
27.99 ~ 28.01mm (1.1020 ~ 1.1028in.)
No. 3 journal :
41.99 ~ 42.01mm (1.6531 ~ 1.6539in.)
3. Measure the inner diameters of the bearings for the balance shafts.
Bearing Inner Diameter
Standard (New)
No. 1 journal :
20.00 ~ 20.02mm (0.7874 ~ 0.7882in.)
No. 2 journal :
28.06 ~ 28.08mm (1.1047 ~ 1.1055in.)
No. 3 journal :
42.06 ~ 42.08 (1.6559 ~ 1.6567in.)
4. Claculate the shafttobearings oil clearances.
BEARING I.D JOURNAL O.D = OIL CLEARANCE
ShafttoBearings Oil clearance
Standard (New)
No. 1 journal :
0.007 ~ 0.041mm (0.00028 ~ 0.00161in.)
No. 2 journal :
0.050 ~ 0.090mm (0.00197 ~ 0.00354in.)
No. 3 journal :
0.050 ~ 0.090mm (0.00197 ~ 0.00354in.)
CRANKSHAFT
Straightness

• Clean the crankshaft oil passages with pipe cleaners or a suitable brush.
• Check the keyway and threads.
1. Support the crankshaft with Vblocks.
2. Measure runout on all main journals to make sure the crank is not bent. Rotate the cranklshaft two complate revolutions.
The difference between measurements on each journal must not be more than the stardard value.
Crankshaft Total Indicator Runout
Standard (New) : 0.06mm (0.002in.) max.
OutofRound and Taper
1) Measure outofround at the middle of each rod and main journal in two places. The difference between measurements on
each journal must not be more than the serivce limit.
Journal OutofRound
2) Measure taper at the edge of each rod and main journal. The difference between measurements on each journal must not
be more than the serive limit.
Journal Taper
Block and Piston
1. Check the piston for distortion or cracks.
2. Measure the piston diameter at a point 10mm (0.4in) from the bottom of the skirt. There are three standardsize pistons (A.
B and C). The letter is stamped on the top of the piston. Letters are also stamped on the block as cylinder bore sizes.
Piston Diameter and Cylinder Bore
Standard value :
Grade A B C
82.92 ~ 82.93mm 82.93 ~ 82.94mm 82.94 ~ 82.95mm
Piston Outer Diameter
(3.2646~3.2650in) (3.2650~3.2653in) (3.2650~3.2657in)
83.00 ~ 83.01mm 83.01 ~ 83.02mm 83.02 ~ 83.03mm
Cylinder Bore
(3.2677~3.2681in) (3.2681~3.2685in) (3.2685~3.2686in)
Clearance 0.070 ~ 0.090mm(0.0028~0.0035in)
3. Measure wear and taper in direction X and Y at three levels in each cylinder as shown. If measurements in any cylinder are
beyond the cylinder bore standard value (Refer to the previous page), replace the block. If the block is to be rebored, refer
to step 6 after reboring.
Oversize
0.25 : 83.250 ~ 83.280mm (3.2776 ~ 3.2787in.)
0.50 : 83.500 ~ 83.530mm (3.2874 ~ 3.2886in.)
Bore Taper
Limit : (Difference betweem first amd thired measurement)
0.01mm (0.0004in.) MAX.
Level 1 : No. 1 piston ring position at TDC(Top Dead Center).
Level 2 : Center of cylinder.
Level 3: Bottom of cylinder.
4. Scored or scratched cylinder bores must be honed.
5. Check the top of the block for warpage. Measure along the edges and across the center.
Engine Block Warpage
Standard (New)
0.042mm (0.00165in.) for width
0.096mm (0.00378in.) for legth
0.012mm (0.00047in.)/50×50mm
Service Limit : 0.10mm (0.004in.)
6. Calculate the difference between the cylinder bore diameter and the piston diameter. If the clearance is near or exceeds the
standard value, inspect the piston and cyllinder block for excessive wear.
PistontoCylinder Clearance
Standard (New) :
0.070 ~ 0.090mm (0.0028 ~ 0.0035in.)
Oversize Piston Diameter :
0.25 : 83.170 ~ 83.200mm (3.2744 ~ 3.2756in.)
0.50 : 83.420 ~ 83.450mm (3.2882 ~ 3.2881in.)
Cylinder Honing
Only a scored or scratched cylinder bore must be honed.
1. Measure the cylinder bores.
If the block is to be reused, hone the cylinders and remeasure the bores.
2. Hone the cylinder bores with honing oil and a fine stone. Do not use stones that are worn or broken.
3. When honing is complate, thoroughly clean the engine block of all metal particles. Wash the cylinder bores with hot soapy
water, then dry and oil them immediately to prevent rusting. Never use solvent, it will redistribute the grit on the cylinder
walls.
4. If scoring or scratches are still present in the cylinder bores after honing to the service limit, rebore the cylinder block.
Some light vertical scoring and scratching is acceptable if it is not deep enough to catch your fingernail and does not run
the full length of the bore.
REASSEMBLY
PISTON
1. Remove the connecting rod caps then install the ring compressor and check that the bearing is securely in place.
2. Position the marks facing the timing belt side of the engine.
3. Position the piston in the cylinder and tap it in using the wooden handle of hammer.
Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
4. Stop after the ring compressor pops free, and check the connecting rodtocrank journal alignment before pushing the
piston into place.
5. Check the connecting rod bearing clearance with plastigauge.
6. Apply engine oil to the bolt threads, then install the rod caps with bearings.
CRANKSHAFT AND BALANCER
1. Install the oil jets, tightening the hexagon socket head bolts with the torque 9 ~ 13Nm (0.9 ~ 1.3kgf.m, 6.5 ~ 9.4lbft)
2. Apply a coat of engine oil to the main bearings.
3. Install the bearing halves in the engine block.
4. Hold the crankshaft so rod journal No. 2 and rod journal No. 3 are straight up.
5. Lower the crankshaft into the block.
6. Install the bearing halves in the bed plate after applying a coat of engine oil.
7. Install the bed plate(C) to the cylinder block after applying the sealant (omniFIT FD2.0, DREIBOND 5105 or HYLOMAR
3000).
Tightening torque
15mm(B)
27.5 ~ 31.4N.m + (2.8 ~ 3.2kgf.m, 20.3 ~23.1lbft) + 120°
12mm(A)
33.3 ~ 37.3N.m (3.4 ~ 3.8kgf.m, 24.6 ~27.5lbft)

Always use new cylinder head bolts.
8. Rotate the crankshaft clockwise to be seated properly.
9. Check the main bearing clearance with plastigauge.
10. Install the piston and connecting rod assemblies.
a. Apply coat of engine oil to the connecting rod bearings.
b. Install the bearing halves in the connecting rods.
c. Insert the assemblies into the cylinder bores.
d. Install the connecting rod caps and bolts finger tight
e. Rotate the crankshaft clockwise, seat the journals into connecting rod No.2 and connecting rod No.3. Install the
connecting rod caps and bolts finger tight. Install caps so the bearing recess is on the same side as the recess in
the rod.
f. Check the connecting rod bearing clearance with plastigage.
g. Apply engine oil to the bolt threads, then install the rod caps within bearings and torque the bolts to 24.5N.m + 90°
(2.5kgf.m + 90°, 18.1lbft + 90°).
11. Using the SST(0923127000), install the crankshaft oil seal(A) squarely.
12. Clean and dry the mating surfaces.
Apply a light coat of oil to the crankshaft and to the lip of the seal.
INSTALLATION
1. Clean and dry the oil pump mating surface.
2. Install the oil pump
a. Install a new crankshaft oil seal in the oil pump.
b. Apply liquid gasket evenly to the block mating surface of the oil pump.
Standard liquid gaskets (or sealants)
LOCTITE5900 or TB1217H
• Apply liquid gasket in a wide bead : 2.5 ± 0.5m
• Apply the liquid gasket without stoping.
• Assemble the oil pump within 5 minutes after applying.
c. Grease the lips of the oil seals.
d. Align the oil pump gear with the crankshaft drive gear and install the oil pump(B).
Tightening torque(A)
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.51lbft)
e. Clean the excess grease off the crankshaft and check the seals for distortion.
3. Install the crankshaft key(A) on the crankshaft assembly.
4. Insert the crankshaft sprocket(B) then tighten the crankshaft bolt(A).
Tightening torque
196.1 ~ 205.9N.m (20.0 ~ 21.0kgf.m, 144.7 ~ 151.9lbft)

Align the timing mark on the sproket.
5. Install oil screen.

The bolt B should be tightened after the installation of the bolt A.
6. Clean and dry the bed plate and the oil pan mating surfaces.
7. Apply liquid gasket evenly to the bed plate mating surface of the oil pan. Install the oil pan.

• Standard liquid gasket : LOCTITE 5900 or TB1217H
• Assemble the oil pan in 5 mimutes after applying the liquid gasket.
• Apply liquid gasket in a 3mm wide bead without stopping.
• The clearance between the liquid gasket end and the flange inner end at Tjoint should be 2~3mm(2places)
8. Tighten the bolt in two or three steps. In the final step, tighten all bolts.
Tightening torque
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)

After installing the oil pump assembly and the oil pan, remove the oil cooler and fill the 50cc engine oil.
9. Install water pump(A) with new gasket(B).
Tighten torque
Bolt A
47.1 ~ 51.0N.m (4.8 ~ 5.2kgf.m, 34.7 ~ 37.6lbft)
Bolt B
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
10. Install the timing belt rear cover(A).
11. Install the autotensioner(A).
Tightening torque
Pivot bolt(B)
49.0 ~ 53.9N.m (5.0 ~ 5.5kgf.m, 36.2 ~ 39.8lbft)
Stop bolt
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
12. Install the air compressor(A). (Refer to Compressor in HA Group)
13. Install the water inlet pipe assembly(A), tightening the bolt(B).
Tightening torque
19.6 ~ 26.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 19.5lbft)
14. Install the heater and oil cooler return pipe(A) assembly.
Tightening torque
Rear side bolt and left side bolt(C, D)
19.6 ~ 26.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 19.5lbft)
Right side bolt(E)
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbft)
15. Install the Crankshaft Position Sensor(CKP)(A) and the oil pressure switch(B).
Tightening torque
(A) : 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lbft)
(B) : 14.7 ~ 21.6N.m (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lbft)
16. Install the cylinder head assembly.
17. Install the intake/exhaust manifold assemblies.
18. Install the oil level gauge(A).
Tightening torque
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)

Apply engine oil to Oring before assembly.
19. Install the timing belt assembly.
2012 > D 2.0 TCID > Engine Mechanical System > Cooling System > Components and Components
English
Location
COMPONENTS
2012 > D 2.0 TCID > Engine Mechanical System > Cooling System > Repair procedures English
REMOVAL
Water Pump
1. Remove radiator cap to speed drain.
2. Drain the engine coolant after removing drain plug(A).
4. Remove the timing belt rear cover(A).
5. Remove the water pump(A) with the gasket(B) by removing four bolts. (One bolt A and three bolt B)
6. Inspect, repair and clean the mating surface on the engine block.
7. Install the water pump, with a new gasket in the reverse order of removal.
Tightening torque
For timing belt rear cover
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lbft)
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For water pump
Bolt A :
47.1 ~ 51.0N.m (4.8 ~ 5.2kgf.m, 34.7 ~ 37.6lbft)
Bolt B :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
8. Clean the spilled engine coolant.
RADIATOR
Tightening torque
7.8 ~ 15.7N.m (0.8 ~ 1.6kgf.m, 5.8 ~ 11.6lbft)
Tightening torque
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbft)
4. Remove the radiator upper hoses(A) and the coolant bleed hose(B).
5. Remove the intercooler hose (A).
7. Disconnect the fan motor connector (A) and remove the radiator mounting bracket (B).
8. Pull radiator upper from engine room.
9. Install is in the reverse order of removal.
THERMOSTAT
1. Drain the engine coolant.
2. Remove the radiator upper hose(A) and coolant bleeder hose(B).
3. Remove the coolant inlet fitting.
4. Remove the thermostat(A).
5. To install, reverse the removal order with a new gasket.
INSPECTION
Thermostat
Replace the thermostat if it is open at room temperature.
1. Immerse thermostat in water heated to over 95°C (203°F), then heat for at least 3 minutes to check valve lift.

• Do not use water below 95°C (203°F).
• Do not directly heat unit as this will damage thermostat.
2. Heat the water and check the temperature with the thermomster. Check the temperature at which the thermostat first
opens, and at which it is fully open.
3. Measure the lift height of the thermostat when it is fully open.
STANDARD THERMOSTAT
Lift height : above 8.0mm (0.31in.)
Starts opening: 85 ± 1.5°C (185 ± 34.7°F)
Fully open : 100°C (212°F)
2012 > D 2.0 TCID > Engine Mechanical System > Cooling System > Troubleshooting English
ENGINE OVERHEAT TROUBLESHOOTING
Inspection Remedy
Reinspect after replenishing
Inspect for shortage of coolant in reservoir tank .
coolant.
Inspect for coolant pollution after removing radiator cap.
Reinspect after replacing
coolant.
Be careful when removing radiator cap from overheated vehicle.
Inspect for leakage and loose coolant hoses (radiator hose, heater Reinspect for leakage after
hose, oil cooler hose, etc.). reinstalling hoses and clamps.
Reinspect for leakage after
replacing Oring.
Inspect for leakage on water inlet fitting mounting part. Reinspect for leakage after
tightening to the specified
torque.
Adjust drive belt tension or
Inspect drive belt (for normal operation of water pump).
Visual inspection replace.
replacing gasket.
Inspect for leakage on water pump gasket mounting part. Reinspect for leakage after
torque.
Reinstall loose connector.
Inspect for loose coolant temperature sensor, cooling fan connector
and pin. Replace relevant part if
connector pin is damaged.
Inspect operation status of cooling fan.
Check operation status by switching ON/OFF the heater control
A/C.
Check mounting status of
ground cable.
Will not operate in cold ambient temperature.
Check coolant temperature
Diagnostic device Inspect selfdiagnostic code using KDS/GDS.
sensor, wiring, connector, etc.
Inspect water pump impeller. Replace water pump.
Inspect unit after removing
Inspect for foreign materials and status of thermostat valve.
foreign materials.
Inspect for stuck thermostat valve.
Immerse thermostat in water heated to over 95°C (203°F), then
heat for at least 3 minutes to check valve lift.
Unit inspection Check valve lift.
Replace thermostat if valve

lift is below specification or
valve is stuck.
English
2012 > D 2.0 TCID > Engine Mechanical System > Lubrication System > Components and Components
English
Location
COMPONENTS
2012 > D 2.0 TCID > Engine Mechanical System > Lubrication System > Repair procedures English
REPLACEMENT
Engine Oil Filter

There are two kinds of oil filters. One is for Europe LHD and the orther is for the rest area except Europe LHD (Left Hand
Drive).
For Europe LHD :
1. Remove the oil filter upper cap from lower case with SST(092632E000 the oil filter wrench.).
2. Inspect the threads and rubber packing. Wipe off the seat on the oil filter assembly, then apply a light coat of oil to the oil
filter assembly upper cap packing.
3. Install the new oil filter by hand to the upper cap.
4. After the rubber seal seats, tighten the oil filter clockwise with the special tool.
Capacity
Total : 7.4 L (7.82 US qt, 6.51 lmp qt)
Oil pan : 6.2 L (6.55 US qt, 5.45 lmp qt)
Drain and refil including oil filter : 6.7 L (7.08 US qt, 5.89lmp qt)
For the rest area except Eurpe LHD :
1) Remove the oil filter(A) with the SST(0926327000, the oil filter wrench).
2) Inspect the threads and the packing on the apply a light coat of new oil filter. Wipe off the seat.
3) Install the new oil filter by hand.
4) After the packing seats, tighten the oil filter clockwise with the SST(0926327000).
REMOVAL
OIL PUMP
1. Drain the engine oil.
2. Remove the crankshaft pulley(A).
English
3. Remove the timing belt assembly.
4. Remove the timing belt tensioner(A).
5. Remove the timing rear cover(A).
6. Separate oil pan(A).

• Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of ①
arrow.
• After tapping the SST with a plastic hammer along the direction of ② arrow around more than 2/3 edge of the oil
pan, remove it from the ladder frame.
7. Remove the oil screen.
8. Remove the crankshaft sproket(B) with bolt(A).
9. Remove the mounting bolts(A) and the oil pump assembly(B).
DISASSEMBLY
OIL PUMP
1. Remove the three hexagon socket head bolts(A) from the oil pump cover(B).
2. Remove the out rotor from the oil pump housing.
3. Remove the old oil seals from the oil pump housing.
4. Remove the O ring(A) from the oil pump housing.
5. Remove the relief cap(A), relief cap washer(B), relief spring(C) and relief plunger(D).
6. Remove the oil filter. Refer to the engine oil filter replacement.
7. Remove the oil cooler and hose assembly after seperating the oil filter fitting.
INSPECTION
OIL PUMP
1. Check the innertoouter rotor tip clearance between the inner rotor(A) and outer rotor(B). If the innertoouter rotor clearance
exceeds the service limit, replace the inner and outer rotors.
Inner RotortoOuter Rotor tip Clearance
Standard (New)
0.08mm (0.00315in.)
2. Check the housingtorotor axial clearance between the rotor and oil pump cover housing. If the housingtorotor axial
clearance exceeds the service limit, replace the set of inner and outer rotors and/or the pump housing.
HousingtoRotor Axial Clearance
Standard (New)
0.020 ~ 0.070mm (0.00079 ~ 0.00276in.)
3. Inspect both rotors and the oil pump cover housing for scoring or other damage. Replace parts if necessary.
OIL PRESSURE SWITCH
1. Remove the oil pressure switch from the engine block.
2. Connect a tester (ohm range) between the terminal and the body of the switch to check for continuity. The switch is normal
if there is continuity. If they is no continuity, replace the switch.
3. Insert a thin rod in the oil hole of the switch and push it in lightly. The switch is normal of no continuity as detected (infinite
resistance on the tester). If there is continuity, replace the switch.
SELECTION OF ENGINE OIL
ACEA classificaton : C3 (with CPF), B4 (without CPF)
SAE viscosity grades : Refer to the recommended SAE viscosity number

For best performance and maximum protection of all types of operation, select only those lubricants which :
1. Satisfy the requirement of the ACEA classification.
2. Have proper SAE grade number for expected ambient temperature range.
• Lubricants that do not have both an SAE grade number and ACEA service classification on the container should not
be used.
• The ACEA certified engine oil is required as a service engine oil. Only in case that ACEA certified engine oil is not
available, the API certified engine oil (API CH4 or above) is allowed restrictively.
• For the vehicle equipped with CPF, the service engine oil quality should meet the ACEA C3 grade. However, oil refill
with small amount of ACEA B4 grade between oil change intervals is possible.
ENGINE OIL
1. Park the vehicle on the flat ground.
2. Turn the engine off.
3. The oil level should be between the 'L' and 'F' marks on the dipstick, then.
If low, check for leakage and add oil up to the "F" mark.

When refill the engine oil, use the same type engine oil with current engine oil.
4. Check the oil for deterioration, entry of coolant or fuel, and engine oil viscosity.
REASSEMBLY
OIL PUMP
1. Insert the relief plunger(D), the relief spring(C) and the relief cap washer(B). Then torque the relief cap(A).
Tightening torque
41.2 ~ 51.0N.m (4.2 ~ 5.2kgf.m, 30.4 ~ 37.6lbft)
2. Install the new O ring(A) to the oil pump housing(B) after applying engine oil.
3. Assemble the inner/outer rotors with engine oil the drive gear and the oil pump cover.
4. Install the oil pump cover(B)assembly to the oil pump housing with the three hexagon socket head bolts(A).
5. The oil seal which was disassembled in 'Disassembly' step is recommended to be installed after the installation of the
crankshaft.
INSTALLATION
1. Install the oil pump assembly and the oil pan on the cylinder block.
Tightening torque
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lbft)

Standard liquid gasket : LOCTITE 5900 or TB1217H
2. Install the oil screen.
3. Install the oil pan.
Tightening torque
9.8 ~ 11.8N.m (1.0~ 1.2kgf.m, 7.2 ~ 8.7lbft)

Standard liquid gasket : LOCTITE 5900 or TB1217H
Assemble the oil pan in 5 minutes after applying the liquid gasket.
Apply liquid gasket in a 3mm wide bead without stopping.
Te clearance between the liquid gasket end and the flange inner end at Tjoint should be 2 ~ 3mm.(2places)
4. Fill the engine oil in the room below the oil cooler (50cc).
5. Tightening the oil filter fitting, install the oil cooler and hose assembly.

Before assembling the oil cooler apply engine oil on the Oring.
Tightening torque
47.1 ~ 51.0N.m (4.8 ~ 5.2kgf.m, 34.7 ~ 37.6lb.ft)
6. Install the oil filter after applying engine oil on the Oring.
7. Install the crankshaft sprocket(B) with bolt(A).
Tightening torque
196.1 ~ 205.9N.m (20.0 ~ 21.0kgf.m, 144.7 ~ 151.9lbft)
8. Install the timing belt rear cover(A).
Tightening torque
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lbft)
9. Install the auto tensioner(A).
Tightening torque
49.0 ~ 53.9N.m (5.0 ~ 5.5kgf.m, 36.2 ~ 39.8lbft)
10. Install timing belt.
Tightening torque
29.4 ~ 33.3N.m (3.0 ~ 3.4kgf.m, 21.7 ~ 24.6lbft)
2012 > D 2.0 TCID > Engine Mechanical System > Intake And Exhaust System > Intercooler > Repair
English
procedures
REPLACEMENT
1. Remove the intercooler hose(A).
2. Disconnect the booster pressure sensor(B).
3. Remove intercooler lower hose and intercooler mounting bracket(C).
4. Installation is in the reverse order of removal.
2012 > D 2.0 TCID > Engine Mechanical System > Intake And Exhaust System > Intake Manifold >
English
COMPONENTS
2012 > D 2.0 TCID > Engine Mechanical System > Intake And Exhaust System > Intake Manifold > Repair
English
procedures
REMOVAL
1. Remove the radiator upper hose(A) and the coolant bleed hose(B).
2. Remove the alternator. (Refer to Alternator in EEC Group).
3. Remove the intercooler hose(A) and the disconnect booster pressure sensor(BPS) connector(B).
4. Disconnector the engine wire harness connectors from intake manifold side.
a. Disconnect the rail pressure sensor connector(A) and the water temperature sensor connector(B).
5. Disconnector the camshaft position sensor(A), pressure control valve(B), valve control actuator (c) and throttle body
actuator(D) connector.
English
6. Remove oil level gauge.
7. Remove the thermostat housing(A).
Tightening torque :
20 ~ 25N.m (2.0 ~ 2.5kgf.m, 15 ~ 18lbft)
8. Remove the EGR throttle body(A).
Tightening torque :
10 ~ 12N.m (1.0 ~ 1.2kgf.m, 7 ~ 9lbft)
9. Remove the thermostat hose(A).
10. Remove the intake manifold(A).
Tightening torque :
14.7 ~ 21.6N.m (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lbft)
2012 > D 2.0 TCID > Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold >
English
COMPONENTS
2012 > D 2.0 TCID > Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold >
English
Repair procedures
REMOVAL
1. Remove the air cleaner.
(1) Disconnect the Air Flow Sensor (AFS) connect(A).
(2) Remove the air intake hose clamp first, then remove the air cleaner assembly(B).
(3) Disconnect the electric control unit(E,C,U) connector(C).
(4) Remove the air cleaner assembly(D).
2. Remove the front muffler(A).
[C.P.F]
3. Remove the intercooler hose(A).
English
4. Disconnect the engine wire harness connectors from exhaust manifold.
(1) Disconnect the injector connector(A).
(2) Lambda sensor connector(B).
(3) VGT exhaust gas temperature sensor connector(C).[Only C.P.F]
(4) Disconnector the EGR actuator(D),fuel temperature sensor(E) and the fuel pressure regulator connector(E).
5. Remove the brake booster vacuum hose(A).
6. Remove the heater hose(A) and EGR cooler hose(B).
7. Remove VGT actuator vacuum hose.
8. Remove the EGR valve and cooler assembly(A).
Tightening torque :
Nuts(B), Bolt(C)
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lbft)
Nuts(D) : 24.5 ~ 29.4N.m (2.5 ~ 3.0kgf.m, 18.1 ~ 21.7lbft)
9. Remove the turbo charger heat protector(A, B).
Tightening torque :
16.7 ~ 21.6N.m (1.7 ~ 2.2kgf.m, 12.3 ~ 15.9lbft)
10. Remove the heater pipe heat protector(A).
Tightening torque :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbft)
11. Disconnect the turbo charger oil feed pipe(A) and oil return hose(B).
12. Remove turbocharger support bracket mounting bolts(C).
Tightening torque :
34.3 ~ 44.1N.m (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lbft)
13. Remove the EGR elbow(A) and turbocharger & exhaust manifold assembly(B).
Tightening torque :
EGR elbow bolt and nuts
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lbft)
Exhaust manifold nuts
29.4 ~ 37.3N.m (3.0 ~ 3.8kgf.m, 21.7 ~ 27.5lbft)
[C.P.F]
2012 > D 2.0 TCID > Engine Mechanical System > Intake And Exhaust System > Turbo Charger >English
COMPONENTS
1. Turbine housing 6. Compressor outlet
2. Turbine inlet 7. Center housing
3. Turbine outlet 8. Actuator
4. Compressor housing 9. Actuator rod
5. Compressor inlet
2012 > D 2.0 TCID > Engine Mechanical System > Intake And Exhaust System > Turbo Charger > Repair
English
procedures
REMOVAL AND INSTALLATION
1. Remove the turbocharger.
(Refer to Intake And Exhaust System "Exhaust Manifold")
Turbocharger Diagnostic Flow
If any problem related with turbocharger, such as lack of engine power, poor acceleration, abnormal engine noise or oil leaks, may
occur, check the turbocharger according to the procedure as follows.
English
1. Check for assembling of the turbocharger and the exhaust fitting (or the after treatment).
– Check if a gasket is installed.
– Check if mounting bolts (or nuts) are tightened properly.
– Check if there is a gas leak.
– Check if there is any damage, such as crack, on the parts.
If a gas leak occur as a gasket was not installed or mounting bolts (or nuts) were tightened inadequately, it may cause
abnormal engine noise.
If the cause of the problem is detected, retighten the mounting bolts (or nuts) as the specified torque or replace the gasket
or damaged parts with new ones if necessary.
2. Check for assembling of the turbocharger and the exhaust manifold.
– Check if the mounting bolts (or nuts) are tightened properly.
3. Check for assembling of the exhaust manifold and the cylinder head.
If the cause of the problem is detected, retighten the mounting bolts (or nuts) as the specified torque or install a new gasket
if necessary.
4. Check the turbocharger oil feed pipe & hose and oil drain pipe & hose.
– Check if the mounting bolts are tightened properly.
– Check if the clamps are positioned in place.
– Check if the oil pipes & hoses are damaged (bent, crushed, torn or cracked).
If a gas leak occur as a gasket was not installed or mounting bolts were tightened inadequately, it may cause oil leaks.
If the oil feed pipe & hose is damaged, engine oil is not supplied sufficiently to the turbocharger then it may damage the
turbocharger. If the oil drain pipe & hose is damaged and clogged, engine oil is not drained smoothly then it may cause oil
leaks from the turbocharger.
5. Check for oil leaks between center housing and compressor housing.
– Check if there is an oil leak.
If the Oring (gasket) between the center housing and the compressor housing is damaged, it may cause oil leaks.
If an oil leak is detected, replace the turbocharger with a new one.
6. Check the setting marks of the turbocharger actuator rod.
– Check if the actuator rod setting mark is aligned in line.
– Check if the minimum flow setting mark is aligned in line.
If the setting marks are not aligned in line, the engine performance is changed by an arbitrary tuneup of the turbocharger
after delivery.
If the setting marks are not aligned in line, replace the turbocharger with a new one.
7. Check the turbocharger actuator vacuum hoses & pipes.
– Check if the vacuum hose is connected to the actuator properly.
– Check if the vacuum hoses & pipes are damaged (bent, detached or torn).
– Check if there is any damage, such as crack, on the vacuum pipes.
– Check if the vacuum hoses are connected to inlet or outlet of the solenoid valve correctly.
If the vacuum pipes & hoses are damaged or disconnected, the actuator does not work properly then it may cause lack of
engine power and poor acceleration.
If the vacuum hoses & pipes are damaged, replace them with new ones.
8. Check the turbocharger actuator.
– Vacuum type actuator: Check for movement of the actuator rod when a vacuum of 60kPa (450mmHg, 8.7psi) is
applied to the actuator or a forced actuator operating mode is performed by GDS. (Refer to DTC guide)
If the turbocharger actuator is damaged, it may cause lack of engine power and poor acceleration.
If the actuator rod does not move, replace the turbocharger with a new one.
9. Check the turbocharger compressor wheel.
– Check if the compressor wheel is damaged (bent or deformed).
– Check if the compressor wheel rotates smoothly.
EX)
If the compressor wheel are damaged, it may cause abnormal noise from the turbocharger and poor acceleration.
If the compressor wheel are damaged or deformed, replace the turbocharger with new ones.
10. Check the turbocharger turbine wheel.
– Check if the turbine wheel is damaged.
– Check if the turbine wheel rotates smoothly.
EX)
If the turbine wheel are damaged, it may cause abnormal noise from the turbocharger and poor acceleration.
If the turbine wheel are damaged or deformed, replace the turbocharger with new ones.
If any problem is not detected in the turbocharger, check the turbochargerrelated parts according to the procedure as follows .
1. Check the blowby hose. (Refer to FL group)
– Check if the breather hose is damaged (bent, clogged).
– Check if the positive crankcase ventilation (PCV) valve is clogged.
If the breather hose is bent or clogged, the internal pressure in the engine increases then engine oil is not supplied
smoothly to the turbocharger. So it may cause damage of the turbocharger and oil leaks.
If the cause of the problem is detected, replace the breather hose or the related parts with new ones.
2. Check the air intake hose connected to the turbocharger.
– Check if the air intake hose is damaged (bent, crushed, detached or torn).
If a crosssection of the hose diminishes as the air intake hose is bent or crushed, intake air to the turbocharger reduces
and the pressure in front of turbocharger drops. So it may cause damage of the turbocharger and oil leaks. If the air intake
hose is detached or torn, a foreign substance goes into the turbocharger and causes damage of it.
If the air intake hose is damaged, replace it with a new one.
3. Check the air cleaner.
– Check the air cleaner filter for pollution state.
– Check the air cleaner filter for water influx.
– Check the air cleaner cover for dirtiness.
– Check if the air cleaner filter is a genuine part..
If the air cleaner filter is moistened or polluted excessively or a nongenuine part is used, intake air to the turbocharger
reduces and the pressure in front of turbocharger drops. So it may cause damage of the turbocharger and oil leaks. .
If the air cleaner filter is moistened or polluted excessively, replace it with a new one.

Replace the air cleaner filter according to the maintenance schedule.
4. Check the intercooler hoses & pipes.
– Check if the intercooler hoses & pipes are connected properly.
– Check if the intercooler hoses & pipes are damaged (bent, detached or torn).
– Check if there is any damage, such as crack, on the intercooler pipes.
If the intercooler hoses & pipes are damaged or disconnected, oil leaks may occur from the hoses & pipes and the
turbocharger may exceed the permissible speed then it may cause damage of the turbocharger.
If the intercooler hoses & pipes are damaged, replace them with new ones.

Use new clamps when replacing the hoses & pipes.
5. Check the intercooler.
– Check if the intercooler tubes and tanks are damaged (oil leak or crack).
If the intercooler is damaged, the turbocharger may exceed the permissible speed then it may cause damage of the
turbocharger.
If the intercooler is damaged, replace them with a new one.

Use new clamps when replacing the intercooler.
6. Check the engine oil.
– Check the engine oil level.
– Check the engine oil for discoloration, water influx and viscosity degradation.
– Check the engine oil grade.
If the engine oil level is low, amount of engine oil fed to turbocharger reduces then the bearings in the turbocharger may
adhere due to insufficient lubrication and cooling.
If the cause of the problem is detected, add or change engine oil.

Change the engine oil according to the maintenance schedule.
7. Check the engine oil pressure.
– Engine oil pressure: Check the oil pressure using an oil pressure gauge after removing the oil pressure switch on the
cylinder block.
– Check the engine oil screen in the oil pan if the engine oil level is low. Then check the injectors for gas leaks if foreign
substances are accumulated on the oil screen.
If the cause of the problem is detected, add or change engine oil. If foreign substances are accumulated on the oil screen,
wash the oil screen and replace the injector’s washer with a new one after checking the injectors for gas leaks. Check the
engine oilrelated parts, such as oil pump, if necessary.

As the turbocharger rotates at high speed of 100,000 rpm or above, deterioration of engine oil can cause damage of
the turbocharger bearings. Check engine oil for discoloration, water influx, viscosity degradation and oil pressure
lowering.
8. Check the solenoid valve of turbocharger. (Refer to DTC guide)
– Damage of the solenoid valve: Check if vacuum is generated at the disconnected vacuum hose from the actuator
when a forced actuator operating mode is performed by GDS..
– Clog of the solenoid valve filter: Check if vacuum is released when a forced actuator operating mode is performed
from max. duty (95%) to min. duty (5%) by GDS. (If the solenoid valve filter is clogged, the vacuum won’t be released
or it will take a long time to be released.)
If the solenoid valve is damaged, the actuator does not work properly then it may cause lack of engine power and poor
acceleration. If the solenoid valve filter is clogged, vacuum is not released then it may cause damage of the turbocharger
by overrunning.
If the solenoid valve is damaged, replace it with a new one.
9. Check the injectors, sensors, EGR valve, etc. (Refer to FL group)
– Check if the injectors operate properly.
– Check if the sensors, such as the mass air flow sensor (MAFS), intake air temperature sensor (IATS), boost pressure
sensor (BPS), operate properly.
– Check if the exhaust gas recirculation (EGR) valve operates properly.
If the injectors, sensors, EGR valve and etc. don’t work properly, it may cause lack of engine power.
If the cause of the problem is detected, replace the related parts with new ones.
2012 > D 2.0 TCID > Engine Mechanical System > Intake And Exhaust System > Front Exhaust Pipe >
English
Repair procedures
REMOVAL
Tightening torque :
40 ~ 60N.m (4.0 ~ 6.0kgf.m, 30 ~ 43lbft)
[C.P.F]
(1) Remove the Catalyzed Particulate Filter(CPF)(A) after disconnecting the differential pressure hoses(B) and exhaust
gas temperature sensor(C).(Only C.P.F)
Tightening torque :
40 ~ 60N.m (4.0 ~ 6.0kgf.m, 30 ~ 43lbft)
2. Remove the catalytic converter(A).
Tightening torque :
40 ~ 60N.m (4.0 ~ 6.0kgf.m, 30 ~ 43lbft)
English
3. Remove the main muffler(A).
Tightening torque :
40 ~ 60N.m (4.0 ~ 6.0kgf.m, 30 ~ 43lbft)
2012 > D 2.0 TCID > Fuel System > General Information > Specifications English
SPECIFICATIONS
FUEL DELIVERY SYSTEM
Items Specification
Fuel Tank Capacity 55 lit. (12.1 Imp.gal., 14.5 U.S.gal.)
Fuel Return System Type Return Type
Fuel Filter Type High pressure type (Built in engine room)
Type Mechanical, Plunger Pumping Type
High Pressure Fuel Pump
Driven by Camshaft
Fuel Pressure (Maximum) Pressure 1,600 bar (160 MPa, 23,206 psi)
INPUT SENSORS
MASS AIR FLOW SENSOR (MAFS)
▷ Type: HotFilm Type
▷ Specification
* At intake air temperature = 20°C(68°F)
Air Flow (kg/h) Frequency (kHz)
8 1.94 ~ 1.96
10 1.98 ~ 1.99
15 2.06 ~ 2.07
75 2.72 ~ 2.75
160 3.36 ~ 3.41
310 4.44 ~ 4.53
640 7.66 ~ 8.01
800 10.13 ~ 11.17
* At intake air temperature = 15°C(5°F) or 80°C(176°F)
10 1.97 ~ 1.99
75 2.71 ~ 2.76
160 3.34 ~ 3.43
310 4.39 ~ 4.58
INTAKE AIR TEMPERATURE SENSOR (IATS) #1 [BUILT IN MAFS]
▷ Type: Thermistor type
▷ Specification
Temperature [°C(°F)] Resistance(kΩ)
40(40) 35.14 ~ 43.76
20(4) 12.66 ~ 15.12
0(32) 5.12 ~ 5.89
20(68) 2.29 ~ 2.55
English
40(104) 1.10 ~ 1.24
60(140) 0.57 ~ 0.65
80(176) 0.31 ~ 0.37
BOOST PRESSURE SENSOR (BPS)
▷ Type: Piezoresistive pressure sensor type
▷ Specification
Pressure (kPa) Output Voltage (V)
32.5 0.5
70 1.02 ~ 1.17
140 2.13 ~ 2.28
210 3.25 ~ 3.40
270 4.20 ~ 4.35
284 4.5
INTAKE AIR TEMPERATURE SENSOR (IATS) #2 [BUILT IN BPS]
▷ Specification
40(40) 40.93 ~ 48.35
20(4) 13.89 ~ 16.03
0(32) 5.38 ~ 6.09
20(68) 2.31 ~ 2.57
40(104) 1.08 ~ 1.21
60(140) 0.54 ~ 0.62
80(176) 0.29 ~ 0.34
ENGINE COOLANT TEMPERATURE SENSOR (ECTS)
▷ Specification
40(40) 48.14
20(4) 14.13 ~ 16.83
0(32) 5.79
20(68) 2.31 ~ 2.59
40(104) 1.15
60(140) 0.59
80(176) 0.32
CAMSHAFT POSITION SENSOR (CMPS)
▷ Type: Hall effect type
▷ Specification
Level Output Pulse (V)
High 5V
Low 0V
Items Specification
Air Gap 1.0 ± 0.5 mm
CRANKSHAFT POSITION SENSOR (CKPS)
▷ Type: Variable reluctance type
▷ Output Voltage (V): 0 ~ 5V
Items Specification
Coil Resistance (Ω)) 774 ~ 946Ω [20°C(68°F)]
ACCELERATOR POSITION SENSOR (APS)
▷ Type: Potentiometer type
▷ Specification
Output Voltage(V)
Test Condition
APS 1 APS 2
Idle 0.7 ~ 0.8 0.275 ~ 0.475
Fully depressed 3.8 ~ 4.4 1.75 ~ 2.35
Specification
Items
APS 1 APS 2
Potentiometer Resistance (kΩ) 0.7 ~ 1.3 1.4 ~ 2.6
FUEL TEMPERATURE SENSOR (FTS)
▷ Specification
30(22) 27.00
20(4) 15.00
10(14) 9.45
0(32) 5.89
20(68) 2.27 ~ 2.73
40(104) 1.17
50(122) 0.83
60(140) 0.60
70(158) 0.43
80(176) 0.30 ~ 0.32
RAIL PRESSURE SENSOR (RPS)
▷ Type: Piezoelectricity type
▷ Specification
Test Condition Rail pressure (bar) Output Voltage(V)

Idle 220 ~ 320 Below 1.7
Fully depressed 1800 Approx. 4.5
LAMBDA SENSOR
▷ Type: Zirconia (ZrO2) Type
▷ Specification
λ Value (A/F Ratio) Pumping Current(A)
0.65 2.22
0.70 1.82
0.80 1.11
0.90 0.50
1.01 0.00
1.18 0.33
1.43 0.67
1.70 0.94
2.42 1.38
Air (Atmosphere) 2.54
Temperature [°C(°F)] Heater Resistance(Ω)
20(68) 9.2
100(212) 10.7
200(392) 13.1
300(572) 14.6
400(752) 17.7
500(932) 19.2
600(1,112) 20.7
700(1,292) 22.5
EXHAUST GAS TEMPERATURE SENSOR (EGTS) #1 FOR VGT
▷ Specification
100(212) 289.0 ~ 481.0
300(572) 5.30 ~ 6.61
600(1,112) 0.35 ~ 0.38
900(1,652) 0.08 ~ 0.09
DIFFERENTIAL PRESSURE SENSOR (DPS)
▷ Specification: Vout = (4.5 1.0) / 100 * ΔP + 1.0 (V)
Differential Pressure [ΔP] (kPa) Output Voltage (V)
0 1.00
10 1.35
20 1.70
30 2.05
40 2.40
50 2.75
60 3.10
70 3.45
80 3.80
90 4.15
100 4.50
EXHAUST GAS TEMPERATURE SENSOR (EGTS) #2 FOR CPF
▷ Specification
100(212) 289.0 ~ 481.0
300(572) 5.30 ~ 6.61
600(1,112) 0.35 ~ 0.38
900(1,652) 0.08 ~ 0.09
VEHICLE SPEED SENSOR (VSS)
▷ Type: Inductive type
OUTPUT ACTUATORS
INJECTOR
▷ Number: 4
▷ Specification
Items Specification
Coil Resistance (Ω) 0.33Ω [20°C(68°F)]
FUEL PRESSURE REGULATOR VALVE
▷ Specification
It ems Specification
Coil Resistance (Ω) 2.9 ~ 3.15Ω [20°C(68°F)]
RAIL PRESSURE REGULATOR VALVE
▷ Specification
Items Specification
THROTTLE CONTROL ACTUATOR
▷ Type : Duty control motor type
▷ Specification
Duty (%) Throttle Valve Position
5 Open
5 ~ 94 Normal operation (Partially open in proportion to duty value)
94 Closed
94 ~ 95 Maintaining the last valid position
95 ~ 97 Fully closed
ELECTRIC EGR CONTROL VALVE
▷ Type: Linear solenoid type
▷ Specification
Items Specification
VGT CONTROL SOLENOID VALVE
▷ Specification
Items Specification
VARIABLE SWIRL CONTROL ACTUATOR
▷ Type: Motor Driven (including Position Sensor)
▷ Specification
Motor
Items Specification
Position Sensor
Items Specification
Coil Resistance (kΩ) 3.44 ~ 5.16kΩ [20°C(68°F)]
SERVICE STANDARD
Neutral,N,Prange 850 ± 100 rpm
A/C OFF
Drange 850 ± 100 rpm
Basic Idle rpm(After warm up)
A/C ON
TIGHTENING TORQUES
ENGINE CONTROL SYSTEM
Item N·m Kgf·m lbf·ft
ECM installation bolts 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Mass air flow sensor clamp installation bolts 2.9 ~ 4.9 0.3 ~ 0.5 2.2 ~ 3.6
Boost pressure sensor installation bolts 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Engine coolant temperature sensor installation 19.6 ~ 39.2 2.0 ~ 4.0 14.5 ~ 28.9
Crankshaft position sensor installation bolt 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
Camshaft position sensor installation bolt 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
Lambda sensor installation 40.2 ~ 59.8 4.1 ~ 6.1 29.7 ~ 44.1
Electric EGR control valve installation bolts 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Variable swirl control actuator installation bolts 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Exhaust gas temperature sensor (For CPF) installation 39.2 ~ 49.1 4.0 ~ 5.0 28.9 ~ 36.2
Exhaust gas temperature sensor (For VGT) installation 39.2 ~ 49.1 4.0 ~ 5.0 28.9 ~ 36.2
DPS & VGT control solenoid valve bracket installation bolts 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Throttle body installation bolts 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pressure switch installation 14.7 ~ 21.6 1.5 ~ 2.2 10.9 ~ 15.9
Glow plug installation 9.8 ~ 13.7 1.0 ~ 1.4 7.2 ~ 10.1
Pipe (DPS ↔ CPF) installation (CPF side) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Item N·m Kgf·m lbf·ft
Injector clamp installation bolt 24.5 ~ 28.4 2.5 ~ 2.9 18.1 ~ 21.0
Common rail installation bolts 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
High pressure fuel pump installation bolts 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3
High pressure pipe (Injector ↔ Common Rail) installation nuts 24.5 ~ 28.4 2.5 ~ 2.9 18.1 ~ 21.0
High pressure pipe (Common RaiI ↔ High Pressure Fuel Pump)
24.5 ~ 28.4 2.5 ~ 2.9 18.1 ~ 21.0
installation nuts
Fuel tank band installation bolts 39.2 ~ 54.0 4.0 ~ 5.5 28.9 ~ 39.8
Fuel pump (Low Pressure) installation bolts 3.9 ~ 5.8 0.4 ~ 0.6 2.8 ~ 4.4
Fuel filter installation nuts 9.8 ~ 14.7 1.0 ~ 1.5 7.2 ~ 10.9
Accelerator pedal module installation bolts 12.8 ~ 15.7 1.3 ~ 1.6 9.4 ~ 11.6
2012 > D 2.0 TCID > Fuel System > General Information > Special Service Tools English
Tool (Number and name) Illustration Application

093514A300 Removing the injector
Injector Remover
0931427110(14mm) Installing the high pressure pipe
0931427120(17mm)
Torque Wrench Socket
Tool Number Tool Name
CTR1000 Common Rail Tester (Standard kit)
CRT1010 Tool Case
CRT1020 Regulator Valve
CRT1021 Plug (for Delphi) M14mm
CRT1022 Plug (for Bosch) M12mm
CRT1023 Adapter (for Bosch)
CRT1030 Flask & Holder
CRT1031 Visible Tube
CRT1032 Injector Return Hose Adapter
CRT1033 Injector Return Hose Plug
CRT1034 Flushing Tube
CRT1035 Dust Cap
CRT1040 High Pressure Meter
CRT1041 Adapter Connector (for Delphi Old)
CRT1042 Adapter Connector (for Delphi New)
CRT1043 Adapter Connector (for Bosch)
CRT1044 IMV Control Valve
CRT1050 Vacuum Gauge
CRT1051 Pressure Gauge
CRT1052 Gauge Connection Tube
CRT1053 Connection Adapter
CRT1054 Connection Adapter with Hose
CRT1055 Hose Clamp
CRT1060 User's Guide English
* To use this Common Rail Tester, refer to the user's guide included in this kit.
2012 > D 2.0 TCID > Fuel System > General Information > Troubleshooting English
BASIC TROUBLESHOOTING
BASIC TROUBLESHOOTING GUIDE
English
CUSTOMER PROBLEM ANALYSIS SHEET
BASIC INSPECTION PROCEDURE
The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be measured at ambient
temperature (20°C, 68°F), unless stated otherwise.

The measured resistance in except for ambient temperature (20°C, 68°F) is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again during testing. An
example would be if a problem appears only when the vehicle is cold but has not appeared when warm. In this case, the technician
should thoroughly make out a "CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and condition which
occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent, broken or corroded pins, and
then verify that the connectors are always securely fastened.
3. Slightly shake the connector and wiring harness vertically and horizontally.
4. Repair or replace the component that has a problem.
5. Verify that the problem has disappeared with the road test.
● SIMULATING VIBRATION
a. Sensors and Actuators
: Slightly vibrate sensors, actuators or relays with finger.

Strong vibration may break sensors, actuators or relays
b. Connectors and Harness
: Lightly shake the connector and wiring harness vertically and then horizontally.
● SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.

• DO NOT heat components to the point where they may be damaged.
• DO NOT heat the ECM directly.
● SIMULATING WATER SPRINKLING
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.

DO NOT sprinkle water directly into the engine compartment or electronic components.
● SIMULATING ELECTRICAL LOAD
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, rear window defogger, etc.).
CONNECTOR INSPECTION PROCEDURE
1. Handling of Connector
a. Never pull on the wiring harness when disconnecting connectors.
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire harness
side.
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from
harness side.

• Use a fine wire to prevent damage to the terminal.
• Do not damage the terminal when inserting the tester lead.
2. Checking Point for Connector
a. While the connector is connected:
Hold the connector, check connecting condition and locking efficiency.
b. When the connector is disconnected:
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
c. Check terminal tightening condition:
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
3. Repair Method of Connector Terminal
a. Clean the contact points using air gun and/or shop rag.

Never use sand paper when polishing the contact points, otherwise the contact point may be damaged.
b. In case of abnormal contact pressure, replace the female terminal.
WIRE HARNESS INSPECTION PROCEDURE
1. Before removing the wire harness, check the wire harness position and crimping in order to restore it correctly.
2. Check whether the wire harness is twisted, pulled or loosened.
3. Check whether the temperature of the wire harness is abnormally high.
4. Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part.
5. Check the connection between the wire harness and any installed part.
6. If the covering of wire harness is damaged; secure, repair or replace the harness.
ELECTRICAL CIRCUIT INSPECTION PROCEDURE
1. Procedures for Open Circuit
• Continuity Check
• Voltage Check
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity Check Method) or Step 3
(Voltage Check Method) as shown below.
2. Continuity Check Method

When measuring for resistance, lightly shake the wire harness above and below or from side to side.
Specification (Resistance)
1Ω or less → Normal Circuit
1MΩ or Higher → Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1MΩ and below 1 Ω respectively. Specifically the
open circuit is line 1 (Line 2 is normal). To find exact break point, check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1) and between (B2) and (A) as
shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1MΩ and the open circuit is
between terminal 1 of connector (C) and terminal 1 of connector (B1).
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and terminal 1 of each
connectors (A), (B) and (C) as shown in [FIG. 4].
The measured voltage of each connector is 5V, 5V and 0V respectively. So the open circuit is between connector (C)
and (B).
● CHECK SHORT CIRCUIT
1. Test Method for Short to Ground Circuit
• Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing Step 2 (Continuity Check
Method with Chassis Ground) as shown below.
2. Continuity Check Method (with Chassis Ground)

Lightly shake the wire harness above and below, or from side to side when measuring the resistance.
1Ω or less → Short to Ground Circuit
1MΩ or Higher → Normal Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis Ground as shown in
[FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ω and higher than 1MΩ respectively. Specifically
the short to ground circuit is line 1 (Line 2 is normal). To find exact broken point, check the sub line of line 1 as
described in the following step.
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and between (B1)
and chassis ground as shown in [FIG. 7].
The measured resistance between connector (B1) and chassis ground is 1Ω or less. The short to ground circuit is
SYMPTOM TROUBLESHOOTING GUIDE TABLE
(SYMPTOM 1) ENGINE DOES NOT START
Possible Cause
• Run out of fuel • Inversion of low pressure fuel connections
• Starter faulty • Fuel filter not adapted
• Fuel pump hose supply cut • Low pressure fuel circuit sealed
• High pressure leakage • Sealed fuel filter
• Fuse out of order • Intermittent fault connection
• Drift of the rail pressure sensor not detected • Air ingress in the low pressure fuel circuit
• Cam and Crank signals missing simultaneously • Fuel return circuit of the pump sealed
• Battery voltage too low • Engine compression too low
• Faulty immobilizer • Leakage at the injector
• Electric EGR control valve blocked open • Low pressure fuel pump faulty
• Fuel pressure regulator valve contaminated, stuck, • High pressure fuel pump faulty
jammed
• Injector jammed open
• Rail pressure regulator valve contaminated, stuck,
jammed • Bug software or hardware fault not detected
• Fuel quality / presence of water • Glow system faulty
(SYMPTOM 2) ENGIEN STARTS WITH DIFFICULTY OR STARTS AND STALLS
Possible Cause
• Run out of fuel
• Inversion of low pressure fuel connections
• Fuel return hose of injector cut
• Low pressure fuel circuit sealed
• High pressure leakage
• Sealed fuel filter
• Fuse faulty
• Oil level too high/too low
• Air filter sealed
• Catalytic converter sealed or damaged
• Alternator or voltage regulator faulty
• Intermittent fault connection
• The compensation of individual injector not adapted
• Air ingress in the low pressure fuel circuit
• Drift of the engine coolant temperature sensor not
detected • Fuel return circuit of the pump sealed
• Drift of the rail pressure sensor not detected • Glow system faulty
• Battery voltage too low • Engine compression too low
• Electric EGR control valve blocked open • Fuel return hose of injector sealed
• Fuel pressure regulator valve contaminated, stuck, • Carbon deposit on the injector (sealed holes)
jammed • Needle stuck (injection possible over a certain pressure)
• Rail pressure regulator valve contaminated, stuck, • Gasoline in fuel
jammed
• Bug software or hardware fault not detected
• Fuel quality / presence of water
(SYMPTOM 3) POOR STARTING WHEN HOT
Possible Cause
• Fuel return circuit of the pump sealed
• Drift of the rail pressure sensor not detected
• Electric EGR control valve blocked open
• Engine compression too low
• Fuel pressure regulator valve contaminated, stuck,
jammed • Intermittent fault connection
• Rail pressure regulator valve contaminated, stuck, • Carbon deposit on the injector (sealed holes)
jammed
• Needle stuck (injection possible over a certain pressure)
• Gasoline in fuel
(SYMPTOM 4) UNSTABLE IDLING
Possible Cause
• Glow system faulty
• Bad flanging of the injector
• Harness resistance increased
• High pressure pump out of order
• Injector not adapted
• Carbon deposit on the injector (sealed holes)
• Fuel return hose of injector sealed
(SYMPTOM 5) IDLE SPEED TOO HIGH OR TOO LOW
Possible Cause
• Drift of the engine coolant temperature sensor not • Clutch not well set
detected • Bug software or hardware fault not detected
• Incorrect state of the electrical pack devices • Electric EGR control valve blocked open
• Alternator or voltage regulator faulty • Throttle control actuator faulty
(SYMPTOM 6) BLUE, WHITE, OR BLACK SMOKES
Possible Cause
detected • Oil suction (engine racing)
• Drift of the rail pressure sensor not detected • Glow system faulty
• Electric EGR control valve blocked open • Engine compression too low
• Fuel pressure regulator valve contaminated, stuck, • Bad flanging of the injector
jammed
• Injector washer not adapted, forgotten, doubled
jammed
(SYMPTOM 7) ENGINE RATTLING, NOISY ENGINE
Possible Cause
• Electric EGR control valve blocked closed (noisy engine)
detected
• Glow system faulty
• Drift of engine coolant temperature sensor not detected
(SYMPTOM 8) BURST NOISE
Possible Cause
• The compensation of individual injector not adapted • Fuel pressure regulator valve contaminated, stuck,
jammed
• Exhaust system sealed jammed
• Drift of the rail pressure sensor not detected • Bug software or hardware fault not detected
(SYMPTOM 9) UNTIMELY ACCELERATION/DECELERATION AND ENGINE RACING
Possible Cause
• Accelerator position sensor blocked • Oil suction (engine racing)
• Electric EGR valve blocked open • Drift of the rail pressure sensor not detected
• Intermittent fault connection • Bug software or hardware fault not detected
(SYMPTOM 10) GAP WHEN ACCELERATING AND AT RECOUPLING (RESPONSE TIME)
Possible Cause
• Air inlet circuit open
• Incorrect state of the electrical pack devices
• Accelerator position sensor blocked jammed
• Electric EGR valve blocked open • Rail pressure regulator valve contaminated, stuck,
jammed
• Turbo charger damaged, vacuum hose line leakage
(SYMPTOM 11) ENGINE STOP OR STALLING
Possible Cause
• Run out of fuel • Rail pressure regulator valve contaminated, stuck,
jammed
• Fuel pump hose supply cut
• Alternator or voltage regulator faulty
• Fuse faulty
• Oil suction (engine racing)
• Low pressure fuel circuit sealed
• Low pressure fuel pump faulty
• High pressure pump faulty
• Crank signals missing simultaneously
• Faulty ignition key
• Electric EGR valve blocked open
jammed • Bug software or hardware fault not detected
(SYMPTOM 12) ENGINE JUDDER
Possible Cause
• Run out of fuel • Glow system faulty
• Fuel return hose of injector cut • Engine compression too low
• Incorrect state of the electrical pack devices • Fuel return hose of injector sealed
• The compensation of individual injector not adapted • Valve clearance
• Electric EGR valve blocked open • Low pressure fuel pump faulty
• Fuel filter not adapted • Injector washer not adapted, forgotten, doubled
• Air ingress in the low pressure fuel circuit • Carbon deposit on the injector (sealed holes)
• Fuel quality / presence of water • Needle stuck (injection possible over a certain pressure)
• Sealed fuel filter • Injector jammed open
• Intermittent fault connection • Gasoline in fuel
• Harness resistance increased • Bug software or hardware fault not detected
(SYMPTOM 13) LACK OF POWER
Possible Cause
• Accelerator position sensor blocked
• Leakage at the injector
• Fuel return circuit of the pump sealed
• Valve clearance
• Turbo charger damaged, vacuum hose line leakage
(SYMPTOM 14) TOO MUCH POWER
Possible Cause
(SYMPTOM 15) EXCESSIVE FUEL CONSUMPTION
Possible Cause
• Leakage at the Fuel pressure regulator valve
• Leakage at fuel temperature sensor
• Leakage at the spacers
• Turbo charger damaged
(SYMPTOM 16) OVER SPEED ENGINE WHEN CHANGING THE GEAR BOX RATIO
Possible Cause
• Accelerator position sensor blocked • Oil suction (engine racing)
• The compensation of individual injector not adapted • Turbo charger damaged
• Intermittent fault connection • Injector not adapted
• Clutch not well set • Bug software or hardware fault not detected
(SYMPTOM 17) EXHAUST SMELLS
Possible Cause
• Electric EGR control valve leakage
(SYMPTOM 18) SMOKES (BLACK, WHITE, BLUE) WHEN ACCELERATING
Possible Cause
• Air heaters out of order
• Catalyzed Particulate Filter (CPF) fail
(SYMPTOM 19) FUEL SMELLS
Possible Cause
• Fuel pump hose supply cut • Leakage at fuel temperature sensor
• Fuel return hose of injector cut • Leakage at the spacers
• Leakage at the Fuel pressure regulator valve • High pressure leakage
(SYMPTOM 20) THE ENGINE COLLAPSES AT TAKE OFF
Possible Cause
• Accelerator position sensor blocked
• Clutch not well set
• Inversion of low pressure fuel connections
• Fuel filter not adapted jammed
• Fuel quality/presence of water • Rail pressure regulator valve contaminated, stuck,
jammed
(SYMPTOM 21) THE ENGINE DOES NOT STOP
Possible Cause
• Faulty ignition key
(SYMPTOM 22) DIFFERENT MECHANICAL NOISES
Possible Cause
• Buzzer noise (discharge by the injectors)
• Clip broken (vibrations, resonance, noises)
• Clutch not well set
• Turbo charger damagedValve clearance
• Valve clearance
2012 > D 2.0 TCID > Fuel System > Engine Control System > Description and Operation English
DESCRIPTION
1) Engine is hard to start or does not start at all.
2) Nstable idle.
3) Poor driveability.

• Before removing or installing any part, read the diagnostic trouble codesand then disconnect the battery negative ()
terminal.
• Before disconnecting the cable from battery terminal, turn the ignition switch to OFF. Removal or connection of the
battery cable during engine operationor while the ignition switch is ON could cause damage to the ECM.
• Wchecking the generator for the charging state, do not disconnect the battery '+' terminal to prevent the ECM from
damage due to the voltage.
• Wcharging the battery with the external charger, disconnect the vehicleside battery terminals to prevent damage to
the ECM.
SELFDIAGNOSIS

If a sensor connector is disconnected with the ignition switch turned on, the diagnostic trouble code (DTC) is recorded. In
this case, disconnect the battery negative terminal () for 15 seconds or more, and the diagnosis memory will be erased.
CHECKING PROCEDURE (SELFDIAGNOSIS)

• When attery voltage is excessively low, diagnostic trouble codes can not be read. Be sure to check the battery for
voltage and the charging system before starting the test
• Diagnosis memory is erased if the battery or the ECM connector is disconnected. Do not disconnect the battery
before the diagnostic trouble codes are completely read and recorded.
INSPECTION PROCEDURE (USING GENERIC SCAN TOOL)
1. Turn OFF the ignition switch.
2. Connect the scan tool to the data link connector on the lower crash pad.
3. Turn ON the ignition switch.
4. Use the scan tool to check the diagnostic trouble code.
5. Repair the faulty part from the diagnosis chart.
6. Erase the diagnostic trouble code.
7. Disconnect the GST.

When deleting diagnostic trouble code, use scan tool as possible. When deleting diagnostic trouble code by
English
disconnecting battery terminal(), data for ECM control may delete simultaneously.
2012 > D 2.0 TCID > Fuel System > Engine Control System > Components and Components Location
English
COMPONENT LOCATION
3. Boost Pressure Sensor (BPS)
1. Mass Air Flow Sensor (MAFS) 4. Intake Air Temperature Sensor (IATS) #2 built in BPS
2. Intake Air Temperature Sensor (IATS) #1 built in MAFS 23. Variable Swirl Control Actuator
English
6. Lambda Sensor
5. Engine Coolant Temperature Sensor (ECTS)
13. Exhaust Gas Temperature Sensor (EGTS) #1 for VGT
8. Crankshaft Position Sensor (CKPS)
7. Camshaft Position Sensor (CMPS)
17. Oil Pressure Switch (OPS)
10. Fuel Temperature Sensor (FTS)
9. Accelerator Pedal Position Sensor (APS)
24. Fuel Pressure Regulator Valve
11. Differential Pressure Sensor (DPS)
12. A/C Pressure Transducer (APT)
21. VGT Control Solenoid Valve
14. Exhaust Gas Temperature Sensor (EGTS) #2 for CPF 15. Rail Pressure Sensor (RPS)
16. Vehicle Speed Sensor (VSS) 18. Water Sensor (included in Fuel Filter)
19. Injector 20. Throttle Control Actuator
22. Electric EGR Control Valve 24. ECM (Engine Control Module)
26. Main Relay
25. Rail Pressure Regulator Valve
27. Fuel Pump Relay
28. Glow Relay
30. MultiPurpose Check Connector
29. Auxiliary Heater Relay (Option)
2012 > D 2.0 TCID > Fuel System > Engine Control System > Engine Control Module (ECM) > English
Specifications
ECM (ENGINE CONTROL MODULE)
1. ECM HARNESS CONNECTOR
2. ECM TERMINAL FUNCTION
CONNECTOR [CDDA]
Pin Description Connected to
1 Injector (Cylinder #3) [HIGH] control output Injector (Cylinder #3)
3
4 Battery power Rail Pressure Regulator Valve
5
6 Sensor ground Position Sensor in Variable Swirl Control Actuator
7 Sensor shield Crankshaft Position Sensor (CKPS)
8 Sensor ground Rail Pressure Sensor (RPS)
9
10
11
Crankshaft Position Sensor (CKPS) [] signal
12 Crankshaft Position Sensor (CKPS)
input
13 Reference voltage (+5V) Boost Pressure Sensor (BPS)
14
15
18
19 Battery power Fuel Pressure Regulator Valve
20 Sensor ground Camshaft Position Sensor (CMPS)
21
22
23 Sensor ground Boost Pressure Sensor (BPS)
24
25 English
26 Reference voltage (+5V) Position Sensor in Variable Swirl Control Actuator

Crankshaft Position Sensor (CKPS) [+] signal
27 Crankshaft Position Sensor (CKPS)
input
28 Reference voltage (+5V) Rail Pressure Sensor (RPS)
29
30 Motor [] control output Variable Swirl Control Actuator
31 Injector (Cylinder #2) [LOW] control output Injector (Cylinder #2)
32
34 Rail Pressure Regulator Valve control output Rail Pressure Regulator Valve
35
36
37 Reference frequency Mass Air Flow Sensor (MAFS)
38
39
40 Boost Pressure Sensor (BPS) signal input Boost Pressure Sensor (BPS)
41 Sensor ground Engine Coolant Temperature Sensor (ECTS)
42 Mass Air Flow Sensor (MAFS) signal input Mass Air Flow Sensor (MAFS)
43 Rail Pressure Sensor (RPS) signal input Rail Pressure Sensor (RPS)
44 Sensor ground MAFS & IATS #1
45 Fuel Pump Relay output Fuel Pump Relay
48
49 Fuel Pressure Regulator Valve control output Fuel Pressure Regulator Valve
50 Camshaft Position Sensor (CMPS) signal input Camshaft Position Sensor (CMPS)
51
52
Intake Air Temperature Sensor (IATS) #2 signal
53 Intake Air Temperature Sensor (IATS) #2 built in BPS
input
54
55
56 Position Sensor signal input Position Sensor in Variable Swirl Control Actuator
57
Engine Coolant Temperature Sensor (ECTS)
58 Engine Coolant Temperature Sensor (ECTS)
signal input
59 Electric EGR Control Valve control output Electric EGR Control Valve
60 Motor [+] control output Variable Swirl Control Actuator
CONNECTOR [CDDK]
1 Batter voltage supply after main relay Main Relay
2 Power ground Chassis Ground
7 Cooling Fan Relay [HIGH] control output Cooling Fan Relay [HIGH]
8 Sensor ground Accelerator Position Sensor (APS) #2
Accelerator Position Sensor (APS) #1 signal
9 Accelerator Position Sensor (APS) #1
input
10 Sensor ground Fuel Temperature Sensor (FTS)
11 Fuel Temperature Sensor (FTS) signal input Fuel Temperature Sensor (FTS)
12 Ground A/C Pressure Transducer
13 A/C Pressure Transducer signal input A/C Pressure Transducer
14 Ground Cruise Control Switch
15 Cruise Control "ACTIVATOR" signal input Cruise Control Switch
16 Ground Immobilizer Control Module
17
18
19
20
21
22 Reference voltage (+5V) A/C Pressure Transducer
23
24 Reference voltage (+5V) Cruise Control Switch
25 Diagnosis Data Line (KLine) Data Link Connector (DLC)
26
27 Fuel consumption signal output Trip computer
28 Ignition switch signal input Ignition Switch
29 VGT Control Solenoid Valve control output VGT Control Solenoid Valve
Accelerator Position Sensor (APS) #2 signal
31 Accelerator Position Sensor (APS) #2
input
Exhaust Gas Temperature Sensor (EGTS) #2
32 Exhaust Gas Temperature Sensor (EGTS) #2 for CPF
signal input
33 Sensor ground Exhaust Gas Temperature Sensor (EGTS) #2 for CPF
34 Exhaust Gas Temperature Sensor (EGTS) #1 [VGT]
signal input
35 Sensor ground Exhaust Gas Temperature Sensor (EGTS) #1 [VGT]
36 Differential Pressure Sensor (DPS) signal input Differential Pressure Sensor (DPS)
37 Sensor ground Differential Pressure Sensor (DPS)
38 Brake Switch "Lamp" signal input Brake Switch
39
40 Water Sensor siganl input Water Sensor in Fuel Filter
41
42 Blower Switch Signal input Blower Switch
43
44 Reference voltage (+5V) Differential Pressure Sensor (DPS)
45 Reference voltage (+5V) Accelerator Position Sensor (APS) #1
46 Reference voltage (+5V) Accelerator Position Sensor (APS) #2
47 Immobilizer Communication Line Immobilizer Control Module
48 Engine speed signal output Tachometer (Cluster)
49 Cruise Control "SET" Lamp control output Cruise Control "SET" Lamp (Cluster)
50
51 Lambda Sensor Heater control output Lambed Sesnor
52
53
54 A/C Switch "ON" signal input A/C Switch
55
56 Thermo Switch signal input A/C Switch
57 Gear Neutral Switch signal input (MT Only) Gear Neutral Switch
58
59
60
61
62
63
64 Lambda Sensor Voltage "NERNST" Lambda Sensor
65 Lambda Sensor Current Pump Lambda Sensor
66
67
68 Malfunction Indicator Lamp (MIL) control output Malfunction Indicator Lamp (MIL)
69 Glow Time Indicator Lamp contorl output Glow Time Indicator Lamp (Cluster)
70 A/C Compressor Relay control output A/C Compressor Relay
71 Cooling Fan Relay [LOW] control output Cooling Fan Relay
72 Main Relay control output Main Relay
73
74
75 Vehicle speed signal input Vehicle Speed Sensor (VSS)
76
77 Feedback signal input Throttle Control Actuator
78
79 Clutch Switch signal input Clutch Switch
80 Brake Switch "Redundant" signal input Brake Switch
81 MT/AT auto reconition signal input M/T: Open, A/T: Ground
82
83 CAN [LOW] Other Control Modules
84 CAN [HIGH] Other Control Modules
85
86 Lambda Sensor Virtual Ground Lambda Sensor
87 Lambda Sensor Current Adjust Lambda Sensor
88
89 Intake Air Temperature Sensor (IATS) #1 in MAFS
input
90 Throttle Control Actuator control output Throttle Control Actuator
91 Cruise Control "MAIN" Lamp control output Cruise Control "MAIN" Lamp (Cluster)
92 Immobilizer Lamp control output Immobilizer Lamp (Cluster)
93 Glow Relay control output Glow Relay
94 PTC Heater Relay control output PTC Heater Relay
3. ECM TERMINAL INPUT/OUTPUT SIGNAL
CONNECTOR [CDDA]
Pin Description Condition Type Level
1 Injector (Cylinder #3) [HIGH] control output Idle Pulse B+ ~ 80V
2 Injector (Cylinder #2) [HIGH] control output Idle Pulse B+ ~ 80V
3
4 Battery power Idle DC Vbatt
5
6 Sensor ground Idle DC Max. 50mV
7 Sensor shield Idle DC Max. 50mV
8 Sensor ground Idle DC Max. 50mV
9
10
11
Crankshaft Position Sensor (CKPS) [] signal
12 Idle Sine Wave Vp_p : Min.1.0V
input
IG OFF Max. 0.5V
13 Reference voltage (+5V) DC
IG ON 4.9 ~ 5.1V
14
15
16 Injector (Cylinder #1) [HIGH] control output Idle Pulse Vbatt ~ 80V
17 Injector (Cylinder #4) [HIGH] control output Idle Pulse Vbatt ~ 80V
18
IG OFF Max. 0.5 V
19 Battery power DC
IG ON Vbatt
20 Sensor ground Idle DC Max. 50 mV
21
22
24
25
IG OFF Max. 0.5V
IG ON 4.9 ~ 5.1V
Crankshaft Position Sensor (CKPS) [+] signal
27 Idle Sine Wave Vp_p : Min.1.0V
input
IG OFF Max. 0.5V
IG ON 4.9 ~ 5.1V
29
30 Motor [] control output Active DC Max.0.5V
Peak Current : 19 ~ 21
A Hold Current : 11~
13 A
31 Injector (Cylinder #2) [LOW] control output Idle Pulse
32
13 A
Hi: Vbatt
Lo: Max. 1.0V
34 Rail Pressure Regulator Valve control output Idle Pulse
Frequency = 1kHz ±
2%
35
36
Hi: Vcc or Vbatt
37 Reference frequency Idle Pulse
Lo: Max. 1.0V
38
39
40 Boost Pressure Sensor (BPS) signal input IG ON Analog 0.5 ~ 4.5V
Hi: Vcc or Vbatt
42 Mass Air Flow Sensor (MAFS) signal input Idle Pulse
Lo: Max. 1.0V
IG ON Max. 1.0V
43 Rail Pressure Sensor (RPS) signal input Idle Analog 1.0 ~ 1.5 V
3000 RPM 1.5 ~ 3.0 V
Relay OFF Vbatt
45 Fuel Pump Relay output DC
Relay ON Max. 1.0V
13 A
13 A
48
Hi: Vbatt
49 Fuel Pressure Regulator Valve control output Idle Pulse
Lo: Max. 1.0V
Hi: Vcc or Vbatt
50 Camshaft Position Sensor (CMPS) signal input Idle Pulse
Lo: Max. 1.0V
51
52
53 Idle Analog 0.5 ~ 4.5V
input
54
55
56 Position Sensor signal input Idle DC 0.5 ~ 4.5V
57
signal input
Hi: Vbatt
59 Electric EGR Control Valve control output Idle Pulse
Lo: Max. 1.0V
Hi: Vbatt
60 Motor [+] control output Active Pulse
Lo: Max. 1.0V
CONNECTOR [CDDK]
Pin Description Condition Type Level
Batter voltage supply after main relay IG OFF Max. 1.0 V

1 DC
IG ON Vbatt
2 Power ground Idle DC Max. 50 mV
IG OFF Max. 1.0 V
3 Batter voltage supply after main relay DC
IG ON Vbatt
5 Batter voltage supply after main relay IG OFF DC Max. 1.0 V
IG ON Vbatt
Relay OFF Vbatt
7 Cooling Fan Relay [HIGH] control output DC
Relay ON Max. 1.0V
Accelerator Position Sensor (APS) #1 signal C.T 0.3 ~ 0.9V

9 Analog
input W.O.T 4.0 ~ 4.8V
11 Fuel Temperature Sensor (FTS) signal input IG ON Analog 0.5 ~ 4.5V
12 Ground Idle DC Max. 50 mV
13 A/C Pressure Transducer signal input A/C On Analog Max. 4.8V
14 Ground Idle DC Max. 50mV
15 Cruise Control "ACTIVATOR" signal input
16 Ground Idle DC Max. 50 mV
17
18
19
20
21
IG OFF Max. 0.5V
IG ON 4.9 ~ 5.1V
23
IG OFF Max. 0.5V
IG ON 4.9 ~ 5.1V
When Hi: Min. Vbatt×80%
transmitting Lo: Max. Vbatt×20%
25 Diagnosis KLine Pulse
Hi: Min. Vbatt×70%
When receiving
Lo: Max. Vbatt×30%
26
Hi: Vbatt or Vcc
27 Fuel consumption signal output Idle Pulse
Lo: Max. 0.5V
IG OFF Max. 1.0V
28 Ignition switch signal input DC
IG ON Vbatt
Hi: Vbatt
29 VGT Control Solenoid Valve control output Idle Pulse
Lo: Max. 0.5V
Accelerator Position Sensor (APS) #2 signal C.T 0.3 ~ 0.9V

31 Analog
input W.O.T 1.5 ~ 3.0V
signal input
signal input

36 Differential Pressure Sensor (DPS) signal input Idle Analog 0.5 ~ 4.5V
Release Max. 0.5V
38 Brake Switch "Lamp" signal input DC
Push Vbatt
39
Full of Water Vbatt
40 Water Sensor siganl input Analog
No Water Max. 1V
41
Blower Off Vbatt
42 Blower Switch Signal input DC
Blower On Max. 2V
43
IG OFF Max. 0.5V
IG ON 4.9 ~ 5.1V
IG OFF Max. 0.5V
IG ON 4.9 ~ 5.1V
IG OFF Max. 0.5V
IG ON 4.9 ~ 5.1V
After IG ON Hi: Min. 8.5V
47 Immobilizer Communication Line when Pulse
communicating Lo: Max. 3.5V
Hi: Vbatt
48 Engine speed signal output Idle Pulse Lo: Max. 5V
Frequency : 50~60Hz
49 Cruise Control "SET" Lamp control output
50
Hi: Vbatt
51 Lambda Sensor Heater control output Vehicle Run Pulse
Lo: Max. 1.0V
52
53
A/C SW OFF Max. 1.0V
54 A/C Switch "ON" signal input DC
A/C SW ON Vbatt
55
A/C OFF Max. 0.5V
56 Thermo Switch signal input DC
A/C ON Vbatt
SW OFF
Vbatt
57 Gear Neutral Switch signal input (MT Only) (Neutral) DC
SW ON (1st) Max. 0.5V
58
59
60
61
62
63
Normal : 450 ± 50 mV
Rich : Max. Normal +
64 Lambda Sensor Voltage "NERNST" Engine Run Analog 150mV
Lean : Min. Normal
150mV
Normal : 0 ± 500 mV
Rich : Min. Normal
65 Lambda Sensor Current Pump Engine Run Analog 1.5V
Lean : Max. Normal +
1.5V
66
67
Lamp OFF Vbatt
68 Malfunction Indicator Lamp (MIL) control output DC
Lamp ON Max. 1.0V
Glow OFF Vbatt
69 Glow Time Indicator Lamp control output DC
Glow ON Max. 1.0V
A/Con OFF Vbatt
70 A/C Compressor Relay control output DC
A/Con ON Max. 1.0V
Relay OFF Vbatt
71 Cooling Fan Relay [LOW] control output DC
Relay ON Max. 1.0V
Relay OFF Vbatt
72 Main Relay control output DC
Relay ON Max. 1.0V
73
74
Hi: Min. 5.0V
75 Vehicle speed signal input Vehicle Run Pulse
Lo: Max. 1.0V
76
Normal Vbatt
77 Feedback signal input DC
Abnormal Max. 0.5V
78
Release Max. 0.5V
79 Clutch Switch signal input DC
Push Vbatt
Release Vbatt
80 Brake Switch "Redundant" signal input DC
Push Max. 0.5V
MT Vbatt
81 MT/AT auto reconition signal input DC
AT Max. 0.5V
82
Recessive 2.0 ~ 3.0 V
83 CAN [LOW] Pulse
Dominant 0.5 ~ 2.25 V
84 CAN [HIGH] Recessive Pulse 2.0 ~ 3.0 V
Dominant 2.75 ~ 4.5 V
85
86 Lambda Sensor Virtual Ground Engine Run Analog 2.4 ~ 2.6V
|Current Pump
87 Lambda Sensor Current Adjust Engine Run Analog
Current Adjust |< 0.2V
88
89 Idle Analog 0.5V ~ 4.5V
input
Hi: Vbatt
90 Throttle Control Actuator control output Key On/Key Off Pulse
Lo: Max. 1V
91 Cruise Control "MAIN" Lamp control output
Lamp OFF Vbatt
92 Immobilizer Lamp control output DC
Lamp ON Max. 1.0V
Relay OFF Vbatt
93 Glow Relay control output DC
Relay ON Max. 1.0V
Relay OFF Vbatt
94 PTC Heater Relay control output DC
Relay ON Max. 1.0V
2012 > D 2.0 TCID > Fuel System > Engine Control System > Engine Control Module (ECM) > Schematic
English
Diagrams
CIRCUIT DIAGRAM
English
2012 > D 2.0 TCID > Fuel System > Engine Control System > Engine Control Module (ECM) > Repair
English
procedures
ECM PROBLEM INSPECTION PROCEDURE
1. TEST ECM GROUND CIRCUIT: Measure resistance between ECM and chassis ground using the backside of ECM
harness connector as ECM side check point. If the problem is found, repair it.
2. TEST ECM CONNECTOR: Disconnect the ECM connector and visually check the ground terminals on ECM side and
harness side for bent pins or poor contact contact pressure. If the problem is found, repair it.
3. If problem is not found in Step 1 and 2, the ECM could be faulty. If so, replace the ECM with a new one, and then check
the vehicle again. If the vehicle operates normally then the problem was likely with the ECM.
4. RETEST THE ORIGINAL ECM : Install the original ECM (may be broken) into a knowngood vehicle and check the
vehicle. If the problem occurs again, replace the original ECM with a new one. If problem does not occur, this is intermittent
problem (Refer to INTERMITTENT PROBLEM PROCEDURE in BASIC INSPECTION PROCEDURE)
REPLACEMENT

After replacing an ECM, MUST input the vehicle mileage and the injector data (7 digit) of each cylinder into a new ECM.
1. Turn ignition switch OFF.
2. Remove the battery negative () cable from the battery.
3. Remove the battery and disconnect the ECM connector (A) in the engine room.
4. Remove the ECM (B) after unscrewing the four mounting bolts.
5. Install a new ECM in to the reverse order of step 1~4.
ECM mounting bolts : 7.8 ~ 11.8 N·m (0.8 ~ 1.2 kgf·m, 5.8 ~ 8.7lbf·ft)
6. Connect a scan tool to Data Link Connector (DLC) and turn ignition switch on.
7. Proceed "ECM CHANGE" procedure.
(1) Select "ENGINE CONTROL". (For example, OPTIMA)
English
(2) Select "MANUAL SELECTION MODE".
(3) Select "D 2.0L VGT DIESEL".
(4) Select "COMPONET CHANGE ROUTINE"
(5) Select "ECU CHANGE".
(6) Press "ENTER" key.
(7) Input the vehicle mileage and press "ENTER" key.
(8) Wait 10 seconds with IG ON.
(9) Turn ignition switch off.
8. Turn ignition switch on.
9. Proceed "INJECTOR CORRECTION" procedure.
(1) Select "ENGINE CONTROL".
(2) Select "MANUAL SELECTION MODE".
(3) Select "D 2.0L VGT DIESEL".
(4) Select "INJECTOR CORRECTION".
(5) Press "ENTER" key.
(6) Input the injector data (7 digit) written on the top of each injector with function keys ([F1] ~ [F6]) and number keys.

When "WRITING FAIL" is displayed on the scan tool, input injector data (7 digits) of each cylinder into a new
ECM again as prior procedure.
2012 > D 2.0 TCID > Fuel System > Engine Control System > Mass Air Flow Sensor (MAFS) > Repair
English
procedures
INSPECTION
MAFS uses a hotfilm type sensing element to measure the mass of intake air entering the engine, and send the signal to ECM.
A large amount of intake air represents acceleration or high load conditions while a small amount of intake air represents deceleration or
idle.
The ECM uses this information to control the EGR solenoid valve and correct the fuel amount.
SPECIFICATION
CIRCUIT DIAGRAM
English
SIGNAL WAVEFORM
COMPONENT INSPECTION
1. Check the MAFS visually.
– Mounting direction correct.
– Any contamination, corrosion or damage on connector.
– Air cleaner's clogging or wet.
– MAFS cylinder's deforming or blocking by any foreign material.
2. Check any leakage on intake system and intercooler system.
REPLACEMENT

After replacing a Mass Air Flow Sensor (MAFS) or Intake Air Temperature Sensor (IATS)#1, MUST proceed below
procedure.
2. Connect a scan tool to Data Link Connector (DLC).
3. Turn ignition switch ON.
4. Select "ENGINE CONTROL". (For example, OPTIMA)
5. Select "MANUAL SELECTION MODE".
6. Select "D 2.0L VGT DIESEL".
7. Select "COMPONET CHANGE ROUTINE"
8. Select "AIR FLOW SENSOR CHANGE".
9. Press "ENTER" key.
10. Wait 10 seconds with IG ON.
11. Turn ignition switch off.
2012 > D 2.0 TCID > Fuel System > Engine Control System > Intake Air Temperature Sensor (IATS) >
English
Repair procedures
INSPECTION
Intake Air Temperature Sensor (IATS) uses a Negative Temperature Characteristics (NTC) thermistor and senses intake air temperature.
Two intake air temperature sensors are installed in this engine.
IATS #1 in Mass Air Flow Sensor (MAFS) and IATS #2 in Boost Pressure Sensor (BPS) are located in front of and behind turbocharger
respectively. IATS #1 senses air temperature entering turbocharger and the other (IATS #2) does air temperature coming out from the
turbocharger.
Comparing these air temperature values from both sensors, more accurate sensing of intake air temperature is possible. ECM uses
these air temperature signals to perform EGR control correction and fuel injection quantity correction.
SPECIFICATION
CIRCUIT DIAGRAM
English
SIGNAL WAVEFORM
2. Disconnect the MAFS (for IATS #1) or BPS (for IATS #2) connector.
3. Measure resistance between IATS signal terminal and sensor ground terminal.
4. Check that the resistance is within the specification.
Specification: Refer to "SPECIFICATION".
REPLACEMENT

After replacing a Mass Air Flow Sensor (MAFS) or Intake Air Temperature Sensor (IATS)#1, MUST proceed below
procedure.
8. Select "AIR FLOW SENSOR CHANGE".
2012 > D 2.0 TCID > Fuel System > Engine Control System > Engine Coolant Temperature Sensor (ECTS)
English
> Repair procedures
INSPECTION
Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the cylinder head for detecting the engine
coolant temperature. The ECTS uses a thermistor whose resistance changes with the temperature. The electrical resistance of the ECTS
decreases as the temperature increases, and increases as the temperature decreases. The reference 5V in the ECM is supplied to the
ECTS via a resistor in the ECM.
That is, the resistor in the ECM and the thermistor in the ECTS are connected in series. When the resistance value of the thermistor in the
ECTS changes according to the engine coolant temperature, the output voltage also changes. During cold engine operation the ECM
increases the fuel injection duration and controls the ignition timing using the information of engine coolant temperature to avoid engine
stalling and improve drivability.
SPECIFICATION
40(40) 48.14
20(4) 14.13 ~ 16.83
0(32) 5.79
20(68) 2.31 ~ 2.59
40(104) 1.15
60(140) 0.59
80(176) 0.32
CIRCUIT DIAGRAM
English
2. Disconnect the engine coolant temperature sensor connector.
3. Remove the sensor.
4. After immersing the thermistor of the sensor into engine coolant, measure resistance between ECTS signal terminal and
ground terminal.
2012 > D 2.0 TCID > Fuel System > Engine Control System > Accelerator Position Sensor (APS) > Repair
English
procedures
INSPECTION
On electronic injection systems, there is no longer a load lever that mechanically controls the fuelling. The flow is caculated by the ECM
depending on a number of parameters, including pedal position, which is measured using a potentiometer. The pedal sensor has two
potentiometers whoses slides are mechanically solid. The two potentiometers are supplied from distinct and different power sources so
there is built in redundancy of information giving reliable driver's request information. A voltage is generated across the potentiometer in
the acceleration position sensor as a function of the acceleratorpedal setting. Using a peogrammed characteristic curve, the pedal's
position is then calculated from this voltage.
SPECIFICATION
Output Voltage(V)
Test Condition
APS 1 APS 2
Idle 0.7 ~ 0.8 0.275 ~ 0.475
Fully depressed 3.8 ~ 4.4 1.75 ~ 2.35
Specification
Items
APS 1 APS 2
CIRCUIT DIAGRAM
English
SIGNAL WAVEFORM
2. Disconnect the accelerator position sensor connector.
3. Measure resistance between voltage supply terminal and ground terminal of APS1.
4. Measure resistance between voltage supply terminal and ground terminal of APS2.
2012 > D 2.0 TCID > Fuel System > Engine Control System > Lambda Sensor > Repair procedures
English
INSPECTION
Lambda Sensor is installed on exhaust manifold and is a linear oxygen sensor. It senses oxygen density of exhaust gas in order to
control EGR acculately through fuel correction and also limits smoke which is generated by reach airfuel mixture at high engine load
condition. ECM controls pumping current in order to fit λvalue from linear lambda sensor to 1.0.
Lean airfuel mixture(1.0 < λ < 1.1): ECM supplies pumping current to lambda sensor (+pumping current) and activates it for lambda
sensor to have the characteristic at λ =1.0 (0.0 pumping current). With the value of pumping current supplied to lambda sensor, ECM
detects lambda density of exhaust gas.
Rich airfuel mixture(0.9 < λ < 1.0): ECM takes away pumping current from lambda sensor (pumping current) and deactivates it for
lambda sensor to have the characteristic at λ =1.0 (0.0 pumping current). With the value of pumping current taken away from lambda
sensor, ECM detects lambda density of exhaust gas.
This performance is the most active and fast at normal operating temperature (450°C ~ 600°C) thus, in order to reach normal operating
temp. and last at that temperature, a heater (heating coil) is integrated with lambda sensor. The heater coil is controlled by ECM as Pulse
With Modulator (PWM). The resistance of heater coil is low when coil is cold thus, current through it increases while resistance is high
when coil is hot thus, current decreases. With this principle, temperature of lambda sensor is measured and lambda sensor heater
operation varies based on the data.
SPECIFICATION
CIRCUIT DIAGRAM
English
SIGNAL WAVEFORM
REPLACEMENT

After replacing a Lambda Sensor, MUST proceed below procedure.
8. Select "LAMBDA SENSOR CHANGE".
2012 > D 2.0 TCID > Fuel System > Engine Control System > Crankshaft Position Sensor (CKPS) > Repair
English
procedures
INSPECTION
Piston position on combustion chamber is the substantial to define the starting of injection timing. All engine pistons are connected to
crankshaft by connecting rod. Sensor on crankshaft can supply the informations concerning all piston positions, revolution speed is
defined by revolution perminute of crankshaft. Prior input variable is determined at ECM by using signal induced from crankshaft position
sensor.
SPECIFICATION
Items Specification
Coil Resistance (Ω) 774 ~ 946Ω [20°C(68°F)]
CIRCUIT DIAGRAM
English
SIGNAL WAVEFORM
2012 > D 2.0 TCID > Fuel System > Engine Control System > Camshaft Position Sensor (CMPS) > Repair
English
procedures
INSPECTION
Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft position by using a hall element. It is related with Crankshaft
Position Sensor (CKPS) and detects the piston position of the each cylinder which the CKPS can't detect. The two CMPS are installed on
engine head cover and uses a target wheel installed on the camshaft. This sensor has a halleffect IC which output voltage changes
when magnetic field is made on the IC with current flow. So the sequential injection of the 4 cylinders is impossible without CMPS signal.
SPECIFICATION
High 12V
Low 0V
Items Specification
Air Gap 1.5 ± 0.1 mm
CIRCUIT DIAGRAM
English
SIGNAL WAVEFORM
2012 > D 2.0 TCID > Fuel System > Engine Control System > Injector > Description and Operation
English
DESCRIPTION
2012 > D 2.0 TCID > Fuel System > Engine Control System > Injector > Repair procedures English
REMOVAL

• Common Rail Fuel Injection System is subject to extremely high pressure (Approximately 1,600 bar)
• Never perform any work on injection system with engine running or within 30 seconds after the engine stops.
• Always pay attention to safety precaution.
• Ensure the absolute cleanliness.
• It is not recommended to remove the injectors without any notice.
1. Disconnect the injector connector (A).
2. After removing the clip (B), disconnect the retun hose (C) from the injectors
3. Disconnect the high pressure pipe (A) connecting the injectors with the common rail.
4. Rotate the lever (A) clockwise and pull it upward.
English
5. Unscrew the clamp tightening bolt (A) and pull the injector upward with the "Injector Remover" and the "Injector Remover
Adapter" (Refer to "SPECIAL SERVICE TOOL" section).
INSTALLATION
1. Install the injector according to the reverse order of "REMOVAL" procedure.

When installing the injector, MUST REPLACE the Oring (A) and apply a grease to that.

When installing the high pressure pipe, apply the specified tightening torques to the flange nuts of the injectors and
the common rail side with SST (Refer to below table).
Item Dimension SST No.

Flange Nut (Injector Side) 14 mm (0.551 in) 0931427110
Flange Nut (Common Rail Side) 17 mm (0.669 in) 0931427120
· Injector clamp mounting bolts: 24.5 ~ 28.4 N·m (2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
· High pressure pipe flange nuts (Injectors ↔ Common Rail): 24.5 ~ 28.4 N·m (2.5 ~ 2.9 kgf·m, 18.1 ~
20.1 lbf·ft)
REPLACEMENT

After replacing (an) injector(s), MUST input the injector data (7 digit) into the ECM.
2. Replace the injector with a new one according to the "REMOVAL" and "INSTALLATION" procedures.
3. Connect a scan tool to Data Link Connector (DLC) and turn ignition switch on.
7. Select "INJECTOR CORRECTION".
9. Input the injector data (7 digit) written on the top of each injector with function keys ([F1] ~ [F6]) and number keys.

When "WRITING FAIL" is displayed on the scan tool, input injector data (7 digits) of each cylinder into a new ECM
again as prior procedure.
INSPECTION
USING HISCAN(PRO)
Test mode
• COMPRESSION TEST
• IDLE SPEED COMPARISON
• INJECT QUANTITY COMPARISON
TEST PROCEDURE
1. Connect Scan tool to the DLC and select "Vehicle" and "Engine Test Function".
2. Information for ECM version is displayed as below.
3. After pressing "[ENTER]" select "COMPRESSION TEST" mode and press "[ENTER]".
4. Set the test condition described as below screen and then, crank engine. When engine stop message being appeared, stop
cranking.
5. Press "ANAL" and the test result is appeared.

During cranking engine does not start.
6. Press "AVG" and the data average of each cylinder is appeared.
Press "HELP" and description of the data is appeared.
7. After pressing "ESC", select "IDLE SPEED COMPARISON" and press "[ENTER]".
8. Set the test condition described as below screen and press "[ENTER]".
9. The rpm data of each cylinder is appeared.
10. Press "AVG" and teh data average of each cylinder is appeared.
Press "HELP" and description of the data is appeared.
11. After pressing "ESC", select "INJECT QUANTITY COMPARISON" and press "[ENTER]".
12. Set the test condition described as below screen and press "[ENTER]".
13. The data of each cylinder about RPM and compensating injection quantity is appeared.
14. Press "HELP" and description of the data is displayed as below.
15. Replace the default injector, and then repeat previous test modes to check if the injector is normal.
2. Disconnect the injector connector.
3. Measure resistance between terminal 1 and 2.
Specification : 0.33Ω at 20°C(68°F)
2012 > D 2.0 TCID > Fuel System > Engine Control System > Rail Pressure Sensor (RPS) > RepairEnglish
procedures
INSPECTION
Rail Pressure Sensor (RPS) is installed at the end of the common rail and measures the instantaneous fuel pressure in the common rail
by using its diaphragm. Its sensing element (semiconductor device) mounted on the diaphragm converts the fuel pressure to an electric
signal.
SPECIFICATION
Test Condition Rail pressure (bar) Output Voltage (V)
Idle 220 ~ 320 Below 1.7
Fully depressed 1,800 Approx. 4.5
CIRCUIT DIAGRAM
English
SIGNAL WAVEFORM
REPLACEMENT

After replacing a Rail Pressure Sensor (RPS), MUST proceed below procedure.
8. Select "RAIL PRESSURE SENSOR CHANGE".
2012 > D 2.0 TCID > Fuel System > Engine Control System > Boost Pressure Sensor (BPS) > Repair
English
procedures
INSPECTION
Boost pressure sensor (BPS) is installed on surge tank to measure the absolute intake manifold pressure. BPS input voltage is changed
in proportion with absolute pressure in manifold. This information is used to control Variable Geometery Turbocharger (VGT) by ECM.
SPECIFICATION
70 1.02 ~ 1.17
140 2.13 ~ 2.28
210 3.25 ~ 3.40
270 4.20 ~ 4.35
CIRCUIT DIAGRAM
English
SIGNAL WAVEFORAM
2012 > D 2.0 TCID > Fuel System > Engine Control System > Rail Pressure Regulator Valve > Repair
English
procedures
INSPECTION
The Fuel Pressure Regulator Valve and the Rail Pressure Regulator Valve are installed on high pressure pump and common rail
respectively. These valves control fuel inlet (feed) from fuel tank via fuel filter and outlet (return) to fuel tank of high pressure fuel circuit.
This system is called "Dual Fuel Pressure Control System" and can precisely and quickly control the fuel pressure in accordance with
various engine conditions by controlling the fuel inlet and outlet simultaneously.
SPECIFICATION
Items Specification
CIRCUIT DIAGRAM
English
SIGNAL WAVEFORM
2. Disconnect the rail pressure regulator valve connector.
3. Measure resistance between terminal 1 and 2 of the valve.
2012 > D 2.0 TCID > Fuel System > Engine Control System > VGT Control Solenoid Valve > Repair
English
procedures
INSPECTION
Variable Geometry Turbocharger (VGT) is used to charge additional air into combustion chamber for improvement of combustion
efficiency.
ECM controls the VGT with controlling duty of the VGT control solenoid valve according to engine load.
SPECIFICATION
Items Specification
CIRCUIT DIAGRAM
SIGNAL WAVEFORM English
2. Disconnect the VGT control solenoid valve connector.
2012 > D 2.0 TCID > Fuel System > Engine Control System > Throttle Flap Control Solenoid Valve >
English
Repair procedures
INSPECTION
The Throttle Control Actuator is mounted on throttle body of diesel engine and controls throttle valve according to PWM (Pulse With
Modulation) signal from ECM.
It consists of;
– a DC motor which actuates the throttle valve,
– a 2step gear (transmission ratio = 1:40) which is located in between the DC motor and the throttle valve and increases
torque of the DC motor,
– a position sensor which is a halleffect sensor and detects status of the throttle valve,
– an electric control unit which is a microcontroller and drives the DC motor by the PWM (Pulse With Modulation) signal
from the ECM,
– and a reset spring which resets the deenergized throttle valve to its open position.
Its function is described below:
1) Antijudder function: When engine is shut off, the ECM can prevent intake air from entering to intake manifold by fully
closing the throttle valve for 1.5 seconds (95% < Duty < 97%) to reduce engine vibration.
2) Intake air control for EGR: When exhaust gas pressure is equal to or lower than intake air pressure (for example, when low
engine speed), the exhaust gas would not enter to the intake manifold. At this time, the ECM partially closes the throttle
valve (5% < Duty < 94%) to reduce the intake air quantity. The intake air pressure thus is lower than the exhaust gas
pressure.
3) Exhaust gas temperature control for CPF regeneration: When the Catalyzed Particulate Filter (CPF) is need to regenerate,
the ECM partially closes the throttle valve (5% < Duty < 94%) to reduce the intake air quantity. At this time, the airfuel
ratio would become rich and the exhaust gas temperature would be high enough to burn the soot inside the CPF.
SPECIFICATION
5 Open
94 Closed
CIRCUIT DIAGRAM
English
SIGNAL WAVEFORM
2. Disconnect the electric throttle control actuator connector.
2012 > D 2.0 TCID > Fuel System > Engine Control System > Variable Swirl Actuator > Repair procedures
English
DESCRIPTION
Variable Swirl Control Actuator consists of DC motor and position sensor which detects the position of the swirl valve.
At idle or below 3000rpm, the swirl valve is closed. This swirl effect increases air flow rate.
Low and Middle Load High Load
Engine speed Below 3000rpm Above 3000rpm
Valve operation CLOSE OPEN
Description
illustration
Failsafe Fully opened

To prevent the swirl valve and the shaft from being stuck by foreign material and to learn max opening and closing
position of the valve, the ECM fully opens and closes the valve twice when engine is being stopped.
SPECIFICATION
CIRCUIT DIAGRAM
English
SIGNAL WAVEFORM
2. Disconnect the electric EGR control valve connector.
3. Check that swirl valve is stuck by foreign material.
4. Measure resistance between motor (+) and () control terminals.
5. Measure resistance between voltage supply terminal and ground terminal of position sensor.
REPLACEMENT

After replacing a Variable Swirl Actuator, MUST proceed below procedure.
8. Select "SWIRL CONTROL VALVE CHANGE".
REMOVAL
1. Disconnect the battery () terminal.
2. Mark painting on the top (A) of the variable swirl actuator coupling of the intake manifold side.
3. Disconnect the variable swirl actuator connector (A).
4. Remove the variable swirl actuator (C) after removing the installation bolt (B).
INSTALLATION
1. Installation is the reverse order of removal.
Variable swirl actuator installation bolt:
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)

If the coupling of the intake manifold side is rotated a 180degree turn, a real gap between the port and the flap in the
intake manifold may be different from measuring it.
Install the actuator after confirming the mark on the top of the coupling.
2. Confirm normal operation of the actuator more than 3 times when the ignition switch OFF after full warm up (Engine Coolant
Temperature > 70 °C).
2012 > D 2.0 TCID > Fuel System > Engine Control System > Fuel Temperature Sensor (FTS) > Repair
English
procedures
INSPECTION
Fuel Temperature Sensor(FTS) is installed in fuel supplying line and senses the termperature of fuel supplied to high pressure pump.
Fuel temperature is limmited to protect fuel such as high pressure pump and injectors from damages due to rapid deterioration by vapor
lock which can occur at high temperature or destruction of oil membrance.
SPECIFICATION
CIRCUIT DIAGRAM
English
SIGNAL WAVEFORM
2. Disconnect the fuel temperature sensor connector.
3. Measure resistance between sensor signal terminal and ground terminal.
2012 > D 2.0 TCID > Fuel System > Engine Control System > EGR (Exhaust Gas Recirculation) Valve >
English
Repair procedures
INSPECTION
The Exhaust Gas Recirculation (EGR) system is used to add the exhaust gas to intake air in order to reduce an excess of air and the
temperature in the combustion chamber. The Electric EGR valve is controlled by ECM’s duty control signal depending on engine load
and the need of intake air and is operated by solenoid valve not vacuum valve.
SPECIFICATION
Items Specification
CIRCUIT DIAGRAM
SIGNAL WAVEFORM English
2. Disconnect the electric EGR control valve connector.
2012 > D 2.0 TCID > Fuel System > Engine Control System > CPF (Catalyzed Particulate Filter) > English
Schematic Diagrams
SCHEMATIC DIAGRAM
English
2012 > D 2.0 TCID > Fuel System > Engine Control System > CPF (Catalyzed Particulate Filter) > English
DESCRIPTION
The Catalyzed Particulate Filter (CPF) system prevents Particulate Matter (PM) from being discharged to the atmosphere and consists of
a filter assembly, two Exhaust Gas Temperature Sensor (EGTS) and a Differential Pressure Sensor (DPS).The filter is integrated in the
catalytic converter assembly and has honeycomb cell structure which can filter the PM in the exhaust gas. While the exhaust gas passes
the CPF, the PM is gathered in the CPF and the others (CO2, NO, etc.) are discharged to the atmosphere via muffler. This gathered PM in
CPF is called "soot".
[CPF Regeneration]
If there are much soot in the CPF, the CPF must be regenerated. ECM can calculate amount of the soot by using the DPS signal, vehicle
mileage or simulation data. If the ECM determines the CPF is need to regenerate, it will perform "Regeneration Procedure" when the
vehicle condition is corresponded with the predetermined one (Regeneration Mode).
To burn the soot, the ECM injects additional fuel in the cylinders during exhaust stroke (two Post Injection) and increases the exhaust gas
temperature to burning temperature of the soot (above 600°C). At this time, the soot are burn and its ash remains in the CPF as a result of
the combustion.
[Regeneration Mode]
1. Mileage > 1,000km
2. Engine Speed: 1,000 ~ 4,000rpm
3. Engine Load = About 0.7bar [8mg/st]
4. Vehicle Speed > 5km/h
5. Engine Coolant Temperature > 40°C
2012 > D 2.0 TCID > Fuel System > Engine Control System > CPF (Catalyzed Particulate Filter) > Repair
English
procedures
CPF REGENERATION
This procedures is to forcibly regenerate the CPF with scan tool when the CPF doesn't have been regenerated during driving. For
example, if the vehicle has repeated "Low speed driving" or "Short distance driving", the CPF regeneration procedure cannot be
proceeded because "Regeneration Mode" doesn't made.

If performing the CPF service regeneration mode indoors, fire or burn injuries may occur by hightemperature exhaust
gas.
Therefore the CPF service regeneration mode must be performed in a outdoor safe zone.
FORCIBLY REGENERATION CONDITION
• Engine coolant temperature: about 70°C
• Engine at idle
• Prange (A/T) or Neutral (M/T)
• Normal battery voltage
• Electrical fully load (A/C ON if equipped, Blower ON with maximum speed, Head Lamp ON, Wiper ON, Other Lamps ON,
etc.)
3. Start engine at idle and Prange (A/T) or neutral (M/T).
4. Apply electrical fully load to the vehicle (A/C ON, Blower ON with maximum speed, Head Lamp ON, Wiper ON, and Other
Lamps ON, etc.)
English
8. Select "CPF SERVICE REGENERATION".
9. Press "ENTER" key after looking around data memorized in ECM.
10. Press "STRT" key.
REMOVAL
2. Lift the vehicle and support CPF assembly with a jack.
3. Disconnect the hoses (A) connected with Differential Pressure Sensor (DPS) from the CPF assembly.
4. Disconnect the Exhaust Gas Temperature Sensor (EGTS) #2 connector (B).
5. Linscrew the mounting nuts (C) and remove the CPF (D) from the vehicle.
INSTALLATION
1. Install the CPF in the reverse order of "REMOVAL" procedure.
CPF Mounting Nuts: 39.2 ~ 58.9N·m (4.0 ~ 6.0 kgf·m, 28.9 ~ 43.4lbf·ft)
REPLACEMENT

After replacing a CPF, MUST proceed below procedure.
8. Select "CPF CHANGE".
2012 > D 2.0 TCID > Fuel System > Engine Control System > CPF Differential Pressure Sensor > Repair
English
procedures
INSPECTION
Differential Pressure Sensor (DPS) measures difference pressure between upstream and downstream exhaust gas of CPF. The ECM
can calculate quantity of soot deposited in CPF with value from this sensor.
SPECIFICATION
CIRCUIT DIAGRAM
English
SIGNAL WAVEFORM
REPLACEMENT

After replacing a Differential Pressure Sensor (DPS), MUST proceed below procedure.
8. Select "D/PRESSURE SENSOR CHANGE".
2012 > D 2.0 TCID > Fuel System > Engine Control System > Water Sensor > Repair procedures English
INSPECTION
Water Sensor is installed on bottom end of fuel filter and detects presence of water in fuel. When the water level reaches the lower level
of the upper electrode, the "WATER" lamp in cluster should flash. If the water level decreases below the lower electrode, the lamp should
turn off.

Without presence of water, the lamp should flash for 2 seconds and turn off afterward in order that this system has
normal condition.
SPECIFICATION
Items Specification
Warning Level of Water Presence (cc) 40 ~ 60
CIRCUIT DIAGRAM
English
2012 > D 2.0 TCID > Fuel System > Engine Control System > Fuel Pressure Control Valve > Repair
English
procedures
INSPECTION
The Fuel Pressure Regulator Valve and the Rail Pressure Regulator Valve are installed on high pressure pump and common rail
respectively. These valves control fuel inlet (feed) from fuel tank via fuel filter and outlet (return) to fuel tank of high pressure fuel circuit.
This system is called "Dual Fuel Pressure Control System" and can precisely and quickly control the fuel pressure in accordance with
various engine conditions by controlling the fuel inlet and outlet simultaneously.
SPECIFICATION
Items Specification
CIRCUIT DIAGRAM
English
SIGNAL WAVEFORM
2. Disconnect the fuel pressure regulator valve connector.
2012 > D 2.0 TCID > Fuel System > Engine Control System > Exhaust Gas Temperature Sensor > Repair
English
procedures
INSPECTION
Exhaust Gas Temperature Sensor (EGTS) #1 for VGT is installed on exhaust manifold and senses the termperature of exhaust gas
flowing into the VGT.
SPECIFICATION
100(212) 289.0 ~ 481.0
300(572) 5.30 ~ 6.61
600(1,112) 0.35 ~ 0.38
900(1,652) 0.08 ~ 0.09
CIRCUIT DIAGRAM
English
SIGNAL WAVEFORM
2. Disconnect the exhaust gas temperature sensor #1 connector.
INSPECTION
Exhaust Gas Temperature Sensor (EGTS) #2 for CPF is installed on Catalyzed Particulate Filter (CPF) assembly and senses the
temperature of exhaust gas flowing into the CPF.
When predetermined engine condition is set, ECM burns soot gathered in CPF with exhaust gas. At this time, the exhaust gas
temperature is an important factor of engine condition.
SPECIFICATION
100(212) 289.0 ~ 481.0
300(572) 5.30 ~ 6.61
600(1,112) 0.35 ~ 0.38
900(1,652) 0.08 ~ 0.09
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
2. Disconnect the exhaust gas temperature sensor #2 connector.
2012 > D 2.0 TCID > Fuel System > Fuel Delivery System > Components and Components Location
English
COMPONENT LOCATION
English
2012 > D 2.0 TCID > Fuel System > Fuel Delivery System > Schematic Diagrams English
SCHEMATIC DIAGRAM
COMPONENTS
FUEL PUMP
The fuel pump is either an electric fuel pump with prefilter, or a geartype fuel pump. The pump draws the fuel from the fuel tank and
continually delivers the required quantity of fuel in the direction of the highpressure pump.
FUEL FILTER
Inadequate filtering can lead to damage at the pump components, delivery valves, and injector nozzles. The fuel filter cleans the fuel
before it reaches the highpressure pump, and thereby prevents premature wear at the pump's sensitive components.
● HIGH PRESSURE FUEL SYSTEM COMPONENTS English
HIGH PRESSURE FUEL PUMP
The highpressure pump pressurizes the fuel to a system pressure of up to 1,600bar. This pressurized fuel then passes through a high
pressure line and into the tubular common rail.
COMMON RAIL (HIGH PRESSURE ACCUMULATOR)
Even after an injector has taken fuel from the rail in order to inject it, the fuel pressure inside the rail remains practically constant. This is
due to the accumulator effect arising from the fuel's inherent elasticity. Fuel pressure is measured by the rail pressure sensor and
maintained at the desired level by the pressurecontrol valve.
INJECTORS
The nozzles of these injectors open when the solenoid valve is triggered and permit the flow of fuel. They inject the fuel directly into the
engine's combustion chamber. The excess fuel which was needed for opening the injector nozzles flows back to the tank through a
collector line. The return fuel from the fuel pressure control valve and from the lowpressure stage is also led into this collector line
together with the fuel used to lubricate the highpressure pump.
HIGH PRESSURE PIPE
These High Pressure Pipes carry the highpressure fuel. They must therefore be able to permanently withstand the maximum system
pressure and, during the pauses in injection, the sometimes highfrequency pressure fluctuations which occur. They are therefore
manufactured from steel tubing.
Normally, they have an outside diameter of about 6.35mm and an internal diameter of about 3.0mm. The injection lines between the
common rail and the injectors must all be of the same length. The differences in length between the common rail and the individual
injectors are compensated for by using slight or pronounced bends in the individual lengths of tubing. Nevertheless, the injection lines
should be kept as short as possible.
2012 > D 2.0 TCID > Fuel System > Fuel Delivery System > Fuel Tank > Repair procedures English
REMOVAL

When lifting up or downing the vehicle, be sure to place blocks between the vehicle and lifter to prevent fuel tank from
being damaged.
1. Remove the mufflers and the Catalyzed Particulate Filter (CPF) assembly passing under the fuel tank (Refer to group "EM"
in this Shop Manual).
2. Remove the rear seat. (Refer to BD group)
3. Open the service covers (A).
4. Disconnet the fuel pump connector (A), the fuel feed tube quickconnector (B) and the return tube guickconnector (C).
5. Lift the vehicle and disconnect the fuel filler hose (A), the fuel leveling hose (B) and the vapor hose (C).
6. Remove the undercover(A).
English
7. Support the fuel tank with a jack, and then remove the two fuel tank band (A).
8. Remove the fuel tank (B) from the vehicle with setting down the jack.
INSTALLATION
1. Install the fuel tank in the reverse order of "REMOVAL" procedure.
Fuel tank band mounting bolts: 39.2 ~ 53.9 N·m (4.0 ~ 5.5 kgf·m, 28.9 ~ 39.8 lbf·ft)
2012 > D 2.0 TCID > Fuel System > Fuel Delivery System > Fuel Pump > Repair procedures English
REMOVAL
1. Remove the rear seat. (Refer to BD group)
2. Open the service cover(A).
3. Disconnet the fuel pump connector (A), the fuel feed tube quickconnector (B), the return tube guickconnector (C).
4. Remove the fuel pump assembly (A) after unscrwing the fuel pump installation bolts.
INSTALLATION
1. Install the fuel pump in the reverse order of "REMOVAL" procedure.
Fuel pump installation bolts : 3.9 ~ 5.8 N·m (0.4 ~ 0.6 kgf·m, 2.8 ~ 4.4 lbf·ft)
2012 > D 2.0 TCID > Fuel System > Fuel Delivery System > Fuel Filter > Components and Components
English
Location
COMPONENTS
2012 > D 2.0 TCID > Fuel System > Fuel Delivery System > Fuel Filter > Repair procedures English
REMOVAL
1. Disconnect the thermostat connector (A), the heater connector (B) and water sensor connector (C).
2. Disconnet the fuel input quickconnector (D) and the fuel output quickconnector (E).
3. Unscrew the mounting bolts (A).
4. Remove the fuel filter assembly (B).
INSTALLATION
1. Install the fuel filter in the reverse order of "REMOVAL" procedure.
2012 > D 2.0 TCID > Fuel System > Fuel Delivery System > Common Rail > Description and Operation
English
DESCRIPTION
In order to comply with the wide variety of engine installation conditions, the common rail with its flow limiters and the provistions for
attaching rail pressure sensor, fuel pressure control valve, and pressure limiter valve is available in a number of different designs.
The available common rail volume is permanently filled with pressurized fuel. The compressibility of the fuel resulting from the high
pressure is utilized to achieve the accumulator effect. When fuel leaves the rail for injection, the pressure variations resulting from the
pulsating fuel supply from the highpressure pump are compensated for.
2012 > D 2.0 TCID > Fuel System > Fuel Delivery System > Common Rail > Repair procedures English
REMOVAL

1. Disconnect the rail pressure sensor connector (A) and rail pressure regulator valve connector (B).
2. Disconnect the high pressure pipe (C) connecting the injectors with the common rail.
3. Disconnect the high pressure pipe (D) connecting the common rail with the high pressure fuel pump.
4. Unscrew the two mounting bolts (E) and remove the common rail (F).
INSTALLATION
1. Install the common rail according to the reverse order of "REMOVAL" procedure.

When installing the high pressure pipe, apply the specified tightening torques to the flange nuts of the injectors, the
high pressure pipe, and the common rail side with SST (Refer to below table).
Item Dimension SST No. English
Flange Nut (Injector Side)
14 mm (0.551 in) 0931427110
Flange Nut (HP Pump Side)
· Common rail mounting bolts: 19.6 ~ 26.5 N·m (2.0 ~ 2.7 kgf·m, 14.5 ~ 19.5 lbf·ft)
· High pressure pipe flange nuts (Injectors ↔ Common Rail): 24.5 ~ 28.4 N·m (2.5 ~ 2.9 kgf·m, 18.1 ~
20.1 lbf·ft)
· High pressure pipe flange nuts (Common Rail ↔ HP Pump): 24.5 ~ 28.4 N·m (2.5 ~ 2.9 kgf·m, 18.1
~ 20.1 lbf·ft)
2012 > D 2.0 TCID > Fuel System > Fuel Delivery System > High Pressure Pump > Description and
English
Operation
DESCRIPTION
The highpressure pump is the interface between the low pressure and the highpressure stages. Under all operating conditions, it is
responsible for providing adequate highpressure fuel through out the vehicle's complete service life. This also includes the provision of
extra as needed for rapid starting and for rapid buildup of pressure in the rail. The high pressure pump continually generates the system
pressure as needed in the highpressure accumulator (common rail). This means therefore, that in contrast to conventional systems, the
fuel does not have to be specially compressed for each individual injection process.
2012 > D 2.0 TCID > Fuel System > Fuel Delivery System > High Pressure Pump > Repair procedures
English
REMOVAL

1. Remove the air cleaner assembly (Refer to group "EM" in this Shop Manual).
2. Disconnect the return hoses (A,B) connected with the injectors and the common rail.
3. Disconnet the fuel feed hose quickconnector (A) and the return hose quickconnector (B).
4. Disconnect the fuel pressure regulator valve connector (A) and the fuel temperature sensor connector (B).
English
5. Disconenct the high pressure pipe (A) connecting the common rail with the high pressure pump.
6. Unscrew the mounting bolts (A) and remove the high pressure fuel pump (B) from the engine.
INSTALLATION
1. Install the high pressure fuel pump according to the reverse order of "REMOVAL" procedure.

When installing the high pressure pipe, apply the specified tightening torques to the flange nuts of the high pressure
pipe side and the common rail side with SST (Refer to below table).

Flange Nut (HP Pump Side) 14 mm (0.551 in) 0931427110
High pressure fuel pump mounting bolts: 19.6 ~ 26.5 N·m (2.0 ~ 2.7 kgf·m, 14.5 ~ 19.5 lbf·ft)
High pressure pipe flange nuts (Common Rail ↔ HP Pump): 24.5 ~ 28.4 N·m (2.5 ~ 2.9 kgf·m, 18.1 ~
20.1 lbf·ft)
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > General Information > SpecificationsEnglish
AIR CONDITIONER
Specification
Item 1.6,2.0 Engine 1.6, 2.0 Engine
(Gasoline) (Diesel)
Type VS16M(Varible Dispacement Swashplate)
Oil type & Capacity FD46XG (PAG), 150 ± 10cc
Compressor 1.6 2.0 1.6 2.0
Pulley type
6PK type 4PK type 5PK type 6PK type
Displacement 160cc/rev
Heat rejection 13,400 5% kcal/hr 12,300 5% kcal/hr
Condenser Dessicant specification
XH9 , 50g
& weight
APT(A/C pressure The method to measure
Voltage = 0.00878835 * Pressure + 0.37081095 [PSIA]
transducer) the pressure
Expansion valve Type Block
Type HFC134a(R134a)
Refrigerant
Capacity [oz.(g)] 17.6 ± 0.88 (500 ± 25)
BLOWER UNIT
Item Specification
Fresh and recirculation Operating method Actuator
Type Sirocco
Blower Speed step Auto + 8 speed (Automatic), 116 speed (Manual)
Speed control Power mosfet
Air filter Type Particle filter
HEATER AND EVAPORATOR UNIT
Item Specification
Type AL BRAZING TYPE
Heating capacity 4300 ± 5% kcal/hr
Heater PTC heater capacity 1000W + 5%/10%
Mode operating method Actuator
Temperature operating method Actuator
Temperature control type Evaporator temperature sensor
Evaporator ON : 2.8 (37)
A/C ON/OFF [°C(°F)]
OFF: 1.3 (34.3)
English
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > General Information > Troubleshooting
English
TROUBLESHOOTING
Problem Symptoms Table
Before replacing or repairing air conditioning components, first determine if the malfunction is due to the refrigerant charge, air flow or
compressor.
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check
each part in order. If necessary, replace these parts.
After correcting the malfunction, check the complete system to ensure that performance is satisfactory.
Standard:
Symptom Suspect Area See page
1. Blower fuse
2. Blower relay
3. Blower motor
No blower operation
4. Power mosfet
5. Blower speed control switch
6. Wire harness
1. Engine coolant capacity
No air temperature control
2. Heater control assembly
1. Refrigerant capacity
2. A/C Fuse
3. Magnetic clutch
4. Compressor
No compressor operation
5. A/C pressure transducer
6. A/C switch
7. Evaporator temperature sensor
8. Wire harness
2. Refrigerant pressure
3. Drive belt
4. Magnetic clutch
5. Compressor
No cool comes out
7. Evaporator temperature sensor
8. A/C switch
10. Wire harness
2. Drive belt
3. Magnetic clutch
4. Compressor
English
Insufficient cooling 5. Condenser
6. Expansion valve
7. Evaporator
8. Refrigerant lines
No engine idleup when A/C switch 1. Engine ECM
ON 2. Wire harness
No air inlet control 1. Heater control assembly
No mode control
2. Mode actuator
1. Cooling fan fuse
2. Fan motor
No cooling fan operation
3. Engine ECM
4. Wire harness
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > General Information > Special Service Tools
English
SPECIAL TOOLS
Tool
Illustration Use
(Number and name)
0997729000 Removal and installation of the disc &
Disc & hub assembly bolt remover hub assembly bolt
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > General Safety
English
Information and Caution
INSTRUCTIONS
When Handling Refrigerant
1. R134a liquid refrigerant is highly volatile. A drop on the skin of your hand could result in localized frostbite. When handling
the refrigerant, be sure to wear gloves.
2. It is standard practice to wear goggles or glasses to protect your eyes, and gloves to protect your hands. If the refrigerant
splashes into your eyes, wash them with clean water immediately.
3. The R134a container is highly pressurized. Never leave it in a hot place, and check that the storage temperature is below
52°C (126°F)
4. An electronic leak detector should be used to check the system for refrigerant leakage. Bear in mind that the R134a, upon
coming into contact with flame, produces phosgene, a highly toxic gas.
5. Use only recommended the lubricant for R134a systems. If lubricants other than the recommended one used, system
failure may occur.
6. PAG lubricant absorbs moisture from the atmosphere at a rapid rate, therefore the following precautions must be observed:
– When removing refrigerant components from a vehicle, cap immediately the components to prevent from the entry of
moisture.
– When installing refrigerant components to a vehicle, do not remove the cap until just before connecting the
components.
– Complete the connection of all refrigerant tubes and hoses without delay to prevent the A/C system from taking on
moisture.
– Use the recommended lubricant from a sealed container only.
7. If an accidental discharge in the system occurs, ventilate the work area before resuming service.
When Replacing Parts On A/c System
1. Never open or loosen a connection before discharging the system.
2. Seal the open fittings of components with a cap or plug immediately to prevent intrusion of moisture or dust.
3. Do not remove the sealing caps from a replacement component until it is ready to be installed.
4. Before connecting an open fitting, always install a new sealing ring. Coat the fitting and seal with refrigerant oil before
making the connection.
English
WHEN INSTALLING CONNECTING PARTS
FLANGE WITH GUIDE PIN
Check the new Oring for damage (use only the specified) and lubricate it using compressor oil. Tighten the nut to specified torque.
Tightening torque [ N.m (kg.m, lbf.ft) ]
Size General bolt, nut
4T 7T
5 6 9 11
M6
(0.5 0.6, 3.6 4.3) (0.9 1.1, 6.5 7.9)
12 14 20 26
M8
(1.2 1.4, 8.7 10) (2.0 2.6, 14 18)
25 28 45 55
M10
(2.5 2.8, 18 20) (4.5 5.5, 32 39)
Flange bolt, nut
Size
4T 7T
5 7 8 12
M6
(0.5 0.7, 3.6 5.0) (0.8 1.2, 5.8 8.6)
10 15 19 28
M8
(1.0 1.5, 7 10) (1.9 2.8, 14 20)
21 31 39 60
M10
(2.1 3.1, 15 22) (3.9 6.0, 28 43)
Handling Tubing And Fittings
The internal parts of the refrigeration system will remain in a state of chemical stability as long as pure moisturefree refrigerant and
refrigerant oil are used. Abnormal amounts of dirt, moisture or air can upset the chemical stability and cause problems or serious
damage.
The Following Precautions Must Be Observed
1. When it is necessary to open the refrigeration system, have everything you will need to service the system ready so the
system will not be left open any longer than necessary.
2. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture.
3. All lines and components in parts stock should be capped or sealed until they are ready to be used.
4. Never attempt to rebind formed lines to fit. Use the correct line for the installation you are servicing.
5. All tools, including the refrigerant dispensing manifold, the gauge set manifold and test hoses, should be kept clean and
dry.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Description and
English
Operation
REFRIGERATION CYCLE
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Components and
English
Components Location
COMPONENT LOCATION INDEX
INTERIOR English
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Repair procedures
English
REFRIGERANT SYSTEM SERVICE BASICS
Refrigerant Recovery
Use only service equipment that is U.Llisted and is certified to meet the requirements of SAE J2210 to remove HFC134a(R134a) from
the air conditioning system.

– Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
– Be careful when connecting service equipment.
– Do not breathe refrigerant or vapor.
If accidental system discharge occurs, ventilate work area before resuming service.
Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
1. Connect an R134a refrigerant
Recovery/Recycling/Charging System (A) to the highpressure service port (B) and the lowpressure service port (C) as
shown, following the equipment manufacturer's instructions.
2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to
install the same amount of new refrigerant oil back into the A/C system before charging.
System Evacuation

English
1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be evacuated using
an R134a refrigerant Recovery/Recycling/Charging System. (If the system has been open for several days, the
receiver/dryer should be replaced, and the system should be evacuated for several hours.)
2. Connect an R134a refrigerant Recovery/Recycling/Charging System (A) to the highpressure service port (B) and the low
pressure service port (C) as shown, following the equipment manufacturer's instructions.
3. If the lowpressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 10 minutes, there is probably a leak in
the system. Partially charge the system, and check for leaks (see Leak Test.).
4. Remove the low pressure valve from the lowpressure service port.
SYSTEM CHARGING

1. Connect an R134a refrigerant Recovery/Recycling/Charging System (A) to the highpressure service port (B) as shown,
following the equipment manufacturer's instructions.
2. Add the same amount of new refrigerant oil to system that was removed during recovery. Use only specified refrigerant oil.
Charge the system with 17.6 ± 0.88 (500 ± 25) of R134a refrigerant. Do not overcharge the system the compressor will be
damaged.
Refrigerant Leak Test
Always conduct a leak test with an electronic leak detector whenever leakage or refrigerant is suspected and when conducting service
operations which are accompanied by disassembly or loosening or connection fittings.

In order to use the leak detector properly, read the manual supplied by the manufacturer.
If a gas leak is detected, proceed as follows:
1. Check the torque on the connection fittings and, if too loose, tighten to the proper torque. Check for gas leakage with a leak
detector (A).
2. If leakage continues even after the fitting has been tightened, discharge the refrigerant from the system, disconnect the
fittings, and check their seating faces for damage. Always replace, even if the damage is slight.
3. Check the compressor oil and add oil if required.
4. Charge the system and recheck for gas leaks. If no leaks are found, evacuate and charge the system again.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor >
English
COMPONENT LOCATION
COMPONENTS
English
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor >
English
Repair procedures
REMOVAL
1. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few minutes,
then shut the engine off.
2. Disconnect the negative cable from the battery.
3. Recover the refrigerant with a recovery/charging station.
4. Loosen the drive belt.
5. Remove the bolts, then disconnect the suction line (A) and discharge line (B) from the compressor. Plug or cap the lines
immediately after disconnecting them to avoid moisture and dust contamination.
6. Disconnect the compressor clutch connector, and then remove 4 mounting bolts and the compressor (A).
INSTALLATION
1. Make sure of the length of compressor mounting bolts, and then tighten it A→B→C→D order.
Bolt R,U,D Engine β Engine
A 100 mm (3.93 in.) 125 mm (4.92in.)
B 100 mm (3.93in.) 109 mm (4.29in.)
C 109 mm (4.29in.) 125 mm (4.92in.)
D 100 mm (3.93in.) 109 mm (4.29in.)
English
2. Install in the reverse order of removal, and note these items.
– If you're installing a new compressor, drain all the refrigerant oil from the removed compressor, and measure its
volume, Subtract the volume of drained oil from 150cc(5.07 oz.) the result is the amount of oil you should drain from
the new compressor (through the suction fitting).
– Replace the Orings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be
sure to use the right Orings for R134a to avoid leakage.
– To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant
oils.
– Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption.
– Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it
off immediately.
– Adjust the drive belt.
– Charge the system and test its performance.
INSPECTION
1. Check the plated parts of the disc & hub assembly (A) for color changes, peeling or other damage. If there is damage,
replace the clutch set.
2. Check the pulley (B) bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one if it is
noisy or has excessive play/drag.
3. Measure the clearance between the pulley (B) and the disc & hub assembly (A) all the way around. If the clearance is not
within specified limits, remove the disc & hub assembly and add or remove shim (gap washer) as needed to increase or
decrease clearance.
Clearance : 0.45 ± 0.1mm (0.018 ± 0.004 in.)

The shims (gap washers) are available in seven thicknesses: 0.7mm, 0.8mm, 0.9mm, 1.0mm, 1.1mm, 1.2mm and
1.3mm.
4. Check operation of the magnetic clutch.
Connect the compressor side terminals to the battery (+) terminal and the ground battery () terminal to the compressor
body.
Check the magnetic clutch operating noise to determine the condition.
DISASSEMBLY
1. Remove the center bolt (A) while holding the disc & hub assembly with a commercially available disc & hub assembly bolt
remover; Special tool number 0997729000.
TORQUE : 10~15N.m (1.02~1.53kgf.m, 7.37~11lb.ft)
2. Remove the disc & hub assembly (A) and shim (gap washer) (B), taking care not to lose the shims. If the clutch needs
adjustment, increase or decrease the number and thickness of shims as necessary, then reinstall the disc & hub
assembly, and recheck its clearance (Refer to HA20).
3. If you remove the field coil, remove retainer ring (A) with retainer ring pliers.

– Be careful not to damage the pulley (B) and compressor during removal/installation.
– Once retainer ring (A) is removed, replace it with a new one.
4. Remove the screw (A) from the field coil ground terminal. Remove the retainer ring (B) and then remove the field coil (C)
from the shaft with a puller. Be careful not to damage the coil and compressor.
5. Reassemble the compressor clutch in the reverse order of disassembly, and note these items :
– Clean the pulley and compressor sliding surfaces with nonpetroleum solvent.
– Install new retainer rings, and make sure they are fully seated in the groove.
– Make sure that the pulley turns smoothly after its reassembled.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor oil >
English
Repair procedures
OIL SPECIFICATION
1. The HFC134a system requires synthetic (PAG) compressor oil whereas the R12 system requires mineral compressor oil.
The two oils must never be mixed.
2. Compressor (PAG) oil varies according to compressor model. Be sure to use oil specified for the model of compressor.
Handling of Oil
1. The oil should be free from moisture, dust, metal powder, etc.
2. Do not mix with other oil.
3. The water content in the oil increases when exposed to the air. After use, seal oil from air immediately. (HFC134a
Compressor Oil absorbs moisture very easily.)
4. The compressor oil must be stored in steel containers, not in plastic containers.
Compressor oil check
The oil used to lubricate the compressor is circulating with the refrigerant.
Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the original amount of oil.
Oil total volume in system:
150 ± 10cc (5.07 ± 0.34 fl.oz)
Oil Return Operation
There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with the refrigerant in the system. When checking the amount of oil in the system, or
replacing any component of the system, the compressor must be run in advance for oil return operation. The procedure is as follows:
1. Open all the doors and the engine hood.
2. Start the engine and air conditioning switch to "ON" and set the blower motor control knob at its highest position.
3. Run the compressor for more than 20 minutes between 800 and 1,000 rpm in order to operate the system.
4. Stop the engine.
Replacement of Component Parts
When replacing the system component parts, supply the following amount of oil to the component parts to be installed.
Component parts to be installed Amount of Oil
Evaporator 50 cc (1.70 fl.oz)
Condenser 30 cc (1.02 fl.oz)
Receiver/dryer 30 cc (1.02 fl.oz)
Refrigerant line (One piece) 10 cc (0.34 fl.oz)
For compressor replacement, subtract the volume of oil drained from the removed compressor from the specified volume, and drain the
calculated volume of oil from the new compressor:
The specified volume volume of removed compressor = volume to drain from the new compressor.

Even if no oil is drained from the removed compressor, don’t drain more than 50cc from new compressor.
English
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser >
English
COMPONENT LOCATION
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser >
English
Repair procedures
INSPECTION
1. Check the condenser fins for clogging and damage. If clogged, clean them with water, and blow them with compressed air.
If bent, gently bend them using a screwdriver or pliers.
2. Check the condenser connections for leakage, and repair or replace it, if required.
REPLACEMENT
Condenser Assembly
1. Recover the refrigerant with a recovery/ recycling/ charging station.
3. Remove 2 nuts (A), and then disconnect the discharge line and liquid line from the condenser.
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
TORQUE: 7.8~11.7N.m (0.8~1.2kgf.m, 5.9~8.7lb.ft)
4. Remove the radiator (A).
(Refer to EM group Radiator)
5. Remove 2 bolts, and then remove the condenser by lifting it up. Be careful not to damage the radiator and condenser fins
when removing the condenser (B).
6. Install in the reverse order of removal, and note these items :
– If you're installing a new condenser, add refrigerant oil NDOIL8.
English
– Be careful not to damage the radiator and condenser fins when installing the condenser.
– Charge the system, and test its performance.
Desiccant
1. Remove the condenser, and then remove the bottom cap (B) with L wrench (A) from the condenser.
TORQUE: 10~15 N.m (1.0~1.5 kgf.m, 7.23~10.84 lb.ft)
2. Remove the desiccant (A) from condenser using a long nose plier. Check for crumbled desiccant and clogged bottom cap
filter.
3. Apply air conditioning compressor oil along the Orings and threads of the new bottom cap.
4. Insert the new desiccant into the receiver drier tank. The desiccant must be sealed in vacuum before it is exposed to air for
use.
5. Install the new bottom cap to the condenser.

– Always replace the desiccant and bottom cap at the same time.
– Replace the Orings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them.
Be sure to use the right Orings for R134a to avoid leakage.
– Be careful not to damage the radiator and condenser fins when installing the condenser.
– Charge the system, and test its performance.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Refrigerant line >
English
COMPONENT LOCATION
[GASOLINE]
English
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Refrigerant line >
English
Repair procedures
REPLACEMENT
1. Discharge refrigerant from refrigeration system.
2. Replace faulty tube or hose.

Cap the open fittings immediately to keep moisture or dirt out of the system.
3. Tighten joint of bolt or nut to specified torque.

Connections should not be torque tighter than the specified torque.
Part tightened N.m Kgf.m lbf.ft

Condenser Discharge hose
8 ~ 12 0.8~1.2 5.8 ~ 8.7
Condenser Liquid tube
Compressor Discharge hose
20~30 2.0~3.0 14.4~21.6
Compressor Suction hose
Expansion valve Evaporator 8 ~ 12 0.8~1.2 5.8 ~ 8.7
4. Evacuate air in refrigeration system and charge system with refrigerant.
Specified amount : 500 ± 25g (17.6 ± 0.88 Oz)
5. Inspect for leakage of refrigerant.
Using a gas leak detector, check for leakage of refrigerant.
6. Inspect A/C operation.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > A/C pressure
English
transducer > Description and Operation
DESCRIPTION
A/C pressure transducer convert the pressure value of high pressure line into voltage value after measure it. By converted voltage value,
engine ECM controls cooling fan by operating it high speed or low speed. Engine ECM stop the operation of compressor when the
temperature of refrigerant line is so high or so low irregularly to optimize air conditioning system.
English
transducer > Components and Components Location
COMPONENT LOCATION
English
transducer > Repair procedures
INSPECTION
1. Measure the pressure of high pressure line by measuring voltage output between NO.1 and NO.2 terminals.
2. Inspect the voltage value whether it is sufficient to be regular value or not.
Voltage = 0.00878835 * Pressure + 0.37081095 [PSIA]
3. If the measured voltage value is not specification, replace the A/C pressure transducer.
REPLACEMENT
2. Recover the refrigerant with a recovery/charging station.
3. Disconnect A/C pressure transducer connector (3P) (A).
4. Remove the A/C pressure transducer (B).

Take care that liquid & suction pipe are not bent.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Evaporator
English
temperature sensor > Description and Operation
DESCRIPTION
The evaporator temperature sensor will detect the evaporator core temperature and interrupt compressor relay power in order to prevent
evaporator freezing by excessive cooling.It is a negative type thermistor whose resistance is inversely proportional to temperature.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Evaporator
English
temperature sensor > Repair procedures
INSPECTION
1. Ignition "OFF"
2. Disconnect evaporator temperature sensor.
3. Using the multitester, Measure resistance between terminal "1" and "2" of evaporator temperature sensor.
[Specification]
Evaporator core temperature [°C(°F)] Resistance [kΩ]
10(14) 43.35
0(32) 27.62
10(50) 18.07
20 (68) 12.11
30(86) 8.30
40(104) 5.81
50(122) 4.15
4. If the measured resistance is not specification, substitute with a knowngood evaporator temperature sensor and check for
proper operation.
5. If the problem is corrected, replace the evaporator temperature sensor.
REPLACEMENT
English
2. Remove the evaporator temperature sensor (B), by pulling it after rorating 90° in a counter clock wise direction.
3. Installation is the reverse order of removal
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Incar sensor >
English
DESCRIPTION
1. Incar air temperature sensor is located at the crash pad.
2. The sensor contains a thermistor which measures the temperature of the inside. The signal decided by the resistance value
which changes in accordance with perceived inside temperature, is delivered to heater control unit and according to this
signal the control unit regulates incar temperature to intended value.
3. It perceives the inside temperature, changes the resistance value, and enters the corresponding voltage into the automatic
temperature control module.
4. It will used for discharge temperature control, sensor failsafe, temperature door control, blower motor level control, and A/C
auto control.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Incar sensor >
English
Repair procedures
INSPECTION
1. Ignition "ON"
2. Blow air with changing temperature to the in car sensor air inlet. Measure sensor resistance between 2 and 4 terminals.
[Specification]
Temperature [°C(°F)] Resistance between terminals 2and 4 (kΩ)
30 509.600 ± 4.0%
15 216.100 ± 3.2%
0 97.710 ± 2.4%
15 47.130 ± 1.7%
25 30.000 ± 1.2%
35 19.590 ± 1.6%
50 10.810 ± 2.2%

In car sensor is negative type thermistor that resistance will rise with lower temperature, and reduce with higher
temperature.
REPLACEMENT
2. Remove the crash pad. (Refer to BD groupcrash pad).
3. Disconnect the connector of incar sensor (A).Loosen the mounting 2 screws and then remove the incar sensor.
English
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor >
English
DESCRIPTION
1. The photo sensor (A) is located at the center of defrost nozzle.
2. The photo sensor contains a photovoltaic (sensitive to sunlight) diode. The solar radiation received by its light receiving
portion, generates an electromotive force in proportion to the amount of radiation received which is transferred to the
automatic temperature control module so that the solar radiation compensation will be performed.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor >
English
Repair procedures
INSPECTION
1. Ignition "ON"
2. Using the scan tool.
3. Emit intensive light toward photo sensor using a lamp, and check the output voltage change.
4. The voltage will rise with higher intensive light and reduce with lower intensive light.
REPLACEMENT
2. With the () driver, remove the photo sensor (B) from the center of defrost nozzle (A).
3. Install in the reverse order of removal.
English
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Water temperature
English
sensor > Description and Operation
DESCRIPTION
1. Water temperature sensor is located at the heater unit.
2. It detects coolant temperature. Its signal is used for cold engine lockout control. When the driver operates the heater before
the engine is warmed up, the signal from sensor causes the heater control unit to reduce blower motor speed until coolant
temperature reaches the threshold value.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Water temperature
English
sensor > Repair procedures
INSPECTION
1. Ignition "ON"
2. Using the multitester, Measure resistance between terminal "1" and "2" of water temperature sensor.
[Specification]
Coolant temperature [°C(°F)] Resistance (kΩ) Voltage (V)
10(14) 55.85 ± 3% 4.24 ± 3%
0(32) 32.91 ± 3% 3.83 ± 3%
10(50) 19.99 ± 3% 3.33 ± 3%
20(68) 12.51 ± 3% 2.78 ± 3%
30(86) 8.047 ± 3% 2.23 ± 3%
40(104) 5.311 ± 3% 1.73 ± 3%
50(122) 3.588 ± 3% 1.32 ± 3%
60(140) 2.476 ± 3% 0.99 ± 3%
70(158) 1.742 ±3% 0.74 ± 3%
80(176) 1.246 ± 3% 0.55 ± 3%
3. If the measured resistance is not specification, substitute with a knowngood water temperature sensor and check for
proper operation.
4. If the problem is corrected, replace the water temperature sensor.

Negative type thermistor that resistance will rise with lower temperature, and reduce with higher temperature.
REPLACEMENT
2. Remove the crashpad lower panal(A).
English
3. Remove the crashpad lower panal(A).
4. Pull the water temperature sensor (B) out at the heater unit with the clamp (C).

Apply caulk to the water temperature sensor.
Make sure that there is no air leakage
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor >
English
DESCRIPTION
1. The ambient temperature sensor is located at the front of the condenser and detects ambient air temperature. It is a
negative type thermistor; resistance will increase with lower temperature, and decrease with higher temperatures.
2. The sensor output will be used for discharge temperature control, temperature regulation door control, blower motor level
control, mix mode control and incar humidity control.

If the ambient temperature is below 0°C (32°F), the A/C compressor will be stopped.
The compressor will be operated by manual operating.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor >
English
Repair procedures
INSPECTION
1. Ignition "OFF"
2. Disconnect ambient temperature sensor.
3. Check the resistance of ambient temperature sensor between terminals 1 and 2 whether it is changed by changing of the
ambient temperature.
[Specification]
Ambient Temperature
Resistance between terminals 1 and 2 (kΩ )
[°C (°F)]
10 158.2± 3%
0 (32) 95.1± 3%
10 (50) 58.8± 3%
20 (68) 37.3± 3%
4. If the measured resistance is not specification, substitute with a knowngood ambient temperature sensor and check for
proper operation.
5. If the problem is corrected, replace the ambient temperature sensor.
REPLACEMENT
2. Remove the radiator grill cover(A).
English
3. Remove the ambient temperature sensor (A).
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Air QualityEnglish
Sensor(AQS) > Description and Operation
DESCRIPTION
1. A.Q.S is located at center support in front of the engine radiator, and detects hazardous elements in ambient air providing
output signal to control.
2. It will detect sulfurous acid gas, carbon dioxide, carbon monoxide, hydrocarbon and allergen.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Air QualityEnglish
Sensor(AQS) > Repair procedures
INSPECTION
1. Ignition "ON"
3. Check the output voltage of AQS between terminals 2 and 3.
[Specification]
Condition Output signal Fresh/recirculation
Heating Condition (IG "ON") 2.5 ± 0.5V Prevlous
Normal Condition 4.3 ± 0.5V Fresh
Hazardous gas detection 0.9 ± 0.5V Recirculation
4. AQS diagnosis and fail safe
Detect the signal without choosing the AQS switch.
If 2.5V or more is detected for 3.5 seconds or more among 7 seconds, be judged the open of AQS signal.
Operate as below fail safe function, while choosing AQS.
Fail safe: Release the AQS (AQS cannot be selected), Fresh/recirculation maintains previous situation of AQS selection.

When IG is turned ON, AQS heats for 34±5 seconds, it will output below 2.5 voltage during this time.
REPLACEMENT
2. Remove the radiator grill cover(A).
English
3. Remove the AQS (B) after loosening the mounting bolts (A).
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Humidity Sensor >
English
DESCRIPTION
1. Humidity sensor is located at the lower crash pad and detected incar humidity for incar humidity control.
2. If ambient air temperature or incar humidity is outside certain range, it will turn on A/C to control incar humidity preventing
in car fogging.
Air conditioner operation depends on ambient temperature and humidity.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Air conditioning System > Humidity Sensor >
English
Repair procedures
INSPECTION
1. Ignition "ON"
3. Check the frequency of humidity sensor between terminals 2 and 3.
Humidity (%) Frequency between terminals 2and 3 (Hz)
30 6976 ± 5%
50 6728 ± 5%
60 6600 ± 5%
70 6468 ± 5%
80 6330 ± 5%
90 6186 ± 5%
4. If the measured resistance is not specification, substitute with a knowngood humidity sensor and check for proper
operation.
5. If the problem is corrected, replace the Humidity sensor.
REPLACEMENT
2. Remove the center facia lower panel (A). (Refer to BD group Crash pad)
3. Disconnect the humidity sensor connector
4. Disconnect the connector of humidity sensor. Loosen the mounting 2 screws and then remove the humidity sensor (B).
English
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Heater > Heater Unit > Components and
English
Components Location
COMPONENT LOCATION
COMPONENTS English
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Heater > Heater Unit > Repair procedures
English
REPLACEMENT
2. Recover the refrigerant with a recovery/ recycling/ charging station.
3. When the engine is cool, drain the engine coolant from the radiator.
4. Remove the expansion valve cover(A).
5. Remove the bolts (A) and the expansion valve (B) from the evaporator core.
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
6. Disconnect the inlet (C) and outlet (D) heater hoses from the heater unit.

Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant
spill on electrical parts or painted surfaces. If any coolant spills, rinse it off immediately.
English
7. Remove the crash pad.
(Refer to BD groupcresh pad)
8. Remove the cowl cross bar assembly.
(Refer to BD groupcresh pad)
9. Disconnect the connectors from the temperature control actuator, the mode control actuator and the evaporator temperature
sensor.
10. Remove the heater & blower unit after loosening 3 mounting nuts.
11. Remove the blower unit (B) from heater unit after loosening 3 screws.
12. Remove the heater core cover (A).
13. Be careful that the inlet and outlet pipe are not bent during heater core removal, and pull out the heater core (A).
14. Remove the heater unit lower case(A).
15. Remove the evaporator core(B).
16. Install the heater core in the reverse order of removal.
17. Installation is the reverse order of removal, and note these items :
– If you're installing a new evaporator, add refrigerant oil (NDOIL8).
– Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.
– Do not spill the refrigerant oil on the vehicle ; it may damage the paint ; if the refrigerant oil contacts the paint, wash
it off immediately.
– Apply sealant to the grommets.
– Make sure that there is no air leakage.
– Charge the system and test its performance.
– Do not interchange the inlet and outlet heater hoses and install the hose clamps securely.
– Refill the cooling system with engine coolant.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator >
English
COMPONENT LOCATION
English
DESCRIPTION
1. Heater unit includes mode control actuator and temperature control actuator.
2. Temperature control actuator is located at the heater unit. It regulates the temperature by the procedure as follows. Signal
from control unit adjusts position of temperature door by operating temperature switch and then temperature will be
regulated by the hot/cold air ratio decided by position of temperature door.
English
Repair procedures
INSPECTION
1. Ignition "OFF"
2. Disconnect the connector of temperature control actuator.
3. Verify that the temperature control actuator operates to the hot position when connecting 12V to the terminal 3 and
grounding terminal 4.
Verify that the temperature control actuator operates to the cool position when connecting in the reverse.
[Drive]
1)
2)
3) Cool position
4) 5V (Vcc)
5) Feedback signal
6) Senser GND
7) Warm position
4. Check the voltage between terminals 5 and 6.
[Specification]
Door position Voltage (56) Error detecting
Max. cooling 0.3 ± 0.15V Low voltage : 0.1V or less
Max. heating 4.7 ± 0.15V High voltage : 4.9V or more
* It will feedback current position of actuator to controls.
5. If the measured voltage is not specification, substitute with a knowngood temperature control actuator and check for
proper operation.
6. If the problem is corrected, replace the temperature control actuator.
[Passenger]
English
1)
2)
3) Cool position
4) 5V (Vcc)
5) Feedback signal
6) Senser GND
7) Warm position
[Specification]
Max. cooling 0.3 ± 0.15V Low voltage :0.1V or less
Max. heating 4.7 ± 0.15V High voltage :4.9V or more
* It will feedback current position of actuator to controls.
8. If the measured voltage is not specification, substitute with a knowngood temperature control actuator and check for
proper operation.
9. If the problem is corrected, replace the temperature control actuator.
REPLACEMENT
2. Remove the crush pad lower panel (A).
3. Disconnect the damper (B) from the glove box (A).
5. Remove the sower duct (A).
6. Disconnect the temperature control actuator connector (A).
7. Loosen the mounting screw and then remove the temperature control actuator (B).
8. Remove the driver's crush pad lower panel (A).
(Refer to BD group "Crash pad")
10. Disconnect the mode control actuator connector (A) after removing the air duct.
11. Loosen the mounting screws and then remove the mode control actuator (B).
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > English
COMPONENT LOCATION
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Description
English
and Operation
DESCRIPTION
The mode control actuator is located at the heater unit.
It adjusts position of mode door by operating mode control actuator based on signal of A/C control unit. Pressing mode select switch
makes the mode control actuator shift in order of vent→ B/L → floor → mix.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Repair
English
procedures
INSPECTION
1. Ignition "OFF"
2. Disconnect the connector of mode control actuator.
3. Verify that the mode control actuator operates to the defrost mode when connecting 12V to the terminal 3 and grounding
terminal 4.
4. Verify that the mode control actuator operates to the vent mode when connecting in the reverse.
1)
2)
3) DEF
4) VENT
5) SENSOR GND
6) Feedback signal
7) 5V (Vcc)

Vent 0.3 ± 0.15V Low voltage : 0.1V or less
Defrost 4.7 ± 0.15V High voltage : 4.9V or more
It will feedback current position of actuator to controls.
6. If the measured voltage is not specification, substitute with a knowngood console temp control actuator and check for
proper operation.
7. If the problem is corrected, replace the console temp control actuator.
REPLACEMENT
2. Remove the driver's crush pad lower panel (A).
(Refer to BD group "Crash pad")
English
4. Disconnect the mode control actuator connector (A) after removing the air duct.
5. Loosen the mounting screws and then remove the mode control actuator (B).
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Heater > Positive Temperature English
coefficient)heater > Description and Operation
DESCRIPTION
PTC (Positive Temperature Coefficient) heater (A) is an electric heater using a PTC element as an auxiliary heating device that
supplements deficiency of interior heat source in highly effective diesel engine (U engine).
An electric heater heats up the interior by directly heating the air that passes through the heater.
PTC = positive Temperature Coefficient
The name itself implies that the element has a proportional resistance change sensitive to temperature. PTC heater is installed at the exit
or the backside of heater core.
OPERATION PRINCIPLE
ECM outputs a PTC on signal. Operate PTC from 1st setting to 3rd setting with an interval of 15 seconds.
Heat up the air, which passes through a heater core.
OPERATION CONDITION
Judge the condition by ambient temperature is below 5°C, coolant temperature is below 70°C, and battery voltage is above 11V and
engine RPM is above 700RPM.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Blower > Blower Unit > Components and
English
Components Location
COMPONENT LOCATION
COMPONENTS English
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Blower > Blower Unit > Repair procedures
English
REPLACEMENT
2. Remove the crash pad.
(Refer to BD group Crash pad)
3. Disconnect the connectors from the intake actuator, the blower motor and power mosfet.
4. Remove the cowl cross bar assembly.
(Refer to BD group Crash pad)
5. Remove the blower unit (A) from the heater unit after loosening a mounting bolt and 3 screws.

– Make sure that there is no air leaking out of the blower and duct joints.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Blower > Blower Motor > Repair procedures
English
INSPECTION
1. Connect the battery voltage and check the blower motor rotation.
2. If the blower motor voltage is not operated well, substitute with a knowngood blower motor and check for proper operation.
3. If the problem is corrected, replace the blower motor.
REPLACEMENT
2. Remove the blower motor cover(A).
3. Disconnect the connector (B) of the blower motor and then remove the blower motor (A) after loosening the mounting
screws
4. Installation is the reverse order of removal. English
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Blower > Blower Relay > Repair procedures
English
INSPECTION
1. There should be continuity between No1 and No.4 terminals when power and ground are connected to No.2 and No.3
terminals.
2. There should be no continuity between No.1 and No.4 terminals when power is disconnected.
3. If the blower motor voltage is not operated well, substitute with a knowngood blower relay and check for proper operation.
4. If the problem is corrected, replace the blower relay.
REPLACEMENT
2. Disconnect the connector of the blower relay at the below blower unit.
3. Remove the blower relay (A) after loosening the mounting screw.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Blower > Power Mosfet > Repair procedures
English
INSPECTION
1. Ignition "ON"
2. Manually operate the control switch and measure the voltage of blower motor between pin 1 and 2.
3. Select the control switch to raise voltage until high speed.
[Specification]
Motor voltage Motor Voltage
Fan
Manual Auto
First speed 3.80±0.5 3.8±0.5
Second speed 4.29±0.5 4.9±0.5
Third speed 4.77±0.5 6.1±0.5
Forth speed 5.29±0.5 7.2±0.5
Fifth speed 5.74±0.5 8.3±0.5
Sixth speed 6.23±0.5 9.5±0.5
Seventh speed 6.71±0.5 10.6±0.5
Eighth speed 7.20±0.5 Battery (+)
Ninth speed 7.69±0.5
Tenth speed 8.17±0.5
Eleventh speed 8.66±0.5
Twelf speed 9.14±0.5
Thirteen speed 9.63±0.5
Fourteen speed 10.11±0.5
Fifteen speed 10.60±0.5
Sixteenth speed Battery (+)
AUTO COOLING: Auto speed (4.5V~B+)
AUTO HEATING: Auto speed (4.6V~10.6V)
4. If the measured voltage is not specification, substitute with a knowngood power mosfet and check for proper operation.
5. If the problem is corrected, replace the power mosfet.
REPLACEMENT English
2. Disconnect the power mosfet connector at the connecting part between heater and blower unit.
3. Remove the power mosfet (B) after loosening the mounting screws.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Blower > Climate control air filtar > English
DESCRIPTION
This has particle filter which eliminates foreign materials and odor. The particle filter includes odor filter as well as conventional dust filter
to ensure comfortable interior environment.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Blower > Climate control air filtar > Repair
English
procedures
REPLACEMENT
1. Open the glove box (A). Lower the glove box down completely by removing the glove box stopper (B) to the glove box.
2. Remove the filter cover (A) with pushing the knob (B).

In case of driving in an airpolluted area or rugged terrain, check and replace the air filter as frequently as possible.
Replacement period: 15,000 km (9320 mile)
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Description and
English
Operation
DESCRIPTION
1. The intake actuator is located at the blower unit.
2. It regulates the intake door by signal from control unit.
3. Pressing the intake selection switch will shift between recirculation and fresh air modes.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Components and
English
Components Location
COMPONENT LOCATION
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Repair procedures
English
INSPECTION
1. Ignition "OFF"
2. Disconnect the intake actuator connector.
3. Verify that the actuator operates to the recirculation position when connecting 12V to the terminal 3 and grounding terminal
4.
4. Verify that the intake actuator operates to the fresh position when connecting in the reverse.

Low voltage :
Fresh 0.3 ± 0.15V
0.1V or less
High voltage :
Recirculation 4.7 ± 0.15V
4.9V or more
It will feedback current position of actuator to controls.
6. If the intake actuator is not operated well, substitute with a knowngood intake actuator and check for proper operation.
7. If the problem is corrected, replace the intake actuator.
REPLACEMENT
2. Remove the crash pad. (Refer to BD group Crash pad).
3. Disconnect the intake actuator connector.
4. Loosen the mounting screw and then remove the intake actuator (A) from the blower unit.
English
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Controller > Blower And A/C Controls
English
(Manual) > Components and Components Location
CONTROL PANEL
Component
Connector Pin Function
Connector Pin Function Connector Pin Function
1 Tail lamp (ILL+) 1 GND
English
2 Battery (+) 2 M / High
3 Rear defog S/W 3 M / LOW
4 Mode actuator (VENT) 4 High
5 Mode actuator (DEF) 5 Low
6 Temp actuator (COOL) 6
7 Temp actuator (WARM)
8 Intake actuator (FRE)
9 Intake actuator (REC)
10 HTD
11 Sensor REF (+5V)
12 Blower ON signal ()
13 PTC ON signal
Connector
Connector 14 Rheostat(ILL)
(B)
(A)
15 IGN2
16 Max blower ON signal
17 PRC relay 2
18 PRC relay 3
19 Temp actuator F/B
20 Mode actuator F/B
21 Intake actuator F/B
22 Evap sensor (+)
23 Amb sensor (+)
24
25 C_CAN HIGH
26 C_CAN LOW
27 Sensor GND
28 GND
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Controller > Blower And A/C Controls
English
(Manual) > Repair procedures
REPLACEMENT
2. Put the SST (A) into the space betwen the center facia (B).
3. Disconnect the connectors (A) from the center facia.
4. Remove the Heater & A/C controller (A) from center facia panel.
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Full
English
Automatic) > Components and Components Location
CONTROL PANEL
Component
Connector Pin Function
Connector Pin Function Connector Pin Function
English
1 Tail lamp (+) 1 Sensor REF (+5V)
2 Battery (+) 2
3 3 Ambient sensor (+)
4 4
5 5
Evaporator temperature
6 Kline 6
sensor (+)
7 C_CAN HIGH 7
8 C_CNA LOW 8
9 HTD 9 FET (G)
10 Rear defog S/W 10 FET (D)
11 11 Blower motor (+)
12 12 Sensor GND
Connector 13 Rheostat Connector 13 Temp actuator DR(cool)
(A) (B)
14 IG2 14 Mode actuator DR(warm)
15 15 Photo sensor LEFT()
16 Temp actuator PS(cool) 16 Photo sensor RIGHT()
17 Temp actuator PS(warm) 17
18 Temp actuator PS F/B 18 Temp actuator DR F/B
19 Mode actuator (vent) 19
20 Mode actuator (def) 20 PTC on signal
21 Mode actuator F/B 21 PTC RLY 2 (diesel only)
22 Intake actuator (fre) 22 PTC RLY 3 (diesel only)
23 Intake actuator (rec)
24 Intake actuator F/B
25 GND
26 GND
2012 > D 2.0 TCID > Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Full
English
Automatic) > Repair procedures
SELFDIAGNOSIS
1. Selfdiagnosis process
2. How to read selfdiagnostic code
After the display panel flickers three times every 0.5 second, the corresponding fault code flickers on the setup temperature
display panel every 0.5 second and will show two figures. Codes are displayed in numerical format.
Fault code
Fault code
Fail description
Control unit DTC
00 Normal
11 B1234 Incar temperature sensor open
12 B1233 Incar temperature sensor short
13 B1238 Ambient temperature sensor open
14 B1237 Ambient temperature sensor short
17 B1242 Evaporator temperature sensor open
18 B1241 Evaporator temperature sensor short
19 B1245 Temperature control actuator feed back open
19 B1246 Temperature control actuator feed back short
20 B2406 Temperature control actuator failure
21 B1249 Mode control actuator open
21 B1250 Mode control actuator short
22 B2409 Mode control actuator failure
English
25 B1208 Intake potentiometer open
25 B1209 Intake potentiometer short
26 B2408 Intake potentiometer failure
3. Fault code display
(1) Continuance operation
(2) Continuance operation : DTC code is more two
(3) Step operation
A. Nomal or one fault code is same a continuance operation.
B. DTC code is more two.
4. If fault codes are displayed during the check, Inspect malfunction causes by referring to fault codes.
5. Fail safe
(1) Incar sensor : Control with the value of 23°C(73.4°F)
(2) Ambient temperature sensor: Control with the value of 20°C(67°F)
(3) Evaporator temperature sensor: Control with the value of 2°C(28.4°F)
(4) Temperature control actuator (Air mix potentiometer):
If temperature setting LO24.5°C, fix at maximum cooling position.
If temperature setting 25°CHI, fix at maximum heating position
(5) Mode control actuator (Direction potentiometer):
Fix vent position, while selecting vent mode.
Fix defrost position, while selecting all except vent mode.
(6) Intake control actuator :
Fix fresh position, while selecting fresh mode.
Fix recirculation position, while selecting recirculation mode.
REPLACEMENT
2. Put the SST (A) into the space betwen the center facia (B).
3. Disconnect the connectors (A) from the center facia.
4. Remove the Heater & A/C controller (A) after loosening 4 screws.
2012 > D 2.0 TCID > Manual Transaxle System > General Information > Specifications (M6GF2) English
SPECIFICATION
Transaxle type M6GF2
Engine type Diesel 2.0
Gear ratio 1st 3.615
2nd 1.794
3rd 1.542
4th 1.176
5th 0.921
6th 0.732
Reverse 3.416
Final gear ratio 4.063/2.955
Service Standard
Items Standard value [in(mm)]
Input shaft rear bearing end play (At 70kgf load) 0.0019T0(0.05T0)
1st output shaft bearing end play (At 70kgf load) 0.0019T0.0039T(0.05T0.10T)
2nd output shaft front bearing end play (At 70kgf load) 0.0019T0.0039T(0.05T0.10T)
Differential bearing end play (At 70kgf load) 0.0059T0.0078T(0.15T0.20T)
T: Indicate tightening of (minus) direction of end play
L: Indicate loosening of +(plus) direction of end play
TIGHTENING TORQUE
Standard value Nm kgf.m lbft
Oil drain plug 6080 6.08.0 43.457.9
Oil filler plug 3035 3.03.5 21.725.3
Shift control cable bracket on transaxle side 1522 1.52.2 10.916.0
Rear roll support bracket bolt 6080 6.08.0 43.457.8
Front roll support bracket bolt 6080 6.08.0 43.457.8
Transaxle support bracket bolts 6080 6.08.0 43.457.8
Transaxle mounting bracket bolts 6080 6.08.0 43.457.8
Transaxle upper mounting bolts 6080 4.35.5 43.457.8
to ENG. Oil pan 3042 3.04.2 21.730.4
Transaxle lower mounting bolts
to ENG. Block 6080 6.08.0 43.457.8

Always follow torque tightening levels. Failure to follow such levels can result in parts breaking if overtightened or
loosening if undertightened. In either case, serious personal injury or death could result to vehicle occupants.
LUBRICATIONS English
Items Recommnend lubricant Quantity

SAE 75W/85
API GL4
Transaxle gear oil TGO7(MS51714) 1.9L(2.0US qt, 1.67lmp qt)
ZIC GF TOP 75W/85
HD GEAR OIL XLS 75W/85
Air bleeder MS72138 As requried
Transaxle housing MS72140 or MS72138 As requried
Surface of release fork and bearing Grease (CASMOLY L9508) As requried
2012 > D 2.0 TCID > Manual Transaxle System > General Information > Special Service Tools (M6GF2)
English
SPECIAL TOOL
TOOL
Illustration Use
(Number and Name)
0920038001 Removal and installation of the
Engine support fixture transaxle
0962438000 Supporting of crossmember
Crossmember supporter
094323K000 Installation of differential oil seal
Oil seal installer
2012 > D 2.0 TCID > Manual Transaxle System > General Information > Troubleshooting (M6GF2)English
TROUBLESHOOTING
Symptom Probable cause Remedy

Vibration, noise Loose or damaged transaxle and engine mounts Tighten or replace mounts
Inadequate shaft end play Correct end play
Worn or damaged gears Replace gears
Inadequate grade of oil Replace with specified oil
Low oil level Replenish
Inadequate engine idle speed Adjust idle speed
Oil leakage Broken or damaged, oil seal or Oring Replace control cable oil seal or Oring
Hard shift Faulty control cable Replace control cable
Poor contact or wear of synchronizer ring and gear cone Correct or replace
Weakened synchronizer spring Replace synchronizer spring
Inadequate grade of oil Replace with specified oil
Jumps out of gear Worn gear shift fork or broken detent pin Replace shift fork or detent pin
Synchronizer hubtosleeve spline clearance too large Replace synchronizer hub and sleeve
2012 > D 2.0 TCID > Manual Transaxle System > Manual Transaxle System > Repair procedures (M6GF2)
English
SERVICE ADJUSTMENT PROCEDURE
TRANSAXLE GEAR OIL LEVEL
INSPECTION
Inspect each component for evidence of leakage.
Check the gear oil level by removing the filler plug.
If the oil is contaminated, it is necessary to replace it with new oil.
1. Remove oil filler plug(A).
2. Check level with finger.
Oil level must be up to fill the hole, if not, add oil until it runs over.
3. Install filler plug.
Torque : 3035Nm (3.03.5 kgf.m, 21.725.3 lbft)
REPLACEMENT
1. With the vehicle parked on a level surface, remove the drain plug.
2. Drain the transaxle oil after loosening the drain plug(A).
English
3. Install the drain plug with new washer.
4. Add new oil through the fille plug hole and, fill it just below the plug opening.
Standard oil SAE 75W/85, API GL4
Oil capacity: 1.9 liter (2.0 US qt, 1.67 lmp qt)
BACKUP LAMP SWITCH
INSPECTION
1. Disconnect the backup lamp switch(A).
2. Check the continuity between no. 1 and 2 terminals of backup lamp switch.
When the shift lever is in reverse, there should be contunuity.
3. If necessary, repair or replace the backup lamp switch.
NEUTRAL SWITCH
INSPECTION
1. Disconnect the common connector (A).
2. Check the continuity between no. 2 and 5 terminals when the shift lever is in neutral position. If there isn’t continuity, go to
next step.
3. Disconnect the neutral switch connector.
4. Check the continuity between no. 1 and 2 terminals of neutral switch, when the shift lever is in neutral position, there
should be continuity.
5. If necessary, repair or replace the neutral switch.
Torque : 3035 Nm (3.03.5 kgf.m, 21.725.3 lbft)
DRIVE SHAFT OIL SEAL
REPLACEMENT
1. Disconnect the drive shaft from the transaxle. (refer to Drive shaft in DS group)
2. Using a flattip screwdriver, remove the oil seal.
3. Using the special tool(094323K000), tap the drive shaft oil seal into the transaxle.
2012 > D 2.0 TCID > Manual Transaxle System > Manual Transaxle System > Manual Transaxle > English
Components and Components Location (M6GF2)
COMPONENTS
2012 > D 2.0 TCID > Manual Transaxle System > Manual Transaxle System > Manual Transaxle > Repair
English
procedures (M6GF2)
REMOVAL

• Use fender covers to avoid damaging painted surfaces.
• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

1. Remove the engine cover. (refer to Engine and Transaxle Assembly in EM group)
2. Remove the battery (A) after removing the battery terminal.
3. Disconnect the air intake hose (A).
4. Remove the air cleaner assembly (D) by disconnecting the clamp (A), the PCM connector (B), and AFS connector (C).
English
5. Remove the ground cable from transaxle (A).
6. Disconnect the vehicle speed sensor connector (A), the back up lamp switch (B) and the neutral position switch (C).
7. Remove the control cable assembly (A) by removing the snap pins (C) and clips (B).
8. After removing the clip(B) with clamping the concentric slave cylinder tube, disconnect the tube(A).
9. Using the special tool (0920038001), support the engine assembly safely.
10. Remove the transaxle upper mounting bolts (A3ea) and the starter motor mounting bolts (B2ea).
11. Remove the transaxle support bracket mounting bolts (A2ea).
12. Remove the steering joint assembly bolt. (refer to Steering column/shaft in ST group)
13. Lifting up the vehicle.
14. Remove the front wheels and tires. (refer to Front suspension system in SS group)
15. Remove the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting nut from the
front knuckles. (refer to Front suspension system in SS group)
16. Remove the under shield cover(A).
17. Remove the roll stopper mounting bolts (A,B).
18. Disconnect the muffler hanger rubber (A).
19. Supporting the sub frame (A) with a jack and the Special tool (0962438000), remove the mounting bolts.(refer to Front
Stabilizer in SS group)
20. Remove the intercooler tube (A) by removing the two bolts (B) and loosening the clamps (C).
21. Disconnect the drive shafts (A,B) from the transaxle.
22. Supporting the transaxle with a jack, remove the transaxle lower mounting bolts(A2ea, B4ea).
23. Lowering the jack slowly, remove the transaxle.
INSTALLATION
1. Install the transaxle lower mounting bolts (A2ea,B4ea) after fitting the transaxle assembly into the engine assembly.
Torque :
[A] 80100Nm (8.010.0kgf.m,57.972.3 lbft)
[B] 3042Nm (3.04.2kgf.m,21.730.4 lbft)
2. Connect the drive shafts(A,B) to the transaxle.
3. Install the intercooler tube (A) by installing the two bolts (B) and tightening the clamps (C).
4. Supporting the sub frame(A) with a jack and the Special tool(0962438000), install the mounting bolts. (refer to Front
Stabilizer in SS group)
Torque : 140160Nm(1416kgf.m,101118 lbft)
5. Install the muffler hanger rubber (A).
6. Install the roll stopper bracket bolts(A,B).
Torque : 5065Nm(56.5kgf.m, 36.247.0 lbft)
7. Install the under shield cover (A).
8. Install the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting nut to the front
knuckles. (refer to Front suspension system in SS group)
9. Install the front wheels and tires. (refer to Front suspension system in SS group)
10. Install the steering joint assembly bolt (A). (refer to Steering column/shaft in ST group)
Torque : 1825Nm (1.82.5kgf.m, 13.018.1 lbft)
11. Install the transaxle support bracket mounting bolts (A2ea).
Torque : 6080Nm (6.08.0kgf.m, 43.457.9 lbft)
12. Install the transaxle upper mounting bolts (A3ea) the starter motor mounting bolts. (B2ea).
Torque :
[A] 4355Nm(4.35.5kgf.m, 43.457.9 lbft)
[B] 4355Nm(4.35.5kgf.m, 31.139.8 lbft)
13. Remove the special tool (0920038001).
14. Connecting the concentric slave cylinder tube(A) install the clip(B).
15. Install the shift cable assembly (A) by installing the clips (B) and pins (C).
16. Connect the vehicle speed sensor connector (A), the back up lamp switch (B) and the neutral position switch (C).
17. Install the ground cable (A) to transaxle.
18. Install the air cleaner assembly (D) by connecting the clamp (A), the ECM connector (B), and the AFS connector (C).
19. Connect the air intake hose (A).
20. Install the battery (A) and the battery terminal.
21. Install the engine cover. (refer to Engine and Transaxle Assembly in EM group)
2012 > D 2.0 TCID > Manual Transaxle System > Manual Transaxle Control System > Shift Lever >
English
COMPONENTS
1. Shift lever knob 4. Select cable assembly
2. Shift lever assembly 5. Retainer
3. Shift cable assembly
2012 > D 2.0 TCID > Manual Transaxle System > Manual Transaxle Control System > Shift Lever > Repair
English
procedures
REMOVAL
Shift Lever Assembly Replacement
1. Remove the floor console assembly.
(Refer to "Interior(Console)" in BD group)
2. Remove the snap pin (A) and the select cable (B).
3. Remove the shift lever assembly (B) after removing shift lever assembly mounting bolts (A).
Tightening torque:
8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lbft)
4. Remove the pin (A) after disconnect the shift cable (B).
5. Remove the boots (A) and knob (B) from the lever assembly by rotating counterclockwise.
English

• Make sure vehicle does not roll before setting room side shift lever and T/M side manual control lever to "N"
position.
Shift Cable Replacement
1. Remove the floor console assembly.
(Refer to "Interior(Console)" in BD group)
2. Remove the snap pin (A) and select cable assembly (B).
3. Remove the shift lever assembly (B) after removing shift lever assembly mounting bolts (A).
Tightening torque:
8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lbft)
4. Remove the pin(A) after disconnect the shift cable (B).
5. Remove the retainer (A) and nut (B).
Tightening torque:
11.7 ~ 14.7 N.m (1.2 ~ 1.5 kgf.m, 8.6 ~ 10.8 lbft)
6. Remove the snap pins (C) and clips (B) and then remove the shift & select cable (A).
7. Remove the shift cable and select cable at cabin room.

position.
INSPECTION
1. Check the select cable for proper operation and for damage.
2. Check the shift cable for proper operation and for damage.
3. Check the boots for damage.
4. Check the boots for wear abrasion sticking, restricted movement or damage.
5. Check for the weak or damaged spring.
INSTALLATION

position.
• Install the guide member (A) of the select cable (B).
• Adjust the slide clip (B) to fit it into the select lever pin (A) and install the snap pin (C).
2012 > D 2.0 TCID > Restraint > General Information > General Safety Information and Caution English
PRECAUTIONS
GENERAL PRECAUTIONS
Please read the following precautions carefully before performing the airbag system service. Observe the instructions described in this
manual, or the airbags could accidentally deploy and cause damage or injuries.
• Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable
from the battery, and wait at least three minutes before beginning work.

The contents in the memory are not erased even if the ignition switch is turned OFF or the battery cables are
disconnected from the battery.
• Use the replacement parts which are manufactured to the same standards as the original parts and quality.
Do not install used SRS parts from another vehicle.
Use only new parts when making SRS repairs.
• Carefully inspect any SRS part before you install it.
Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation.
• Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS
connector.
AIRBAG HANDLING AND STORAGE
Do not disassemble the airbags; it has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused.
For temporary storage of the air bag during service, please observe the following precautions.
• Store the removed airbag with the pad surface up.
• Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly.
• Store the removed airbag on secure, flat surface away from any high heat source (exceeding 85°C/185°F).
English
• Never perform electrical inspections to the airbags, such as measuring resistance.
• Do not position yourself in front of the airbag assembly during removal, inspection, or replacement.
• Refer to the scrapping procedures for disposal of the damaged airbag.
• Be careful not to bump or impact the SRS unit or the side impact sensors whenever the ignition switch is ON, wait at least
three minutes after the ignition switch is turned OFF before begin work.
• During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the SRS unit
and the side impact sensor. The airbags could accidentally deploy and cause damage or injury.
• After a collision in which the airbags were deployed, replace the front airbags and the SRS unit. After a collision in which
the side airbag was deployed, replace the side airbag, the front impact sensor and side impact sensor on the side where
the side airbag deployed and the SRS unit. After a collision in which the airbags or the side air bags did not deploy,
inspect for any damage or any deformation on the SRS unit and the side impact sensors. If there is any damage, replace
the SRS unit, the front impact sensor and/or the side impact sensors.
• Do not disassemble the SRS unit, the front impact sensor or the side impact sensors
• Turn the ignition switch OFF, disconnect the battery negative cable and wait at least three minutes before beginning
installation or replacement of the SRS unit.
• Be sure the SRS unit, the front impact sensor and side impact sensors are installed securely with the mounting bolts.
• Do not spill water or oil on the SRS unit,or the front impact sensor or the side impact sensors and keep them away from
dust.
• Store the SRS unit, the front impact sensor and the side impact sensors in a cool (15 ~ 25°C/59 ~ 77°F) and dry (les30 ~
80% relative humidity, no moisture) area.
WIRING PRECAUTIONS
SRS wiring can be identified by special yellow outer covering (except the front wiring harness).
Observe the instructions described in this section.
• Never attempt to modify, splice, or repair SRS wiring.
If there is an open or damage in SRS wiring, replace the harness.
• Be sure to install the harness wires so that they are not pinched, or interfere with other parts.
• Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metaltometal contact.
Poor grounding can cause intermittent problems that are difficult to diagnose.
PRECAUTIONS FOR ELECTRICAL INSPECTIONS
• When using electrical test equipment, insert the probe of the tester into the wire side of the connector.
Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector.
• Use a ushaped probe. Do not insert the probe forcibly.
• Use specificed service connectors for troubleshooting.
Using improper tools could cause an error in inspection due to poor metal contact.
AIRBAG CONNECTOR
DISCONNECTING
To release the lock, pull the springloaded sleeve (A) and the slider (B), while holding the opposite half of the connector. Pull the
connector halves apart. Be sure to pull on the sleeve and not on the connector half.
CONNECTING
Hold both connector halves and press firmly until the projection (C) of the sleeveside connector clicks to lock.
2012 > D 2.0 TCID > Restraint > General Information > General Information English
GENERAL
The supplemental restraint system (SRS) is designed to supplement the seat belt to help reduce the risk or severity of injury to the driver
and passenger by activating and deploying the driver, passenger, side airbag and belt pretensioner in certain frontal or side collisions.
The SRS (Airbag) consists of : a driver side airbag module located in the center of the steering wheel, which contains the folded cushion
and an inflator unit ; a passenger side airbag module located in the passenger side crash pad contains the folded cushion assembled
with inflator unit ; side airbag modules located in the front seat contain the folded cushion and an inflator unit ; curtain airbag modules
located inside of the headliner which contains folded cushions and inflator units. The impact sensing function of the SRSCM is carried
out by electronic accelerometer that continuously measure the vehicle's acceleration and delivers a corresponding signal through
amplifying and filtering circuitry to the microprocessor.
SRSCM (SRS CONTROL MODULE)
SRSCM will detect front impact with front impact sensor, and side impact with side impact sensor, and determine airbag module
deployment.
1. DC/DC converter: DC/DC converter in power supply unit includes up/down transformer converter, and provide ignition
voltage for 2 front airbag ignition circuits and the internal operation voltage of the SRSCM. If the internal operation voltage
is below critical value setting, it will perform resetting.
2. Safety sensor: Safety sensor is located in airbag ignition circuit. Safety sensor will operate airbag circuit at any deployment
condition and release airbag circuit safely at normal driving condition. Safety sensor is a double contact electromechanical
switch that will close detecting deceleration above certain criteria.
3. Back up power supply: SRSCM has separate back up power supply, that will supply deployment energy instantly in low
voltage condition or upon power failure by front crash.
4. Self diagnosis: SRSCM will constantly monitor current SRS operation status and detect system failure while vehicle power
supply is on, system failure may be checked with trouble codes using GDS. (GDS)
5. Airbag warning lamp on: Upon detecting error, the module will transmit signal to SRSCM indicator lamp located at cluster.
MIL lamp will indicate driver SRS error. Upon ignition key on, SRS lamp will turn on for about six seconds.
6. Trouble code registration: Upon error occurrence in system, SRSCM will store DTC corresponding to the error. DTC can be
cleared only by GDS. However, if an internal fault code is logged or if a crash is recorded the fault clearing should not
happen.
7. Self diagnostic connector: Data stored in SRSCM memory will be output to GDS or other external output devices through
connector located below driver side crash pad.
8. Once airbag is deployed, SRSCM should not be used again but replaced.
2012 > D 2.0 TCID > Restraint > General Information > Special Service Tools English
Tool(Number and Name) Illustration Use

Deployment tool Airbag deployment tool
0957A34100A
Deployment adapter Use with deployment tool.
0957A3F100 (SAB)
Deployment adapter Use with deployment tool.
0957A38500 (DAB, PAB, CAB, BPT)
Dummy Simulator to check the resistance of
0957A38200 each wiring harness
Dummy adapter Use with dummy
0957A3F000 (SAB)
Dummy adapter Use with dummy
0957A2G000 (DAB, PAB, CAB, BPT)
English
DAB : Driver Airbag
PAB : Passenger Airbag
SAB : Side Airbag
CAB : Curtain Airbag
BPT : Seat Belt Retractor Pretensioner
2012 > D 2.0 TCID > Restraint > General Information > Description and Operation English
WARNING LAMP ACTIVATION
WARNING LAMP BEHAVIOR AFTER IGNITION ON
As soon as the operating voltage is applied to the SRSCM ignition input, the SRSCM activates the warning lamp for a bulb check.
The lamp shall turn on for 6 seconds during the initialization phase and be turned off afterward. However, in order to indicate the driver,
the warning lamp shall turn on for 6 seconds and off for one second then on continuously after the operating voltage is applied if any
active fault exists.
1. Active fault or historical fault counter is greater or equal to 10
2. Normal or historical fault counter is less than 10
SRSCM INDEPENDENT WARNING LAMP ACTIVATION
There are certain fault conditions in which the SRSCM cannot function and thus cannot control the operation of the standard warning
lamp. In these cases, the standard warning lamp is directly activated by appropriate circuitry that operates independently of the SRSCM.
These cases are:
1. Loss of battery supply to the SRSCM : warning lamp turned on continuously.
2. Loss of internal operating voltage : warning lamp turned on continuously.
3. Loss of Microprocessor operation : warning lamp turned on continuously.
4. SRSCM not connected : warning lamp turned on continuously through the shorting bar.
PASSENGER AIRBAG DEACTIVATION (PAD) LAMP OPERATION
The SRSCM is designed with circuitry and software to drive a PAD lamp, which is used for depowered airbag system. For the PAD
indicator circuitry to function properly, both the SRSCM and PAD indicator are sourced from the ignition line. After ignition on, the PAD
indicator will be turned on for 4 seconds and off for 3 seconds during the initialization phase. Thereafter the lamp will be turned on as
long as the PAD switch is in the disabled position.
PASSENGER RESTRAINTS ACTIVATION WITH PAD SWITCH
The PAD switch affects the activation of the front passenger airbag only and the switch is controlled manually. The PAD switch will be
functioned as follows:
PAD Switch status PAD Lamp PAB

Phaseup ON → OFF Enabled
OFF ON Disabled
ON OFF Enabled English
Fault OFF Enabled
2012 > D 2.0 TCID > Restraint > General Information > Components and Components Location English
COMPONENTS
English
COMPONENTS LOCATION
DRIVER AIRBAG (DAB) / PASSENGER AIRBAG (PAB
SIDE AIRBAG (SAB)
CURTAIN AIRBAG (CAB)
SEAT BELT RETRACTOR PRETENSIONER (BPT)
SUPPLEMENTAL RESTRAINT SYSTEM CONTROL MODULE (SRSCM)
FRONT IMPACT SENSOR (FIS)
SIDE IMPACT SENSOR (SIS)
2012 > D 2.0 TCID > Restraint > General Information > Repair procedures English
COMPONENT REPLACEMENT AFTER DEPLOYMENT

Before doing any SRS repairs, use the HiScan Pro to check for DTCs. Refer to the Diagnostic Trouble Code list for
repairing of the related DTCs.
When the front airbag(s) deployed after a collision, replace the following items.
– SRSCM
– Deployed airbag(s)
– Seat belt pretensioner(s)
– Front impact sensors
– SRS wiring harnesses
– Inspect the clock spring for heat damage.
If any damage found, replace the clock spring.
When the seat belt pretensioner(s) deployed after a collision, replace the following items.
– Seat belt pretensioner(s)
– SRSCM (if B1658 detected)
– Front impact sensors
When the side/curtain airbag(s) deployed after a collision, replace the following items.
– SRSCM
– Deployed airbag(s)
– Side impact sensor(s) for the deployed side(s)
After the vehicle is completely repaired, confirm the SRS airbag system is OK.
– Turn the ignition switch ON, the SRS indicator should come on for about 6 seconds and then go off.
2012 > D 2.0 TCID > Restraint > General Information > Specifications English
SPECIFICATION
Item Resistance (Ω)
Driver Airbag (DAB) 1.7 ~ 2.3
Passenger Airbag (PAB) 1.7 ~ 2.3
Side Airbag (SAB) 1.7 ~ 2.3
Curtain Airbag (CAB) 1.7 ~ 2.3
Seat Belt Retractor Pretensioner (BPT) 1.8 ~ 2.5
TIGHTENING TORQUES
Item kgf·m Nm lbft

Driver Airbag (DAB) 0.8 ~ 1.1 7.8 ~ 10.8 5.8 ~ 8
Passenger Airbag (PAB) 1.8 ~ 2.7 17.2 ~ 26.5 13.0 ~ 19.5
Curtain Airbag (CAB) 0.7 ~ 0.9 6.9 ~ 8.8 5.0 ~ 6.5
Side Airbag (SAB) 0.6 ~ 0.8 6.0 ~ 8.0 4.4 ~ 5.9
Seat Belt Anchor Bolt (BPT) 4.0 ~ 5.5 39.2 ~ 53.9 28.9 ~ 39.8
SRSCM 1.0 ~ 1.4 9.5 ~ 13.6 7.0 ~ 10.0
Front Impact Sensor (FIS) Mounting Bolt 0.7 ~ 0.8 6.8 ~ 7.9 5.0 ~ 5.8
Side Impact Sensor (SIS) Mounting Bolt 0.7 ~ 0.8 6.8 ~ 7.9 5.0 ~ 5.8
2012 > D 2.0 TCID > Restraint > Supplemental Restraint System Control Module (SRSCM) > Schematic
English
Diagrams
CIRCUIT DIAGRAM
English
SRSCM CONNECTOR TERMINAL
HARNESS CONNECTOR
2012 > D 2.0 TCID > Restraint > Supplemental Restraint System Control Module (SRSCM) > SRS Control
English
Module (SRSCM) > Description and Operation
DESCRIPTION
The primary purpose of the SRSCM (Supplemental Restraints System Control Module) is to discriminate between an event that warrants
restraint system deployment and an event that does not. The SRSCM must decide whether to deploy the restraint system or not. After
determining that pretensioners and/or airbag deployment is required, the SRSCM must supply sufficient power to the pretensioners and
airbag igniters to initiate deployment.
The SRSCM determines that an impact may require deployment of the pretensioners and airbags from data obtained from impact
sensors and other components in conjunction with a safing function. The SRSCM will not be ready to detect a crash or to activate the
restraint system devices until the signals in the SRSCM circuitry stabilize. It is possible that the SRSCM could activate the safety restraint
devices in approximately 2 seconds but is guaranteed to fully function after proveout is completed. The SRSCM must perform a
diagnostic routine and light a system readiness indicator at keyon. The system must perform a continuous diagnostic routine and
provide fault annunciation through a warning lamp indicator in the event of fault detection. A serial diagnostic communication interface
will be used to facilitate servicing of the restraint control system.
English
Module (SRSCM) > Components and Components Location
COMPONENTS
English
Module (SRSCM) > Repair procedures
REMOVAL
1. Remove the ignition key from the vehicle.
2. Disconnect the battery negative cable and wait for at least three minutes before beginning work.
3. Disconnect the DAB, PAB, SAB, CAB and BPT connectors.
4. Remove the floor console and heater ducts. (Refer to BD group)
5. Press the lock(1), then pull back the connector lever(2) until it clicks.
6. Disconnect the SRSCM harness connector(A) and (B) from the SRSCM.
7. Remove the SRSCM mounting nuts(3EA) from the SRSCM, then remove the SRSCM.
INSTALLATION
3. Install the SRSCM with the SRSCM mounting nuts.
Tightening torque (SRSCM Mounting bolt)
: 1.0 ~ 1.4 kgf.m (9.5 ~ 13.6 Nm, 7.0 ~ 10.0 lb.ft)

Use new mounting bolts when replacing the SRSCM after a collision.
English
4. Connect the SRSCM harness connector.
5. Install the heater ducts and floor console. (Refer to BD group)
6. Connect the DAB, PAB, SAB, CAB and BPT connectors.
7. Reconnect the battery negative cable.
8. After installing the SRSCM, confirm proper system operation:
• Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.
2012 > D 2.0 TCID > Restraint > Supplemental Restraint System Control Module (SRSCM) > Front Impact
English
Sensor (FIS) > Description and Operation
DESCRIPTION
The front impact sensor (FIS) is installed on the upper of the side panal in Front End Module (FEM). They are remote sensors that detect
acceleration due to a collision at its mounting location. The primary purpose of the Front Impact Sensor (FIS) is to provide an indication of
a collision. The Front Impact Sensor(FIS) sends acceleration data to the SRSCM.
English
Sensor (FIS) > Components and Components Location
COMPONENTS
English
Sensor (FIS) > Repair procedures
REMOVAL

• Removal of the airbag must be performed according to the precautions/ procedures described previously.
• Before disconnecting the front impact sensor connector, disconnect the front airbag connector(s).
• Do not turn the ignition switch ON and do not connect the battery cable while replacing the front impact sensor.
2. Remove the front bumper.(Refer to BD group)
3. Disconnect the Front Impact Sensor connector.
4. Remove the Front Impact Sensor mounting bolt.
5. Remove the Front Impact Sensor.
INSTALLATION

• Do not turn the ignition switch ON and do not contact the battery cable while replacing the front impact sensor.
1. Install the new Front Impact Sensor.
2. Tighten the Front Impact Sensor mounting bolt.
Tightening torque
: 0.7 ~ 0.8 kgf.m (6.8 ~ 7.9 Nm, 5.0 ~ 5.8 lb.ft)
3. Connect the Front Impact Sensor connector.
4. Install the front bumper.(Refer to BD group)
6. After installing the Front Impact Sensor, confirm proper system operation: Turn the ignition switch ON the SRS indicator
light should be turned on for about six seconds and then go off.
2012 > D 2.0 TCID > Restraint > Supplemental Restraint System Control Module (SRSCM) > Side Impact
English
Sensor (SIS) > Description and Operation
DESCRIPTION
The Side Impact Sensor (SIS) system consists of two front SIS which are installed in the center pillar (LH and RH) and two rear SIS which
are installed in the rear pillar (LH and RH). They are remote sensors that detect acceleration due to collision at their mounting locations.
The primary purpose of the Side Impact Sensor (SIS) is to provide an indication of a collision. The Side Impact Sensor (SIS) sends
acceleration data to the SRSCM.
English
Sensor (SIS) > Components and Components Location
COMPONENTS
English
Sensor (SIS) > Repair procedures
REMOVAL

• Removal of the airbag must be performed according to the precautions/procedures described previously.
• Before disconnecting the side impact sensor connector(s), disconnect the side airbag connector(s).
• Do not turn the ignition switch ON and do not connect the battery cable while replacing the side impact sensor.
2. Remove the lower anchor bolt.
3. Remove the door scuff trim. (Refer to BD group)
4. Remove the center pillar trim. (Refer to BD group)
5. Disconnect the Side Impact Sensor connector and remove the Side Impact Sensor mounting bolt.
INSTALLATION

• Do not turn the ignition switch ON and do not connect the battery cable while replacing the side impact sensor.
1. Install the new Side Impact Sensor with the bolt then connect the SRS harness connector to the Side Impact Sensor.
Tightening torque
: 0.7 ~ 0.8 kgf.m (6.8 ~ 7.9 Nm, 5.0 ~ 5.8 lb.ft)
2. Install the center pillar trim. (Refer to BD group)
3. Install the door scuff trim. (Refer to BD group)
4. Install the lower anchor bolts.
6. After installing the Side Impact Sensor, confirm proper system operation: Turn the ignition switch ON, the SRS indicator
light should be turned on for about six seconds and then go off.
2012 > D 2.0 TCID > Restraint > Airbag Module > Description and Operation English
AIRBAG DISPOSAL
SPECIAL TOOL REQUIRED
Before scrapping any airbags or side airbags (including those in a whole vehicle to be scrapped), the airbags or side airbags must be
deployed. If the vehicle is still within the warranty period, before deploying the airbags or side airbags, the Technical Manager must give
approval and/or special instruction. Only after the airbags or side airbags have been deployed (as the result of vehicle collision, for
example), can they be scrapped.
If the airbags or side airbags appear intact (not deployed), treat them with extreme caution. Follow this procedure.
DEPLOYING AIRBAGS IN THE VEHICLE
If an SRS equipped vehicle is to be entirely scrapped, its airbags or side airbags should be deployed while still in the vehicle. The
airbags or side airbags should not be considered as salvageable parts and should never be installed in another vehicle.
1. Turn the ignition switch OFF, and disconnect the battery negative cable and wait at least three minutes.
2. Confirm that each airbag or side airbag is securely mounted.
3. Confirm that the special tool is functioning properly by following the check procedure.
DRIVER'S AIRBAG :
1. Remove the driver's airbag and install the SST(0957A38500).
2. Install the driver's airbag on the steering wheel.
FRONT PASSENGER'S AIRBAG :
1. Remove the glove box, then disconnect the 2P connector between the front passenger's airbag and SRS main harness.
2. Install the SST(0957A38500).
SIDE AIRBAG :
1. Disconnect the 2P connector between the side airbag and side wire harness.
2. Install the SST (0957A3F100).
CURTAIN AIRBAG :
1. Disconnect the 2P connector between the curtain airbag and wire harness.
SEAT BELT PRETENSIONER :
1. Disconnect the 2P connector from the seat belt pretensioner.
3. Place the deployment tool at least thirty feet (10 meters) away from the airbag.
4. Connect a 12 volt battery to the tool.
5. Push the tool's deployment switch. The airbag should deploy (deployment is both highly audible and visible: a loud noise
and rapid inflation of the bag, followed by slow deflection)
6. Dispose of the complete airbag. No part of it can be reused. Place it in a sturdy plastic bag and seal it securely.
English
Deploying the airbag out of the vehicle
If an intact airbag has been removed from a scrapped vehicle, or has been found defective or damage during transit, storage or service, it
should be deployed as follows:
1. Confirm that the special tool is functioning properly by following the check procedure on this page.
2. Position the airbag facing up and EFD (Emergency Fastening Device) and Active Hood Actuator must be placed in piled
up, at least, 5 tires, outdoors on flat ground at least thirty feet (10meters) from any obstacles or people.
3. Connect a 12 volt battery to the tool.
4. Push the tool’s deployment switch. The airbag should deploy (deployment is both highly audible and visible: a loud noise
and rapid inflation of the bag, followed by slow deflation)
5. Dispose of the complete airbag. No parts can be reused. Place it in a sturdy plastic bag and seal it securely.

– When EFD and Active Hood Actuator are deployed, broken parts are exploded and scattered.
– EFD and Active Hood Actuator must be placed in the piled up 5 tires to avoid exploded broken parts.
– Technicians should wear an eye protector and extremely be cautions of exploded broken parts.
DISPOSAL OF DAMAGED AIRBAG
1. If installed in a vehicle, follow the removal procedure of driver's airbag front passenger's and side airbag.
2. In all cases, make a short circuit by twisting together the two airbag inflator wires.
3. Package the airbag in exactly the same packing that the new replacement part come in.
2012 > D 2.0 TCID > Restraint > Airbag Module > Driver Airbag (DAB) Module and Clock Spring >English
DESCRIPTION
Driver Airbag (DAB) is installed in steering wheel and electrically connected to SRSCM via clockspring. It protects the driver from danger
by deploying a bag when frontal crash occurs. The SRSCM determines deployment of Driver Airbag (DAB).

Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the specified tester. If
the circuit resistance is measured with a tester, accidental airbag deployment will result in serious personal injury.
2012 > D 2.0 TCID > Restraint > Airbag Module > Driver Airbag (DAB) Module and Clock Spring >English
COMPONENTS
2012 > D 2.0 TCID > Restraint > Airbag Module > Driver Airbag (DAB) Module and Clock Spring > Repair
English
procedures
REMOVAL
2. Remove the airbag module mounting bolts(2EA).
3. Release the connector locking pin, then disconnect the driver airbag module connector(A).

The removed airbag module should be stored in a clean, dry place with the pad cover face up.
4. Remove the steering wheel and steering wheel column cover. (Refer to ST group)
5. Disconnect the clock spring and horn connector, then remove the clock spring.
2. Disconnect the battery negative cable from battery and wait for at least three minutes before beginning work.
3. Connect the clock spring harness connector and horn harness connector to the clock spring.
4. Set the center position by getting marks between the clock spring and the cover into line. Make an array the mark (▶◀) by
turnig the clock spring clockwise to the stop and then 3 revolutions counterclockwise.
5. Install the steering wheel column cover and the steering wheel. (Refer to ST group)
6. Connect the Driver Airbag (DAB) module connector and horn connector, then install the Driver Airbag (DAB) module on the
steering wheel.
7. Secure the Driver Airbag (DAB) with the new mounting bolts.
Tightening torque (DAB Mounting Bolt)
: 0.8 ~ 1.1 kgf.m (7.8 ~ 10.8 Nm, 5.8 ~ 8 lb.ft)
8. Connect the battery negative cable.
9. After installing the airbag, confirm proper system operation:
• Make sure horn button works.
INSPECTION
DRIVER AIRBAG (DAB)
If any improper parts are found during the following inspection, replace the airbag module with a new one.

1. Check pad cover for dents, cracks or deformities.
2. Check the airbag module for denting, cracking or deformation.
3. Check hooks and connectors for damage, terminals for deformities, and harness for binds.
4. Check airbag inflator case for dents, cracks or deformities.
5. Install the airbag module to the steering wheel to check for fit or alignment with the wheel.
CLOCKSPRING
1. If, as a result of the following checks, even one abnormal point is discovered, replace the clock spring with a new one.
2. Check connectors and protective tube for damage, and terminals for deformities.
2012 > D 2.0 TCID > Restraint > Airbag Module > Passenger Airbag (PAB) Module > Description and
English
Operation
DESCRIPTION
The passenger Airbag (PAB) is installed inside the crash pad and protects the front passenger in the event of a frontal crash. The
SRSCM determines if and when to deploy the PAB.

2012 > D 2.0 TCID > Restraint > Airbag Module > Passenger Airbag (PAB) Module > Components and
English
Components Location
COMPONENTS
2012 > D 2.0 TCID > Restraint > Airbag Module > Passenger Airbag (PAB) Module > Repair procedures
English
REMOVAL
2. Remove the glove box. (Refer to BD group)
3. Disconnect the PAB connector.
4. Remove the PAB mounting bolts(2EA).
5. Remove the crash pad. (Refer to BD group)

If the crash pad is damaged when the PAB is deployed, replace the damaged crash pad and PAB together.
6. Remove the heater duct from the crash pad.
7. Remove the mounting nuts(5EA) from the crash pad. Then remove the passenger airbag.

The removed airbag module should be stored in a clean and dry place with the pad cover face up.
INSTALLATION
2. Disconnect the battery negative cable from battery and wait for at least three minutes before beginning work.
English
3. Place a Passenger Airbag (PAB) on the crash pad and tighten the Passenger Airbag (PAB) mounting nuts.
Tightening torque
: 1.8 ~ 2.7 kgf.m (17.2 ~ 26.5 N.m, 13.0 ~ 19.5 lb.ft)
4. Install the heater duct to the crash pad.
5. Install the crash pad. (Refer to BD group)
6. Tighten the PAB mounting bolt.
Tightening torque
: 1.8 ~ 2.7 kgf.m (17.2 ~ 26.5 N.m, 13.0 ~ 19.5 lb.ft)
7. Connect the Passenger Airbag (PAB) harness connector to the SRS main harness connector.
8. Reinstall the glove box. (Refer to BD group)
10. After installing the Passenger Airbag (PAB), confirm proper system operation:
2012 > D 2.0 TCID > Restraint > Airbag Module > Side Airbag (SAB) Module > Description and Operation
English
DESCRIPTION
The Side Airbags (SAB) are installed inside the front seat and protect the driver and front passenger from danger when side crash
occurs. The SRSCM determines deployment of side airbag by using Side Impact Sensor (SIS) signal.

2012 > D 2.0 TCID > Restraint > Airbag Module > Side Airbag (SAB) Module > Components and English
Components Location
COMPONENTS
2012 > D 2.0 TCID > Restraint > Airbag Module > Side Airbag (SAB) Module > Repair procedures English
REMOVAL
1. Disconnect the battery negative cable and wait for at least 3 minutes before beginning work.
2. Remove the front seat assembly.(Refer to BD group)
3. Remove the seatback cover.(Refer to BD group)

When the side airbag depoyed after a collision, replace the seatback as an assembly.
4. Loosen the SAB mounting nuts and remove the SAB module.
INSTALLATION

Ensure that the harness is installed and routed properly to prevent damage to the wiring.

• Do not open the lid of the side airbag cover.
• Use a new mounting nuts when you replace a side airbag.
• Make sure that the seatback cover is installed properly. Improper installation may prevent the proper deployment.
1. Remove ignition key from the vehicle.
2. Disconnect the battery negative cable and wait for at least three minutes.
3. Place a Side Airbag (SAB) on the seatback frame and tighten the side airbag mounting nuts.
Tightening torque
: 0.6 ~ 0.8 kgf.m (6.0 ~ 8.0 Nm, 4.4 ~ 5.9 lb.ft)
English
4. Install the new seatback cover.(Refer to BD group)
5. Install the seat assembly, then connect the Side Airbag (SAB) harness connector.
6. Recline and slide the front seat forward fully, make sure the harness wires are not pinched or interfering with other parts.
8. After installing the Side Airbag (SAB), confirm proper system operation:
2012 > D 2.0 TCID > Restraint > Airbag Module > Curtain Airbag (CAB) Module > Description andEnglish
Operation
DESCRIPTION
Curtain airbags are installed inside the headliner (LH and RH) and protect the driver and passenger from danger when side crash
occurs. The SRSCM determines deployment of curtain airbag by using side impact sensor (SIS) signal.

Never attempt to measure the circuit resistance of the airbag module even if you are using the specified tester. If the
circuit resistance is measured with a tester, accidental airbag deployment will result in serious personal injury.
2012 > D 2.0 TCID > Restraint > Airbag Module > Curtain Airbag (CAB) Module > Components and
English
Components Location
COMPONENTS
2012 > D 2.0 TCID > Restraint > Airbag Module > Curtain Airbag (CAB) Module > Repair procedures
English
REMOVAL
1. Disconnect the battery negative cable and wait for at least 3 minutes before beginning work.
2. Remove the following parts. (Refer to BD group)
– Rear Seat, Luggage side trim
– Rear pillar trim, Center Pillar trim
– Front pillar trim, Head Lining
3. Disconnect the Curtain Airbag harness connector.
4. After loosening the mounting bolts and nuts remove the curtain airbag.
INSTALLATION
3. Install a Curtain Airbag (CAB) on the mounting bracket.
4. Tighten the CAB mounting bolts and nuts.
Tightening torque
: 0.7 ~ 0.9 kgf.m(6.9 ~ 8.8 Nm, 5.0 ~ 6.5 lb.ft)
English

• Never twist the airbag module when installing it. If the module is twisted, airbag module may operate abnormally.
5. Connect the CAB connector.
6. Install the following parts. (Refer to BD group)
– Head Lining, Rear pillar trim
– Front pillar trim, Center pillar trim
– Luggage side trim, Rear seat
8. After installing the Curtain Airbag (CAB), confirm proper system operation:
2012 > D 2.0 TCID > Restraint > Seat Belt Pretensioner > Seat Belt Pretensioner (BPT) > Description and
English
Operation
DESCRIPTION
The Seat Belt Pretensioners (BPT) are installed inside Center Pillar (LH & RH). When a vehicle crashes with a certain degree of frontal
impact, the pretensioner seat belt helps to reduce the severity of injury to the front seat occupants by retracting the seat belt webbing.
This prevents the front occupants from thrusting forward and hitting the steering wheel or the instrument panel when the vehicle crashes.

Never attempt to measure the circuit resistance of the Seat Belt Pretensioner (BPT) even if you are using the specified
tester. If the circuit resistance is measured with a tester, the pretensioner will be ignited accidentally. This will result in
serious personal injury.
2012 > D 2.0 TCID > Restraint > Seat Belt Pretensioner > Seat Belt Pretensioner (BPT) > Components and
English
Components Location
COMPONENTS
2012 > D 2.0 TCID > Restraint > Seat Belt Pretensioner > Seat Belt Pretensioner (BPT) > Repair English
procedures
REMOVAL
2. Remove the lower anchor bolt.
3. Remove the door scuff trim. (Refer to BD group)
4. Remove the center pillar trim. (Refer to BD group)
5. Remove the upper anchor bolt.
6. Loosen the Seat Belt Pretensioner mounting bolt.
7. Disconnect the Seat Belt Pretensioner connector and remove the Seat Belt Pretensioner.
INSTALLATION
3. Connect the Seat Belt Pretensioner (BPT) connector.
4. Install the Seat Belt Pretensioner (BPT) with a bolt.
5. Install the upper anchor bolts.
Tightening torque (Seat Belt Anchor Bolt)
: 4.0 ~ 5.5 kgf.m (39.2 ~ 53.9 Nm, 28.9 ~ 39.8 lb.ft)
6. Install the center pillar trim. English
7. Install the door scuff trim.
8. Install the lower anchor bolts.
Tightening torque
: 4.0 ~ 5.5 kgf.m (39.2 ~ 53.9 Nm, 28.9 ~ 39.8 lb.ft)
10. After installing the Seat Belt Pretensioner (BPT), confirm proper system operation:
2012 > D 2.0 TCID > General > Description and Operation Language
Language
2012 > D 2.0 TCID > AntiLock Brake System(ABS) > Schematic Diagrams
AntiLock Brake System (ABS) (1) SD5871
HOT IN ON OR START
I/P PCM/
See Power Distribution JUNCTION ECM
(SD11010) BOX PHOTO
PHOTO 45 36/37
CLUSTER
10A 39 CGGK (G4FA/G4FC, With ETC)
See Passenger 64 CGGMK (G4FA/G4FC, M/T / W/O ETC)
Compartment Fuse Details 20 CGGAK (G4FA/G4FC, A/T / W/O ETC)
(SD1201) 12 CBGK (G4GC)
3 I/PC
0.3R/O 0.5O
0.3R/O Except
7 M01C Euro II See Stop Lamps
INSTRUMENT (SD9271) (SD9272)
CLUSTER
PHOTO 49 FRONT
P S WHEEL
PARKING SENSOR LH
ABS BRAKE PHOTO 70
( )! ( )P
( )ABS
BRAKE 2 1 E82 0.5G/O(D4FB, G4GC)
0.5P(D4EA, G4FA/G4FC)
0.5L 0.5R
M I C O M 8 4 EC11
PHOTO 115
0.5L 0.5R
CAN TRANSCEIVER 34 22 30 CGG41 (G4FA/G4FC)
Low High 34 22 30 CBG41 (G4GC)
27 CGG41 34 22 30 CUD41 (D4FB)
27 CBG41 16 5 20 CDD41 (D4EA)
2 3 M01A
0.5Y 0.5W ABS
12 2 JM01 Wheel Speed Power Signal Stop Lamp ABS CONTROL
Sensor Output Switch UNIT MODULE
See Data JOINT PHOTO
Link Details CONNECTOR CCAN 7/13
(SD2001) PHOTO 4
High Low Power Signal Power Signal Power Signal
13 3 JM01
0.5Y 0.5W
18 8 JM03 26 14 18 6 33 20 19 31 CGG41 (G4FA/G4FC)
26 14 18 6 33 20 19 31 CBG41 (G4GC)
See Data JOINT 26 14 18 6 33 20 19 31 CUD41 (D4FB)
Link Details CONNECTOR 26 15 9 10 6 17 8 19 CDD41 (D4EA)
(SD2001) PHOTO 54
0.5W 0.5Y 0.5G 0.5O 0.5G 0.5O 0.5Br 0.5W
20 10 JM03
3 1 2 6 CF11
0.5Y 0.5W CGG43 (G4FA/G4FC)
20 11 JM04 8 1 JC01 PHOTO 115
CBG43 (G4GC) 0.5G 0.5O 0.5Br 0.5W
JOINT JOINT CUD43 (D4FB)
See Data See Data 2 1 CDD43 (D4EA)
CONNECTOR Link Details CONNECTOR 2 1 F13 2 1 F14
Link Details
(SD2003) PHOTO 68 (SD2003) PHOTO 54 FRONT REAR REAR
WHEEL WHEEL WHEEL
19 12 JM04 5 4 JC01 SENSOR RH SENSOR SENSOR
0.5Y 0.5W 0.5W 0.5Y PHOTO 70 LH RH
P S P S P S
14 15 MC21 PHOTO 57 PHOTO PHOTO 94
121
HOT IN ON OR START HOT AT ALL TIMES
E/R
See Power Distribution FUSE &
(SD1108) RELAY
ABS1 ABS2 BOX
ABS 40A 20A
10A
PHOTO 115
PHOTO 48 MULTIPURPOSE
DATA LINK CHECK
CONNECTOR CONNECTOR
1 M10 18 CGG47 (G4FA/G4FC)
CBG47 (G4GC)
0.3P 0.5P CUD47 (D4FB) 0.5W 3.0W 2.0R
CDD47 (D4EA)
26 MC11 34 1 2 EC11
PHOTO 75 PHOTO 115
0.3P 0.5W 3.0W(D4EA) 2.0R
3.0R(W/O D4EA)
17 32 1 25 CGG41 (G4FA/G4FC)
17 32 1 25 CBG41 (G4GC)
17 32 1 25 CUD41 (D4FB)
11 18 2 3 CDD41 (D4EA)
ABS
CONTROL
MODULE
Diagnosis Vbatt VR ABS PHOTO
motor relay actuation UNIT 7/13
+ECU
Motor MR Valve
Ground monitoring Actuation Monitoring
C1
MOTOR 2A 2B 4A 4B 3A 3B 1A 1B VALVE
RELAY VALVE RELAY BLOCK
T2 T1 T0 D0
IN OUT IN OUT IN OUT IN OUT
RR RL FR FL
M
C2
38 13 CGG41 (G4FA/G4FC)
38 13 CBG41 (G4GC)
38 13 CUD41 (D4FB)
4 1 CDD41 (D4EA)
2.0B 3.0B
GGG16 (G4FA/G4FC)
GBG16 (G4GC)
GUD17 (D4FB)
GDD16 (D4EA) PHOTO 112
CBGK CBG41
94 93 92
*90 89 88 87
* * * * 82 81 80 5779 78 77 * 5375 74 73 6 5
13 * * 22* * 20* 19* 186 17* * * 14* 1
** * 70 69 67 66 65 64
** **** *** * * 4 3 ** * **
* 4927 26* 4725 * 23* 22* 21* 42 41 1840 1739 3816 1537 14* 1*3 12* * 10* *9 *8 297 2 1
28
* ** *
38
* * * 34 33 32 31 30 * * 27 26 25
CBG43 CBG47 CDD41 CDD43
1 2 * * * * 1 2 3 4
5 6
* 8 9 10 11 12
* 14 15 1 2
* * * * * * * 5
18
16 17 18 19 20 22
* * * * 26
* * * * * * *
CDD47 CGGAK
94 93
*91 90 89 88
* 86 * * 8361 6082 * 80 5779 * 77 * 75 * 7351 6 5
* * * *
72 71 70
*68 67 66
**** ** ***** 4 3 BLANK
* * * * * * * 5
18
* * * * * * * * 4927 26* 25* 24* * 22* * 20* 41 * 17* 38 * * 3513 * * 1032 319 308 * 2 1
* * * * * *** ** *
CGGMK CGGK
94 93 92 91 90
* 66* 87 8664 6385 6284 8361 6082 8159 80 * * 77 54* * * 7351 6 * 94
* 92 91 90 89 88 87 86 85 * 83 * 81 80 79 78 77 76 75 74 73 6 5
72 71 70 69 68
* * ** * * * * * 71 70 69 68 67 66 65 * 63 62 61 * 59 58 57 56 * 54 53 52 51
* 3 4 3
28 27 26 25 24 23 22 21 * 19 18 17 16 15 * 36 3513 12* 3311 32 319 * 297 2 1 * 25* 24* 23* 4422 4321 4220 4119 4018 3917 38 15* 36 3513 3412 3311 32 319 308 297
50 49 48 47 46 45 44 43 41 40 39 38 50 49
2 1
* * * * 28 27 26
* * *
CGG41 CGG43 CGG47
13 * * 22* * 20* 19* 186 17* * * 14* 1 1 2 * * * *

** * ** 12
* * * * * 6 5
38
* * * 34 33 32 31 30 * * 27 26 25 * * * * * 14 *
18
CUD41 CUD43 CUD47
13 * * 22* * 20* 19* 186 17* * * 14* 1 1 2 * * * *

** * ** * * * * * * * 5
38
* * * 34 33 32 31 30 * * * 26 25 * * 18 * * * * *
E82 F13 F14 M10
1 2 1 2 1 2 * * 6 5 4 3 2 1
* * * 13 12 11 * 9
2012 > D 2.0 TCID > Audio(2010.07.04~) > Schematic Diagrams
Audio (1) SD9611
HOT IN ACC OR ON HOT AT ALL TIMES
With AUTO CRUISE I/P
See Power Distribution JUNCTION
(SD11010) BOX
POWER
CONNECTOR PHOTO
CLOCK AUDIO 45
ROOF 10A 15A
ANTENNA
PHOTO 92 See Passenger
Compartment
C IR C UIT Fuse Details
(SD1201)
AM/FM GPS 2 I/PB 1 I/PA See Vehicle See Backup

Speed System Lamps
2 1 R41 1 R22 (SD4361)(SD4362) (SD9261)(SD9262)
0.5R/O From DCDC Converter
(SD9617)
1 2 12 FR12
0.5R/O PHOTO
2 1 MR21 66/88 0.3Y 0.5Y/B 0.85W 0.85R 0.3Gr/O
20 MF12 23 MC11
1 2 2 1
PHOTO W/O ISG With ISG With ISG W/O ISG PHOTO 75
0.3R/B
0.5R/O 43
1 M92 1 M91 3 6 4 1 5 M54A
AM/FM GPS Antenna(+) Memory AUDIO

ACC/ON Speed Backup
Remocon Input Power Signal Signal PHOTO
F/cable 60
CAN CAN
Signal Ground Low High ILL(+) ILL() Ground
5 6 M54C2 3 8 M54C3 2 7 8 M54A
0.5Y 0.5W 0.3P 0.3Gr 0.5B See Indicators

See Illuminations & Gauges
(SD9412) (SD9404)
See Data Link Details See Illuminations
0.3P 0.3Gr 0.3G 0.3B (SD2003) (SD9412) GM11 PHOTO 46 0.3Br/O
3 2 4 5 8 9 M02R PHOTO 50
See MFI Control/
Cruise Control System MULTI
(SD3137)(SD31331) CLOCK FUNCTION
(SD31341)(SD31351) SPRING SWITCH
(SD9641)
3 2 4 5 8 9 MM01 PHOTO 53
0.3B
STEERING
WHEEL 3 JM02
See Ground JOINT
2 1 4 M85 2 1 7 6 M59 PHOTO 53 AUDIO REMOTE CONTROL SWITCH (With Cruise) 1 2 4 5 6 M86 CONNEC
Distribution
(SD1301) TOR
(+) () (+) () () (+)
SEEK SEEK MODE MUTE VOL VOL VOICE TRIP
END SEND UP DOWN UP DOWN 1 JM02
ILL. ILL. ILL. 1.25B PHOTO 47
B/T B/T VOICE
IN OUT OUT
AUDIO REMOTE 5 M85 8 5 M59 3 M86 AUDIO REMOTE
CONTROL SWITCH LH CONTROL SWITCH RH GM21
(Bluetooth) PHOTO 53 PHOTO 53 (Trip Voice) PHOTO 46
Audio (2) SD9612
W/O AUTO CRUISE HOT IN ACC OR ON HOT AT ALL TIMES
See Power Distribution I/P
(SD11010) JUNCTION
ROOF POWER BOX
ANTENNA CONNECTOR PHOTO
PHOTO 92 CLOCK AUDIO 45
10A 15A
C IR C UIT See Passenger
Compartment
Fuse Details
AM/FM GPS (SD1201)
1 R22 2 I/PB 1 I/PA See Vehicle See Backup

2 1 R41 Speed System Lamps
0.5R/O
From DCDC Converter (SD4361)(SD4362) (SD9261)(SD9262)
1 2 12 FR12 (SD9617)
0.5R/O PHOTO
2 1 MR21 66/88
20 MF12 0.3Y 0.5Y/B 0.85W 0.85R 23 MC11
1 2 2 1
PHOTO PHOTO 75
W/O ISG With ISG With ISG W/O ISG 0.3Gr/O 0.3R/B
0.5R/O 43
1 M92 1 M91 3 6 4 1 5 M54A
AM/FM GPS Antenna(+) Memory AUDIO
ACC/ON Speed Backup
Input Power Signal Signal PHOTO
F/cable Remocon 60
CAN Low CAN High ILL(+) ILL() Ground GND SIG
3 8 M54C3 2 7 8 M54A 6 5 M54C2

0.3P 0.3Gr 0.5B See Illuminations See Indicators
0.5Y 0.5W (SD9412) & Gauges
(SD9404)
See Illuminations 0.3B 0.3B 0.3Gr 0.3P 0.3Br/O 0.3B
(SD9412) 5 4 2 3 8 9 M02R
See Data Link Details
(SD2003) MULTI
CLOCK FUNCTION
PHOTO 46 GM11 SPRING SWITCH
PHOTO
50/53
5 4 2 3 8 9 MM01
STEERING
WHEEL
2 1 4 M85 1 2 6 7 M57 8 6 7 1 2 M58 1 2 4 5 6 M86 3 JM02

See Ground JOINT
(+) () () (+) () (+) () (+) Distribution CONNEC
VOL VOL Mute Mode Seek Seek (SD1301) TOR
End Send Down UP Down Up PHOTO
Voice Trip
1 JM02 47
ILL. ILL.
ILL.
1.25B
ILL. Voice
B/T IN B/T Out Out
AUDIO REMOTE 5 M85 8 5 M57 AUDIO REMOTE AUDIO REMOTE CONTROL SWITCH RH 3 M86 AUDIO REMOTE
CONTROL SWITCH LH CONTROL SWITCH PHOTO 53 CONTROL SWITCH RH
(Bluetooth) PHOTO 53 LH PHOTO 53 GM21
PHOTO 53 (Trip Voice)
PHOTO 46
Audio (5) SD9615
WITH NAVIGATION 5DOOR/WAGON
REAR VIEW AUDIO
CAMERA & AUX PHOTO
REAR VIEW CAMERA
TAIL GATE 59/60
HANDLE 'P' Position Door IN IN IN Cabs CAN CAN
SWITCH Signal ALT_L Unlock Left Right REF Detect IN GND Low High
Handle 5 3 6 M54C1 2 1 3 4 M54C2 6 1 3 8 M54C3
GND S/W B+ GND VOUT VGND
0.3G/B 0.5Y 0.5W
PHOTO
1 2 4 3 5 6 R35 75 0.3W 0.3Br 0.3B 0.3W 0.3Y 0.3O 0.5Y 0.3B
39 MC11 (With ISG)
0.3B 0.5P 0.3R 0.3B 0.3W 0.3Br 0.3G/B 0.3L 0.3W/B See Data Link Details
(W/O ISG) See Power (SD2003)
Door Locks
See Indicator (SD8132)
& Gauges (SD8133)
(SD9402)
See Charging
GR11 0.3W 0.3Br System
5 1 9 7 13 RR11 (SD3731)(SD3732)
(SD3733)(SD3734)
PHOTO (SD3735)(SD3736)
0.5P 0.3R 0.3B 0.3W 0.3Br 61/97
0.3W 0.3Br See Illuminations

(SD9412)
9 1 16 13 14 FR12
PHOTO
0.3P 0.3R 0.3B 0.3W 0.3Br 66/88
0.3P 0.3Gr 0.3B 0.3B 0.3W 0.3Y 0.5Y 0.3B
6 11 8 1 2 7 3 4 10 M77
0.3W 0.3Br ILL(+) ILL() GND IN IN IN Detect Video GND AUX & USB
Left Right REF IN JACK
(Navigation)
1 27 39 19 33 MF12
AUX PHOTO 62
PHOTO
0.3P 0.3R 0.3B 0.3W 0.3Br 43
GND
19 M04A
12 M77
HDL
S/W 0.3W 0.3Br 0.3B
13 14 15 16 M90
BCM
NAVIGATION
PHOTO B+ GND VOUT VGND CAMERA
57
GM11 PHOTO 46
Audio (6) SD9616
WITH NAVIGATION
3DOOR
REAR VIEW AUDIO
CAMERA & AUX PHOTO
REAR VIEW CAMERA
TAIL GATE 59/60
HANDLE 'P' Position Door IN IN IN Cabs CAN CAN
SWITCH Signal ALT_L Unlock Left Right REF Detect IN GND Low High
Handle 5 3 6 M54C1 2 1 3 4 M54C2 6 1 3 8 M54C3
GND S/W B+ GND VOUT VGND
0.3G/B
0.5Y 0.5W
PHOTO
75
1 2 4 3 5 6 R35 0.3W 0.3Br 0.3B 0.3W 0.3Y 0.3O 0.5Y 0.3B
39 MC11 (With ISG)
0.3G/B 0.3L 0.3W/B See Data Link Details
0.3B 0.5P 0.3R 0.3B 0.3W 0.3Br (W/O ISG) See Power (SD2003)
Door Locks
See Indicator (SD8132)
& Gauges (SD8133)
(SD9402)
0.3W 0.3Br See Charging
GR11 System
(SD3731)(SD3732)
9 1 16 13 14 FR12 (SD3733)(SD3734)
(SD3735)(SD3736)
PHOTO
0.3P 0.3R 0.3B 0.3W 0.3Br 66/88
See Illuminations
(SD9412)
0.3W 0.3Br
0.3P 0.3Gr 0.3B 0.3B 0.3W 0.3Y 0.5Y 0.3B

1 27 39 19 33 MF12
PHOTO
0.3P 0.3R 0.3B 0.3W 0.3Br 43 6 11 8 1 2 7 3 4 10 M77
ILL(+) ILL() GND IN IN IN Detect Video GND AUX & USB
19 M04A JACK
Left Right REF IN
(Navigation)
HDL AUX PHOTO 62
S/W 0.3W 0.3Br
BCM GND
PHOTO 12 M77
57
0.3B
13 14 15 16 M90
NAVIGATION
B+ GND VOUT VGND CAMERA
GM11 PHOTO 46
Audio (7) SD9617
M85 M86 M90 R18
*54*2 1 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
1 2
* *
24 23 22 21 20 19 18 17 16 15 14 13
AMP 09362895 AMP 09362892 AMP_025_24F_W AMP_MQS_04M_B
R22 R35 FR12
1 2 3 4
7 8 4 3 2 1
5 6 9 10
1 1 2
10 9
8 7
6 5
1112 13 14 1516
3 4 5 6 16 15 13 14 12 11
AMP_PLM1_01F_B KET_090II_06M_W KET_1809_16M_W KET_1809_16F_W
MF12 RR11
1 2 3 4 5 6 7 8 9 10 11 12 13 13 12 11 10 9 8 7 6 5 4
1 2 3 4 5 6 7 7 6 5 4 3
14 15 16 17 18 19 20 21 22 23 24 25 26 26 25 24 23 22 21 20 19 18 17
27 28 29 30 31 32
* 34 35 36 37 38 39 39 38 37 36 35 34
* 32 31 30
8 9 10
* 12
13 12
* 10 9
KET_LIF0409_39M_Gr KET_LIF0409_39F_Gr AMP_0725_13M_W AMP_0725_13F_W

2012 > D 2.0 TCID > Audio(~2010.07.03) > Schematic Diagrams
Audio (1) SD9611
With AUTO CRUISE I/P
(SD11010) BOX
POWER
CONNECTOR PHOTO
CLOCK AUDIO 45
ROOF 10A 15A
ANTENNA
LW/MW AMP FM BPF PHOTO 92 See Passenger
Compartment
Fuse Details
LW/MW AMP FM AMP (SD1201)
2 I/PB 1 I/PA See Vehicle See Backup

Speed System Lamps
1 R22 (SD4361) (SD4362) (SD9261) (SD9262)
0.5R/O From DCDC Converter
(SD9617)
12 FR12
0.5R/O PHOTO
66/88 0.3Y 0.5Y/B 0.85W 0.85R 0.3Gr/O
20 MF12 23 MC11
Feeder
PHOTO cable W/O ISG With ISG With ISG W/O ISG PHOTO 75
0.3R/B
0.5R/O 43
3 M54A 6 4 1 5 M54A
Antenna(+) F/cable Memory AUDIO

ACC/ON Speed Backup
Remocon Input Power Signal Signal PHOTO
CAN CAN 60
Signal Ground Low High ILL(+) ILL() Ground
5 6 M54C2 3 8 M54C3 2 7 8 M54A
0.5Y 0.5W 0.3P 0.3Gr 0.5B See Indicators

See Illuminations & Gauges
(SD9412) (SD9404)
See Data Link Details See Illuminations
0.3P 0.3Gr 0.3G 0.3B (SD2003) (SD9412) GM11 PHOTO 46 0.3Br/O
3 2 4 5 8 9 M02R PHOTO 50
See MFI Control/
Cruise Control System MULTI
(SD3137) (SD31331) CLOCK FUNCTION
(SD31341) (SD31351) SPRING SWITCH
(SD9641)
3 2 4 5 8 9 MM01 PHOTO 53
0.3B
STEERING
WHEEL 3 JM02
See Ground JOINT
2 1 4 M85 2 1 7 6 M59 PHOTO 53 AUDIO REMOTE CONTROL SWITCH (With Cruise) 1 2 4 5 6 M86 CONNEC
Distribution
(SD1301) TOR
(+) () (+) () () (+)
SEEK SEEK MODE MUTE VOL VOL VOICE TRIP
END SEND UP DOWN UP DOWN 1 JM02
ILL. ILL. ILL. 1.25B PHOTO 47
B/T B/T VOICE
IN OUT OUT
AUDIO REMOTE 5 M85 8 5 M59 3 M86 AUDIO REMOTE
CONTROL SWITCH LH CONTROL SWITCH RH GM21
(Bluetooth) PHOTO 53 PHOTO 53 (Trip Voice) PHOTO 46
Audio (2) SD9612
W/O AUTO CRUISE HOT IN ACC OR ON HOT AT ALL TIMES

I/P
See Power Distribution
(SD11010) JUNCTION
POWER BOX
CONNECTOR PHOTO
ROOF CLOCK AUDIO 45
ANTENNA 10A 15A
LW/MW AMP FM BPF PHOTO 92
See Passenger
Compartment
LW/MW AMP FM AMP Fuse Details
(SD1201)
2 I/PB 1 I/PA
See Vehicle See Backup
1 R22 Lamps
Speed System
0.5R/O (SD4361) (SD4362) (SD9261) (SD9262)
From DCDC Converter
12 FR12 (SD9617)
0.5R/O PHOTO
66/88
20
MF12 Feeder 0.3Y 0.5Y/B 0.85W 0.85R 23 MC11
PHOTO cable PHOTO 75
W/O ISG With ISG With ISG W/O ISG 0.3Gr/O 0.3R/B
0.5R/O 43
3 M54A 6 4 1 5 M54A
Antenna(+) F/cable Memory AUDIO

ACC/ON Speed Backup
Input Power Signal Signal PHOTO
Remocon 60
CAN CAN
Low High ILL(+) ILL() Ground GND SIG
3 8 M54C3 2 7 8 M54A 6 5 M54C2

0.3P 0.3Gr 0.5B See Illuminations See Indicators
0.5Y 0.5W (SD9412) & Gauges
(SD9404)
See Illuminations 0.3B 0.3B 0.3Gr 0.3P 0.3Br/O 0.3B
(SD9412) 5 4 2 3 8 9 M02R
See Data Link Details
(SD2003) MULTI
CLOCK FUNCTION
PHOTO 46 GM11 SPRING SWITCH
PHOTO
50/53
5 4 2 3 8 9 MM01
STEERING
WHEEL
2 1 4 M85 1 2 6 7 M57 8 6 7 1 2 M58 1 2 4 5 6 M86 3 JM02

See Ground JOINT
(+) () () (+) () (+) () (+) Distribution CONNEC
VOL VOL Mute Mode Seek Seek (SD1301) TOR
End Send Down UP Down Up PHOTO
Voice Trip
1 JM02 47
ILL. ILL.
ILL.
1.25B
ILL. Voice
B/T IN B/T Out Out
AUDIO REMOTE 5 M85 8 5 M57 AUDIO REMOTE AUDIO REMOTE CONTROL SWITCH RH 3 M86 AUDIO REMOTE
CONTROL SWITCH LH CONTROL SWITCH PHOTO 53 CONTROL SWITCH RH
(Bluetooth) PHOTO 53 LH PHOTO 53 GM21
PHOTO 53 (Trip Voice)
PHOTO 46
Audio (3) SD9613
37 FD12 26 FD22
PHOTO 41 PHOTO 41
0.85G 0.85W 0.85O 0.85B
1 D05 2 D04 2 D25 1 D24
DRIVER PASSENGER PASSENGER
DRIVER TWEETER
TWEETER DOOR DOOR
SPEAKER SPEAKER SPEAKER
SPEAKER
PHOTO 81 PHOTO 81 PHOTO 82 PHOTO 82
2 D05 1 D04 1 D25 2 D24
0.85O 0.85B 0.85G 0.85Y
24 FD12 39 FD22
PHOTO 41 PHOTO 41
0.85B 0.85W(LHD) 0.85B 0.85Y(LHD)
0.85Y(RHD) 0.85W(RHD)
26 13 MF12 (LHD) 30 31 MF22 (LHD)

30 31 MF22 (RHD) 26 13 MF12 (RHD)
PHOTO PHOTO
0.85B 0.85W(LHD) 43/75 0.85B 0.85Y(LHD) 43/75
0.85Y(RHD) 0.85W(RHD)
7(LHD) 3(LHD) 6(LHD) 2(LHD)

6(RHD) 2(RHD) 7(RHD) 3(RHD) M54B
AUDIO
Driver() Driver(+) Passenger() Passenger(+)
PHOTO
60
Rear Speaker LH Rear Speaker RH
(+) () (+) ()
4 8 1 5 M54B
0.85R 0.85L 0.85R/O 0.85L/O
8 21 MF12 32 21 MF22
PHOTO 43 PHOTO 75
5DR/WGN 3DR 5DR/WGN 3DR
0.85R 3DR 5DR/WGN 0.85R 3DR 5DR/WGN
10 FD11 10 FD21
0.85R PHOTO 85 0.85R 0.85L 0.85L 0.85R PHOTO 85 0.85R 0.85L 0.85L
2 D44 2 F43 2 D54 2 F44
REAR REAR 4 FD11 REAR REAR 4 FD21
DOOR SPEAKER DOOR SPEAKER
SPEAKER LH PHOTO 85 SPEAKER RH PHOTO 85
LH PHOTO 86 0.85L RH PHOTO 111 0.85L
PHOTO 86 PHOTO 86
1 D44 1 F43 1 D54 1 F44

Audio (4) SD9614
AUDIO
USB/IPOD AUX PHOTO
AUX 59/60
D(+)/ D()/ 'R' Position Door IN IN IN Cabs
SHIELD VDD RX TX GND L(In) R(In) Detect Signal ALT_L Unlock Left Right REF Detect IN GND MIC(+) MIC(-)
4 1 2 3 M54D 3 2 1 4 M54C2 5 3 6 M54C1 2 1 3 4 M54C2 6 1 M54C3 1 2 M54C1
With With With 0.3W 0.3B

AV AV AV
0.3B 0.3Y 0.3B 0.3W 0.3Y 0.3B 0.3W 0.3O 0.3G/B 0.3W 0.3Br 0.3B 0.3W 0.3Y 0.3O 0.5Y 0.3B
See BackUp See Power
Lamps Door Locks 0.3W 0.3B
(SD9261) (SD8132)
(SD9262) (SD8133) 5 18 MF12
PHOTO 43
See Charging
System 0.3W 0.3B
(SD3731) (SD3732)
(SD3733) (SD3734)
(SD3735) (SD3736)
0.3W 0.5B
0.3B 7 14 FR11
See Illuminations
(SD9412) PHOTO 42
0.3W 0.5B
0.3B 0.3B 0.3Y 0.3B 0.3W 0.3Br 0.3Y 0.3B 0.3W 0.3P 0.3Gr 0.3P 0.3Gr 0.3B 0.3B 0.3W 0.3Y 0.5Y 0.3B
0.3W 0.5B
9 4 1 3 2 15 6 7 16 14 5 13 M76 6 11 8 1 2 7 3 4 10 M77 1 2 R18
Shield Shield VDD D(+)/ D()/ Shield GND L(In) R(In) Detect ILL(+) ILL() ILL(+) ILL() GND IN IN IN Detect Video GND MIC
MIC(+) MIC()
RX TX Left Right REF IN PHOTO
AUX 76
USB/IPOD GND GND AUX
MIC
AUX & USB JACK (Audio) PHOTO 62 11 M76 12 M77 AUX & USB JACK (Navigation) PHOTO 62
0.3B 0.3B
WITH BLUE TOOTH
0.3B
GM11 PHOTO 46
Audio (5) SD9615
D04 D05 D24 D25
2 1 2 1
2 1 2 1
D44 D54 F43 F44
2 1 2 1 2 1 2 1
M02R M54A M54B M54C1
2 1
4 3 2 1 4 3 2 1
6 5 4 3 2
* 8 7 6 5 8 7 6 5 * 3
12 11 10 9 8
* 6 5
M54C2 M54C3 M54D M57
2 1 3 2 1
4 3 5 4 3 2 1 1 2
* * 5 6 7 8
4
6 5 8 7 6 * *
M58 M59 M76 M77
1 2
* * * 6 7 8 1 2
* * 5 6 7 8 7 6 5 4 3 2 1
6
* 4 3 2 1
16 15 14 13
* 11 * 9
*
12 11 10
* 8 7
Audio (6) SD9616
M85 M86 R18 R22
*54*2 1 6 5 4 3 2 1 1 2
* * 1
2012 > D 2.0 TCID > Auto Cruise System > Schematic Diagrams
Auto Cruise System (1) SD9641
G4GC ONLY STEERING WHEEL
HOT IN ON OR START
E/R
HOT AT ALL TIMES HOT IN ON OR START
I/P
See Power See Power Distribution
Distribution FUSE & (SD11010) JUNCTION
CRUISE REMOTE CONTROL SWITCH RELAY BOX
(SD1109)
BOX PHOTO 45
SNSR STOP CLUSTER
CRUISE CANCEL SET/ RESUME/ 15A 10A
MAIN COAST ACCEL 10A
ILL.
See Passenger
Compartment Fuse Details
1.25R (SD1201)
1 JE01 15 I/PB 3 I/PC
(+) ()
See Power JOINT 0.5R 0.3R/O
2 1 7 6 8 M60 PHOTO 53 Distribution CONNECTOR
PHOTO 114 0.3R/O
(SD1109)
See Audio 7 M01C
(SD9611) 24 MC11
2 4 JE01 INSTRUMENT
1.25R 1.25R PHOTO 75
CLUSTER
3 2 11 12 10 MM01 PHOTO 53 18 EC11 PHOTO 49
MULTIFUNCTION 0.5R PHOTO 115 0.5R CRUISE
CRUISE
CLOCK SWITCH 3 2 CBG77 SET
SPRING
A : Closed with brake STOP SET
pedal depressed B A LAMP
B : Open with brake SWITCH
pedal depressed PHOTO
3 2 11 12 10 M02R 55 M I C O M
0.3P 0.3Gr 0.3L 0.3B 0.3R/O PHOTO 50 4 1 CBG77
29 EC11
9 6 MC21 37 MC11 0.5P/B 6 12 M01A
PHOTO
PHOTO PHOTO 75 115 0.5Br 0.5P/B 0.5G/O 0.3G/B 0.3Y
0.5L 0.5B 57 7 8 MC21 PHOTO 57
See Illuminations 0.5R
(SD9412) 0.5R 0.5Br See Stop Lamps 0.5G 0.5Y
11 2 7 1 (SD9271) 5 9 3 CBG59
AUTO
Signal Ground ON/START Input Actuator Clutch Stop Lamp 'CRUISE' 'SET' CRUISE
Switch Input Indicator IndicatorCONTROL
ACTUATOR MODULE
M
CLUTCH PHOTO 9
2 or
Vehicle MOTOR DRIVER Low Gear O/D
Ground Speed Input Inform Control
8 6 M/T 10 A/T 4 CBG59
0.5Br/O 0.5B 0.5W 0.5Y

0.85B 0.5Gr 2 CBG71
See Ground CLUTCH
Distribution SWITCH
(SD1306) PHOTO
See Vehicle 4
0.85B Speed System 52 39 14 CBGA
(SD4361) 1 CBG71 PCM
0.5B PHOTO
37
GBG15 PHOTO 69 GBG14 PHOTO 13

2012 > D 2.0 TCID > Auto Cruise System > Schematic Diagrams
Auto Cruise System (2) SD9642
CBGA CBG59 CBG71
* * 58 57 56 55 3954 3853 52 * 5035 3449 48 * 46

* ***** ** *** 6 5 4 3 2 1 1
* 14* * 12* 11* 10* *9 *8 *7 *6 4 2 1
20 19 18 17 16
* 11 10 9 8 7
15
* * * 2
CBG77 M01A M01C M02R
6 5 4 3 2 1 8 7 6 5 4 3 2 1
2 1 6 5 4 3 2
*
4 3
12 11 10 9 8 7 16 15 14 13 12 11 10 9 12 11 10 9 8
*
M60
1 2
* * * 6 7 8 BLANK BLANK BLANK
2012 > D 2.0 TCID > Auto Lights > Schematic Diagrams
Auto Lights (1) SD9511
HOT IN ON 5DOOR/WAGON HOT AT ALL TIMES

See Power I/P E/R
Distribution JUNCTION FUSE &
(SD11010) BOX RELAY
PHOTO BOX
H/LP
HEAD 45 20A
LAMP
10A
0.3R/O 0.85L
5 1 E47 5 1 E43
HEAD HEAD
9 I/PD LAMP LAMP
RELAY RELAY
0.3R/O (LOW) (HIGH)
PHOTO PHOTO
20 M08B 3 2 E47 31 3 2 E43 31
ICM 0.5R
RELAY 0.5R 0.5R
BOX
PHOTO 46 0.3G 0.3R
8 M08B 17 7 12 I/PG H/LP H/LP
LO RH LO LH
I/P 10A
JUNCTION 10A
0.3R/O 0.5B NOTICE
If you want the DRL off, BOX
DRL open the driver's side fuse
21 EM31 OFF panel cover (I/P junction box)
PHOTO
PHOTO 43 and insert any spare fuse into 45
0.3R/O the DRL OFF position. 0.5O 0.85G 0.5Y 0.85G
GE11
3 2 E77
PHOTO 1 17 I/PD 15 I/PC 10 I/PD 28 32 EC11 HEAD
PHOTO 115 LAMP
0.3R/O 0.3R/B 0.3W 0.3R/B 0.3W 0.3Br 0.5O 0.85Br 0.5G LO HI LH
3 10 9 M02L (G4GC/D4EA) PHOTO
0.75G 3
MULTI (G4FA/D4FB,
FUNCTION 5 4 E77
LIGHT DIMMER/ G4FC) CGG75 (G4FA/G4FC)
HEAD SWITCH LOW PASSING SWITCH CBG75 (G4GC) 1.25B 1.25B
PARK SWITCH CUD75 (D4FB)
PHOTO
FLASH 50 3 2 CDD75 (D4EA) 13 EM31
OFF AUTO HIGH
PASS HEAD PHOTO 43
LAMP RH
LO HI PHOTO 0.5G GE11 PHOTO 1
6
4 2 M02L
0.3Y 5 4 CGG75 (G4FA/G4FC) 10 M01A
0.3B CBG75 (G4GC)
19 M04B 31 M04A 14 M04B 33 M04A INSTRUMENT
CUD75 (D4FB) CLUSTER
H/LP Auto H/LP Head BCM 1.25B 1.25B CDD75 (D4EA)
Escort Light SW LO Relay Lamp SW PHOTO HIGH PHOTO
2 JM02 49
57 BEAM
Auto Light JOINT
See Ground CONNECTOR
Signal Power Ground Distribution
(SD1301) PHOTO 47
1 7 2 M04B GGG15 (G4FA/G4FC)
0.3L 0.3R/B 0.3Br 1 6 10 JM02 GBG15 (G4GC)
1.25B 1.25B 0.5B GUD14 (D4FB) PHOTO
3 2 1 M21 GDD14 (D4EA) 69 1 M01A
AUTO LIGHT
SIG PWR GND AUTO & PHOTO
LIGHT SENSOR
PHOTO 117
GM21 PHOTO 46
HOT IN ON 3DOOR HOT AT ALL TIMES

See Power I/P E/R
(SD11010) BOX RELAY
PHOTO BOX
H/LP
HEAD 45 20A
LAMP
10A
0.3R/O 0.85L
5 1 E47 5 1 E43
HEAD HEAD
9 I/PD LAMP LAMP
RELAY RELAY
0.3R/O (LOW) (HIGH)
PHOTO PHOTO
20 M08B 3 2 E47 31 3 2 E43 31
ICM 0.5R
RELAY 0.5R 0.5R
BOX
PHOTO 46 0.3G 0.3R
8 M08B 17 7 12 I/PG H/LP H/LP
LO RH LO LH
I/P 10A
JUNCTION 10A
0.3R/O 0.5B NOTICE
If you want the DRL off,
BOX
DRL
21 EM31 OFF
open the driver's side fuse PHOTO
panel cover (I/P junction box)
PHOTO 43 and insert any spare fuse into 45
0.3R/O the DRL OFF position. 0.5O 0.85G 0.5Y 0.85G
GE11
3 2 E111
PHOTO 1 17 I/PD 15 I/PC 10 I/PD 28 32 EC11 HEAD
PHOTO 115 LAMP
0.3R/O 0.3R/B 0.3W 0.3R/B 0.3W 0.3Br 0.5O 0.85Br 0.5G LO HI LH(3DR)
3 10 9 M02L (G4FC/D4EA) PHOTO
0.75G 3
MULTI (G4FA/G4FC
LIGHT DIMMER/ FUNCTION 5 4 E111
/D4FB) CGG96 (G4FA/G4FC)
HEAD SWITCH LOW PASSING SWITCH CBG96 (G4GC) 1.25B 1.25B
PARK SWITCH CUD96 (D4FB)
PHOTO
FLASH 50 3 2 CDD96 (D4EA) 13 EM31
OFF AUTO HIGH
PASS HEAD PHOTO 43
LAMP
LO HI RH(3DR) 0.5G GE11 PHOTO 1
PHOTO
4 2 M02L 6
0.3Y 5 4 CGG96 (G4FA/G4FC) 10 M01A
0.3B CBG96 (G4GC)
19 M04B 31 M04A 14 M04B 33 M04A INSTRUMENT
CUD96 (D4FB) CLUSTER
H/LP Auto H/LP Head BCM 1.25B 1.25B CDD96 (D4EA)
Escort Light SW LO Relay Lamp SW PHOTO HIGH PHOTO
2 JM02 49
57 BEAM
Auto Light JOINT
Signal Power Ground Distribution
(SD1301) PHOTO 47
1 7 2 M04B GGG15 (G4FA/G4FC)
0.3L 0.3R/B 0.3Br 1 6 10 JM02 GBG15 (G4GC)
1.25B 1.25B 0.5B GUD14 (D4FB) PHOTO
3 2 1 M21 GDD14 (D4EA) 69 1 M01A
AUTO LIGHT
SIG PWR GND AUTO & PHOTO
LIGHT SENSOR
PHOTO 119
GM21 PHOTO 46
3 2 1 3 2 1 3 2 1 3 2 1
6 5 4 6 5 4 6 5 4 6 5 4
CGG75 CGG96 CUD75 CUD96
3 2 1 3 2 1 3 2 1 3 2 1
6 5 4 6 5 4 6 5 4 6 5 4
E43 E47 E77 E111
1 1
2 2 3 2 1 3 2 1
5 * 3 5 * 3 6 5 4 6 5 4
M01A M02L M04A
6 5 4 3 2 1 13 12 11 10 9
* 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 * 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21
M04B M08B M21 M54C1
2 1
10
* * 7 6 5 4 3 2 1
8
* * 5 4
* 2
*
20
* * 17 16 15 14 13 12 11 10 9 6 5 4 3 2 1 * 3
20 19 18 17 16 15 14 13 12 11 6 5
2012 > D 2.0 TCID > BackUp Lamps > Schematic Diagrams
BackUp Lamps (1) SD9261
HOT IN ON OR START
E/R AUDIO INSTRUMENT
See Power Distribution CLUSTER
(SD1108) FUSE & PHOTO 59
RELAY PHOTO 49
BOX
B/UP
10A 5DOOR/3DOOR 5 M54C1 11 M01A
With
A/V
0.3G/B 0.5G/B
0.5R 16 I/PD
I/P
30 EC11 JUNCTION
PHOTO 115 BOX
PHOTO 45
M/T A/T
15 I/PD 13 14 I/PF
REAR PARKING
0.5R 0.5R ASSIST CONTROL
3DR 5DR MODULE
CGG01 (G4FC) PHOTO
CBG01 (G4GC) 0.5R 0.3Gr 0.5Br 0.5Br 74/89
CGG50 (G4FA/G4FC) 8 CUD01 (D4FB) 8 F22
CBG50 (G4GC) TRANSAXLE 2 FR11 5DR 3DR 3DR 5DR
CUD50 (D4FB) RANGE PHOTO 42
2 CDD50 (D4EA) SWITCH
BACKUP PHOTO 33 0.3Gr 0.5R 0.5R 0.5Br 0.5Br
LAMP P D
SWITCH
PHOTO R N
35/106 6 F08 6 F10
1 CGG50 (G4FA/G4FC) 7 CGG01 (G4FC) REAR REAR
CBG50 (G4GC) CBG01 (G4GC) BACK COMBI BACK COMBI
CUD50 (D4FB) CUD01 (D4FB) UP NATION UP NATION
CDD50 (D4EA) LAMP LAMP LH LAMP LAMP RH
0.5Br 0.5Br
PHOTO PHOTO
3 F08 66 3 F10 111
0.5L(G4FC/ 0.5L(G4FC/
G4GC), G4GC),
0.5Br/B(D4FB) 0.5Br/B(D4FB) 3 F50 3 F49
3 R01
ELECTRO REAR REAR
8 CGGA (G4FC, With ETC) CHROMIC BACK COMBI BACK COMBI
88 CGGAK (G4FC, W/O ETC) MIRROR UP NATION UP NATION
23 CUDAT (D4FB) LAMP LAMP LH LAMP LAMP RH
M/T A/T 7 CBGA (G4GC) PHOTO
79 PHOTO
PCM/ 6 F50 88 6 F49
TCM
PHOTO
23 MC11 PHOTO 75 PHOTO 89
36/37/110 3DR
0.85B 0.85B See Ground 0.85B See Ground 0.85B
0.5L 0.5R/B
Distribution Distribution
(SD1304) 0.85B (SD1304) 0.85B
CGG70 (G4FA/G4FC)
CBG70 (G4GC)
3 CUD70 (D4FB) 5 M54A
ESP AUDIO
CONTROL PHOTO
MODULE 60
PHOTO PHOTO PHOTO
7/13 GF51 66/88 GF61 89/111
HOT IN ON OR START
See Power Distribution E/R AUDIO INSTRUMENT
(SD1108) FUSE & PHOTO 59 CLUSTER
RELAY PHOTO 49
BOX
B/UP
10A WAGON 5 M54C1 11 M01A
With
A/V
0.3G/B 0.5G/B
0.5R
30 EC11
PHOTO 115
16 I/PD
M/T A/T I/P
JUNCTION
BOX
PHOTO 45
0.5R 0.5R
15 I/PD 13 14 I/PF
CGG01 (G4FC)
CBG01 (G4GC) REAR PARKING
8 CUD01 (D4FB) ASSIST CONTROL
CGG50 (G4FA/G4FC) MODULE
CBG50 (G4GC) TRANSAXLE 0.5R 0.3Gr 0.5Br
CUD50 (D4FB) RANGE PHOTO
2 CDD50 (D4EA) SWITCH 2 FR11 74/89
BACKUP PHOTO 8 F22
PHOTO 33 0.3Gr
LAMP P D 42
SWITCH LHD RHD
PHOTO R N
35/106 0.5R 0.5R 0.5Br
1 CGG50 (G4FA/G4FC) 7 CGG01 (G4FC)
CBG50 (G4GC) CBG01 (G4GC)
CUD50 (D4FB) CUD01 (D4FB)
CDD50 (D4EA)
0.5Br 0.5Br 0.5W/B 0.5W/B
0.5L(G4FC/ 0.5L(G4FC/ LHD RHD LHD RHD

G4GC), G4GC), 30 MF12
0.5Br/B(D4FB) 0.5Br/B(D4FB) 6 F09 0.5W/B PHOTO 6 F07
43
REAR REAR
8 CGGA (G4FC, With ETC) 3 R01 BACK COMBI BACK COMBI
88 CGGAK (G4FC, W/O ETC) ELECTRO UP NATION UP NATION
23 CUDAT (D4FB) CHROMIC LAMP LAMP RH LAMP LAMP LH
M/T A/T 7 CBGA (G4GC) (LHD)/ (RHD)/
MIRROR (LOW) (LOW)
PCM/ PHOTO REAR PHOTO 74 REAR PHOTO 73
TCM 79 FOG FOG
LAMP LAMP
23 MC11 PHOTO 75 PHOTO (RHD) (LHD)
36/37/110
0.5L 0.5R/B 3 F09 3 F07
See Front Fog &
CGG70 (G4FA/G4FC) Rear Fog Lamps
CBG70 (G4GC) 0.85B See Ground (SD9241) 0.85B
3 CUD70 (D4FB) 5 M54A Distribution
0.85B (SD1304)
ESP AUDIO
CONTROL PHOTO
MODULE 60
PHOTO PHOTO PHOTO
7/13 GF61 89/111 GF51 66/88
CBGA CBG01 CBG50
* * 58 57 56 55 3954 3853 52 * 5035 3449 48 * 46

* ***** ** *** 6 5
* 3 2 1
2 1
* 14* * 12* 11* 10* *9 *8 *7 *6 4 2 1
20 19 18 17 16 10 9 8 7
15
* * *
CBG70 CDD50
13
12
***** 6 5 * 3 * 1 BLANK
* * 22 * 20 19 18 17 16 * 14 2 1
38
* * * 34 33 32 31 30 * * 27 26 25
CGGA CGGAK
60 59 58 57
* 55 54 53 * * 50 49 * 47 46 94 93
* 91 90 89 88
* 86 * * 8361 6082 * 80 5779 * 77 * 75 * 7351 6 5
45
* * * * * 39 * * * * * * 32 * 72 71 70
*68 67 66
**** ** ***** 4 3
30
* * * * * * * * * * * 18 17 16 * 4927 26* 25* 24* * 22* * 20* 41 * 17* 38 * * 3513 * * 1032 319 308 * 2 1
* 14 13 12 11 * 9 8 7 6 * * * 2 1 * * * * * *** ** *
CGG01 CGG50 CGG70
6 5
* 3 2 1 13
12
***** 6 5 * 3 * 1
10 9 8 7 2 1 * * 22 * 20 19 18 17 16 * 14
38
* * * 34 33 32 31 30 * * 27 26 25
CUDAT CUD01 CUD50
6 7 8 9 10 5 4
* 12 * 14 * * 36* 18
37
19 20 21 22 23 24
* * * * * * * * * * * * * * * * * 3 6 5
* 3 2 1
2 1
44
* * * * * * * * 53 * * * * 58 59 * 61 62 10 9 8 7
* * * * * * * * * * * 74 * * * 78 * * * 2 1
CUD70 F07 F08
13
12
***** 6 5 * 3 * 1 2 1
* * 22 * 20 19 18 17 16 * 14 * 2
38
* * * 34 33 32 31 30 * * * 26 25 3 4 5 6 6 5
* 3
F09 F10 F22 F49
2 1 1 2
* 2 * 156 145 13 12 114 3 2 1 3 4

* 6
3 4 5 6 6 5
* 3 * * 9 8
F50 M01A M54A M54C1
2 1
1 2 4 3 2 1
3 4
* 6 6 5 4 3 2 1
8 7 6 5 * 3
12 11 10 9 8 7 6 5
R01
BLANK BLANK BLANK

3 2 1
* * * *
2012 > D 2.0 TCID > Battery Harness > Schematic Diagrams
2012 > D 2.0 TCID > Blower & A/C Control System (Auto)(2010.07.16~) > Schematic Diagrams
Blower & A/C Control System (Auto) (1) SD9711
HOT AT ALL TIMES HOT IN ON HOT AT ALL TIMES
E/R I/P
MULTI FUSE & See Power JUNCTION
FUSE RELAY Distribution BOX
BOX (SD11010)
BLOWER PHOTO
40A POWER 45
CONNECTOR
A/CON ROOM LP
5 I/PG 10A 15A
3.0W 0.3R/B
1 2 E41
BLOWER
RELAY A/CON See Passenger See Passenger
PHOTO SW Compartment Compartment
31 10A Fuse Details Fuse Details
(SD1202) (SD1203)
5 4 E41 7 I/PA 5 I/PB 21 I/PB 13 I/PC

AMBIENT
3.0Y 0.5B SENSOR
0.5R/B 3.0P 0.3R 0.3R/B 0.5R #1
18 EM31
PHOTO D4FB PHOTO
3.0Y 2
43
GE11 PHOTO 1 1 2 E841
3.0Y
0.3L 0.5B
1 M16 A 8 7 EE12
BLOWER PHOTO 1
MOTOR 0.3B
M To PTC 0.3L/O
PHOTO 120 Heater Relay #2
(SD9714) 10 11 EM31
PHOTO 43
2 M16 0.3B
2.0Y 3.0P 11 1 JM03 7 JM04
3.0P JOINT JOINT
See Passenger See Passenger From Joint CONNECTOR
1 M24 CONNECTOR B Connector
Compartment Compartment
FET Fuse Details Fuse Details PHOTO 54 (SD9712) PHOTO 68
(Field Effect (SD1202) (SD1203) See Ground
Transistor) Distribution
PHOTO 71 13 3 JM03
3 4 1 JM04
3 2 M24
0.5L 3.0B 0.3R/B 0.5R 0.5L 0.5B 0.5B 1.25B
GM41 PHOTO 120
11 9 10 M05B 14 2 M05A 3 M05B 26 25 M05A
Blower FET FET ON Input Battery A/C
AMB Sensor CONTROL
Motor(+) (GATE) Defogger (DRAIN) Voltage Input Ground
Switch CAN MODULE
PHOTO 59
Switch IND. KLine High Low ILL. () ILL. (+)
10 9 6 7 8 13 1 M05A
0.3L 0.3G 0.3G 0.5W 0.5Y 0.3Gr 0.3P
See Rear Glass & Mirror Defogger See Data Link Details See Illuminations

(SD8791) (SD2001)(SD2003) (SD9412) PHOTO 120 GM41
JOINT
To Joint CONNECTOR
B Connector PHOTO 68
(SD9711)
10 7 8 6 JM04
0.3Br 0.3Br 0.3Br 0.3Br 0.3Br PHOTO SENSOR AUTO

LIGHT &
PHOTO
6 M78 2 M23 SENSOR
PASSENGER EVAPORA PHOTO
TEMPERATURE TOR 117
ACTUATOR SENSOR
M PHOTO 71 PHOTO 6 4 5 M21
71
7 3 5 4 M78 1 M23
PHOTO 112
PHOTO 68 0.3Br
DRIVER
INTAKE TEMPERATURE
ACTUATOR 5 M39 6 M79 ACTUATOR 5 M51
MODE
ACTUATOR
PHOTO 54
M M M
3 4 6 7 M39 7 6 4 3 M51
4 5 3 7 M79
0.3P/B 0.3Y/B 0.3G/B 0.3O 0.3B 0.3W 0.3Gr 0.3O 0.3G/B 0.3O 0.5G/B 0.5Y/B 0.3P/B 0.3W/B 0.3G 0.3O 0.3O 0.3R/B 0.3W/B 0.3L/O
16 JM03 15 JM03
JOINT
CONNECTOR
PHOTO 54
17 JM03
0.3O
12 M05B 17 16 18 23 22 24 M05A 6 1 18 13 14 15 16 M05B 21 19 20 M05A
EVAP. Sensor F/B COOL WARM DRI(+) PASS(+) F/B Vent BEF A/C
Ground WARM COOL F/B REC FRE F/B CONTROL
Sensor REF
(+) (+5V) MODULE
Passenger Temp. Intake Driver Temperature Photo Actuator Mode Actuator
Actuator Actuator Actuator PHOTO
59
HOT AT ALL TIMES
EMS
BOX
PHOTO
114
ECU 1 A/CON
30A 10A
ENGINE
CONTROL
RELAY
A/C
PRESSURE
TRANSDUCER
PHOTO 8
P See Power Distribution INJ
(SD1103)(SD1105) 15A
(SD1106)
1 2 3 CGG72 (G4FC)
CBG72 (G4GC)
CUD72 (D4FB)
0.5W
A/CON
RELAY
0.5W
G4FA/G4FC
With ISG 14 17 E/RCGG1 (G4FA/G4FC)
E/RCBG1 (G4GC)
See MFI E/RCUD1 (D4FB)
0.5B 0.5L 0.5W Control System 0.3W(G4FA/G4FC, With ETC)
(SD3136) 0.3O(G4GC)
0.3L(D4FB) G4FA/G4FC, G4GC D4FB
0.5R
14 EC11
PHOTO
0.5R 0.5R 115
3 EB11
PHOTO 5
0.5W
40 25 42 CGGK (G4FA/G4FC, With ETC) 76 CGGK (G4FA/G4FC, With ETC) CGG28 (G4FA/G4FC)
57 13 47 CBGK (G4GC) 87 CBGK (G4GC) CBG28 (G4GC) E97 (D4FB)
17 32 26 CUDK(D4FB) 22 CUDA(D4FB) 1 1
ECM/
Ground Signal Supply A/C Relay PCM A/C A/C
Control COMPRESSOR COMPRESSOR
PHOTO
APT 36/37/38 PHOTO PHOTO
15/22 25/108
From A/CON 10A
(SD9711)
HOT AT ALL TIMES
D4FB HOT WITH ENGINE
CONTROL RELAY ON
A
FUSIBLE See Power EMS
LINK Distribution BOX
BOX (SD1106) PHOTO
0.5R/B
PTC PTC PTC 114
HEATER #3 HEATER #2 HEATER #1
22 EC11 PHOTO 115 50A 50A 50A SNSR1
10A
0.5R 0.5R 5.0R 5.0R 5.0R 0.5Y
See Power Distribution 14 E/RCUD2
0.5R (SD1106)
5 CUD94 4 5 CUD93 4 5 CUD92 5 4 CUD91
FUEL PTC PTC PTC
FILTER HEATER HEATER HEATER
HEATER RELAY #3 RELAY #2 RELAY #1
RELAY PHOTO PHOTO PHOTO
PHOTO 11 11 11 11
3 CUD94 2 1 CUD93 2 1 CUD92 1 2 CUD91
0.5Br 0.5G 5.0W 0.5L 5.0R 5.0W 0.75Gr
See Fuel Filter 5 3 1 CUD87
Heating System
(SD3611) PTC 0.75Gr
HEATER
PHOTO
57
4 2 CUD87
5.0B 5.0B
0.5Gr
GUD18 (D4FB) PHOTO 55
25 26 12 MC21
PHOTO 57
0.5G 0.5L 0.5Gr
22 21 20 M05B 58 CUDA
A/C Auxiliary ECM
PTC Heater PTC Heater PTC ON CONTROL Eletric
Relay #3 Relay #2 Signal(Low) MODULE PHOTO
Heater 38
PHOTO
59
CBGK CBG28 CBG72
94 93 92
*90 89 88 87
* * * * 82 81 80 5779 78 77 * 5375 74 73 6 5
** * 70 69 67 66 65 64
** **** *** * * 4 3
1 3 2 1
* 4927 26* 4725 * 23* 22* 21* 42 41 1840 1739 3816 1537 14* 1*3 12* * 10* *9 *8 297 2 1
28
* ** *
AMP_ECU_94F_B KUM_NMWP_01F_B KET_040WP_03F_B
CGGK CGG28 CGG72
94
* 92 91 90 89 88 87 86 85 * 83 * 81 80 79 78 77 76 75 74 73 6 5
* 71 70 69 68 67 66 65 * 63 62 61 * 59 58 57 56 * 54 53 52 51 4 3
1 3 2 1
50 49
* 25* 24* 23* 4422 4321 4220 4119 4018 3917 38 15* 36 3513 3412 3311 32 319 308 297 2 1
28 27 26
* * *
AMP_ECU_94F_B KUM_NMWP_01F_B KET_040WP_03F_B
CUDA CUDK
60
* 58 57 56 55 54 53 52 51 50 49 * 47 46 94 93 92
*90 89
*
87 86 85 84 83
* * 7856 7755 76 5375 52* 5173
81 80
6 5
* 44 * 42 41 40 39 38 37 36 35 34 33 32 31 72 71 70 69 68 67 66
*
64 63 62 61 60 59 58
* * 4 3
* 1429 1328 12* * 10* * * 227 *6 * 194 * 172 161 50

* 26* 47 2446 * 4422 * 20* 1941 40 17* 38 15* 14* 1335 12* 1133 1032 *9 30 *7 2 1
* * ** * * 28 27
* * * * * *
AMP_ECU_60F_B_A AMP_ECU_94F_B
CUD72 CUD87 CUD91 CUD92
1 1
5 4 3 2 1 4 2 4 2
3 2 1 * *
5 5
KET_040WP_03F_B AMP_PTC_05F_B CR05F019 CR05F019
CUD93 CUD94 E41 E841
1 1 1
4 2 2 4 2
* * 2 1
5 5 * 3 5
CR05F019 CR05F011 CR05F056 KET_SWP_02F_B

E97 E107 M05A M05B
1 1
13
* * 10 9 8 7 6
** * 2 1 11 10 9
* * 6 * * 3 * 1
26 25 24 23 22 21 20 19 18 17 16
* 14 22 21 20
* 18 * 16 15 14 13 12
KUM_NMWP_01F_B KUM_NMWP_01F_B AMP_0407_26F_W_HD AMP_0407_22F_W_HD
M16 M21 M23 M24
1 1
6 5 4 3 2 1 2 1
2 3 2
KUM_DSD_02F_W KET_91A_06F_W KET_090II_02F_W_L KUM_DSD_03F_B
M39 M51 M78 M79
* * * * * * * *
7 6 5 4 3 7 6 5 4 3 7 6 5 4 3
7 6 5 4 3
KUM_CDR_07F_L KUM_CDR_07F_L KUM_CDR_07F_W KUM_CDR_07F_W
EB11 (G4GC/D4FB) EC11 (G4FA/G4FC)
4 8 12 16 20 24 28 32 36 36 32 28 24 20 16 12 8 4
1 1
1 2
2 1 2
5 9 13 17
* 29 33 37
21 37 33
* 21 17 13 9 5
29
2
3
*
6 10
* 18 * * 30 34 38 38 34 30
* * 18 * 10 6
* 3 3
* 11 * * * * * * * * * * * * * * 11 *
3
KUM_NMWP_04M_B KUM_NMWP_04F_B KET_0409LIF_39M_W KET_0409LIF_39F_W
EC11 (G4GC) EC11 (D4FB)
16 20 24 28 32 36
1
4 8
* 16
* 24 28 32 36 36 32
* 16 * 8 4
28 24 1 1
4 8 12 36 32 28 24 20 16 12 8 4 1
2 * 9 13 17
* 29 33 37
21 37 33
* 21 17 13 9 *
29
2 2 * * * 29 33 37
9 13 17 37 33
* * 17 13 9 *
29
2
6
* * 18 * * 30 34 * * 34 30 * * 18 * * 6
6
* 14 18 22 * 30 34 38 38 34 30
* 22 18 14 * 6
3
7
** * * * * * * * * * * * *** 7
3
* *** * * * * * * * * * * * **** *
KET_0409LIF_39M_W KET_0409LIF_39F_W KET_0409LIF_39M_W KET_0409LIF_39F_W

EM31 MC21(G4FA/G4FC)
1 2
* 13* 5 * 7 8 9 9
8 7
* 5 13* ** 11 10
2 1
* 2 3 4 5 6
** 9
* 11
**
10 11
* * * * 17 18 18
17
* * 23* *
14 15
* 17 18 19 20 21 22 23 24
** * * 11
* 9
* * 6 5 4 3 2
*
19 20 21
* 23 * 25 26 27
21 20 19
* * 24 23 22 21 20 19 18 17
* 15 14
* 29 30 31
27 26 25
* 31 30 29 *
KET_LIF187_31M_W KET_LIF187_31F_W AMP_09III_26M_W AMP_090III_26F_W
MC21(G4GC) MC21(D4FB)
** 3 4 5 6 7 8 9
* 11 * * * * 11
* 9 8 7 6 5 4 3
* * * 2 3 4 5 6
** 9
* 11 12
*
14 15
* * * 19 20 * * 23 24 * * 24 23 20 19 15 14
14 15
* 17 18 19 20 21 22 23 24 25 26 * 12 11
* 9
* * 6 5 4 3 2
*
* * * * * * * 26 25 24 23 22 21 20 19 18 17
* 15 14
AMP_09III_26M_W AMP_090III_26F_W AMP_09III_26M_W AMP_090III_26F_W

2012 > D 2.0 TCID > Blower & A/C Control System (Auto)(~2010.07.15) > Schematic Diagrams
E/R I/P
MULTI FUSE & See Power JUNCTION
FUSE RELAY Distribution BOX
BOX (SD11010)
BLOWER PHOTO
40A POWER 45
CONNECTOR
A/CON ROOM LP
5 I/PG 10A 15A
3.0W 0.3R/B
1 2 E41
BLOWER
RELAY A/CON See Passenger See Passenger
PHOTO SW Compartment Compartment
31 10A Fuse Details Fuse Details
(SD1202) (SD1203)
5 4 E41 7 I/PA 5 I/PB 21 I/PB 13 I/PC

AMBIENT
3.0Y 0.5B SENSOR
0.5R/B 0.3P 3.0R 0.3R/B 0.5R #1
18 EM31
PHOTO D4FB/ PHOTO
3.0Y D4EA 2
43
GE11 PHOTO 1 1 2 E841
3.0Y
0.3L 0.5B
1 M16 A 8 7 EE12
BLOWER PHOTO 1
MOTOR 0.3B
M To PTC 0.3L/O
PHOTO 120 Heater Relay #2
(SD9714) 10 11 EM31
PHOTO 43
2 M16 0.3B
2.0Y 3.0P 11 1 JM03 9 JM04
3.0P JOINT JOINT
See Passenger See Passenger From Joint CONNECTOR
1 M24 CONNECTOR B Connector
FET Fuse Details Fuse Details PHOTO 54 (SD9712) PHOTO 68
See Ground
(Field Effect (SD1202) (SD1203) Distribution
Transistor) (SD1302)
PHOTO 71 13 3 JM03
3 4 1 JM04
3 2 M24
0.5L 3.0B 0.3R/B 0.5R 0.5L 0.5B 0.5B 1.25B
GM41 PHOTO 120
11 9 10 M05B 14 2 M05A 3 M05B 26 25 M05A
Blower FET FET ON Input Battery A/C
AMB Sensor CONTROL
Motor(+) (GATE) Defogger (DRAIN) Voltage Input Ground
Switch CAN MODULE
PHOTO 59
Switch IND. KLine High Low ILL. () ILL. (+)
10 9 6 7 8 13 1 M05A
0.3L 0.3G 0.3G 0.5W 0.5Y 0.3Gr 0.3P
See Rear Glass & Mirror Defogger See Data Link Details See Illuminations

(SD8791) (SD2001) (SD2003) (SD9412) PHOTO 120 GM41
JOINT
To Joint CONNECTOR
B Connector PHOTO 68
(SD9711)
10 7 8 6 JM04
0.3Br 0.3Br 0.3Br 0.3Br 0.3Br PHOTO SENSOR AUTO

LIGHT &
PHOTO
6 M78 2 M23 SENSOR
PASSENGER EVAPORA PHOTO
TEMPERATURE TOR 117
ACTUATOR SENSOR
M PHOTO 71 PHOTO 6 4 5 M21
71
7 3 5 4 M78 1 M23
PHOTO 112
PHOTO 68 0.3Br
DRIVER
INTAKE TEMPERATURE
ACTUATOR 5 M39 6 M79 ACTUATOR 5 M51
MODE
ACTUATOR
PHOTO 54
M M M
3 4 6 7 M39 7 6 4 3 M51
4 5 3 7 M79
0.3P/B 0.3Y/B 0.3G/B 0.3O 0.3B 0.3W 0.3Gr 0.3O 0.3G/B 0.3O 0.5G/B 0.5Y/B 0.3P/B 0.3W/B 0.3G 0.3O 0.3O 0.3R/B 0.3W/B 0.3L/O
16 JM03 15 JM03
JOINT
CONNECTOR
PHOTO 54
17 JM03
0.3O
12 M05B 17 16 18 23 22 24 M05A 6 1 18 13 14 15 16 M05B 21 19 20 M05A
EVAP. Sensor F/B COOL WARM DRI(+) PASS(+) F/B Vent BEF A/C
Ground WARM COOL F/B REC FRE F/B CONTROL
Sensor REF
(+) (+5V) MODULE
Passenger Temp. Intake Driver Temperature Photo Actuator Mode Actuator
Actuator Actuator Actuator PHOTO
59
HOT AT ALL TIMES
EMS
BOX
PHOTO
114
ECU 1 A/CON
30A 10A
ENGINE
CONTROL
RELAY
PHOTO 8
P See Power Distribution INJ
(SD1103) (SD1104) 15A
(SD1105) (SD1106)
1 2 3 CGG72 (G4FC) (SD1107)
CBG72 (G4GC)
CUD72 (D4FB)
0.5W CDD72 (D4EA)
A/CON
RELAY
0.5W
G4FA/G4FC
E/RCBG1 (G4GC)
See MFI E/RCUD1 (D4FB)
0.5B 0.5L 0.5W Control System 0.3O 0.3O(G4FC, W/O ETC) E/RCDD1 (D4EA)
(SD3136) 0.3W(G4FA/G4FC, With ETC)
0.3O(G4GC) G4FA/G4FC, G4GC D4FB/D4EA
(SD31316)
0.3L(D4FB/D4EA)
G4FA/G4FC, M/T 0.5R
W/O ETC, ISG
14EC11
PHOTO
0.5R 0.5R 115
40 25 42 CGGK (G4FA/G4FC, With ETC) 76 CGGK (G4FA/G4FC, With ETC) 3 EB11

33 40 59 CGGMK (G4FA/G4FC, M/T, W/O ETC) 50 CGGMK (G4FA/G4FC, M/T, W/O ETC) PHOTO 5
30 79 57 CGGAK (G4FC, A/T, W/O ETC) 38 CGGAA (G4FC, A/T, W/O ETC) 0.5W
57 13 47 CBGK (G4GC) 87 CBGK (G4GC) CGG28 (G4FA/G4FC) E97 (D4FB)
17 32 26 CUDK(D4FB) 22 CUDA(D4FB) CBG28 (G4GC) E107 (D4EA)
12 13 22 CDDK(D4EA) 70 CDDK(D4EA) 1 1
45 CGGMK (G4FA/G4FC, M/T, W/O ETC)
ECM/
Ground Signal Supply PCM A/C A/C
A/C Relay COMPRESSOR COMPRESSOR
PHOTO
APT Control 36/37/38 PHOTO PHOTO
15/22 25/108
From A/CON 10A
(SD9711)
HOT AT ALL TIMES
D4FB / D4EA HOT WITH ENGINE
CONTROL RELAY ON
A
BOX (SD1106) PHOTO
0.5R/B
PTC PTC PTC (SD1107) 114
10A
0.5R 0.5R 5.0R 5.0R 5.0R 0.5Y
See Power Distribution 14 E/RCUD2
0.5R (SD1106) (SD1107) 14 E/RCDD2
CUD94 (D4FB) CUD93 (D4FB) CUD92 (D4FB) CUD91 (D4FB)
5 CDD94 (D4EA) 4 5 CDD93 (D4EA) 4 5 CDD92 (D4EA) 5 4 CDD91 (D4EA)
FUEL PTC PTC PTC
PHOTO 11 11 11 11
3 CUD94 (D4FB) 2 1 CUD93 (D4FB) 2 1 CUD92 (D4FB) 1 2 CUD91 (D4FB)
CDD94 (D4EA) CDD93 (D4EA) CDD92 (D4EA) CDD91 (D4EA)
0.5Br 0.5G 5.0W 0.5L 5.0R 5.0W 0.75Gr(D4FB)

0.75L(D4EA)
CUD87 (D4FB)
See Fuel Filter 5 3 1 CDD87 (D4EA)
Heating System
(SD3611) PTC 0.75Gr(D4FB)
HEATER 0.75L(D4EA)
PHOTO
57
4 2 CUD87 (D4FB)
CDD87 (D4EA)
5.0B 5.0B
0.5Gr
GUD18 (D4FB)
25 26 12 MC21
PHOTO 57
0.5G 0.5L 0.5Gr
58 CUDA(D4FB)
22 21 20 M05B 94 CDDK(D4EA)
A/C Auxiliary ECM
Heater 38
PHOTO
59
CBGK CBG28 CBG72
94 93 92
*90 89 88 87
* * * * 82 81 80 5779 78 77 * 5375 74 73 6 5
** * 70 69 67 66 65 64
** **** *** * * 4 3
1 3 2 1
* 4927 26* 4725 * 23* 22* 21* 42 41 1840 1739 3816 1537 14* 1*3 12* * 10* *9 *8 297 2 1
28
* ** *
CDDK CDD72 CDD87
94 93 92
*90 89
* 87 86 * 84 83 * * 80 79 * 77 76 75 * * 6 5
72 71 70 69 68
* * 65 64 * * * * * * 57 56 * * * * 51 4 3 5 4 3 2 1
* * * 4725 2446 45 4422 * * 19* 40 * 1638 3715 1436 1335 1234 1133 1032 319 308 297 2 1 3 2 1
28
** * ** **
CDD91 CDD92 CDD93 CDD94
1 1 1 1
4 2 4 2 4 2 2
* * *
5 5 5 5 * 3
CGGAA CGGAK
* 44* 5843 57 56 5540 * 38* 3752 5136 50 3449 4833 32* * 94 93

*
91 90 89 88
* 86 * * 8361 6082 * 80 5779 * 77 * 75 * 7351 6 5
* ** * * * 72 71 70
*68 67 66
**** ** ***** 4 3
15 * * 12 11
30 27
* * *9 238 22 216 * * * 172 161 * 4927 26* 25* 24* * 22* * 20* 41 * 17* 38 * * 3513 * * 1032 319 308 * 2 1
** * * * * * * * * * * *** ** *
CGGMK CGGK
94 93 92 91 90
* 66* 87 8664 6385 6284 8361 6082 8159 80 * * 77 54* * * 7351 6 * 94
* 92 91 90 89 88 87 86 85 * 83 * 81 80 79 78 77 76 75 74 73 6 5
72 71 70 69 68
* * ** * * * * * 71 70 69 68 67 66 65 * 63 62 61 * 59 58 57 56 * 54 53 52 51
* 3 4 3
28 27 26 25 24 23 22 21 * 19 18 17 16 15 * 36 3513 12* 3311 32 319 * 297 2 1 * 25* 24* 23* 4422 4321 4220 4119 4018 3917 38 15* 36 3513 3412 3311 32 319 308 297
50 49 48 47 46 45 44 43 41 40 39 38 50 49
2 1
* * * * 28 27 26
* * *
CGG28 CGG72 CUDA
60
* 58 57 56 55 54 53 52 51 50 49 * 47 46
* 44 * 42 41 40 39 38 37 36 35 34 33 32 31
1 3 2 1
* 1429 1328 12* * 10* * * 227 *6 * 194 * 172 161
* * ** * *
CUDK CUD72 CUD87
94 93 92
*90 89
*
87 86 85 84 83
* * 7856 7755 76 5375 52* 5173
81 80
6 5
72 71 70 69 68 67 66
*
64 63 62 61 60 59 58
* * 4 3 5 4 3 2 1
50
* 26* 47 2446 * 4422 * 20* 1941 40 17* 38 15* 14* 1335 12* 1133 1032 *9 30 *7 2 1 3 2 1
28 27
* * * * * *
1 1 1 1
4 2 4 2 4 2 2
* * *
5 5 5 5 * 3
E41 E841 E97 E107
1
4 2
* 2 1 1 1
5
M05A M05B M16 M21
* * 6 * * 3 * 1
13
* * 10 9 8 7 6
** * 2 1 11 10 9 1
6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16
* 14 22 21 20
* 18 * 16 15 14 13 12
2
M23 M24 M39 M51
1
2 1 * * * *
3 2 7 6 5 4 3 7 6 5 4 3
M78 M79
BLANK BLANK
* * * *
7 6 5 4 3 7 6 5 4 3
2012 > D 2.0 TCID > Blower & A/C Control System (Manual) > Schematic Diagrams
Blower & A/C Control System (Manual) (1) SD9719

I/P E/R See Power I/P
JUNCTION MULTI FUSE & JUNCTION
FUSE Distribution
BOX RELAY (SD11010) BOX
A/CON SW PHOTO BOX POWER PHOTO
BLOWER CONNECTOR
10A 45 40A ROOM 45
A/CON
10A LP
15A
3.0W
5 I/PB 7 I/PA 1 2 E41
BLOWER See Passenger See Passenger
RELAY Compartment Compartment
Fuse Details Fuse Details
PHOTO (SD1203)
31 (SD1202)
5 I/PG 21 I/PB 13 I/PC

5 4 E41
0.3Gr 3.0R 3.0Y 0.5B 0.3R/B 0.3R/B 0.5R

18 EM31 0.5R/B
PHOTO 43 D4FB/D4EA
3.0Y
1 M16 A
BLOWER BLOWER
RESISTOR MOTOR To PTC
PHOTO M PHOTO Heater Relay
71 120 (SD97112) 11 1 JM03
3 1 2 4 M70 2 M16 JOINT
See Passenger See Passenger CONNECTOR
0.85Y 1.25O 2.0L 3.0R 3.0R Fuse Details Fuse Details PHOTO 54
(SD1202) (SD1203)
14 3 JM03
0.5Y 0.85Y 3.0R 0.5O 0.5R
GE11 PHOTO 1
16 12 M06B 5 3 2 4 M06A 15 2 M06B
MAX Blower Blower ON Input Battery A/C

Low M/Low M/High High CONTROL
ON Signal ON Signal II Voltage
() I III MODULE
IIII PHOTO 59
Rear Defogger CAN
Ground Ground ILL.(+) ILL.() IND. Switch High Low

1 M06A 28 1 14 10 3 25 26 M06B
3.0B 0.5B 0.3P 0.3Gr 0.3G 0.3L 0.5W 0.5Y
4 JM04
See Ground Distribution JOINT
(SD1302) CONNECTOR See Illuminations See Rear Glass & See Data Link Details
PHOTO 68 (SD9412) Mirror Defogger (SD2003)
1 JM04 (SD8791)
1.25B
GM41 PHOTO 120
JOINT
CONNECTOR
PHOTO 68
7 8 1 6 9 JM04
0.3B
11 EM31
PHOTO
43
0.3Br 0.3Br 0.3Br 1.25B 0.3Br 0.3B
7 EE12
PHOTO
GM41 PHOTO 120 1
0.3B
2 M23 5 M39 6 M43 5 M51 2 E841

EVAPORATOR INTAKE TEMPERATURE MODE AMBIENT
SENSOR ACTUATOR ACTUATOR ACTUATOR SENSOR #1
PHOTO 71 M PHOTO 68 M PHOTO 71 M PHOTO 54 PHOTO 2
4 3 6 7 M39 4 5 7 3 M43 7 6 4 3 M51

1 M23 0.3O 0.3O 0.3O 1 E841
0.3L/O
8 EE12
PHOTO
1
0.3G/B 0.3G 0.3B 0.3L 0.3Gr 0.3W 0.3Y 0.3R/B 0.3W/B 0.3L/O 0.3Br 0.3L/O
16 15 JM03
10 EM31
JOINT
CONNECTOR PHOTO
43
PHOTO 54 0.3L/O
17 JM03 ISG
0.3O
22 8 9 21 19 7 6 11 20 4 5 27 23 M06B
Evaporator FRE REC F/B F/B WARM COOL F/B VENT DEF Sensor AMB A/C
Sensor CONTROL
Sensor(+) REF(+5V) Ground Sensor(+)
Intake Actuator Temperature Actuator Mode Actuator MODULE
PHOTO
59
HOT AT ALL TIMES
EMS
BOX
PHOTO
114
ECU 1 A/CON
30A 10A
ENGINE
CONTROL
RELAY
P PHOTO 8
See Power Distribution INJ
(SD1103) (SD1104) 15A
(SD1105) (SD1106)
1 2 3 CGG72 (G4FA/G4FC) (SD1107)
CBG72 (G4GC)
CUD72 (D4FB)
CDD72 (D4EA)
0.5W A/CON
RELAY
0.5W
G4FA/G4FC,
E/RCBG1 (G4GC)
E/RCUD1 (D4FB)
See MFI E/RCDD1 (D4EA)
Control System
(SD3136) G4FA/G4FC, G4GC D4FB, D4EA
0.5B 0.5L 0.5W 0.3O 0.3O(G4FA/G4FC, W/O ETC)
(SD31316) 0.3W(G4FA/G4FC, With ETC)
G4FA/G4FC, 0.3O(G4GC) 0.5R
M/T, W/O ETC, 0.3L(D4FB/D4EA)
W/O ISG
14 EC11
PHOTO
0.5R 0.5R 115
40 25 42 CGGK (G4FA/G4FC, With ETC) 3 EB11

76 CGGK (G4FA/G4FC, With ETC)
33 40 59 CGGMK (G4FA/G4FC, M/T, W/O ETC) 50 CGGMK (G4FA/G4FC, M/T, W/O ETC) PHOTO 5
30 79 57 CGGAK (G4FC, A/T, W/O ETC) 38 CGGAA (G4FC, A/T, W/O ETC) 0.5W
57 13 47 CBGK (G4GC) 87 CBGK (G4GC) CGG28 (G4FA/G4FC) E97 (D4FB)
17 32 26 CUDK(D4FB) 22 CUDA(D4FB) 1 CBG28 (G4GC) 1 E107 (D4EA)
12 13 22 CDDK(D4EA) 45 CGGMK (G4FA/G4FC, M/T, W/O ETC) 70 CDDK(D4EA)
ECM/
Ground Signal Supply PCM A/C A/C
A/C Relay COMPRESSOR COMPRESSOR
PHOTO
APT Control 36/37/38 PHOTO PHOTO
15/22 25/108
From A/CON 10A
(SD9719)
HOT AT ALL TIMES
D4FB / D4EA HOT WITH ENGINE
CONTROL RELAY ON
A
BOX (SD1106) PHOTO
0.5R/B
PTC PTC PTC (SD1107) 114
10A
0.5R 0.5R 5.0R 5.0R 5.0R 0.5Y
14 E/RCUD2
0.5R 14 E/RCDD2
CUD94 (D4FB) CUD93 (D4FB) CUD92 (D4FB) CUD91 (D4FB)
5 CDD94 (D4EA) 4 5 CDD93 (D4EA) 4 5 CDD92 (D4EA) 5 4 CDD91 (D4EA)
FUEL PTC PTC PTC
PHOTO 11 11 11 11
3 CUD94 (D4FB) 2 1 CUD93 (D4FB) 2 1 CUD92 (D4FB) 1 2 CUD91 (D4FB)
CDD94 (D4EA) CDD93 (D4EA) CDD92 (D4EA) CDD91 (D4EA)
0.5Br 0.5G 5.0W 0.5L 5.0R 5.0W 0.75Gr(D4FB)

0.75L(D4EA)
CUD87 (D4FB)
See Fuel Filter 5 3 1 CDD87 (D4EA)
Heating System
(SD3611) PTC
HEATER
PHOTO
57
4 2 CUD87 (D4FB)
CDD87 (D4EA)
5.0B 5.0B 0.5Gr 0.75Gr(D4FB)
0.75L(D4EA)
GUD18 (D4FB)
25 26 12 MC21
PHOTO 57
0.3G 0.3L 0.3G
58 CUDA(D4FB)
18 17 13 M06B 94 CDDK(D4EA)
A/C Auxiliary ECM
Heater
38
PHOTO
59
CBGK CBG28 CBG72
94 93 92
*90 89 88 87
* * * * 82 81 80 5779 78 77 * 5375 74 73 6 5
** * 70 69 67 66 65 64
** **** *** * * 4 3
1 3 2 1
* 4927 26* 4725 * 23* 22* 21* 42 41 1840 1739 3816 1537 14* 1*3 12* * 10* *9 *8 297 2 1
28
* ** *
CDDK CDD72 CDD87
94 93 92
*90 89
* 87 86 * 84 83 * * 80 79 * 77 * 75 * * 6 5
72 71 70 69 68
* * 65 64 * * * * * * 57 * * * * * 51 4 3 5 4 3 2 1
* * * 4725 2446 45 4422 * * 19* 40 * 1638 3715 1436 1335 1234 1133 1032 319 308 297 2 1 3 2 1
28
** * ** **
1 1 1 1
4 2 4 2 4 2 2
* * *
5 5 5 5 * 3
CGGAA CGGAK
* 44* 5843 57 56 5540 * 38* 3752 5136 50 3449 4833 32* * 94 93

*
91 90 89 88
* 86 * * 8361 6082 * 80 5779 * 77 * 75 * 7351 6 5
* ** * * * 72 71 70
*68 67 66
**** ** ***** 4 3
15 * * 12 11
30 27
* * *9 238 22 216 * * * 172 161 * 4927 26* 25* 24* * 22* * 20* 41 * 17* 38 * * 3513 * * 1032 319 308 * 2 1
** * * * * * * * * * * *** ** *
CGGMK CGGK
94 93 92 91 90
* 66* 87 8664 6385 6284 8361 6082 8159 80 * * 77 54* * * 7351 6 * 94
* 92 91 90 89 88 87 86 85 * 83 * 81 80 79 78 77 76 75 74 73 6 5
72 71 70 69 68
* * ** * * * * * 71 70 69 68 67 66 65 * 63 62 61 * 59 58 57 56 * 54 53 52 51
* 3 4 3
28 27 26 25 24 23 22 21 * 19 18 17 16 15 * 36 3513 12* 3311 32 319 * 297 2 1 * 25* 24* 23* 4422 4321 4220 4119 4018 3917 38 15* 36 3513 3412 3311 32 319 308 297
50 49 48 47 46 45 44 43 41 40 39 38 50 49
2 1
* * * * 28 27 26
* * *
CGG28 CGG72 CUDA
60
* 58 57 56 55 54 53 52 51 50 49 * 47 46
* 44 * 42 41 40 39 38 37 36 35 34 33 32 31
1 3 2 1
* 1429 1328 12* * 10* * * 227 *6 * 194 * 172 161
* * ** * *
CUDK CUD72 CUD87
94 93 92
*90 89
*
87 86 85 84 83
* * 7856 7755 76 5375 52* 5173
81 80
6 5
72 71 70 69 68 67 66
*
64 63 62 61 60 59 58
* * 4 3 5 4 3 2 1
50
* 26* 47 2446 * 4422 * 20* 1941 40 17* 38 15* 14* 1335 12* 1133 1032 *9 30 *7 2 1 3 2 1
28 27
* * * * * *
1 1 1 1
4 2 4 2 4 2 2
* * *
5 5 5 5 * 3
E41 E842 E97 E107
1
4 2
* 2 1 1 1
5
M06A M06B M16 M23
1
3 2 1 14
* 12 11 10 9 8 7 6 5 4 3 2 1
2 1
* 5 4
28 27 26 25 24 23 22 21 20 19 18 17
* 15
2
M39 M43 M51 M70
* * * * * * 2 1
7 6 5 4 3 7 6 5 4 3 7 6 5 4 3
4 3
2012 > D 2.0 TCID > Body Control Module (BCM) System > Schematic Diagrams
Body Control Module (BCM) System (1) SD9521
HOT IN ON OR START HOT IN ON HOT AT ALL TIMES
See Power Distribution See Power Distribution I/P
(SD11010) (SD11010) JUNCTION
POWER BOX
CLUSTER A/CON ROOM CONNECTOR PHOTO 45
10A 10A LP
15A
See Passenger See Passenger See Passenger
Compartment Fuse Details Compartment Fuse Details Compartment Fuse Details
(SD1201) (SD1202) (SD1203)
3 I/PC 21 I/PB 13 14 I/PC 3 I/PD 6 I/PE
0.3R/O 0.3R/B 0.5R
0.3R/O 0.3W
11 1 JM03
7 M01C
See Passenger JOINT
INSTRUMENT CONNECTOR
CLUSTER Compartment Fuse Details
(SD1202) (SD1203) PHOTO 54
PHOTO 49
SEAT 4 2 JM03
BELT 0.5R
0.5R/O 0.5R 0.5R 0.3L
4 M66 17 M82A
6 4 M19
SEAT SECURITY SRS
INDICATOR IGNITION CONTROL
PHOTO KEY ILL. & MODULE
ILL. DOOR WARNING
117 PHOTO 67
SWITCH
6 M01B 6 M66
5 3 M19
0.3R/O 0.3O 0.3R/B 0.3L/O 0.5Gr 0.5G PHOTO 51
2 M04A 11 M04C 13 M04A 16 M04B 10 M04C 4 1 7 M04A
BCM
ON/START Seat Belt ON Input Security Key Hole Key In Battery Crash
Input IND. IND. ILL. Switch Power Input PHOTO
57
CHIME Over Vehicle Front Front Deicer
BUZZER Driver Seat Belt Passenger SBR Tail Lamp Tail Lamp Speed Speed Deicer Relay
T/GATE Ground
Handle Switch Switch SIG. Relay Control Switch Input Out Input SwitchV Control
19 32 36 12 M04A 12 4 M04C 28 5 30 37 M04A 13 M04B

0.3P 0.3Gr/O 0.3G/B
1 MF12 PHOTO 43 29 15 MF22
0.3P 0.3B 0.3B 0.3L 0.3L 0.3L 0.3G
0.3Gr/O 0.3G/B PHOTO 75
9 FR12 1 F42 0.3L
PHOTO
66/88 SBR
2 F40 MAT
3DR 5DR/WGN DRIVER PHOTO
SEAT BELT 84
0.5P R25 (5DR/WGN) BUCKLE 2 F42 0.3R/B
0.5P 5 RR11 1 R29 (3DR) SWITCH 0.3L See Vehicle
0.5P PHOTO HANDLE PHOTO 83 2 F41 See Tail, Parking Speed System See Front Wiper
61/97 SWITCH 1 F40 & License Lamps Deicer
PASSENGER (SD4361)
PHOTO SEAT BELT (SD9281) (SD4362) (SD8611)
61/97/109 BUCKLE
SWITCH
2 R25 (5DR/WGN) PHOTO 84
R29 (3DR) 1 F41
0.5B 0.3B 0.3B 9 M01C
INSTRUMENT
CLUSTER
PHOTO 49
GR11 (5DR+WGN) PHOTO PHOTO PHOTO
GR12 (3DR) 61/97/109 GF31 PHOTO 85 GF41 PHOTO 85 GM31 119 GM41 120
See Front Wiper & Washer/ See Rear Glass &
Rear Wiper & Washer See Head Lamps See Auto Lights Mirror Defogger
(SD9811) (SD9812) (SD9821) (SD9211) (SD9212) (SD9511) (SD9512) (SD8791)
0.5L/O 0.5 R 0.5Y/O 0.5G 0.5G/O 0.5L/B 0.3Gr 0.3W 0.3W 0.3R/O 0.3Y 0.3R/B 0.3L 0.3Br 0.3R/B 0.3R 0.3L
10 38 14 15 17 29 M04A 5 M04C 18 14 19 M04B 33 31 M04A 1 2 7 M04B 3 M04C 4 M04B

Rear MIST Washer Wiper Rear INT Wiper Rear Wiper Head Lamp Head Lamp Head Lamp Auto Light Signal Ground Power Defogger Defogger BCM
Wiper Switch Switch INT Washer Volume Relay Relay Low Relay Escort Switch Input Switch Relay Switch PHOTO
Switch Switch Switch Control Control Control Auto Light Sensor Control Input 57
Driver/
Passenger Driver Passenger C/DR Passenger Door Lock/unlock
Door Room Door Switch Door Trunk Lid Rear Door Driver Door Door Key Door Key Lock/ Door Key Dead C/DR Relay Control Rear Door
Open Lamp unlock Relay unlock unlock unlock Lock Unlock Unlock Lock Relay Lock Unlock
IND. Control RL Passenger Driver RR Switch Control Switch LH Switch Switch Switch SW Switch Control IND. Lock Unlock Switch
16 1 M04C 22 21 20 39 9 18 6 8 26 25 35 34 M04A 7 15 6 M04C 15 3 M04B
RHD
0.3B 0.5Y 0.3W 0.3L/O 0.3R 0.3G/O 0.3W 0.3B 0.3L 0.3B/O 0.3Y 0.3G 0.3W 0.3L 0.3L 0.3B/O 0.3Y/O 0.3Y 0.3W
(LHD) (LHD)
0.3G 0.3W
(RHD) (RHD)
See Courtesy & Trunk Lamps See Power Door Locks/
(SD9291) (SD9292) (SD9293) Keyless Entry & Burglar Alarm System
(SD8131) (SD8132) (SD8133) (SD8141)
HOT IN ON OR START
See Power I/P
Distribution JUNCTION
(SD11010) BOX
PHOTO
T/SIG 45
See Keyless Entry & See Data See Turn & See Charging System 10A
Burglar Alarm System See Courtesy & Link Details Hazard (SD3731) (SD3732)
(SD8141) Trunk Lamps (SD2001) Lamps (SD3733) (SD3734)
(SD9292) (SD9293) (SD9251) (SD3735) (SD3736)
3 I/PA
0.3G/O 0.3G 0.5G/B 0.3Br 0.3L 0.3G 0.3W(With ISG) 0.5R/O

0.3W/B(W/O ISG)
6 M61A
8 M04C 24 23 16 M04A 14 9 M04C 3 M04A
BCM SWITCH
Burglar Hood T/GATE Code KLine Hazard ALTL IG1 MODULE
Alarm Horn Switch Switch Save Relay PHOTO
Relay Control Control 57 PHOTO 59
Power EHS
Rear Fog Front Fog Safety Window Head Passenger
Lamp Relay Front Fog Lamp Relay Rear Fog Power Relay Lamp Seat Belt ASS SBR_CTR SBR LH SBR RH
Control Switch Control Switch Window Control Switch IND. SBR IND. IND. IND.
IND.
13 M04C 6 17 5 11 12 10 20 M04B
4 12 11 23 M61A
0.3G/O 0.3G/O 0.3G/O 0.3W/B 0.3P/B 0.3Gr 0.3W 0.3Y 0.3O 0.3L 0.3G
With
ISG
25 10 28 MF22
PHOTO 75
0.3O 0.3L 0.3G
See MFI
See Front Fog & Rear Fog Lamps See Power Windows Control System
(SD9241) (SD9242) (SD8241) (SD8244) (SD3136) 4 2 F45 2 F46
(SD8246) (SD31316)
(SD31341) REAR REAR
SBR SBR
LH RH
PHOTO PHOTO
100 100
1 F46
3 1 F45
0.3B 0.3B 0.3B
See Ground
Distribution
(SD1304)
0.3B 0.85B
PHOTO
GF41 PHOTO 85 GF61 89/111
F40 F41 F42 F45
2 1 2 1 2 1 1 2 3 4
F46 M01B M01C
BLANK
1 2 6 5 4
* 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
M04A M04B M04C
8 7 6 5 4 3 1
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1 10
* * 7 6 5 4 3 2 1
*
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
M19 M61A M66 M82A
* * * * * * 6 5 4 3 2 1
1 2 12 11 10 9 8 7 6 5 4 3 2 1
6 * 4 * * * 24 23 22 21 20 18 17 14 13
3 4 5 6 24 23 22 21 20 19 18 17 16 15 14 13 * * *
R25 R29
BLANK BLANK
1 2 1 2
2012 > D 2.0 TCID > Charging System > Schematic Diagrams
Charging System (1) SD3731
HOT AT ALL TIMES
G4FA/G4FC W/O ISG IGNITION
SWITCH
PHOTO 50
LOCK START
E/R
FUSE & ACC ON
MULTI RELAY
FUSE BOX
20B ALT 6 M35
150A 0.3W 3.0L
8 I/PG 2 I/PA
(SD11010) JUNCTION
BOX
ECM/
PCM PHOTO
CLUSTER 45
BATTERY PHOTO 10A
36
See Passenger
15 CGGK (With ETC) 10 EC11 Compartment Fuse Details
66 CGGMK (M/T / W/O ETC) (SD1201)
17 CGGAK (A/T / W/O ETC) PHOTO
115
1 I/PD 3 I/PC
0.3R/O
20B 20B 0.5W(W/O ETC, A/T/ 0.5L 0.3W/B 0.3W/B 0.3R/O 0.3R/O

With ETC) With A/V
0.5L(W/O ETC, M/T) 7 M01C
INSTRUMENT
CLUSTER
PHOTO 49
BATTERY
BODY
GROUND
1 2 CGG06
1 E50
ALTERNATOR 1 M65
BATTERY FR L PRE
PHOTO 15
EXCITATION
M I C O M RESISTOR
2.2 F
PHOTO
4
4 M01B 2 M65
0.3W/B 0.3W/B
I.C REGULATOR
FIELD 0.3W/B 0.3W/B

COIL
STATOR COIL 3 M54C1 5 M61A 3 M04A
AUDIO SWITCH BCM
Engine
PHOTO MODULE Running PHOTO
59 PHOTO Input 57
RECTIFIER 59
HOT AT ALL TIMES
IGNITION
E/R G4FA/G4FC M/T Only With I SG SWITCH
FUSE & PHOTO 50
MULTI RELAY LOCK START
FUSE BOX ISG : Idle Stop & Go
20B ACC ON
ALT
150A
6 M35
3.0L
2 I/PA
I/P
(SD11010) BOX
ECM/PCM
PHOTO PHOTO
BATTERY CLUSTER 45
36
10A
32 15 CGGK (With ETC)
94 66 CGGMK (M/T, W/O ETC)
See Passenger
(SD1201)
8 I/PG 1 I/PD 3 I/PC See Audio

0.3R/O (SD9614)
20B
20B 0.5R 0.5L 0.3W 0.3W/B 0.3W/B 0.3R/O
(W/O ETC) (W/O ETC)
0.5G/B 0.5W 7 M01C 12 M01B
(With ETC) (With ETC) INSTRUMENT
10 EC11 CLUSTER
PHOTO 2 M65 With
ISG PHOTO 49
115 PRE
BODY 0.5L EXCITATION
GROUND RESISTOR
PHOTO BATTERY
1 3 2 CGG56 4
1 E50
ALTERNATOR With
BATTERY C FR L
PHOTO 1 M65 ISG
15 0.3R/O
1.5 F
M I C O M
Alt_L_Out
4 M01B 4 M01A
I.C REGULATOR 0.3W
0.3W 0.3W 0.3W

STATOR COIL With A/V
FIELD 5 M61A 3 M04A 3 M54C1

COIL
SWITCH EngineBCM AUDIO
RECTIFIER MODULE PHOTO PHOTO
Running
PHOTO Input 57 59
59
HOT AT ALL TIMES
IGNITION
G4GC SWITCH
PHOTO 50
LOCK START
E/R
FUSE & ACC ON
MULTI RELAY
FUSE BOX
20B ALT 6 M35
150A 3.0L
2 I/PA
I/P
(SD11010) BOX
PCM PHOTO
PHOTO 45
BATTERY 37 CLUSTER
10A
74 CBGK See Passenger
0.5W (SD1201)
8 I/PG 1 I/PD 3 I/PC

7 EC11 0.3R/O
PHOTO
115
0.5W 0.3L/O 0.3W/B 0.3W/B 0.3R/O 0.3R/O
With A/V 7 M01C
INSTRUMENT
3 2 EB11 CLUSTER
PHOTO 5 PHOTO 49
20B 20B 0.5W 0.5L/O

BATTERY
3 2 E61
1 E60
ALTERNATOR 1 M65
BATTERY FR L
PHOTO 21 3 M54C1 PRE
AUDIO EXCITATION
1.5 F M I C O M RESISTOR
PHOTO
59 PHOTO
4
4 M01B 2 M65
0.3W/B 0.3W/B
I.C REGULATOR
FIELD
COIL 0.3W/B 0.3W/B
STATOR COIL 5 M61A 3 M04A
SWITCH Engine
BCM
MODULE Running PHOTO
PHOTO Input 57
RECTIFIER 59
BODY
GROUND
HOT AT ALL TIMES
IGNITION
D4FB W/O ISG SWITCH
PHOTO 50
LOCK START
E/R
FUSE & ACC ON
MULTI RELAY
FUSE BOX
20B ALT 6 M35
150A 3.0L
2 I/PA
I/P
(SD11010) BOX
PHOTO
45
BATTERY CLUSTER
10A
See Passenger
(SD1201)

0.3R/O
0.3L/O 0.3W/B 0.3W/B 0.3R/O 0.3R/O

With A/V 7 M01C
INSTRUMENT
2 EB11 CLUSTER
PHOTO 5 PHOTO 49
20B 20B 0.5R

BATTERY
1 E90 2 E91
ALTERNATOR 1 M65
BATTERY L
PHOTO 32
PRE
EXCITATION
1.5 F M I C O M RESISTOR
PHOTO
4
4 M01B 2 M65
0.3W/B 0.3W/B
I.C REGULATOR
FIELD
COIL 0.3W/B 0.3W/B
STATOR COIL 3 M54C1 5 M61A 3 M04A
AUDIO SWITCH BCM
Engine
PHOTO MODULE Running PHOTO
59 PHOTO Input 57
RECTIFIER 59
BODY
GROUND
HOT AT ALL TIMES
D4FB M/T Only With ISG IGNITION
SWITCH
PHOTO 50
ISG : Idle Stop & Go LOCK START
E/R
FUSE & ACC ON
MULTI RELAY
FUSE BOX
20B ALT 6 M35
150A 3.0L
2 I/PA
I/P
(SD11010) BOX
PHOTO
45
BATTERY CLUSTER
10A
ECM
See Passenger
PHOTO Compartment Fuse Details
38 (SD1201)
8 I/PG 1 I/PD 3 I/PC See Audio

73 CUDK 42 CUDA 0.3R/O (SD9614)
0.3L/O 0.3W/B 0.3W/B 0.3R/O

0.5L 0.5G
7 M01C 12 M01B
INSTRUMENT
3 4 CB21 2 EB11 2 M65 CLUSTER
With
PHOTO PHOTO 5 ISG PHOTO 49
PRE
27 EXCITATION
20B 20B 0.5L 0.5G 0.5R RESISTOR
PHOTO BATTERY
4
1 3 2 E93 With
1 E90
ALTERNATOR 1 M65 ISG
BATTERY C FR L
PHOTO 32 0.3R/O
1.5 F M I C O M
Alt_L_Out
4 M01B 4 M01A
0.3W
I.C REGULATOR
0.3W 0.3W 0.3W
FIELD With A/V
COIL
STATOR COIL
5 M61A 3 M04A 3 M54C1
SWITCH Engine BCM AUDIO
MODULE Running PHOTO PHOTO
RECTIFIER PHOTO Input 57 59
BODY 59
GROUND
HOT AT ALL TIMES
5.0W D4EA IGNITION
SWITCH
E/R EMS PHOTO 50
FUSE & BOX LOCK START
MULTI RELAY PHOTO ACC ON
FUSE BOX 114
ECU 3
ALT 10A
20R 150A 6 M35
3.0L
2 I/PA
6 E/RCDD1 I/P
(SD11010) BOX
0.5L
PHOTO
45
BATTERY CLUSTER
10A
See Passenger
5 EC11 Compartment Fuse Details
PHOTO (SD1201)
115
0.3R/O
0.5L 0.3L/O 0.3W/B 0.3W/B 0.3R/O 0.3R/O

With A/V 7 M01C
INSTRUMENT
4 2 EB11 CLUSTER
PHOTO 5 PHOTO 49
30B 20R 0.5R 0.5L/O

BATTERY
1 2 E101
1 E100
ALTERNATOR 1 M65
BATTERY FR L
PHOTO 3 M54C1 PRE
100 EXCITATION
1.5 F AUDIO M I C O M
PHOTO RESISTOR
59 PHOTO
4
4 M01B 2 M65
0.3W/B 0.3W/B
I.C REGULATOR
FIELD
COIL 0.3W/B 0.3W/B
STATOR COIL 5 M61A 3 M04A
SWITCH Engine
BCM
MODULE Running PHOTO
PHOTO Input 57
RECTIFIER 59
BODY
GROUND
CBGK CGGAK
94 93 92
*90 89 88 87
* * * * 82 81 80 5779 78 77 * 5375 74 73 6 5
94 93
*
91 90 89 88
* 86 * * 8361 6082 * 80 5779 * 77 * 75 * 7351 6 5
** * 70 69 67 66 65 64
** **** *** * * 4 3
72 71 70
*68 67 66
**** ** ***** 4 3
* 4927 26* 4725 * 23* 22* 21* 42 41 1840 1739 3816 1537 14* 1*3 12* * 10* *9 *8 297 2 1 * 4927 26* 25* 24* * 22* * 20* 41 * 17* 38 * * 3513 * * 1032 319 308 * 2 1
28
* ** * * * * * * *** ** *
CGGMK CGGK
94 93 92 91 90
* 66* 87 8664 6385 6284 8361 6082 8159 80 * * 77 54* * * 7351 6 * 94
* 92 91 90 * 88 87 86 85 * 83 * 81 80 79 78 77 76 75 74 73 6 5
72 71 70 69 68
* * ** * * * * * 71 70 69 68 67 66 65 * 63 62 61 * 59 58 57 56 * 54 53 52 51
* 3 4 3
28 27 26 25 24 23 22 21 * 19 18 17 16 15 * 36 3513 12* 3311 32 319 * 297 2 1 * 25* 24* 23* 4422 4321 4220 4119 4018 3917 38 15* 36 3513 3412 3311 32 319 308 297
50 49 48 47 46 45 44 43 41 40 39 38 50 49
2 1
* * * * 28 27 26
* * *
CGG06 CGG56 CUDA
60
* 58 57 56 55 54 53 52 51 50 49 * 47 46
* 44 * 42 41 40 39 38 37 36 35 34 33 32 31
2 1 3 2 1
* 1429 1328 12* * 10* * * 227 *6 * 194 * 172 161
* * ** * *
CUDK E50 E60
94 93 92
*90 89
*
87 86 85 84 83
* * 7856 7755 76 5375 52* 5173
81 80
6 5
72 71 70 69 68 67 66
*
64 63 62 61 60 59 58
* * 4 3
50
* 26* 47 2446 * 4422 * 20* 1941 40 17* 38 15* 14* 1335 12* 1133 1032 *9 30 *7 2 1 1 1
28 27
* * * * * *
E61 E90 E91 E93
1
3 2 3 2 1
* 2 *
E100 E101 M01A M01B
1
2 1
6 5 4 3 2 1 6 5 4
* 2 1
12 11 10 9 8 7 12 11 10 9 8 7
M01C M04A M35
8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1 3 2 1
16 15 14 13 12 11 10 9 * 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21 6 5 4
M54C1 M61A M65
2 1
2 1 BLANK
* 3 12 11 10 9 8 7 6 5 4 3 2 1
6 5 24 23 22 21 20 19 18 17 16 15 14 13
* *
2012 > D 2.0 TCID > Clock & Cigarette Lighter (Power Outlet) > Schematic Diagrams
Clock & Cigarette Lighter (Power Outlet) (1) SD9451
HOT AT ALL TIMES HOT IN ACC OR ON
(SD11010) JUNCTION
BOX
POWER PHOTO 45
CONNECTOR
RR
P/OUTLET AUDIO CLOCK C/LIGHTER P/OUTLET
15A 10A 10A 15A 15A
See Passenger
See Passenger Compartment
Compartment Fuse Details Fuse Details
(SD1201) (SD1203) (SD1201)
12 I/PF 1 I/PA 1 6 7 I/PB

See Illuminations See Illuminations
WGN (SD9411) (SD9411)
1.25W 0.3P 0.5R 0.3Y 0.85Y 0.3P 0.85W 0.3P

2 5 1 M18
4 12 10 M62 0.5R 0.5Y 0.5L 2 M80
1 F34 Memory ACC/ON TRIP
COMPUTER CIGARETTE ASHTRAY
REAR Power Input 1 M181 1 M182 1 M183 LIGHTER & ILL.
POWER CLOCK PHOTO CIGARETTE CIGARETTE FRONT FRONT
OUTLET 59 LIGHTER LIGHTER POWER PHOTO
POWER 56
PHOTO ILL. OUTLET OUTLET
74
ILL. PHOTO
PUSH:ON 62 1 M80
2 F34
2 M181 2 M183
S.GND P.GND 0.5B 0.5B 0.5B
5 11 23 M62 0.5B
6 3 M18
1.25B 0.3Gr 0.3B 0.5B 0.85B 0.85B 0.3B
5 2 JM04 5 JM02
See Ground JOINT See Ground JOINT

See Illuminations CONNECTOR CONNECTOR
(SD9411) Distribution Distribution
(SD1302) PHOTO 68 (SD1301) PHOTO 47
1 JM04 1 JM02
1.25B 1.25B
PHOTO PHOTO
GF61 89/111 GM31 PHOTO 119 GM41 PHOTO 120 GM21 46
2012 > D 2.0 TCID > Clock & Cigarette Lighter (Power Outlet) > Schematic Diagrams
Clock & Cigarette Lighter (Power Outlet) (2) SD9452
F34 M18 M181 M182
1 2 1 1
1
2 6 5
* 3 2
M183 M62 M80
1
BLANK
12 11 10 9 8
* * 5 4
* 2 1
2 1
2 24 23 22 21 20 19 18 17 16 15
* 13
2012 > D 2.0 TCID > Component Locations > Schematic Diagrams
2012 > D 2.0 TCID > Connector Configurations > Schematic Diagrams Language
Language
2012 > D 2.0 TCID > Control Harness > Schematic Diagrams
2012 > D 2.0 TCID > Cooling Sysetm > Schematic Diagrams
Cooling System (1) SD2531
G4FA/G4FC/G4GC
HOT AT ALL TIMES HOT AT ALL TIMES
EMS E/R
BOX MULTI FUSE &
PHOTO FUSE RELAY
ECU 1 114 C/FAN BOX
30A 40A
ENGINE
CONTROL 3.0L 3.0L 0.5O
RELAY
2 1 E49 1 2 E48
CONDENSER CONDENSER
FAN RELAY FAN RELAY
(LOW) (HIGH)
SNSR1 PHOTO PHOTO
10A 31 31
4 5 E49 5 4 E48
11 E/RCGG1 (G4FA/G4FC) 15 E/RCGG2 (G4FA/G4FC)

E/RCBG1 (G4GC) E/RCBG2 (G4GC)
0.5O 0.5O 0.5R 3.0W 3.0R 0.5L
2 1 E71
13 9 EC11 6 EC11
COOLING
PHOTO FAN MOTOR PHOTO
115 PHOTO 5 115
M
ENGINE
COOLANT 3 E71
SENSOR TEMPERATURE
SENSOR 3.0B 0.3Gr(G4FA/ G4FC, W/O ETC)
PHOTO 0.3L(G4GC, G4FA/G4FC, With ETC)
18/19
1 3 CGG11 (G4FA/G4FC) See Blower & A/C Control System
3 1 CBG11 (G4GC) GE12 PHOTO 1 (SD9713) (SD97111)
0.5B/O(G4FA/G4FC, 0.5B(G4FA/ G4FC, 0.5W(G4FA/G4FC) 0.3Y/O 0.3O 0.3O(G4FA/G4FC, W/O ETC)

W/O ETC) W/O ETC) 0.5O(G4GC) 0.3W(G4FA/G4FC, With ETC)
0.5O(G4FA/G4FC, 0.5L(G4GC, W/O 0.3O(G4GC)
ISG
With ETC) G4FA/G4FC
0.5L(G4GC) With ETC)
30 63 44 31 CGGK (G4FA/G4FC, With ETC) 76 53 CGGK (G4FA/G4FC, With ETC)

22 35 77 28 CGGMK (G4FA/G4FC, M/T, W/O ETC) 50 23 CGGMK (G4FA/G4FC, M/T, W/O ETC)
9 73 77 21 CGGAA (G4FC, A/T, W/O ETC) 38 23 CGGAA (G4FC, A/T, W/O ETC)
64 14 15 65 CBGK (G4GC) 45 CGGMK (G4FA/G4FC, M/T, W/O ETC) 87 88 CBGK (G4GC)
Engine Ground Signal Fan Relay Fan Relay ECM/

Control Control Control PCM
A/Con Relay
Relay (LOW) Control (HIGH) PHOTO
ECT Sensor 36/37
Control
D4FB/D4EA
EMS E/R
BOX MULTI FUSE &
PHOTO FUSE RELAY
ECU 1 114 C/FAN BOX
30A 40A
ENGINE
CONTROL 3.0L 3.0L 0.5O
RELAY
2 1 E49 1 2 E48
CONDENSER CONDENSER
FAN RELAY FAN RELAY
(LOW) (HIGH)
SNSR1 PHOTO PHOTO
10A 31 31
4 5 E49 5 4 E48
11 E/RCUD1 (D4FB) 15 E/RCUD2 (D4FB)

E/RCDD1 (D4EA) E/RCDD2 (D4EA)
0.5O 0.5O 0.5R 3.0W 3.0R 0.5L
2 1 E72
13 9 EC11 6 EC11
COOLING
PHOTO FAN MOTOR PHOTO
115 115
PHOTO 5
M
3 E72
0.3Y/O 3.0B
ENGINE
COOLANT
SENSOR TEMPERATURE
SENSOR
PHOTO GE12 PHOTO 1
27/101
3 1 CUD11 (D4FB) See Blower & A/C Control System
CDD11 (D4EA) (SD9713) (SD9714) (SD97111) (SD97112)
0.5G 0.5B/O 0.5W 0.3L 0.75Gr(D4FB) 0.3L

0.75L(D4EA)
47 CUDK(D4FB) 50 37 CUDA(D4FB) 94 CUDK(D4FB) 22 58 CUDA(D4FB) 93 CUDK(D4FB)

72 CDDK(D4EA) 41 58 CDDA(D4EA) 71 CDDK(D4EA) 70 94 CDDK(D4EA) 7 CDDK(D4EA)
Engine Ground Signal Fan Relay A/Con Relay Auxiliary Fan Relay ECM

Control Control Control Electric Control PHOTO
Relay (LOW) Heater (HIGH) 38
ECT Sensor
Control
CBGK CBG11
94 93 92
*90 89 88 87
* * * * 82 81 80 5779 78 77 * 5375 74 73 6 5
** * 70 69 67 66 65 64
** **** *** * * 4 3 BLANK
3 1
* 4927 26* 4725 * 23* 22* 21* 42 41 1840 1739 3816 1537 14* 1*3 12* * 10* *9 *8 297
28
* ** *
2 1 *
CDDA CDDK
60 59 58
* * * 53 37* * 50 4934 33* 47 4631
56 94 93 92
*90 89
* 87 86 * 84 83 * * 80 79 * 77 * 75 * * 6 5
45 44 43 42 41 40
** * * * 72 71 70 69 68
* * 65 64 * * * * * * 57 * * * * * 51 4 3
30
* 1328 1227 26 * * 238 *7 *6 20 194 * 172 161 * * * 4725 2446 45 4422 * * 19* 40 * 1638 3715 1436 1335 1234 1133 1032 319 308 297 2 1
* * *** * *
28
** * ** **
CDD11 CGGAA
* 44* 5843 57 56 5540 * 38* 3752 5136 50 3449 4833 32* *

* ** * * * BLANK
3 1
* 15 * * 12 11
30 27
* * *9 238 22 216 * * * 172 161
** * * * * *
CGGAK CGGMK
94 93
*
91 90 89 88
* 86 * * 8361 6082 * 80 5779 * 77 * 75 * 7351 6 5
94 93 92 91 90
* 66* 87 8664 6385 6284 8361 6082 8159 80 * * 77 54* * * 7351 6 *
72 71 70
*68 67 66
**** ** ***** 72 71 70 69 68
* * ** * * * *
4 3
* 3
* 4927 26* 25* 24* * 22* * 20* 41 * 17* 38 * * 3513 * * 1032 319 308 * 2 1
28 27 26 25 24 23 22 21 * 19 18 17 16 15
50 49 48 47 46 45 44 43 41 40 39 38
* 36 3513 12* 3311 32 319 * 297 2 1
* * * * * *** ** * * * * *
CGGK CGG11
94
* 92 91 90 89 88 87 86 85 * 83 * 81 80 79 78 77 76 75 74 73 6 5
BLANK
* 71 70 69 68 67 66 65 * 63 62 61 * 59 58 57 56 * 54 53 52 51 4 3
3 1
50 49
* 25* 24* 23* 4422 4321 4220 4119 4018 3917 38 15* 36 3513 3412 3311 32 319 308 297 2 1 *
28 27 26
* * *
CUDA CUDK
60
* 58 57 56 55 54 53 52 51 50 49 * 47 46 94 93 92
*90 89
*
87 86 85 84 83
* * 7856 7755 76 5375 52* 5173
81 80
6 5
* 44 * 42 41 40 39 38 37 36 35 34 33 32 31 72 71 70 69 68 67 66
*
64 63 62 61 60 59 58
* * 4 3
* 1429 1328 12* * 10* * * 227 *6 * 194 * 172 161

50
* 26* 47 2446 * 4422 * 20* 1941 40 17* 38 15* 14* 1335 12* 1133 1032 *9 30 *7 2 1
* * ** * *
28 27
* * * * * *
CUD11 E48 E49 E71
1 1
4 2 4 2
3
* 1 * * 3 2 1
5 5
E72
BLANK BLANK BLANK

3 2 1
2012 > D 2.0 TCID > Courtesy & Trunk Lamps > Schematic Diagrams
Courtesy & Trunk Lamps (1) SD9291
HOT AT ALL TIMES
(SD11010) JUNCTION
POWER BOX
CONNECTOR PHOTO
ROOM LP 45
15A
See Passenger
Compartment Fuse Details A To Instrument Cluster
(SD1203) (SD9292) (SD9293)
8 I/PF
0.5R
3 FR11 PHOTO 42
0.5R
11 JR01
JOINT
CONNECTOR
PHOTO 78
12 13 15 14 JR01
0.5R 0.5R 0.5R 0.5R
1 R08 1 R12 3 R16 2 R06
VANITY VANITY SUNROOF ROOM
LAMP LAMP SWITCH LAMP
MAP
SWITCH SWITCH LAMP PHOTO 77 PHOTO
RH LH 87
PHOTO 76 PHOTO 76 MAP MAP
2 R08 2 R12 See DOOR ON
Sunroof
(SD8161) OFF OFF
0.5G 0.5G ON DOOR ON
OFF OFF OFF 1 3 R06

0.5Y
1 R11 1 R10
0.5B
VANITY VANITY 4 FR11
LAMP RH LAMP LH PHOTO 42
4 2 R16 0.5Y
PHOTO PHOTO
76 76 14 MF12
2 R11 2 R10 0.5Y PHOTO 43
1 M04C
0.5B 0.5B 0.5B 0.5Y Room BCM
Lamp PHOTO
Control 57
3 2 6 7 JR01
See Ground
Distribution
(SD1303)
8 JR01
1.25B
6 FR11 PHOTO 42
1.25B
GF11 PHOTO 42
W/O ISG
I/P
From ROOM JUNCTION
LP 15A A BOX
(SD9291) PHOTO
45
12 I/PC 7 I/PF
0.5R 0.5R
BCM 8 M01C 2 F48
PHOTO INSTRUMENT LUGGAGE
Door Switch Door 57 CLUSTER LAMP
T/Gate Open PHOTO
49 PHOTO
Driver RL RR Passenger Switch IND. 66/73/88
DOOR TRUNK
20 22 39 21 23 M04A 16 M04C OPEN OPEN
1 F48
0.3R 0.3W 0.3G/O 0.3L/O 0.5G/B 0.3B
0.3R 0.3W 0.3G/O 0.3L/O 0.5G/B 0.5G/B

11 M01B 11 M01C
0.5G/B 0.5G
See Multi Display See Multi Display See Multi Display

(SD9422) (SD9422) (SD9422) 11 MF12
PHOTO 43
LHD RHD 0.5G/B
RHD LHD
10 FR12 PHOTO 66/88
5DR/WGN 3DR
0.3R 0.3R 0.3W 0.3G/O 0.3L/O 0.3L/O 0.5G 0.5G

8 RR11 PHOTO
0.5G 61/97
3 MF22 31 16 MF12 16 3 MF22 31 MF12 R28 (5DR/WGN)

PHOTO PHOTO PHOTO PHOTO 2 R31 (3DR)
75 43 75 43 TAIL GATE
SWITCH ACTUATOR
PHOTO
61/109
0.3R 0.3R 0.3W 0.3G/O 0.3L/O 0.3L/O
1 R28 (5DR/WGN)
R31 (3DR)
5DR/WGN 3DR
2 F04 2 F05 2 F06 2 F03
DRIVER REAR REAR PASSENGER
DOOR DOOR DOOR DOOR 0.5B 0.5B
SWITCH SWITCH SWITCH SWITCH
PHOTO LH RH PHOTO
85 PHOTO PHOTO 85 PHOTO PHOTO
88 89
GR11 61/97 GR12 109
HOT IN ON OR START With ISG
(SD11010) JUNCTION
BOX
From ROOM PHOTO
CLUSTER 45
10A LP 15A A
(SD9291)
See Passenger
(SD1201)
3 12 I/PC 7 I/PF
0.3R/O
0.5R 0.5R
0.3R/O
7 8 M01C 2 F48
INSTRUMENT LUGGAGE
CLUSTER LAMP
PHOTO PHOTO
MICOM DOOR TRUNK 49 66/73/88
OPEN OPEN
1 F48
Driver
Door
3 M01C 11 M01B 11 M01C

0.3B 0.5G/B 0.5G
16 M04C
BCM
Door
Open IND. PHOTO 11 MF12 PHOTO 43
Door Switch 57
T/Gate 0.5G/B
Driver RL RR Passenger Switch
10 FR12 PHOTO 66/88
20 22 39 21 23 M04A 5DR/WGN 3DR
0.3R 0.3R 0.3W 0.3G/O 0.3L/O 0.5G/B 0.5G/B
0.5G 0.5G
8 RR11
0.3R 0.3W 0.3G/O 0.3L/O 0.5G/B
0.5G PHOTO 61/97
See Multi Display See Multi Display See Multi Display R28 (5DR/WGN)

(SD9422) (SD9422) (SD9422) 2 R31 (3DR)
TAIL GATE
RHD LHD LHD RHD
SWITCH ACTUATOR
0.3R 0.3R PHOTO
0.3W 0.3G/O 0.3L/O 0.3L/O 61/109
3 MF22 31 16 MF12 16 3 MF22 31 MF12
0.3R 0.3R 0.3W 0.3G/O 0.3L/O 0.3L/O
1 R28 (5DR/WGN)
R31 (3DR)
2 F04 2 F05 2 F06 2 F03 5DR/WGN 3DR
DRIVER REAR REAR PASSENGER
DOOR DOOR DOOR DOOR 0.5B 0.5B
SWITCH SWITCH SWITCH SWITCH
PHOTO LH RH PHOTO
85 PHOTO PHOTO 85 PHOTO PHOTO
88 89 GR11 61/97 GR12 109
F03 F04 F05 F06
* 2
* * 2
* * 2
* * 2
*
F48 M01B M01C
1 BLANK
6 5 4
* 2 1 8 7 6 5 4 3 2 1
2 12 11 10 9 8 7 16 15 14 13 12 11 10 9
M04A M04C R06
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3
* 1 3 2 1
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21 16 15 14 13 12 11 10 9
R08 R10 R11 R12
2 1 2 1
2 1 2 1
R16 R28 R31
2 1
BLANK
4 3 2 1 4 3 2 1
6 5 4 3
2012 > D 2.0 TCID > DCDC Converter > Schematic Diagrams
DCDC Converter (1) SD9617
HOT IN ACC OR ON HOT AT ALL TIMES HOT IN ON OR START

I/P E/R
See Power See Power
Distribution Distribution JUNCTION
BOX
FUSE &
RELAY
With ISG
(SD11010) (SD11010)
POWER PHOTO
BOX (G4FA/G4FC/D4FB)
CONNECTOR 45
CLOCK AUDIO CLUSTER ISG : Idle Stop & Go
10A 15A 10A
See
See Passenger See Passenger Starting System
Compartment Compartment (SD3602)
Fuse Details Fuse Details
(SD1201) (SD1201)
2 I/PB 1 I/PA 2 I/PC
0.3Br 0.5L
AUDIO MULTI AUDIO INSTRUMENT

PHOTO DISPLAY PHOTO CLUSTER 5 JM03
60 PHOTO 60 PHOTO JOINT
59 49 CONNECTOR 20 EC11
PHOTO 54 PHOTO
6 M54A 9 M62 4 M54A 12 M01B 115
6 JM03
0.5W 0.85W 0.5W
0.5Y 0.5Y/B 0.85R 0.85W 0.5R 0.5L 0.5B
24 23 21 22 MC21 3 MC11 34 MC11

PHOTO PHOTO PHOTO
57 75 75
0.5Y 0.5Y/B 0.85R 0.85W 0.5R 0.5B
CGG60 (G4FA/G4FC)
8 9 1 4 6 7 10 CUD60 (D4FB)
DCDC
ACC ACC B+ B+ IG1 ISG GND CONVERTER
Input Output Input Output START
PHOTO
52
A/D
C P U CONVERTER
GM41
PHOTO 120
2012 > D 2.0 TCID > DCDC Converter > Schematic Diagrams
DCDC Converter (2) SD9618
CGG60 CUD60 M01A M54A
4 3 2 1
4
* *6 1 4
* *6 1 6 5 4 3 2 1
8 7 6 5
* 10 9 8 7
* * 10 9 8 7
* 12 11 10 9 8 7
M62
BLANK BLANK BLANK

12 11 10 9 8
* * 5 4 * 2 1
24 23 22 21 20 19 18 17 16 15
* 13
2012 > D 2.0 TCID > DRL(Daytime Running Light) > Schematic Diagrams
DRL (Daytime Running Lights) (1) SD9581
I/P E/R
See Power JUNCTION
Distribution FUSE &
BOX RELAY
(SD11010)
PHOTO BOX
TAIL H/LP
45 20A
LAMP HEAD
RELAY LAMP
10A 0.3R/O
1 5 E47 5 1 E43
See Passenger HEAD HEAD
Compartment LAMP LAMP
Fuse Details RELAY RELAY
(SD1206) (LOW) (HIGH)
RHEO
STAT TAIL RH PHOTO 31 PHOTO
RELAY 10A 2 3 E47 3 2 E43 31
0.5R 0.85G
A B
To Head Lamp LH To Head Lamp LH
6 I/PD 11 I/PC 18 I/PB 9 I/PD (SD9582) (SD9582)
0.3L 0.3L 0.85P 0.3R/O
20 M08B 0.3R/O 0.3G 0.3R
ICM 21 EM31 7 12 I/PG
RELAY
BOX PHOTO 43 I/P
See Illuminations 0.3R/O JUNCTION
(SD9411) PHOTO 46
BOX
8 M08B PHOTO 45
15 I/PC 10 I/PD
0.3L 0.3R/O 0.3W 0.3Y 0.3L 0.3W 0.3Br

4 M04C 28 M04A 19 14 M04B 33 M04A 4 1 10 9 M02L
Tail Lamp Tail Lamp Head Lamp H/Lp Head BCM MULTIFUNCTION

Relay SW Input Escort LO Lamp PHOTO LIGHT DIMMER/ SWITCH
57 PARK SWITCH LOW PASSING
Control Relay SW PHOTO
SWITCH 50
DRL HEAD OFF Pass HIGH From
Deactivation Instrument Cluster
(SD9582)
31 M04A
0.3R/B C
17 I/PD 2 M02L
0.3B 0.5B
NOTICE 2 JM02 10 JM02
DRL If you want the DRL off, open the driver's side JOINT
OFF fuse panel cover (I/P junction box) and insert See Ground Distribution CONNECTOR
any spare fuse into the DRL OFF position. (SD1301)
PHOTO 47
1 6 JM02
17 I/PG 1.25B 1.25B
0.5B
GE11 PHOTO 1 GM21 PHOTO 46

E/R
FUSE &
From Head Lamp From Head Lamp RELAY
Relay(Low) Relay(High) BOX
(SD9581) (SD9581)
A B
0.5R 0.5R
H/LP H/LP
LO LH LO RH
10A 10A
0.5O 0.85G
W/O 3DR With 3DR W/O 3DR With 3DR

28 32 EC11 PHOTO 115
0.5G
13 EM31
0.5Y 0.85G 0.5Y 0.85G 0.5O 0.85Br 0.5O 0.85Br PHOTO 43
(G4GC/D4FB) (G4GC/D4FB) 0.5G
0.75G 0.75G
(G4FA/G4FC/D4EA) CGG75 (G4FA/G4FC) (G4FA/G4FC/D4EA) CGG96 (G4FA/G4FC) 10 M01A
CBG75 (G4GC) CBG96 (G4GC) INSTRUMENT
CUD75 (D4FB) CUD96 (D4FB) CLUSTER
3 2 E77 3 2 E111 3 2 CDD75 (D4EA) 3 2 CDD96 (D4EA) PHOTO
HIGH 49
HEAD HEAD HEAD HEAD BEAM
LAMP LAMP LAMP LAMP
LH LH RH RH
LO HI PHOTO LO HI PHOTO LO HI PHOTO LO HI PHOTO
3 3 6 6
1 M01A
5 4 E77 5 4 E111 5 4 CGG75 (G4FA/G4FC) 5 4 CGG96 (G4FA/G4FC)
1.25B 1.25B 1.25B 1.25B 1.25B 1.25B CDD75 (D4EA) 1.25B 1.25B CDD96 (D4EA) 0.5B
C
To Ground
(GM21)
GGG15 (G4FA/G4FC) (SD9581)
GBG15 (G4GC)
GUD14 (D4FB) PHOTO
GE11 PHOTO 1 GDD14 (D4EA) 69
3 2 1 3 2 1 3 2 1 3 2 1
6 5 4 6 5 4 6 5 4 6 5 4
3 2 1 3 2 1 3 2 1 3 2 1
6 5 4 6 5 4 6 5 4 6 5 4
E43 E47 E77 E111
1 1
2 2 3 2 1 3 2 1
5 * 3 5 * 3 6 5 4 6 5 4
M01A M02L M04A
6 5 4 3 2 1 13 12 11 10 9
* 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21
M04B M04C M08B
8 7 6 5 4 3 1
8
* * 5 4
* 2
* BLANK
10
* * 7 6 5 4 3 2 1
* 20
* * 17 16 15 14 13 12 11 10 9
20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
2012 > D 2.0 TCID > Data Link Details > Schematic Diagrams
Data Link Details (1) SD2001
HOT AT ALL TIMES
I/P
(SD11010) BOX
POWER
CONNECTOR PHOTO
ROOM 45
LP
122Ω±1% 15A
See Passenger
(SD1203)
4 5 12 I/PC
0.5Y 0.5W
See Vehicle From ABS/ESP
19 11 JM02 From ECM/PCM Speed System Control Module
(SD2002) (SD4361) (SD2002)
JOINT (SD4362)
CONNECTOR A
PHOTO 47 D E
20 18 13 12 JM02
0.5Y 0.5Y 0.5W 0.5W 0.5G 0.5O 0.3Gr/O 0.5Y 0.5W 0.5R 0.3P
5 6 M49
M10
Low High EPS DATA LINK
CONTROL
8 7 6 5 4 3 2 1
CONNECTOR
CAN MODULE
PHOTO 48
PHOTO 47
11 1 JM01 CAN1 Vehicle Ground Ground CAN ECM ABS
High Speed High KLine KLine
JOINT
CONNECTOR CAN1 Body Code CAN Memory
PHOTO 4 Low KLine Save Low Power
13 12 2 3 JM01
16 15 14 13 12 11 10 9
0.5Y 0.5Y 0.5W 0.5W
2 3 M01A 0.3L 0.5B 0.3Br 0.5B 0.5G/B
Low HighINSTRUMENT
CLUSTER
CAN PHOTO 49 0.3G 0.3G 0.3L
18 8 JM03 Auto GM21 GM31 28 MC11
4 I/PD
A/C PHOTO 46 PHOTO 119 PHOTO 75
JOINT I/P
CONNECTOR JUNCTION
PHOTO 54 BOX
PHOTO 45
20 19 9 10 JM03 8 I/PE
0.5Y 0.5Y 0.5W 0.5W 0.3G 0.5G(D4EA)
1 2 M62
MULTI 6 M05A 14 M82A 14 M04C 16 M04A 25 CDDK(D4EA)
Low High
DISPLAY A/C SRS BCM ECM
CAN PHOTO 59 CONTROL CONTROL PHOTO PHOTO
B C MODULE MODULE 57 38
PHOTO 59 PHOTO
67
From Joint Connector
(SD2003)
HOT AT ALL TIMES
EMS
BOX
PHOTO
ECU 3 114
10A
See Power
Distribution
(SD1103) CGG47 (G4FA/G4FC)
(SD1104) CBG47 (G4GC)
CUD47 (D4FB)
16 E/RCGG1
4 3 2 1
CDD47 (D4EA)
MULTIPURPOSE
CHECK
CONNECTOR
PHOTO
0.5R
G4FA/G4FC 12
Memory
11 10 9 8 7 6 5 115
CAN1 High Ground
Power
20 19 18 17 16 15 14 13
KLine CAN1 Low
0.5P
To Data To Data
Link Connector Link Connector
26 MC11 (SD2001) (SD2001)
PHOTO 75
0.3P
D E
A
0.5G 0.5G/B 0.5W/B 0.5O 0.5B
To Data
Link Connector G4FA/G4FC, G4FA/G4FC,
(SD2001) ETC ETC
18 17 MC21
ESP ABS PHOTO 57
0.3P 0.3P 0.5G/B 0.5W/B

(G4FA/G4FC, ETC) (G4FA/G4FC, ETC)
0.5G(D4FB,With ISG) 0.5G(D4FB,With ISG)
CGG70 (G4FA/G4FC) CGG41 (G4FA/G4FC)

17(W/O D4EA) CUD70 (D4FB) 17(W/O D4EA) CUD41 (D4FB) 59 81 CGGK (G4FA/G4FC, ETC)
11(D4EA) CDD70 (D4EA) 11(D4EA) CDD41 (D4EA) 86 64 CUDK(D4FB)
ESP ABS ECM/
CONTROL CONTROL PCM
MODULE MODULE PHOTO GGG13 (G4FA/G4FC)
PHOTO PHOTO 36/38 GBG13 (G4GC)
7/13 7/13 GUD12 (D4FB) PHOTO
GDD12 (D4EA) 7/13
TIRE
PRESSURE
CAN MONITORING
MODULE
Low High
PHOTO 58
6 5 M46
JOINT
CONNECTOR
PHOTO 68
19 20 18 13 11 12 JM04
0.3Y 0.5Y 0.5Y 0.5Y 0.5W 0.5Y 0.5W 0.5W 0.5W 0.3W
8 7 M05A (Auto A/C)
B 3 8 M54C3 26 25 M06B (Manual A/C) C
Low High AUDIO A/C
PHOTO CONTROL
To Data CAN 60 MODULE To Data
Link Connector PHOTO Link Connector
(SD2001) 59 (SD2001)
14 15 MC21
PHOTO 57
0.5Y 0.5W
4 5 JC01
JOINT
CONNECTOR
PHOTO 54
3 1 2 7 8 6 JC01
0.5L(G4FA/G4FC, M/T W/O ETC) 0.5Y 0.5W 0.5W
0.5B(W/O G4FA/G4FC, M/T W/O ETC)
14 26 CGG70 (G4FA/G4FC)
14 26 CBG70 (G4GC)
ABS ESP 14 26 CUD70 (D4FB) ESP ABS
14 35 CDD70 (D4EA)
0.5Y 0.5Y Low High ESP 0.5W 0.5W

CONTROL
3 CAN MODULE 2 CGG10 (G4FA/G4FC)
3 PHOTO 2 CBG10 (G4GC)
3 7/13 2 CUD10 (D4FB)
3 2 CDD10 (D4EA)
Low High YAW RATE

SENSOR
14 26 CGG41 (G4FA/G4FC)
14 CAN PHOTO 26 CBG41 (G4GC)
14 64 26 CUD41 (D4FB)
15 26 CDD41 (D4EA)
79 57 CGGK (G4FA/G4FC, With ETC)
62 Low High ABS 84 CGGMK (G4FA/G4FC, M/T W/O ETC)
27 CONTROL 12 CGGAA (G4FC, A/T W/O ETC)
78 CAN MODULE 77 CBGK (G4GC)
36 PHOTO 37 CUDAT (D4FB, A/T)
87 7/13 66 CUDK(D4FB)
83 84 CDDK(D4EA)
ECM/PCM/
Low High TCM
CAN PHOTO
36/37/38
CBGK CBG10
94 93 92
*90 89 88 87
* * * * 82 81 80 5779 78 77 * 5375 74 73 6 5
1
** * 70 69 67 66 65 64
** **** *** * * 4 3 2 BLANK
* 4927 26* 4725 * 23* 22* 21* 42 41 1840 1739 3816 1537 14* 1*3 12* * 10* *9 *8 297 2 1 3
28
* ** * 4
CBG41 CBG47
13 * * 22* * 20* 19* 186 17* * * 14* 1 * * * * BLANK

** * ** * * * * * * * 5
18
38
* * * 34 33 32 31 30 * * 27 26 25 * * * * * * *
CBG70 CDDK
12
***** 6 5 * 3 * 1
94 93 92
*90 89
* 87 86 * 84 83 * * 80 79 * 77 * 75 * * 6 5
13
* * 22 * 20 19 18 17 16 * 14
72 71 70 69 68
* * 65 64 * * * * * * 57 * * * * * 51 4 3
* * * 4725 2446 45 4422 * * 19* 40 * 1638 3715 1436 1335 1234 1133 1032 319 308 297 2 1
38
* * * 34 33 32 31 30 * * 27 26 25 28
** * ** **
CDD10 CDD41 CDD47
1
2 1 2 3 4
5 6
*
8 9 10 11
* * * 15 * * * * BLANK
3
16 17 18 19 20
* * * * * 26 * * * * * * * 5
4 * * 18 * * * * *
CDD70 CGGAA
* 44* 5843 57 56 5540 * 38* 3752 5136 50 3449 4833 32* *

1 2 3 4
5 6
* 8 9 10 11
* 13 14 * * * * * * * * * * * * ** * * *
26 27 28 29 30 31
* * * 35 * * * * * * * * * * *
15 * * 12 11 *** ***
30 27 23 22 21 17 16
** *9 8* 6 * * * 2 1
CGGMK CGGK
94 93 92 91 90
* 66* 87 8664 6385 6284 8361 6082 8159 80 * * 77 54* * * 7351 6 * 94
* 92 91 90 89 88 87 86 85 * 83 * 81 80 79 78 77 76 75 74 73 6 5
72 71 70 69 68
* * ** * * * * * 71 70 69 68 67 66 65 * 63 62 61 * 59 58 57 56 * 54 53 52 51
* 3 4 3
28 27 26 25 24 23 22 21 * 19 18 17 16 15 * 36 3513 12* 3311 32 319 * 297 2 1 * 25* 24* 23* 4422 4321 4220 4119 4018 3917 38 15* 36 3513 3412 3311 32 319 308 297
50 49 48 47 46 45 44 43 41 40 39 38 50 49
2 1
* * * * 28 27 26
* * *
CGG10 CGG41 CGG47
1
2
13 * * 22* * 20* 19* 186 17* * * 14* 1 * * * *
** * ** 12
* * * * * 6 5
3 * * 18 * * * 14 *
4
38
* * * 34 33 32 31 30 * * 27 26 25
CGG70 CUDAT
6 7 8 9 10 5 4
* 12 * 14 * * 36* 18 19 20 21 22 23 24
13
12
***** 6 5 * 3 * 1 * * * * * * * * * * * 37
* * * * * *
* * 22 * 20 19 18 17 16 * 14 44
3
38
* * * 34 33 32 31 30 * * 27 26 25 * * * * * * * * 53 * * * * 58 59 * 61 62
* * * * * * * * * * * 74 * * * 78 * * * 2 1
CUDK CUD10
94 93 92
*90 89
*
87 86 85 84 83
* * 7856 7755 76 5375 52* 5173
81 80
6 5
1
72 71 70 69 68 67 66
*
64 63 62 61 60 59 58
* * 4 3 2 BLANK
50
* 26* 47 2446 * 4422 * 20* 1941 40 17* 38 15* 14* 1335 12* 1133 1032 *9 30 *7 2 1 3
28 27
* * * * * * 4
CUD41 CUD47
13 * * 22* * 20* 19* 186 17* * * 14* 1 * * * *

** * ** * * * * * * * 5
BLANK
38
* * * 34 33 32 31 30 * * * 26 25 * * 18 * * * * *
CUD70 M01A
13
12
***** 6 5 * 3 * 1 BLANK
* * 22 * 20 19 18 17 16 * 14 6 5 4 3 2 1
38
* * * 34 33 32 31 30 * * * 26 25 12 11 10 9 8 7
M04A M04C M05A
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3
* 1 13
* * 10 9 8 7 6
** * 2 1
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21 16 15 14 13 12 11 10 9
26 25 24 23 22 21 20 19 18 17 16
* 14
M06B M10 M46 M49
14 13 12 11 10 9 8 7 6 5 4 3 2 1
* 7 6 5 4 3 2 1
* *
28 27 26 25
* 23 22 21 20 19 18 17 16 15 * 15 * 13 12 11 * 9 * 9 188 7 6 5 * 3 * 1 6 5 4
*
** ** ** ** *
M54C3 M62 M82A
3
* 1
* * * * * * 6 5 4 3 2 1
* * 12 11 10 9 8
* * 5 4
* 2 1 BLANK
8
* 6 24 23 22 21 20 19 18 17 16 15
* 13 24 23 22 21 20
* 18 17
* * 14 13
2012 > D 2.0 TCID > Door Harness > Schematic Diagrams
2012 > D 2.0 TCID > Electro Chromic Mirror > Schematic Diagrams
Electro Chromic Mirror (1) SD8511
HOT IN ON HOT IN ON OR START
I/P E/R
See Power Distribution JUNCTION See Power Distribution
(SD11010) (SD1108) FUSE &
BOX RELAY
PHOTO 45 BOX
A/CON B/UP
10A 10A
See Passenger
(SD1202) 0.5R
10 I/PF 30 EC11
PHOTO 115
M/T A/T
0.5P
0.5R 0.5R
1 FR11
PHOTO 42 CGG01 (G4FC)
CBG01 (G4GC)
CGG50 (G4FA/G4FC) 8 CUD01 (D4FB)
0.5P CBG50 (G4GC) TRANSAXLE
CUD50 (D4FB) RANGE
2 CDD50 (D4EA) SWITCH
BACKUP PHOTO 33
16 JR01 LAMP P D
See Passenger JOINT SWITCH
See Ground CONNECTOR R N
Compartment PHOTO
Distribution Fuse Details 35/106
(SD1303) PHOTO 78
(SD1202) 1 CGG50 (G4FA/G4FC) 7 CGG01 (G4FC)
8 5 19 JR01 CUD50 (D4FB) CUD01 (D4FB)
CDD50 (D4EA)
0.5Br 0.5Br
See Automatic
1.25B 0.5B 0.5W Transaxle Control System
(SD4501) (SD4502)
(SD4505) (SD4507)
0.5G(G4FC)
6 FR11 0.5L(G4GC)
PHOTO 42 0.5Br/B(D4FB)
0.5Gr
2 1 3 R01
ELECTRO
Ground 'ON' input Transaxle range switch "R" position/ CHROMIC
Backup lamp switch "ON" MIRROR 23 MC11
PHOTO 79 PHOTO 75
P . C . B
0.5R 0.5L
1.25B
15 I/PD
I/P
See Backup Lamps JUNCTION
(SD9261) (SD9262) BOX
13 I/PF 5 M54A
PHOTO 45 AUDIO
0.5Gr PHOTO 60
2 FR11
GF11
IND SW SNR PHOTO 42
PHOTO 42
2012 > D 2.0 TCID > Electro Chromic Mirror > Schematic Diagrams
Electro Chromic Mirror (2) SD8512
CBG01 CBG50 CDD50 CGG01
6 5 3 2 1 6 5 3 2 1
* 2 1 2 1 *
10 9 8 7 10 9 8 7
CGG50 CUD01 CUD50 M54A
4 3 2 1
6 5 3 2 1
2 1 * 2 1
10 9 8 7 8 7 6 5
R01
BLANK BLANK BLANK

3 2 1
* * * *
2012 > D 2.0 TCID > Electronic Stability Program (ESP)System(2010.09.15~) > Schematic Diagrams
Electronic Stability Program (ESP) System (1) SD5881
HOT IN ON OR START
See Power I/P
BOX PCM/
(SD11010) ECM
PHOTO 45
CLUSTER MDPS PHOTO
10A 15A 36/37
See Passenger
Compartment Fuse Details 39 CGGK (G4FA/G4FC, With ETC)
(SD1201) 53 CBGK (G4GC)
3 I/PC 8 I/PB See Illuminations

0.3R/O (SD9412)
0.3R/O PHOTO 49 0.5P 0.5P

7 M01C INSTRUMENT CLUSTER 4 6 M22 CGG71 (G4FA/G4FC)
CBG71 (G4GC)
ESP OFF 1 CUD71 (D4FB)
SWITCH
CLUTCH
ON ILL. PHOTO SWITCH
ESP OFF 116
OFF ESP PARKING PHOTO
ABS BRAKE 4
( )! ( )P FRONT
( )ABS 5 3 M22 P S WHEEL 0.5O
BRAKE 2 CGG71 (G4FA/G4FC)
0.5W 0.5Gr SENSOR Except CBG71 (G4GC)
LH Euro II 0.5Br/B CUD71 (D4FB) 0.5B
(G4FA/G4FC,
See Illuminations 2 1 E82 D4FB)
(SD9412) 0.5Br/O See BackUp
M I C O M PHOTO 70 (G4GC)
0.5L 0.5R Lamps GGG14 (G4FA/G4FC)
2 MC11 (SD9261) GBG14 (G4GC)
CAN TRANSCEIVER PHOTO 75 8 4 EC11 (SD9262) GUD13 (D4FB)
0.5W PHOTO 115 PHOTO 7/13
Low High 0.5L 0.5R
23 MC11
2 3 M01A 22 CGG70 (G4FA/G4FC)
0.5Y 0.5W
8 34 0.5L CGG70 (G4FA/G4FC)
8 34 22 CBG70 (G4GC) CBG70 (G4GC)
12 2 JM01 8 34 22 CUD70 (D4FB) 27 CGG70 (G4FA/G4FC) 23 24 CUD70 (D4FB)
See Data JOINT ESP
Link Details CONNEC ESP CONTROL
TOR ESP Power Signal Wheel Speed Clutch Rear Gear UNIT MODULE
(SD2001) Switch Sensor Output Switch
PHOTO CCAN PHOTO
13 3 JM01 4 Parking 7/13
0.5Y 0.5W High Low Power Signal Brake switch Power Signal Power Signal
18 8 JM03
See Data JOINT 26 14 18 6 10 33 20 19 31 CGG70 (G4FA/G4FC)
Link Details CONNEC 26 To Yaw 14 18 6 10 33 20 19 31 CBG70 (G4GC)
(SD2001) TOR 26 Rate Sensor 14 18 6 10 33 20 19 31 CUD70 (D4FB)
PHOTO (SD5882) 0.5G 0.5L 0.3L(G4FA/G4FC, 0.5G 0.5L 0.5Br 0.5W
20 10 JM03 54 (G4FA/G4FC, D4FB) (G4FA/G4FC,
0.5Y 0.5W D4FB) 0.3Y(G4GC) D4FB)
20 11 JM04 A B 0.5O(G4GC) 0.5O(G4GC)
See Data JOINT 0.5W 0.5W 0.5B 0.5B 39 MC11 3 1 2 6 CF11
Link Details CONNEC PHOTO 115
(SD2003) TOR 7 8 1 2 JC01 CGG43 (G4FA/G4FC) 0.5G 0.5O 0.5Br 0.5W
PHOTO CBG43 (G4GC)
19 12 JM04 68 JOINT 2 1 CUD43 (D4FB) 2 1 F13 2 1 F14
0.5Y 0.5W CONNEC FRONT See Indicators REAR REAR
TOR WHEEL & Gauges WHEEL WHEEL
14 15 MC21 (SD9402)
SENSOR RH SENSOR LH SENSOR RH
0.5B 0.5W PHOTO 57 5 4 JC01 P S PHOTO 70 P S PHOTO 121 P S PHOTO 94
PHOTO 54
E/R
(SD1108) RELAY
ABS BOX
ABS1 ABS2
10A 40A 20A
YAW RATE See Stop
SENSOR Lamps
CAN PHOTO 64 (SD9271)
ON/START
Input Ground Low High (SD9272)
1 4 3 2 CGG10 (G4FA/G4FC)
CBG10 (G4GC)
CUD10 (D4FB)
0.5W 0.5W 0.5B 0.5B 0.5W 0.5P 3.0W 2.0R
(G4FA/G4FC, D4FB)
34 EC11 0.5G/O 1 2 EC11
B A (G4GC) PHOTO 115
PHOTO 115
0.5W 3.0R 2.0R
From ESP
GGG16 (G4FA/G4FC) Control Module
GBG16 (G4GC) (SD5881)
32 GUD17 (D4FB) PHOTO 30 1 25 CGG70 (G4FA/G4FC)
32 112 30 1 25 CBG70 (G4GC)
32 30 1 25 CUD70 (D4FB)
Brake Light ESP
Switch CONTROL
MODULE
Stop Lamp Vbatt VR ESP
PHOTO
+ECU Switch Motor Relay Actuation UNIT 7/13
Motor MR Valve

Ground Monitoring Actuation Monitoring Pressure Sensor
C1
MOTOR VALVE
6 8 5 7 2A 2B 4A 4B 3A 3B 1A 1B D0 BLOCK
RELAY
T2 T1 VALVE
IN OUT IN OUT IN OUT IN OUT RELAY
M
T0
HSV2 HSV1 TCV2 TCV1 RR RL FR FL
38 13 CGG70 (G4FA/G4FC)
38 13 CBG70 (G4GC)
38 13 CUD70 (D4FB)
2.0B 3.0B
GGG16 (G4FA/G4FC)
GBG16 (G4GC) PHOTO
GUD17 (D4FB) 112
CBGK CBG10 CBG43
94 93 92
*90 89 88 87
* * * * 82 81 80 5779 78 77 * 5375 74 73 6 5 1
** * 70 69 67 66 65 64
** **** *** * * 4 3 2 1 2
* 4927 26* 4725 * 23* 22* 21* 42 41 1840 1739 3816 1537 14* 1*3 12* * 10* *9 *8 297 2 1 3
4
28
* ** *
AMP_ECU_94F_B AMP_MQSWP_04F_B KET_090IIWP_02M_Gr
CBG70 CBG71
13 * * * 208 19* 186 * * * 14* 1

10
*
24 23 22
*** 1 BLANK
38
* * * 34 33 32 31 30 * * 27 26 25 2
DEL_ABS_38F_B_A KET_250DL_02F_W
CGGK CGG10 CGG43
94
* 92 91 90 89 88 87 86 85 * 83 * 81 80 79 78 77 76 75 74 73 6 5 1
* 71 70 69 68 67 66 65 * 63 62 61 * 59 58 57 56 * 54 53 52 51 4 3
2 1 2
3
50 49
* 25* 24* 23* 4422 4321 4220 4119 4018 3917 38 15* 36 3513 3412 3311 32 319 308 297 2 1 4
28 27 26
* * *
AMP_ECU_94F_B AMP_MQSWP_04F_B KET_090IIWP_02M_Gr
CGG70 CGG71 CUD10
13
12
* * 208 19* 186 * * * 14* 1
10 1
2
*
24 23 22
*** 1
3
38
* * * 34 33 32 31 30 * * 27 26 25 2
4
DEL_ABS_38F_B_A KET_250DL_02F_W AMP_MQSWP_04F_B
CUD43 CUD70 CUD71
1 2
13
12
* * 208 19* 186 * * * 14* 1
10
24 23 22
* *** 1
38
* * * 34 33 32 31 30 * * * 26 25 2
KET_090IIWP_02M_Gr DEL_ABS_38F_B_A KET_250DL_02F_W
E82 F13 F14 M10
1 2 1 2 1 2 * 7 6 5 4 3 2 1
* 15 * 13 12 11 * 9
KET_090IIWP_02M_Gr KET_090IIWP_02M_Gr KET_090IIWP_02M_Gr MLX_OBDII_16F_B
M22 EC11 (G4FA/G4FC)
12 16 20 24 28 32 36 36 32 28 24 20 16 12 8 4 1
*6 5 4
*3 13 17
* 29 33 37
21 37 33
* 21 17 13 9 5
29
2
BLANK
* 18 * * 30 34 38 38 34 30
* * 18 * 10 6 3
* * * * * * * * * * * * * * 11 *
AMP_090III_06F_R_2 KET_0409LIF_39M_W KET_0409LIF_39F_W
EC11 (G4GC) EC11 (D4FB)
* * * 16 * 8 4
4 8 16 24 28 32 36 36 32 28 24 4 8 12 16 20 24 28 32 36 36 32 28 24 20 16 12 8 4
1 1 1 1
2 * 9 13 17
* 29 33 37
21 37 33
* 21 17 13 9 *
29
2 2 * * * 29 33 37
9 13 17 37 33
* * 17 13 9 *
29
2
6
* * 18 * * 30 34 * * 34 30 * * 18 * * 6
6
* 14 18 22 * 30 34 38 38 34 30
* 22 18 14 * 6
3
7
** * * * * * * * * * * * *** 7
3
* *** * * * * * * * * * * * **** *
KET_0409LIF_39M_W KET_0409LIF_39F_W KET_0409LIF_39M_W KET_0409LIF_39F_W
CF11
2 1
1 2 BLANK
6 5 4 3
3 4 5 6
AMP_090III_06M_W AMP_090III_06F_W_2
2012 > D 2.0 TCID > Electronic Stability Program (ESP)System(~2010.09.15) > Schematic Diagrams
HOT IN ON OR START
See Power I/P
BOX PCM/
(SD11010) ECM
PHOTO 45
CLUSTER MDPS PHOTO
10A 15A 36/37
See Passenger
Compartment Fuse Details 39 CGGK (G4FA/G4FC, With ETC)
(SD1201) 64 CGGMK (G4FA/G4FC, M/T W/O ETC)
20 CGGAK (G4FA/G4FC, A/T W/O ETC)
3 I/PC 8 I/PB See Illuminations 53 CBGK (G4GC)
0.3R/O (SD9412)
0.3R/O PHOTO 49 0.5P 0.5P

7 M01C INSTRUMENT CLUSTER 4 6 M22 CGG71 (G4FA/G4FC)
CBG71 (G4GC)
ESP OFF 1 CUD71 (D4FB)
SWITCH
CLUTCH
ON ILL. PHOTO SWITCH
ESP OFF 116
OFF ESP PARKING PHOTO
ABS BRAKE 4
( )! ( )P FRONT
( )ABS 5 3 M22 P S WHEEL 0.5O
BRAKE 2 CGG71 (G4FA/G4FC)
0.5W 0.5Gr SENSOR Except CBG71 (G4GC)
LH Euro II 0.5Br/B CUD71 (D4FB) 0.5B
(G4FA/G4FC,
See Illuminations 2 D4FB) See BackUp
1 E82 Lamps
(SD9412) 0.5Br/O
M I C O M PHOTO 70 (G4GC) (SD9261)
0.5L 0.5R (SD9262) GGG14 (G4FA/G4FC)
2 MC11
GBG14 (G4GC)
CAN TRANSCEIVER PHOTO 75 8 4 EC11 0.5L GUD13 (D4FB)
0.5W PHOTO 115 PHOTO 7/13
Low High 0.5L 0.5R
5 34 22 CGG70 (G4FA/G4FC)
2 3 M01A 5 34 22 CBG70 (G4GC) CGG70 (G4FA/G4FC)
0.5Y 0.5W 5 34 22 CUD70 (D4FB) 27 CGG70 (G4FA/G4FC) CBG70 (G4GC)
12 2 JM01 31 26 5 CDD70 (D4EA) 27 CBG70 (G4GC) 16 3 CUD70 (D4FB)
See Data JOINT ESP
Link Details CONNEC ESP CONTROL
TOR ESP Power Signal Wheel Speed Clutch Rear Gear UNIT MODULE
(SD2001) Switch Sensor Output Switch
PHOTO CCAN PHOTO
13 3 JM01 4 Parking 7/13
0.5Y 0.5W High Low Power Signal Brake switch Power Signal Power Signal
18 8 JM03
See Data JOINT 26 To Yaw 14 18 6 12 33 20 19 31 CGG70 (G4FA/G4FC)
Link Details CONNEC 26 Rate Sensor 14 18 6 12 33 20 19 31 CBG70 (G4GC)
(SD2001) TOR 26 (SD5882) 14 18 6 12 33 20 19 31 CUD70 (D4FB)
PHOTO 35 14 9 10 13 6 27 8 29 CDD70 (D4EA)
20 10 JM03 54 0.3L(G4FA/G4FC, D4FB)
0.5Y 0.5W 0.3Y(G4GC, D4EA) 0.5G 0.5O 0.5Br 0.5W
20 11 JM04 A B
0.5G 0.5O 3 1 2 6 CF11
See Data JOINT 0.5W 0.5Y 0.5Y 0.5Y PHOTO 115
Link Details CONNEC CGG43 (G4FA/G4FC) 0.5G 0.5O 0.5Br 0.5W
(SD2003) TOR 7 8 1 2 JC01 CBG43 (G4GC)
PHOTO CUD43 (D4FB) See Indicators
19 12 JM04 68 JOINT 2 1 CDD43 (D4EA) & Gauges 2 1 F13 2 1 F14
0.5Y 0.5W CONNEC FRONT (SD9402) REAR REAR
TOR WHEEL WHEEL WHEEL
14 15 MC21
SENSOR RH SENSOR LH SENSOR RH
0.5Y 0.5W PHOTO 57 5 4 JC01 P S PHOTO 70 P S PHOTO 121 P S PHOTO 94
PHOTO 54
E/R
(SD1108) RELAY
ABS BOX
ABS1 ABS2
10A 40A 20A
YAW RATE See Stop PHOTO 115

SENSOR Lamps PHOTO 48
CAN MULTIPURPOSE
ON/START PHOTO 64 (SD9271) DATA LINK CHECK
Input Ground Low High (SD9272) CONNECTOR CONNECTOR
1 4 3 2 CGG10 (G4FA/G4FC) 1 M10 18 CGG47 (G4FA/G4FC)
0.5W 0.5W 0.5B 0.5Y 0.5W CDD10 (D4EA) 0.5P 0.3P 0.5P CDD47 (D4EA) 3.0W 2.0R
(G4FA/G4FC, D4FB)
34 EC11 0.5G/O 26 MC11 1 2 EC11
A B (G4GC, D4EA) PHOTO 115
PHOTO 115 PHOTO 75
0.5W 0.3P 3.0W(D4EA) 2.0R
3.0R(W/O D4EA)
From ESP
GGG16 (G4FA/G4FC) Control Module
32 GBG16 (G4GC) 30 17 1 25 CGG70 (G4FA/G4FC)
32 (SD5881) 30 17 1 25 CBG70 (G4GC)
GUD17 (D4FB) PHOTO
32 GDD16 (D4EA) 112 30 17 1 25 CUD70 (D4FB)
28 30 11 2 3 CDD70 (D4EA)
ESP
CONTROL
MODULE
Stop Lamp Diagnosis Vbatt VR ESP
PHOTO
+ECU Switch Motor Relay Actuation UNIT 7/13
DG
Motor MR Valve
Ground Monitoring Actuation Monitoring VO VI VS GND
C1
MOTOR VALVE
6 8 5 7 2A 2B 4A 4B 3A 3B 1A 1B D0 BLOCK
RELAY
T2 T1 VALVE
IN OUT IN OUT IN OUT IN OUT RELAY
M DS T0
HSV2 HSV1 USV2 USV1 RR RL FR FL
38 13 CGG70 (G4FA/G4FC)
38 13 CBG70 (G4GC)
38 13 CUD70 (D4FB)
4 1 CDD70 (D4EA)
2.0B 3.0B
GGG16 (G4FA/G4FC)
GBG16 (G4GC) PHOTO
GUD17 (D4FB) 112
GDD16 (D4EA)
CBGK CBG10 CBG43
94 93 92
*90 89 88 87
* * * * 82 81 80 5779 78 77 * 5375 74 73 6 5 1
** * 70 69 67 66 65 64
** **** *** * * 4 3 2 1 2
* 4927 26* 4725 * 23* 22* 21* 42 41 1840 1739 3816 1537 14* 1*3 12* * 10* *9 *8 297 2 1 3
4
28
* ** *
CBG47 CBG70 CBG71
* * * * 13
12
***** 6 5 * 3 * 1
* * * * * * * 5 * * 22 * 20 19 18 17 16 * 14 1
* * 18 * * * * * 38
* * * 34 33 32 31 30 * * 27 26 25 2
CDD10 CDD43 CDD47
1
2 1 2 * * * * BLANK
3 * * * * * * * 5
18
4 * * * * * * *
CDD70 CGGAK
94 93
*91 90 89 88
* 86 * * 8361 6082 * 80 5779 * 77 * 75 * 7351 6 5
1 2 3 4
5 6
* 8 9 10 11
* 13 14 * * * * * * * * * * * 72 71 70
*68 67 66
**** ** ***** 4 3
26 27 28 29 30 31
* * * 35 * * * * * * * * * * * * 4927 26* 25* 24* * 22* * 20* 41 * 17* 38 * * 3513 * * 1032 319 308 * 2 1
* * * * * *** ** *
CGGMK CGGK
94 93 92 91 90
* 66* 87 8664 6385 6284 8361 6082 8159 80 * * 77 54* * * 7351 6 * 94
* 92 91 90 89 88 87 86 85 * 83 * 81 80 79 78 77 76 75 74 73 6 5
72 71 70 69 68
* * ** * * * * * 71 70 69 68 67 66 65 * 63 62 61 * 59 58 57 56 * 54 53 52 51
* 3 4 3
28 27 26 25 24 23 22 21 * 19 18 17 16 15 * 36 3513 12* 3311 32 319 * 297 2 1 * 25* 24* 23* 4422 4321 4220 4119 4018 3917 38 15* 36 3513 3412 3311 32 319 308 297
50 49 48 47 46 45 44 43 41 40 39 38 50 49
2 1
* * * * 28 27 26
* * *
CGG10 CGG43 CGG47
1
2 1 2 * * * * BLANK
3
12
* * * * * 6 5
4 * * 18 * * * 14 *
CGG70 CGG71 CUD10
13
12
***** 6 5 * 3 * 1 1
2
* * 22 * 20 19 18 17 16 * 14 1
3
38
* * * 34 33 32 31 30 * * 27 26 25 2
4
CUD43 CUD47 CUD70
1 2 * * * * 13
12
***** 6 5 * 3 * 1
* * * * * * * 5 * * 22 * 20 19 18 17 16 * 14
18
* * * * * * * 38
* * * 34 33 32 31 30 * * * 26 25
CUD71 E82 F13 F14
1 1 2 1 2 1 2
M10 M22
* 7 6 5 4 3 2 1
*6 * BLANK BLANK
5 4 3
* 15 * 13 12 11 * 9
2012 > D 2.0 TCID > Floor & Air Bag Harness > Schematic Diagrams
2012 > D 2.0 TCID > Floor & Air Bag Harness > Schematic Diagrams
2012 > D 2.0 TCID > Front & Front End Module Harness > Schematic Diagrams
2012 > D 2.0 TCID > Front Fog & Rear Fog Lamps > Schematic Diagrams
Front Fog & Rear Fog Lamps (1) SD9241
5DOOR/WAGON HOT AT ALL TIMES 2 I/PH
E/R See Power I/P
MULTI FUSE & JUNCTION
FUSE Distribution
RELAY (SD11010) BOX
ALT B+1 BOX TAIL PHOTO
150A 50A LAMP 45
F/FOG RELAY RR FOG
15A 10A
See Passenger
0.85R Compartment
1 5 E44 Fuse Details
(SD1206) TAIL 19 I/PB
FRONT RH 0.5L
FOG 10A 11 M08B
LAMP
RELAY ICM
RELAY
PHOTO 85 30 BOX
5.0W 4 I/PG 6 I/PD
2 3 E44 31 REAR PHOTO
0.5P 0.3L
FOG 46
4 M04C
LAMP
BCM RELAY
Tail Lamp
0.85O 0.85O 0.5O 0.3R Relay Control PHOTO
57
16 EC11 1 5 EM31 Front Fog Front Fog Tail Lamp Rear Fog 86 87
PHOTO 43 Lamp Relay Rear Fog Lamp Switch Lamp Relay
PHOTO Control Switch Switch Input Control
115 9 2 10 M08B
1 E75 17 5 6 M04B 28 M04A 13 M04C
0.5O 0.3G/O 0.3G/O 0.3Y/O 0.5W/B
FRONT
FOG 0.3W/B 0.3G/O 0.3L
LAMP 30 MF12
LH 7 8 M01A 7 6 1 M02L PHOTO 43
INSTRU MULTIFUNCTION
2 E75 FRONT REAR MENT LIGHT SWITCH WGN 5DR
CLUSTER REAR
PHOTO FOG FOG FOG PARK HEAD SWITCH PHOTO 50
PHOTO ON LAMP PHOTO
1 0.5W/B 95
0.85B 49 SWITCH
OFF LHD RHD REAR
OFF AUTO 1 F33
FOG LAMP
0.75Br 0.5W/B 0.5W/B
(G4FA/G4FC) FRONT
OFF FOG 6 F07 6 F09
0.85O 1 1
(G4GC/D4FB CGG85 (G4FA/G4FC) 1 M01A LAMP REAR REAR
ON SWITCH REAR REAR LH RH
/D4EA) CBG85 (G4GC) COMBI COMBI
CUD85 (D4FB) FOG NATION FOG NATION
1 CDD85 (D4EA) LAMP LAMP LAMP LAMP
(LHD) / LH(LOW) (RHD)/ RH(LOW)
FRONT BACK BACK
FOG 5 2 M02L UP PHOTO UP PHOTO
LAMP RH 73 LAMP 74 2 2
LAMP
PHOTO 0.5B 0.3B 0.3B (RHD) (LHD)
10 10 5 2 JM04
2 CGG85 (G4FA/G4FC) JOINT 3 F07 3 F09 2 F33
CBG85 (G4GC) See Ground CONNECTOR
Distribution 0.85B See Ground 0.85B
0.85B CUD85 (D4FB) (SD1301) PHOTO 68
CDD85 (D4EA) Distribution
(SD1304) 0.85B 0.5B
6 1 JM02
1.25B 1.25B
GGG15 (G4FA/G4FC)
GBG15 (G4GC)
GE11 GUD14 (D4FB) PHOTO PHOTO PHOTO
PHOTO 1 GDD14 (D4EA) 69
GM21 PHOTO 46 GF51 66/88 GF61 89/111
3DOOR HOT AT ALL TIMES 2 I/PH

E/R See Power I/P
MULTI FUSE &
FUSE Distribution JUNCTION
RELAY (SD11010) BOX
ALT B+1 BOX TAIL
150A LAMP PHOTO
50A RR FOG 45
F/FOG RELAY
15A 10A
See Passenger
0.85R Compartment
1 5 E44 Fuse Details
(SD1206) TAIL
RH 19 I/PB
FRONT
FOG LAMP 10A 0.5L
RELAY 11 M08B
PHOTO ICM
31 5.0W RELAY
4 I/PG 6 I/PD 85 30 BOX
2 3 E44
0.5P 0.3L REAR PHOTO
FOG 46
4 M04C
LAMP
BCM RELAY
Tail Lamp
0.85O 0.85O 0.5O 0.3R Relay Control PHOTO
57
16 EC11 1 5 EM31 Rear Fog 86 87
PHOTO 43 Front Fog Lamp Rear Fog Front Fog Tail Lamp Lamp Relay
PHOTO Relay Control Switch Lamp Switch Switch Input Control
115 9 2 10 M08B
0.5O 0.3G/O 17 5 6 M04B 28 M04A 13 M04C
0.3G/O 0.3Y/O 0.5W/B
1 E113 0.3W/B 0.3G/O 0.3L
FRONT 7 8 M01A
FOG 7 6 1 M02L
LAMP LH INSTRU MULTIFUNCTION 30 MF12 PHOTO 43
PHOTO FRONT REAR MENT LIGHT SWITCH
1 CLUSTER REAR
FOG FOG FOG PARK HEAD SWITCH PHOTO
PHOTO ON LAMP 50
2 E113
49 SWITCH
OFF 0.5W/B
OFF AUTO
0.85B 0.75O
FRONT
OFF FOG
CGG98 (G4FA/G4FC) 1 M01A LAMP 2 F25
CBG98 (G4GC) ON SWITCH
LICENSE
CUD98 (D4FB)
1 CDD98 (D4EA) REAR LAMP
FOG PHOTO 95
FRONT LAMP
FOG 5 2 M02L
LAMP RH
PHOTO 0.5B 0.3B 0.3B 3 F25
10 10 5 2 JM04
2 CGG98 (G4FA/G4FC) JOINT
CBG98 (G4GC) See Ground CONNECTOR
Distribution 0.5B
0.85B CUD98 (D4FB) (SD1301) PHOTO 68
CDD98 (D4EA)
6 1 JM02
1.25B 1.25B
GGG15 (G4FA/G4FC)
GBG15 (G4GC) GF61 PHOTO
GE11 GUD14 (D4FB) PHOTO 89/111
PHOTO 1 GDD14 (D4EA) 69
GM21 PHOTO 46
2 1 2 1 2 1 2 1
2 1 2 1 2 1 2 1
E44 E75 E113 F07
1
2
2 1 2 1 * 2
5 * 3 3 4 5 6
F09 F25 F33 M01A
* 2 3 2 1 2 1
6 5 4 3 2 1
3 4 5 6 12 11 10 9 8 7
M02L M04A M04B
13 12 11 10 9
* 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1 10
* * 7 6 5 4 3 2 1
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11
M04C M08B
8 7 6 5 4 3 1
8
* * 5 4
* 2
*
* 20
* * 17 16 15 14 13 12 11 10 9
BLANK BLANK
16 15 14 13 12 11 10 9
2012 > D 2.0 TCID > Front Wiper & Washer > Schematic Diagrams
Front Wiper & Washer (1) SD9811
HOT IN ON
See Power
Distribution
I/P
JUNCTION
E/R
FUSE &
With RAIN SENSOR
5 1 E46
(SD11010) FR BOX RELAY
A/CON FRONT BOX From A/CON 10A
10A WIPER PHOTO
45 WIPER (SD9811)
See Passenger 25A
RELAY A
Compartment
Fuse Details PHOTO 31
(SD1202) 0.3R/B
3 2 4 E46
21 I/PB 10 I/PF 20 I/PB 13 I/PG 11 JM03
0.3R/B 0.5P 2.0R 2.0L 2.0L 2.0L 2.0W PHOTO 38
See Passenger JOINT
8 5 JE01 6 JE01 ECM CONNECTOR
Compartment
JOINT 2.0G Fuse Details PHOTO 54
CONNEC (SD1202)
A TOR 23 EM31
PHOTO 53 CUDK PHOTO 12 JM03
To Rain 7 JE01 114 43
BCM 0.75G
Sensor Relay Wiper PHOTO 2.0R 0.3R
(SD9811) Relay 57
1 FR11 0.5Gr 0.5W 2.0G
Control
PHOTO 42 16 18 M08A
0.5P 5 M04C 17 26 EM31 2.0L 2.0W PHOTO Z01
WASHER 115 DIODE ICM
MOTOR 0.3Gr PHOTO 43 30 85 RELAY
16 JR01 17 36 EC11 PHOTO
M PHOTO 52 RAIN BOX
See Passenger JOINT 0.3G 0.5L D4FB
10 SENSOR PHOTO
Compartment CONNECTOR 7 12 MF12 2.0L 2.0W With AMS RELAY 46
Fuse Details PHOTO PHOTO 43 2.0W
(SD1202) 78 0.5G 0.5L
12 11 FR11 CGG07 (G4FA/G4FC)
17 JR01 From Rain 2.0W CBG07 (G4GC)
B Sensor Relay 0.5G PHOTO 42 87a 87 86
0.5P 0.5P 0.5L CUD07 (D4FB)
(SD9811) 3 2 CDD07 (D4EA)
5 7 8 2 R17 17 9 8 M08A
3 1 2 CGG67 FRONT
(G4FA/G4FC) ON Rain Sensor Wiper Parking RAIN WIPER 0.3P
1.25G/O 1.25B 1.25Y/O CBG67 (G4GC) Input Relay Control Relay Switch SENSOR M MOTOR
(W/O D4EA) CUD67 (D4FB) Control PHOTO
1.25L(D4EA) CDD67 (D4EA) HI PHOTO 15 MF12
79 Parking Switch LO 39
See Rear Washer Auto(Volume) Ground (Shown with PHOTO 43
Wiper & Washer 21 MC11 Wipers at Rest)
(SD9821) 3 4 6 R17 2.0L 2.0P 0.3P
PHOTO 75 0.5B
1.25Y/O 1 5 4 CGG07
0.5Y/O 0.5G 4 JR01 (G4FA/G4FC) 10 FR11
2.0B 2.0P 2.0G CBG07 (G4GC) PHOTO 42
13 15 FR11 See Ground JOINT CUD07 (D4FB) 0.5P
GGG13 (G4FA/G4FC) PHOTO Distribution CONNECTOR CDD07 (D4EA)
0.5Y/O 0.5G 42 (SD1303) PHOTO B
GBG13 (G4GC)
GUD12 (D4FB) 78
8 JR01 10 13 MC11
GDD12 (D4EA) 4 17 MF12 GGG14 To Rain
1.25B PHOTO 75
PHOTO PHOTO (G4FA/G4FC) 2.0P 2.0G Sensor
0.5Y/O 0.5G 43 6 FR11 PHOTO 42 GBG14 (G4GC) (SD9811)
7/13
1.25B PHOTO GUD13 (D4FB)
7/13 GDD13 (D4EA)
2.0P
0.5R 0.5Y/O
11 12 7 4 3 14 GF11 PHOTO 42 13 5 6 M02W
38 M04A MULTIFUNCTION
WASHER MIST AUTO LO AUTO LO WIPER SWITCH
Mist BCM SWITCH SWITCH HI AUTO LO SWITCH
HI PHOTO
PHOTO OFF OFF OFF HI 51
57
Delay Control
HOT IN ON
W/O RAIN SENSOR See Power Distribution
I/P
JUNCTION
(SD11010) BOX
FR PHOTO
WIPER 45
25A
WASHER
MOTOR
M PHOTO 20 I/PB 13 I/PG
10
2.0L 2.0L E/R
5 1 E46 FUSE &
8 5 JE01 RELAY
JOINT FRONT BOX
CONNECTOR WIPER
PHOTO 114 RELAY
PHOTO 31
7 6 JE01
3 1 2 CGG67 (G4FA/G4FC)
CBG67 (G4GC) 3 2 4 E46
2.0L 2.0L
CUD67 (D4FB)
CDD67 (D4EA) 2.0W
1.25G/O 1.25B 1.25Y/O 0.5Gr 17 36 EC11 PHOTO 115

(W/O D4EA) 2.0W
1.25L(D4EA)
CGG07 (G4FA/G4FC) D4FB
21 MC11 17 EM31
2.0L 2.0W CBG07 (G4GC) With AMS 2.0G
PHOTO 75 PHOTO 43 CUD07 (D4FB)
See Rear 2.0W
Wiper & Washer 3 2 CDD07 (D4EA)
(SD9821) FRONT Z01
1.25Y/O 2.0R 0.5Y/O 0.3Gr DIODE
WIPER
14 M04A 5 M04C M MOTOR PHOTO 52
BCM Parking Switch HI 2.0G
Washer Wiper
(Shown with LO PHOTO 23 EM31
Switch Relay 39 PHOTO
Control Wiper Wipers at Rest) 43
0.75G
INT. 2.0L
GGG13 (G4FA/G4FC) Mist INT.(Volume) Switch 1 5 4 CGG07 (G4FA/G4FC)
GBG13 (G4GC) 2.0B 2.0P 2.0G CBG07 (G4GC)
GUD12 (D4FB) 38 29 15 M04A CUD07 (D4FB) 53 CUDK
GDD12 (D4EA) PHOTO CDD07 (D4EA)
ECM
PHOTO 7/13 57 10 13 MC11
0.5R 0.5L/B 0.5G PHOTO GGG14 (G4FA/G4FC) PHOTO
7/13 GBG14 (G4GC) PHOTO 75 38
GUD13 (D4FB) 2.0P 2.0G
11 12 7 3 14 GDD13 (D4EA) 13 5 M02W
MULTIFUNCTION
WASHER MIST INT LO WIPER SWITCH
SWITCH INT LO INT LO
SWITCH HI SWITCH
HI PHOTO
OFF OFF OFF HI 51
Delay Control
4 6 M02W
0.5B
1.25B 6 8 JM02
See Ground JOINT
Distribution CONNECTOR
(SD1301) PHOTO 47
GM21 PHOTO 46
2 1 2 1
5 4 3 2 1 3 5 4 3 2 1 3
CGG07 CGG67 CUDK
94 93 92
*
90 89
*
87 86 85 84 83
* * 7856 7755 76 5375 52* 5173
81 80
6 5
2 1
72 71 70 69 68 67 66
*
64 63 62 61 60 59 58
* * 4 3
5 4 3 2 1 3 50
* 26* 47 2446 * 4422 * 20* 1941 40 17* 38 15* 14* 1335 12* 1133 1032 *9 30 *7 2 1
28 27
* * * * * *
CUD07 CUD67 E46 M02W
1
2 1 2
5 4 3 2 1 3
7 6 5 4 3 2
*
5 * 3 14 13 12 11 10 9
*
M04A M04C M08A
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3
* 1 9 8 7 5
* 3 2 1
*
18 17 16 15 14 13 12 11 10
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21 16 15 14 13 12 11 10 9
R17 Z01
BLANK BLANK
4 3 2
* 2 1
8 7 6 5
2012 > D 2.0 TCID > Front Wiper Deicer > Schematic Diagrams
Front Wiper Deicer (1) SD8611
HOT AT ALL TIMES
(SD11010) JUNCTION
BOX
PHOTO 45
DEICER
15A
14 I/PB
0.5W
10 M08A
ICM
30 85 RELAY
BOX
FRONT PHOTO 46
DEICER
RELAY
See Charging System
(SD3731) (SD3732) (SD3733)
87 86 (SD3734) (SD3735) (SD3736)
1 2 M08A 0.3W/B(W/O ISG)
0.85Y 0.3G 0.3W(With ISG)
13 M04B 3 M04A
Relay Engine BCM
Control Running Input PHOTO
12 MC11 57
Front Deicer Defogger
PHOTO 75 See Rear Glass & Switch Switch
Mirror Defogger
(SD8791) 37 M04A 4 M04B
0.3L 0.3L
0.75Y(G4FA/G4FC, D4FB) 0.3G 0.3L
0.85L(G4GC/D4EA) 9 10 M05A (Auto A/C)
10 3 M06B (Manual A/C)
CGG53 (G4FC/G4FA)
CBG53 (G4GC) A/C
CUD53 (D4FB) DEFOGGER CONTROL
1 CDD53 (D4EA) SWITCH MODULE
IND.
FRONT PHOTO
DEICER 59
PHOTO
39
25 M05A (Auto A/C)
2 CGG53 (G4FC/G4FA) 28 M06B (Manual A/C)
CBG53 (G4GC) 0.5B
CUD53 (D4FB)
CDD53 (D4EA) 4 JM04
0.85B
(SD1302) CONNECTOR
PHOTO 68
1 JM04
1.25B
GGG13 (G4FC/G4FA)
GBG13 (G4GC)
GUD12 (D4FB) PHOTO
GDD12 (D4EA) 7/13 GM41 PHOTO 120
2012 > D 2.0 TCID > Front Wiper Deicer > Schematic Diagrams
Front Wiper Deicer (2) SD8612
CBG53 CDD53 CGG53 CUD53
2 1 2 1 2 1 2 1
M04A M04B M05A
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1 10
* * 7 6 5 4 3 2 1 13
* * 10 9 8 7 6
** * 2 1
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11
26 25 24 23 22 21 20 19 18 17 16
* 14
M05B M08A
BLANK BLANK
11 10 9
* * 6 * * 3 * 1 9 8 7
*5
*
3 2 1
22 21 20
* 18 * 16 15 14 13 12 18 17 16 15 14 13 12 11 10
2012 > D 2.0 TCID > Fuel Filter Heating System > Schematic Diagrams
Fuel Filter Heating System (D4FB/D4EA) (1) SD3611
HOT AT ALL TIMES HOT IN ON
FUSIBLE I/P
LINK (SD11010)
BOX BOX
FUEL PHOTO 45
FILTER
HEATER A/CON
30A 10A
See Passenger
(SD1202)
5 I/PG
3.0W 0.5R/B
22 EC11
PHOTO 115
0.5R
CDD94
1 5 CUD94
FUEL FILTER
HEATER RELAY
PHOTO
11
2 3 CDD94
CUD94
3.0R 0.5Br
CDD83 CDD82
2 CUD83 2 CUD82
FUEL FUEL
FILTER FILTER
HEATER SENSOR
PHOTO PHOTO
29/104 29/104
1 CDD83 1 CDD82
CUD83 CUD82
3.0B 0.5B
GDD13 PHOTO GDD21 PHOTO

GUD13 7 GUD21 38
2012 > D 2.0 TCID > Fuel Filter Heating System > Schematic Diagrams
Fuel Filter Heating System (D4FB/D4EA) (2) SD3612
CDD82 CDD83 CDD94 CUD82
1
2
2 1 2 1
2 1 5 * 3
CUD83 CUD94
1
2 BLANK BLANK
2 1 5 * 3
2012 > D 2.0 TCID > Fuse & Relay Information > Schematic Diagrams
Fuse & Relay Information (1) SD1001
I/P JUNCTION BOX
< FRONT> <REAR >
LHD RHD
I/PA (MAIN)
I/PH (FRONT)
10A 10A 25A 25A *
START CLOCK P/WDW RH P/WDW LH 2
3
1 2 3 4
10A 15A 15A 10A 25A 10A 4
A/CON SW C/LIGHTER P/OUTLET TAIL LH SAFETY P/WDW LH RR FOG 5 6 7 8
10A 20A 10A 10A 25A

(DRL OFF)
HTD MIRR DR LOCK T/SIG TAIL RH SAFETY P/WDW RH
16
1
15A 15A 10A 15A 15A 15A
11 12 13
1
17
2
SEAT HTR DEICER A/BAG IND RR P/OUTLET T/LID RR WIPER
2
18
3
*
4
10A 15A 10A 15A 15A 25A
14 15 16 17 18 19
4
20
AUDIO
I/PB (MAIN)
A/CON STOP CLUSTER MDPS FR WIPER
5
21
3
6
I/PF (FLOOR)
13
POWER CONNECTOR
4
15A
22
14
7
10A 15A 15A 15A 10A
ROOM LP
6
I/PG (FRONT)
23
HEAD LAMP A/BAG A/BAG HEAD LAMP
15
8
ROOM LP
7
POWER CONNECTOR
*
9
*
7
25A 15A 10A 15A 10A
20 21 22
17
10
25
8
15A
8
FR WIPER MDPS CLUSTER STOP A/CON
9
*
AUDIO
26
11
* *
*
19
12
27
15A 15A 15A 10A 15A 15A
20
13
28
11
* *
10 11
1
RR WIPER T/LID RR P/OUTLET A/BAG IND DEICER SEAT HTR
21
12
14
* *
2
*
12 13 14 15 16
25A 10A 10A 20A 10A
3
(DRL OFF)
I/PC (MAIN)
SAFETY P/WDW RH TAIL RH T/SIG DR LOCK HTD MIRR
4
12 11 10
5
10A 25A 10A 15A 15A 10A * 17 16 15 14
* * * 10 9
I/PE (A/BAG)
* *
5
RR FOG SAFETY P/WDW LH TAIL LH P/OUTLET C/LIGHTER A/CON SW
6
8 7 6
* 4 3 2 1
*
9
18
7
25A 25A 10A 10A
8
I/PD (MAIN)
* *
8
*
P/WDW LH P/WDW RH CLOCK START
*
1
USE THE DESIGNATED FUSE ONLY
CIRCUIT DIAGRAM
FUSE (A) Circuit Protected
START 10A Start Relay, Transaxle Range Switch, ECM (G4FA/G4FC)
A/CON SW 10A A/C Control Module, Blower Motor, FET (Field Effect Transistor), Blower Resistor
HTD MIRR 10A A/C Control Module, ECM (G4FA/G4FC), PCM (G4FA/G4FC), Driver/Passenger Power Outside Mirror
SEAT HTR 15A Front Seat Warmer Control Module LH/RH
A/CON 10A A/C Control Module, Electro Chromic Mirror, Fusible Link Box (PTC Heater Relay #2/#3, Fuel Filter Heater Relay), BCM
Sunroof Control Module, ICM Relay Box (Rain Sensor Relay), Rain Sensor, Blower Relay, Instrument Cluster
HEAD LAMP 10A H/LP Lo Relay, H/LP Hi Relay, BCM
FR WIPER 25A Multifunction Switch, Front Wiper Relay, Front Wiper Motor
RR WIPER 15A Multifunction Switch, Rear Wiper Relay, Rear Wiper Motor
RR FOG 10A ICM Relay Box (Rear Fog Lamp Relay)
P/WDW LH 25A Power Window Main Switch, Rear Power Window Switch LH
CLOCK 10A Audio, ATM Key Lock Control Module, Power Outside Mirror Switch, Trip Computer, Glove Box Lamp, DCDC Converter,
Transaxle Range Switch, PCM (G4FA/G4FC, G4GC), TCM (D4FB)
C/LIGHTER 15A Cigarette Lighter & Front Power Outlet
DR LOCK 20A Sunroof Control Module, ICM Relay Box (Door Unlock/Lock Relay, Dead Lock Relay (RHD))
DEICER 15A ICM Relay Box (Front Deicer Relay)
STOP 15A ATM Lever Switch, Stop Lamp Switch, Stop Lamp Failure Module
ROOM LP 15A Luggage Lamp, Data Link Connector, Instrument Cluster (IND.), Room Lamp, Vanity Lamp Switch LH/RH, A/C Control Module
POWER
BCM, Ignition Key ILL. & Door Warning Switch, Sunroof Switch, Security Indicator, Tire Pressure Monitoring Module, Piezo Buzzer
CONNECTOR
AUDIO 15A Audio, Trip Computer, DCDC Converter
T/LID 15A Trunk Lid Relay, Power Outside Mirror Switch
SAFETY P/WDW RH 25A Rear Safety Power Window Module RH, Passenger Safety Power Window Module
SAFETY P/WDW LH 25A Driver Safety Power Window Module, Rear Safety Power Window Module LH
P/WDW RH 25A Power Window Main Switch, Rear Power Window Switch RH, Passenger Power Window Switch
P/OUTLET 15A Cigarette Lighter & Front Power Outlet
T/SIG 10A Switch Module
A/BAG IND 10A Instrument Cluster (Air Bag IND.)
CLUSTER 10A Instrument Cluster (IND.), BCM, ATM Key Lock Control Module, PreExcitation Resistor, ISG Switch, Stop Lamp Failure Module
Tire Pressure Monitoring Module, Trip Computer, Front Seat Warmer Control Module LH/RH
A/BAG 15A SRS Control Module
MDPS 15A EPS Control Module, ESP Switch
RR P/OUTLET 15A Rear Power Outlet, Switch Module, Sound Relay
TAIL RH 15A Rear Combination Lamp RH (UP), Head Lamp RH (W/O 3DR), Shunt Connector, E/R Fuse & Relay Box (Front Fog Lamp Relay)
Rear Combination Lamp RH, Rear Combination Lamp RH (Low), Instrument Cluster, Rheostat Relay, BCM, Multifunction Switch
Head Lamp RH (3DR), Rear Combination Lamp RH (5DR)
TAIL LH 10A Head Lamp LH (W/O 3DR ), License Lamp, Rear Combination Lamp LH, Rear Combination Lamp LH (UP), Rear Combination Lamp LH (Low)
Rear Combination Lamp LH (5DR), Head Lamp LH (3DR)
(DRL OFF) (15A) BCM
NOTICE
If you want the DRL off, open the driver's side fuse panel cover (I/P junction box) and insert any spare fuse into the DRL OFF position.
E/R FUSE & RELAY BOX
EMS BOX (Rear)
EMS BOX E/RCGG1(G4FA/G4FC)
E/RCBG1(G4GC)
MAIN ABS E/RCUD1(D4FB)
RELAY 10A E/RCDD1(D4EA)
ECU1
(ENGINE FUEL 30A
A/CON PUMP B/UP
CONTROL RELAY RELAY 10A
RELAY)
SPARE SPARE
20A 15A ECU
10A 1 10
11 20
SNSR2 ECU2 SNSR1 ECU4 INJ A/CON ECU3 F/PUMP
15A 10A 10A 20A 15A 10A 10A 15A SNSR E/REMS
10A
20 10
E45 9 1
E43
E41 HORN E48
HEAD LAMP RELAY
RELAY CONDENSER
BLOWER (HIGH)
RELAY E46 FAN RELAY
E44 (HIGH) E/RCGG2(G4FA/G4FC)
WIPER E/RCBG2(G4GC)
FRONT RELAY E/RCUD2(D4FB)
FOG LAMP E49 E/RCDD2(D4EA)
E42 RELAY
E47 CONDENSER
START H/LP H/LP FAN RELAY RELAY NO. RELAY NAME TYPE
RELAY LO LH LO RH SPARE HEAD LAMP (LOW)
10A RELAY E41 Blower Relay PLUG MINI
10A 10A (LOW)
E42 Start Relay PLUG MINI
E43 Head Lamp Relay (High) PLUG MICRO
ABS1 ABS2 BATT FUSE B+ 2
F/FOG H/LP HORN
40A 20A 15A
SNSR
PULLER 50A 20A 15A E44 Front Fog Lamp Relay PLUG MICRO
10A
E45 Horn Relay PLUG MICRO
E46 Wiper Relay PLUG MICRO
MDPS IGN2 RR HTD C/FAN BLOWER ALT IGN1 B+ 1 SPARE
E47 Head Lamp Relay (Low) PLUG MICRO
80A 40A 40A 40A 40A 150A 30A 50A 50A E48 Condenser Fan Relay (High) PLUG MINI
E49 Condenser Fan Relay (Low) PLUG MINI
RLY.1 Main (Engine Control) Relay PLUG MINI
EMS
MULTI FUSE RLY.2 A/CON Relay PLUG MICRO
BOX
RLY.3 Fuel Pump Relay PLUG MICRO
USE THE DESIGNATED FUSE AND RELAY ONLY
CIRCUIT
B+ 1 50A I/P Junction Box (Relay Tail Lamp, Power Window, FUSE TAIL LH/RH 10A, P/WDW LH/RH 25A
SAFETY P/WDW LH/RH 25A, RR FOG 10A)
SAFETY
IGN1 30A Ignition Switch
Alternator, Fusible Link Box (GLOW PLUG 80A, PTC HEATER #1/2/3 50A, FUEL FILTER HEATER 30A)
MULTI ALT 150A MULTI FUSE (MDPS 80A, IGN2 40A, RR HTD 40A, C/FAN 40A, BLOWER 40A)
FUSE FUSE (ABS1 40A, F/FOG 15A, ABS2 20A, BATT SNSR 10A)
BLOWER 40A Blower Relay
C/FAN 40A Condenser Fan Relay High/Low, EMS Box (FUSE SNSR1 10A)
RR HTD 40A I/P Junction Box (REAR DEFOGGER RELAY, FUSE HTD MIRR 10A)
IGN2 40A Start Relay, Ignition Switch
MDPS 80A EPS Control Module
ECU 1 30A Engine Control Relay, PCM (G4GC)
F/PUMP 15A Fuel Pump Relay (G4FA/G4FC/G4GC/D4EA)
ECU 3 10A TCM (D4FB),PCM (G4FC), Multipurpose Check Connector (G4FA/G4FC), Alternator (D4EA)
A/CON 10A A/Con Relay
INJ 15A A/Con Relay (G4FA/G4FC/G4GC/D4FB/D4EA), Injector #1/2/3/4 (G4FA/G4FC/G4GC), Throttle Flap Actuator (D4FB)
EGR Control Actuator (D4FB), VGT Actuator (D4FB)
ECU 4 20A ECM (D4FB/D4EA),EGR Control Valve (D4EA), PCM (G4FC W/O ETC), ECM (G4FA/G4FC W/O ETC), Idle Speed Control Actuator
FUSE Condenser Fan Relay (Low), Oil Control Valve (G4GC), Idle Speed Control Actuator (G4GC), VGT Actuator (D4EA)
(EMS BOX) SNSR1 10A Fusible Link Box (Glow Plug Relay, PTC Heater Relay #1)(D4FB/D4EA), Immobilizer Module (D4FB/D4EA)
Fuel Pump Relay (G4FA/G4FC/G4GC/D4EA), Purge Control Solenoid Valve (G4GC), ECM(G4FA/G4FC With ETC)
Electrical Throttle Control Actuator (D4EA), Air Heater Relay (D4FB)
ECU 2 10A PCM (G4FC With ETC/G4GC), E/R Fuse & Relay Box (Start Relay)(G4FA/G4FC), Stop Lamp Switch (D4FB/D4EA)
Immobilizer Module (G4FA/G4FC/G4GC), Camshaft Position Sensor (G4FA/G4FC/G4GC, D4FB/D4EA), Lambda Sensor (D4FB/D4EA)
SNSR2 15A Oxygen Sensor Up/Down (G4FA/G4FC/G4GC), Crankshaft Position Sensor (G4GC), Purge Control Solenoid Valve (G4FA/G4FC)
Fuel Pressure Regulating Valve (D4FB), Oil Control Valve(G4FA/G4FC)
ABS 10A ABS Control Module, ESP Control Module, Yaw Late Sensor
B/UP 10A Backup Lamp Switch, Transaxle Range Switch (G4FC/G4GC/D4FB)
ECU 10A Start Relay (G4FA/G4FCM/T W/O ETC, With ISG), Ignition Coil #1/2/3/4 (G4FA/G4FC), PCM (G4GC)
TCM (D4FB), PCM (G4FC/G4GC), ECM (G4FA/G4FC/D4FB/D4EA), Stop Lamp Switch (G4FA/G4FC With ETC/G4GC)
SNSR 10A Fuel Filter Warning Switch (D4FB/D4EA), Pulse Generator 'A'/'B' (G4FC/G4GC/D4FB), Air Flow Sensor (D4FB/D4EA), Speed Sensor
DCDC Converter(G4FA/G4FC, D4FB), Auto Cruise Control Module(G4GC), Condenser(G4FA/G4FC), Multifunction Switch(G4GC)
Pulse Generator 'B' (D4FB)
H/LP LO RH 10A Head Lamp RH (W/O 3DR), Head Lamp Leveling Device Actuator RH (W/O 3DR), Head Lamp Leveling Device Actuator RH (3DR)
Head Lamp RH (3DR)
FUSE H/LP LO LH 10A Head Lamp LH (W/O 3DR), Head Lamp Leveling Device Switch, Head Lamp Leveling Actuator LH (W/O 3DR), Head Lamp LH (3DR)
Head Lamp Leveling Device Actuator LH (3DR)
HORN 15A Horn Relay, ICM Relay Box (Burglar Alarm Relay)V
H/LP 20A Head Lamp Relay High
B+ 2 50A I/P Junction Box (FUSE POWER CONNECTOR(AUDIO 15A, ROOM LP 15A), DEICER 15A, T/LID 15A, STOP 15A, DR LOCK 20A
RR P/OUTLET 15A)
BATT SNSR 10A Battery Sensor
F/FOG 5A Front Fog Lamp Relay
ABS2 20A ABS Control Module, ESP Control Module
ABS1 40A ABS Control Module, ESP Control Module
FUSIBLE LINK BOX (D4FB/D4EA)
LAYOUT
CUD90 / CDD90 CUD91 / CDD91 CUD92 /CDD92 CUD93 /CDD93

1 1 1 1
4 2 4 2 4 2 4 2
* * * *
5 5 5 5
GLOW PLUG PTC HEATER PTC HEATER PTC HEATER
RELAY RELAY #1 RELAY #2 RELAY #3
CUD94 /CDD94
GLOW
3 5
PLUG
80A *
2
PTC PTC PTC FUEL
HEATER HEATER HEATER FILTER 1
#1 #2 #3 HEATER
50A 50A 50A 30A FUEL FILTER
HEATER RELAY
CIRCUIT DIAGRAM

GLOW PLUG 80A Glow Plug Relay, Air Heater Relay (D4FB)
PTC HEATER #1 50A PTC Heater Relay #1
FUEL FILTER HEATER 30A Fuel Filter Heater Relay
USE THE DESIGNATED FUSE AND RELAY ONLY
ICM RELAY BOX
LAYOUT
RELAY NO. RELAY NAME
1 RAIN SENSOR RELAY
RELAY RELAY RELAY RELAY RELAY RELAY RELAY
5 6 7 3 4 1 2 2 DEAD LOCK RELAY (RHD)
3 BURGLAR ALARM HORN RELAY
4 FRONT DEICER RELAY
5 DOOR LOCK RELAY
M08B M08A 6 DOOR UNLOCK RELAY
7 REAR FOG LAMP RELAY
* 2
* 4 13 14 15 16 5
* * 8 1 2 3
* 5
* 7 8 9
9 10 11 12 17
* * 20 10 11 12 13 14 15 16 17 18
2012 > D 2.0 TCID > Ground Distribution > Schematic Diagrams
Ground Distribution (1) SD1301
PASSENGER
AUX & STOP AIR BAG SRS
USB JACK SIGNAL ASHTRAY ISG OFF MULTI INSTRUMENT ON/OFF CONTROL
AUDIO (NAVIGATION) RELAY RHEOSTAT ILL. MULTIFUNCTION SWITCH SWITCH DISPLAY CLUSTER BCM SWITCH MODULE
DATA LINK
CONNECTOR
8 M54A 12 M77 4 M90 2 M27 1 M80 5 2 12 M02L 4 M02W 4 M71 4 M10 11 M62 4 M01C 12 M04A 2 M84 2 M82A
0.5B 0.5B 0.3B 0.3B 0.3B 0.5B 0.5B 0.5B
4 5 2 8 7 JM02
JOINT
AUX & CONNECTOR
USB JACK
(AUDIO)
1 3 6 10 9 JM02
1.25B 0.3B 0.3B 1.25B 0.5B 0.85B 0.85B 0.5B 0.3B 0.5B 0.3B 0.5B 0.5B
DATA LINK 3 M34 9 M02R RHD
CONNECTOR
13 M08A 13 M08B
11 M76 5 M10
1 M01A 87a 87a 87a
0.5B 0.3B 0.3B 0.5B
HEAD LAMP MULTIFUNCTION
LEVELING SWITCH
DEVICE (REMOCON)
SWITCH
INSTRUMENT DEAD DOOR DOOR
CLUSTER LOCK LOCK UNLOCK
RELAY (RHD) RELAY RELAY
GM11 (MAIN) GM21 (MAIN) ICM RELAY BOX GM31 (MAIN) GM51 (MAIN)

HEAD LAMP HEAD LAMP
LEVELING LEVELING FRONT FRONT FRONT
DEVICE DEVICE FOG FOG IMPACT SIDE EPS
MULTIFUNCTION HORN HORN ACTUATOR ACTUATOR HEAD HEAD LAMP LAMP SENSOR REPEATER E/R FUSE & COOLING CONTROL
BCM SWITCH (HIGH) (LOW) LH LH(3DR) LAMP LH LAMP LH (3DR) LH LH(3DR) SHIELD LAMP LH RELAY BOX FAN MOTOR MODULE
BLOWER START
RELAY RELAY
31 M04A 3 M02L 1 E86 1 E87 1 E76 1 E112 5 4 E77 5 4 E111 2 E75 2 E113 2 E81 3 E71 3 E72 1 E79
0.3R/B 0.3R/B 0.85B 0.85B

4 E41 4 E42
17 I/PD 0.85B 0.5B 0.5B 1.25B 1.25B 1.25B 1.25B 0.85B 0.85B 0.5B 0.5B 0.5B 0.85B 3.0B 3.0B 8.0B
I/P
JUNCTION W/O
DRL OFF BOX ISG
W/O With W/O With W/O With
3 EE12 3RD 3RD 3RD 3RD 3RD 3RD
17 I/PG 0.85B
0.5B G4FC/ D4FB/

G4GC D4EA
GE11 GE12 GE13

(FRONT) (FRONT) (FRONT)
GLOVE CIGARETTE ATM KEY TIRE A/C A/C PASSENGER
BOX LIGHTER & LOCK PRESSURE CONTROL CONTROL TEMPERATURE
LAMP FRONT CONTROL MONITORING MODULE MODULE ACTUATOR
SWITCH POWER MODULE MODULE
OUTLET
2 M75 3 6 M18 11 M12 9 M46 28 M06B 25 M05A 12 M05B 6 M78
0.3B 0.5B Auto Auto
0.5B 0.5B 0.5B A/C A/C
0.3Br 0.3Br
0.85B 0.85B Manual A/C Auto A/C
2 5 4 10 JM04
JOINT
CONNECTOR
1 FET A/C 9 7 3 6 8 JM04

(Field Effect MULTI CONTROL DCDC
Transistor) BCM DISPLAY MODULE CONVERTER 0.3Br
0.3B 0.3B
1.25B Manual
Manual A/C &
A/C
ISG or Auto A/C Auto Auto Manual
11 19 EM31 A/C A/C A/C
0.3B 0.3B 0.3Br 0.5B 0.5B 0.3Br 0.3Br 0.3Br 0.3Br
2 M24 12 M04C 23 M62 1 M06A 18 CGG60 (G4FC) 7 9 EE12
0.3B 0.3B 0.5B 0.3B 0.5B CUD60 (D4FB) 0.5B 0.3B
Manual 27 M06B 2 E841 2 E842 5 M39 26 M05A 18 M61A 6 M79 5 M51 2 M23 6 M43
34 MC11
A/C
0.5B
With ISG
A/C AMBIENT AMBIENT INTAKE A/C SWITCH DRIVER MODE EVAPORATOR TEMPERATURE
CONTROL SENSOR SENSOR ACTUATOR CONTROL MODULE TEMPERATURE ACTUATOR SENSOR ACTUATOR
MODULE #1 #2 MODULE ACTUATOR
5DR/WGN GM41 (MAIN)
3DR
HIGH HIGH
REAR REAR REAR MOUNTED MOUNTED REAR REAR REAR
LICENSE HANDLE TAIL GATE WIPER TAIL GATE WIPER HANDLE COMBINATION STOP STOP COMBINATION COMBINATION COMBINATION
LAMP SWITCH ACTUATOR MOTOR ACTUATOR MOTOR SWITCH LAMP LH (5DR) LAMP LAMP LAMP LH (LOW) LAMP LH (UP) LAMP LH
2 R26 2 R25 1 4 R28 1 R27 1 4 R31 1 R30 2 R29 6 F50 2 R24 2 R21 1 F31 3 F08
3 F07
0.85B 0.85B
3.0B 0.85B 0.5B 0.85B
3.0B 3DR 5DR/WGN 3DR
0.5B 0.5B 0.5B 0.85B 0.85B 10 RR11 0.5B 0.85B 0.85B 0.5B 15 FR12 0.85B
0.5B
3.0B
5DR/WGN 3DR
8 FR12
3.0B
GR12 (TAIL GATE EXT.)
GR11 (TAIL GATE) GF51 (FLOOR)
JOINT JOINT
CONNEC CONNEC
TOR TOR
3 2 6 5 4 1 JD01 8 7 6 5 4 3 2 1 JR01
W/O With
Safety Safety
2.0B 2.0B 2.0B 0.5B 0.5B 0.5B 2.0B 1.25B 0.5B 0.5B 0.5B 0.5B 0.5B 0.5B 0.5B
D01 (LHD) 3 D07 (LHD)

12 D01R (RHD) 5 D01 (LHD) 3 D03 2 D10 5 D11 5 D07R (RHD) 34 FD12 3 R06 4 R16 2 R01 6 R17 2 R11 2 R10 2 R07
RHD LHD
POWER WINDOW DRIVER DRIVER POWER DRIVER ROOM SUNROOF ELECTRO RAIN VANITY VANITY SUNROOF
MAIN SWITCH SAFETY POWER OUTSIDE DOOR LOCK LAMP SWITCH CHROMIC SENSOR LAMP LAMP CONTROL
POWER OUTSIDE MIRROR ACTUATOR MIRROR RH LH MODULE
WINDOW MIRROR SWITCH
MODULE
PASSENGER REAR
PASSENGER SAFETY PASSENGER REAR SAFETY FRONT SEAT DRIVER
POWER POWER PASSENGER POWER REAR DOOR LOCK POWER WARMER SEAT BELT
WINDOW WINDOW DOOR LOCK OUTSIDE WIPER ACTUATOR WINDOW CONTROL BUCKLE
SWITCH MODULE ACTUATOR MIRROR RELAY LH MODULE LH MODULE LH SWITCH
6 D21 3 D23 5 D27 (LHD) 2 D30 4 F35 3 D47 3 D43 7 F36 1 F40
3 D27R (RHD)
0.5B 2.0B 2.0B 0.5Y 0.5B 2.0B 0.3B 0.5B 2.0B 0.85B 0.3B
11 FD22 With
6 FR11 Safety
2.0B LHD RHD
22 FD22 0.5B 0.5B

14 FD11
0.3B(W/O Safety)
2.0B(With Safety)
2.0B 1.25B
GF21 (FLOOR) GF11 (FLOOR) GF31 (FLOOR)

FUEL FUEL PASSENGER FRONT SEAT REAR REAR REAR REAR

SENDER & SENDER & SEAT BELT WARMER DOOR LOCK SAFETY SBR DEFOGGER
FUEL PUMP FUEL PUMP BUCKLE CONTROL ACTUATOR POWER LH ()
MOTOR MOTOR SWITCH MODULE RH RH WINDOW
MODULE
RH 1 F24
6 F01 3 F47 1 F41 7 F37 5 D57 3 D53
1 3 F45
0.3B 0.85B 0.5B 2.0B 0.3B 0.3B

1.25B 1.25B With 3.0B
Safety
G4FA/G4FC/ D4EA
G4GC 13 FD21
0.3B(W/O Safety) 0.3B
2.0B(With Safety)
GF71 (FLOOR) GF41 (FLOOR) GF81 (RR HTD)
LICENSE STOP REAR REAR REAR REAR REAR REAR REAR REAR
LAMP (3DR) LAMP COMBINATION COMBINATION SBR COMBINATION COMBINATION FOG PARKING POWER
FAILURE LAMP LAMP RH RH LAMP RH LAMP RH (UP) LAMP ASSIST OUTLET
MODULE RH(5DR) (3DR) (LOW, Wagon) CONTROL
MODULE
3 F25 4 F38 6 F49 3 F10 1 F46 3 F09 1 F32 2 F33 9 F22 2 F34
5DR/
3DR WGN
0.5B 0.5B 0.85B 0.85B 3DR 5DR 0.3B 0.85B 0.5B 0.5B 0.5B 1.25B
3DR WGN
0.3B 0.3B
0.85B 0.85B
0.85B
GF61 (FLOOR)
IGNITION
IMMOBILIZER
COIL
#1,2,3,4
G4FA/G4FC KNOCK
SENSOR
ATM
SOLENOID FRONT
NEUTRAL
PCM PCM MODULE SHIELD PCM ECM SWITCH SHIELD VALVE WIPER MOTOR
4 3 77 CGGK 2 CGGAK 3 M09 3 1 24 25 CGGAK 51 73 CGGMK 2 E58 7 CGG04 1 CGG07

(With ETC) (W/O ETC) (W/O ETC) (W/O ETC)
IGNITION BRAKE
0.5B KNOCK ATM VEHICLE COIL FLUID
SENSOR #1,2,3,4 1.25B LEVEL CLUTCH
SOLENOID SPEED SWITCH
ECM CONDENSER SHIELD VALVE SENSOR SHIELD PCM SENSOR
2 CGGMK 2 17 CGGA 1 CGG45 1 CGG71

1 CGG19 7 CGG04 1 CGG52 A/T A/T
(W/O ETC) 1.25B
2.0 1.25 0.85 2.5B 2.5B 0.5B 0.5B 2.5B 2.5B 0.5B 0.5B 0.75B 1.25B 1.25B 0.5B 0.5B 0.85B 0.5B 1.25B 0.5B 2.0B 0.5B
B B B 17 MC11 1.25B
W/O 2 CB11
0.5B 1.25B ETC
With
A/T M/T 0.5B ISG
With
ISG
W/O With
ETC ETC
GGG11 (CONTROL) HEAD HEAD GGG12 (CONTROL) GGG14 (CONTROL)

LAMP LAMP
LEVELING LEVELING
FRONT WASHER BURGLAR SIDE DEVICE DEVICE FRONT FRONT ABS ESP
FRONT WASHER LEVEL ALARM REPEATER HEAD HEAD LAMP ACTUATOR ACTUATOR FOG LAMP FOG LAMP CONTROL CONTROL
DEICER MOTOR SWITCH HORN LAMP RH LAMP RH RH(3DR) RH RH(3DR) RH RH(3DR) MODULE MODULE
MULTIPURPOSE
CHECK
CONNECTOR
2 CGG53 1 CGG67 5 CGG47 2 CGG76 2 CGG46 2 CGG65 5 4 CGG75 5 4 CGG96 1 CGG73 1 CGG97 2 CGG85 2 CGG98 13 38 CGG41 13 38 CGG70
0.85B 1.25B 0.5B 0.3B 0.5B 0.5B 1.25B 1.25B 1.25B 1.25B 0.85B 0.85B 0.85B 3.0B 2.0B 3.0B 2.0B YAW
RATE
HOOD SENSOR
SWITCH
W/O 3RD With 3RD W/O 3RD With 3RD W/O 3RD With 3RD

ABS ESP
4 CGG10
2 CGG74
0.5B
0.5B
GGG13 (CONTROL) GGG15 (CONTROL) GGG16 (CONTROL)

G4GC
BRAKE
VEHICLE KNOCK FRONT FLUID FRONT ABS ESP YAW
SPEED SENSOR FRONT WASHER LEVEL WIPER CLUTCH CONTROL CONTROL RATE
SENSOR PCM SHIELD PCM DEICER MOTOR SENSOR MOTOR SWITCH MODULE MODULE SENSOR
MULTIPURPOSE
CHECK
CONNECTOR
1 CBG52 1 3 5 CBGK 20 34 35 CBGA 2 CBG53 5 CBG47 1 CBG67 1 CBG45 1 CBG07 1 CBG71 13 38 CBG41 13 38 CBG70 4 CBG10
0.5B 2.0B 2.0B 2.0B 0.5B 1.25B 1.25B 1.25B 0.85B 0.5B 1.25B 0.5B 2.0B 0.5B 3.0B 2.0B 3.0B 2.0B 0.5B
ABS ESP
GBG11 (CONTROL) GBG12 (CONTROL) GBG13 (CONTROL) GBG14 (CONTROL) GBG16 (CONTROL)
HEAD LAMP HEAD LAMP
LEVELING AUTO LEVELING
FRONT FRONT DEVICE CRUISE DEVICE BURGLAR SIDE WASHER
FOG LAMP FOG LAMP HEAD LAMP HEAD LAMP ACTUATOR CONTROL ACTUATOR HOOD ALARM REPEATER LEVEL
RH(3DR) RH RH(3DR) RH RH(3DR) MODULE RH SWITCH HORN LAMP RH SWITCH
2 CBG98 2 CBG85 5 4 CBG96 5 4 CBG75 1 CBG97 8 CBG59 1 CBG73 2 CBG74 2 CBG46 2 CBG65 2 CBG76
With W/O
3DR 3DR
0.85B 0.85B 1.25B 1.25B 1.25B 1.25B 0.85B 0.5B 0.85B 0.85B 0.5B 0.5B 0.5B 0.3B
0.85B 0.85B
With 3RD W/O 3RD With 3RD W/O 3RD With 3RD W/O 3RD
GBG15 (CONTROL)
D4FB
FUEL BRAKE
VEHICLE FUEL FILTER FRONT FLUID FRONT FUEL
SPEED NEUTRAL FILTER WARNING FRONT WASHER LEVEL WIPER CLUTCH FILTER
TCM ECM SENSOR SWITCH SENSOR SWITCH DEICER MOTOR SENSOR MOTOR SWITCH HEATER
MULTIPURPOSE
CHECK
CONNECTOR
3 4 CUDAT 4 56 2 40 76 6 CUDK 1 CUD52 2 E98 1 CUD82 3 CUD84 2 CUD53 5 CUD47 1 CUD67 1 CUD45 1 CUD07 1 CUD71 1 CUD83
A/T A/T Euro5 With With M/T
ESP ISG
2 CB21
0.5B
M/T
GUD16 (CONTROL) GUD11 (CONTROL) GUD21 (CONTROL) GUD12 (CONTROL) GUD13 (CONTROL)
HEAD HEAD
LAMP LAMP
FRONT FRONT LEVELING LEVELING
FOG FOG DEVICE DEVICE BURGLAR SIDE WASHER ABS ESP YAW
LAMP LAMP HEAD LAMP HEAD LAMP ACTUATOR ACTUATOR HOOD ALARM REPEATER LEVEL CONTROL CONTROL RATE PTC
RH(3DR) RH RH(3DR) RH RH(3DR) RH SWITCH HORN LAMP RH SWITCH MODULE MODULE SENSOR HEATER
2 CUD98 2 CUD85 5 4 CUD96 5 4 CUD75 1 CUD97 1 CUD73 2 CUD74 2 CUD46 2 CUD65 2 CUD76 13 38 CUD41 13 38 CUD70 4 CUD10 2 4 CUD87

ABS ESP
GUD14 (CONTROL) GUD17 (CONTROL) GUD18 (CONTROL)

D4EA
HEAD HEAD
LAMP LAMP
FUEL FRONT FRONT LEVELING LEVELING
FRONT FILTER FOG FOG DEVICE DEVICE BURGLAR SIDE WASHER
FRONT WASHER WARNING LAMP LAMP HEAD LAMP HEAD LAMP ACTUATOR ACTUATOR HOOD ALARM REPEATER LEVEL
DEICER MOTOR SWITCH RH(3DR) RH RH(3DR) RH RH(3DR) RH SWITCH HORN LAMP RH SWITCH
MULTIPURPOSE
CHECK
CONNECTOR
2 CDD53 5 CDD47 1 CDD67 3 CDD84 2 CDD98 2 CDD85 5 4 CDD96 5 4 CDD75 1 CDD97 1 CDD73 2 CDD74 2 CDD46 2 CDD65 2 CDD76
0.85B 0.5B 1.25B 0.5B 0.85B 0.85B 1.25B 1.25B 1.25B 1.25B 0.85B 0.85B 0.5B 0.5B 0.5B 0.3B
GDD12 (CONTROL) GDD14 (CONTROL)

BRAKE ELECTRICAL
FUEL FLUID FRONT VEHICLE THROTTLE FUEL ABS ESP YAW
FILTER LEVEL WIPER CLUTCH SPEED NEUTRAL CONTROL FILTER CONTROL CONTROL RATE PTC
HEATER SENSOR MOTOR SWITCH SENSOR ECM SWITCH ACTUATOR SENSOR MODULE MODULE SENSOR HEATER
1 CDD83 1 CDD45 1 CDD07 1 CDD71 2 CDD52 4 2 19 6 CDDK 2 CDD64 4 CDD95 1 CDD82 1 4 CDD41 1 4 CDD70 4 CDD10 2 4 CDD87
With
ESP
ABS ESP
GDD13 (CONTROL) GDD11 (CONTROL) GDD21 (CONTROL) GDD16 (CONTROL) GDD17 (CONTROL)
2012 > D 2.0 TCID > Head Lamps > Schematic Diagrams
Head Lamps (1) SD9211
HOT IN ON HOT AT ALL TIMES
5DOOR/WAGON
See Power I/P E/R
(SD11010) BOX RELAY
PHOTO BOX
H/LP
HEAD 45 20A
LAMP
10A
0.3R/O 0.85L
5 1 E47 5 1 E43
HEAD HEAD
9 I/PD LAMP LAMP
0.3R/O RELAY RELAY
(LOW) (HIGH)
20 M08B PHOTO PHOTO
ICM 3 2 E47 31 3 2 E43 31
RELAY 0.5R
BOX 0.5R
PHOTO 46
8 M08B
H/LP H/LP
LO RH LO LH
0.3R/O 0.3R/O 10A 10A
PHOTO 43 0.3R/O 0.3G 0.3R
21 EM31
19 M04B 7 12 I/PG
0.5O 0.85G 0.5G 0.5Y 0.85G
H/LP Relay BCM I/P
Escort PHOTO JUNCTION 28 32 EC11 13 EM31
57 BOX PHOTO 115
0.5O PHOTO
Head H/LP PHOTO 0.85Br 43
Lamp SW LO Relay 45 (G4GC/D4FB/D4EA)
0.75G CGG75 (G4FA/G4FC)
15 I/PC 10 I/PD
33 M04A 14 M04B (G4FA/G4FC) CBG75 (G4GC) 0.5G
CUD75 (D4FB)
0.3W 3 2 CDD75 (D4EA) 10 M01A 3 2 E77
HEAD INSTRUMENT HEAD
0.3Y 0.3W 0.3Br CLUSTER
LAMP RH LAMP
4 10 9 M02L LO HI LH
LO HI PHOTO PHOTO
MULTI 6 HIGH 49 PHOTO
FUNCTION BEAM 3
LIGHT DIMMER/ SWITCH
PARK SWITCH LOW PASSING 5 4 CGG75 (G4FA/G4FC) 5 4 E77
SWITCH PHOTO 1.25B 1.25B CBG75 (G4GC)
50 CUD75 (D4FB)
HEAD
OFF PASS HIGH CDD75 (D4EA)
1 M01A
GGG15 (G4FA/G4FC)
2 M02L GBG15 (G4GC)
0.3B GUD14 (D4FB) PHOTO 0.5B 0.85B 1.25B
GDD14 (D4EA) 69
2 10 JM02
JOINT
See Ground Distribution CONNECTOR
(SD1301)
PHOTO 47
1 6 JM02
1.25B 1.25B
GM21 PHOTO 46 GE11 PHOTO 1

3DOOR
See Power I/P E/R
(SD11010) BOX RELAY
PHOTO BOX
H/LP
HEAD 45 20A
LAMP
10A
0.3R/O 0.85L
5 1 E47 5 1 E43
HEAD HEAD
9 I/PD LAMP LAMP
0.3R/O RELAY RELAY
(LOW) (HIGH)
20 M08B PHOTO PHOTO
ICM 3 2 E47 31 3 2 E43 31
RELAY 0.5R
BOX 0.5R
PHOTO 46
8 M08B
H/LP H/LP
LO RH LO LH
0.3R/O 0.3R/O 10A 10A
PHOTO 43 0.3R/O 0.3G 0.3R
21 EM31
19 M04B 7 12 I/PG
0.5O 0.85G 0.5G 0.5Y 0.85G
H/LP Relay BCM I/P
Escort PHOTO JUNCTION 28 32 EC11 13 EM31
57 BOX PHOTO 115
0.5O PHOTO 43
Head H/LP PHOTO 0.85Br
Lamp SW LO Relay 45 (G4GC/D4EA)
15 I/PC 10 I/PD 0.75G CGG96 (G4FA/G4FC)
33 M04A 14 M04B (G4FA/G4FC/D4FB) CBG96 (G4GC) 0.5G
CUD96 (D4FB)
0.3W 3 2 CDD96 (D4EA) 10 M01A 3 2 E111
HEAD INSTRU HEAD
0.3Y 0.3W 0.3Br MENT
LAMP LAMP
4 10 9 M02L CLUSTER LO HI LH(3DR)
LO HI RH(3DR)
MULTI PHOTO 6 HIGH PHOTO PHOTO
FUNCTION BEAM 49 3
PARK SWITCH LOW PASSING 5 4 CGG96 (G4FA/G4FC) 5 4 E111
PHOTO
SWITCH
50 1.25B 1.25B CBG96 (G4GC)
HEAD CUD96 (D4FB)
OFF PASS HIGH CDD96 (D4EA)
1 M01A
GGG15 (G4FA/G4FC)
2 M02L GBG15 (G4GC)
GUD14 (D4FB) PHOTO
0.3B GDD14 (D4EA) 69 0.5B 1.25B 1.25B
2 10 JM02
JOINT
See Ground Distribution CONNECTOR
(SD1301)
PHOTO 47
1 6 JM02
1.25B 1.25B
GM21 PHOTO 46 GE11 PHOTO 1

3 2 1 3 2 1 3 2 1 3 2 1
6 5 4 6 5 4 6 5 4 6 5 4
3 2 1 3 2 1 3 2 1 3 2 1
6 5 4 6 5 4 6 5 4 6 5 4
E43 E47 E77 E111
1 1
2 2 3 2 1 3 2 1
5 * 3 5 * 3 6 5 4 6 5 4
M01A M02L M04A
6 5 4 3 2 1 13 12 11 10 9
* 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 * 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21
M04B M08B
10
* * 7 6 5 4 3 2 1
8
* * 5 4
* 2
*
17 16 15 14 13 12 11 10
20 19 18 17 16 15 14 13 12 11
20
* * 9
2012 > D 2.0 TCID > Head lamp Leveling Device > Schematic Diagrams
Head Lamp Leveling Device (1) SD9221
I/P E/R
5DOOR, See Power Distribution
(SD11010) JUNCTION FUSE &
BOX RELAY
WAGON HEAD PHOTO See Power BOX
LAMP 45 Distribution
10A (SD1102)
See Passenger 5 1 E47
Compartment
Fuse Details H/LP LO
(SD1202) RELAY
PHOTO
15 I/PC 12 I/PG 10 I/PD 7 I/PG 9 I/PD 31
0.3W 0.3W 0.3R 0.3Br 0.3G 0.3R/O 3 2 E47

14 M04B
See Head Lamps 20 M08B
BCM 0.5R 0.5R
(SD9211) ICM RELAY
PHOTO BOX
57 H/LP H/LP
PHOTO 46
LO RH LO LH
8 M08B 10A 10A
33 M04A See Power
0.3Y 0.3R/O Distribution
(SD1102)
21 EM31
PHOTO 43
0.3R/O
0.5Y
4 10 9 M02L PHOTO 43
MULTIFUNCTION 25 EM31
PARK LOW PASSING See Illuminations
SWITCH PHOTO (SD9412)
SWITCH 50
HEAD FLASH HIGH
OFF 0.3R/O 0.3P
0.5O 3 4 1 M34
HEAD
2 5 M02L 28 EC11 LAMP
PHOTO 115 ILL. LEVELING
0.3B 0.3B 0.3B DEVICE
SWITCH
2 5 3 JM02 PHOTO
5 2 M34 116
See Ground JOINT 0.3Gr
Distribution CONNECTOR 0.3G 0.3G
(SD1301) PHOTO 47 See Illuminations
7 MC11 2 EM31 (SD9412)
1 JM02 PHOTO PHOTO 43
75
1.25B 0.85B 0.5G 0.5O 0.5Y 0.5G 0.5B
CGG73 (G4FA/G4FC) PHOTO

CBG73 (G4GC) GE11 1
CUD73 (D4FB)
1 3 2 CDD73 (D4EA) 3 2 1 E112
HEAD LAMP HEAD LAMP
LEVELING LEVELING
GGG15 (G4FA/G4FC) DEVICE DEVICE
GBG15 (G4GC) ACTUATOR ACTUATOR
GUD14 (D4FB) PHOTO M RH M LH(3DR)
GDD14 (D4EA) 69 PHOTO 6 PHOTO 3
GM21 PHOTO 46
I/P E/R
3DOOR See Power Distribution
(SD11010) JUNCTION FUSE &
BOX RELAY
HEAD PHOTO See Power BOX
LAMP 45 Distribution
10A (SD1102)
See Passenger 5 1 E47
Compartment
Fuse Details H/LP LO
(SD1202) RELAY
PHOTO
15 I/PC 12 I/PG 10 I/PD 7 I/PG 9 I/PD 31
0.3W 0.3W 0.3R 0.3Br 0.3G 0.3R/O 3 2 E47

14 M04B 20 M08B
See Head Lamps 0.5R 0.5R
BCM (SD9212) ICM RELAY
PHOTO BOX
57 PHOTO 46 H/LP H/LP
LO RH LO LH
8 M08B 10A 10A
33 M04A See Power
0.3R/O
0.3Y Distribution
21 EM31 (SD1102)
PHOTO 43
0.3R/O
0.5Y
4 10 9 M02L PHOTO 43
25 EM31
MULTIFUNCTION
LIGHT DIMMER/ SWITCH See Illuminations
PARK SWITCH LOW PASSING (SD9412)
PHOTO
SWITCH 50
HEAD FLASH HIGH 0.3R/O 0.3P
OFF
0.5O 3 4 1 M34
HEAD
2 5 M02L LAMP
28 EC11 LEVELING
ILL.
PHOTO 115 DEVICE
0.3B 0.3B 0.3B SWITCH
5 2 M34 PHOTO
116
2 5 3 JM02 0.3Gr
0.3G 0.3G
See Ground JOINT
Distribution CONNECTOR See Illuminations
PHOTO 47 7 MC11 2 EM31 (SD9412)
(SD1301)
PHOTO PHOTO 43
1 JM02 75
1.25B 0.85B 0.5G 0.5O 0.5Y 0.5G 0.5B

CGG97 (G4FA/G4FC) PHOTO
CBG97 (G4GC) GE11 1
CUD97 (D4FB)
1 2 3 CDD97 (D4EA) 3 2 1 E76
HEAD LAMP HEAD LAMP
LEVELING LEVELING
GGG15 (G4FA/G4FC) DEVICE DEVICE
GBG15 (G4GC) ACTUATOR ACTUATOR
M RH(3DR) M LH
GUD14 (D4FB) PHOTO
GM21 PHOTO 46 GDD14 (D4EA) 69 PHOTO 6 PHOTO 3
2 1 2 1
3 2 1 3 2 1
3 3
2 1 2 1
3 2 1 3 2 1
3 3
E47 E76 E112 M02L
1
2 13 12 11 10 9 7 6 5 4 3 2 1
3 2 1 3 2 1 *
5 * 3
M04A M04B M08B
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1 10
* * 7 6 5 4 3 2 1
8
* * 5 4
* 2
*
17 16 15 14 13 12 11 10
20
* * 9
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11
M34
1 BLANK BLANK BLANK

5 4 3 2
2012 > D 2.0 TCID > Horns > Schematic Diagrams
Horns (1) SD9681
HOT AT ALL TIMES
E/R
FUSE &
RELAY
BOX
HORN
15A
See Power
Distribution
0.85R (SD1102)
0.85R
3 1 E45
HORN
RELAY
PHOTO 31
5 2 E45
0.5Gr 0.85P 0.85P
8 EM31 2 1 EE12
PHOTO 43 PHOTO 1
0.3Gr 0.85P 0.85P
2 E87 2 E86
HORN HORN
6 M02R (LOW) (HIGH)
MULTIFUNCTION
SWITCH Dual Horn
CLOCK 1 E87 1 E86
SPRING PHOTO
50/53 PHOTO 2 PHOTO 2
0.85B 0.85B
6 MM01
STEERING 0.85B
WHEEL
HORN 3 EE12
SWITCH PHOTO 1
0.85B
GE11 PHOTO 1
2012 > D 2.0 TCID > Horns > Schematic Diagrams
Horns (2) SD9682
E45 E86 E87 M02R
1
2 2 1 2 1 6 5 4 3 2
*
5 * 3 12 11 10 9 8
*
2012 > D 2.0 TCID > Illuminations > Schematic Diagrams
Illuminations (1) SD9411
To Joint JOINT
See Power I/P CONNECTOR
See Power JUNCTION A Connector
TAIL Distribution BOX (SD9412) PHOTO 4
Distribution
LAMP (SD11010)
(SD11010) PHOTO
RELAY 14 17 15 JM01
45
0.3P 0.3P
CLOCK 17 M61A 4 M62
10A
SWITCH MULTI 0.3P
TAIL RH MODULE DISPLAY
10A PHOTO PHOTO 59
See Passenger
Compartment 59 0.3P
Fuse Details 2 M80 5 M18
(SD1206) 19 M61A 5 M62
See Passenger With DRL W/O DRL
0.3Gr 0.3Gr ASHTRAY CIGARETTE
Compartment ILL. LIGHTER &
Fuse Details FRONT
(SD1201) 8 JM01 PHOTO
RHEOSTAT 56 POWER
RELAY JOINT OUTLET
SHUNT From Joint CONNECTOR
(With DRL) CONNECTOR B Connector
P HOTO 1 M80 6 M18
(SD9412)
4 PHOTO 62
5 JM01
0.3P 0.3Gr
0.3Gr 0.3P 0.85B
1 I/PB 6 I/PD 11 I/PC 18 I/PB 34 29 MF12
PHOTO 43 4 3 M27
0.3R 0.3L 0.3L 0.85P 0.3P 0.3Gr ILL() ILL(+) RHEOSTAT
PHOTO
1 M74 116
GLOVE ILL.
BOX C
LAMP D
PHOTO
118 To Joint From Joint
0.3L Connector Connector
2 M74 (SD9412) (SD9412) 2 M27
0.3L
1 M02L 0.5B 0.3B
0.3B 4 M04C 28 M04A
4 5 JM02
BCM MULTIFUNCTION
Tail Lamp Tail Lamp PHOTO PARK LIGHT SWITCH JOINT
1 M75 Relay Switch HEAD SWITCH See Ground CONNECTOR
57 PHOTO Distribution
GLOVE Control Input 50 PHOTO 47
BOX OFF (SD1301)
LAMP
SWITCH 2 1 JM02
1.25B
PHOTO 2 M02L
2 M75 118
0.3B
0.3B GM21 PHOTO 46
2 5 JM04
See Ground JOINT
(SD1302) PHOTO 68
1 JM04
1.25B
GM41 PHOTO 120
JOINT
CONNECTOR
PHOTO 43
5 6 7 JF01
0.3P 0.3P 0.3P 0.3P 0.3P

To Joint
1 FD22 1 FD21 1 FD11 Connector
17 FD12 (SD9411)
C PHOTO 41 PHOTO 85 PHOTO 85
PHOTO 41 0.3P 0.3P 0.3P
From Joint JOINT
With Safety W/O Safety D From Tail CONNECTOR
Connector
A Lamp Relay
(SD9411) PHOTO 4
(SD9411)
0.3P 0.3P
D01 (LHD) D01 (LHD) 16 JM01
4 D01R (RHD) 3 D01R (RHD) 8 D21 8 D51 8 D41
POWER POWER PASSENGER REAR REAR
POWER POWER POWER 0.3P 0.3P
WINDOW WINDOW
MAIN MAIN WINDOW WINDOW WINDOW 3 M02R
SWITCH SWITCH SWITCH SWITCH RH SWITCH LH
MULTIFUNCTION
PHOTO 80 PHOTO 80 PHOTO 82 PHOTO 86 PHOTO 86 CLOCK SWITCH
13 D01 (LHD) 5 D01 (LHD) 3 D21 3 D51 3 D41 SPRING PHOTO
D01R (RHD) D01R (RHD) 0.3B 0.3B 0.3B 0.3Gr 50/53
0.3B 0.3B
28 FD22 11 FD21 11 FD11 3 MM01
27 FD12 PHOTO 41 PHOTO 41 PHOTO 85 PHOTO 85
STEERING
0.3B 0.3B 0.3B 0.3B WHEEL
3 2 4 1 JF01 M57 (W/O Cruise) M58 (W/O Cruise)
2 M59 (With Cruise) 2 M60 (With Cruise) 1 M01B
AUDIO AUDIO/ INSTRU
REMOTE CRUISE MENT
CONTROL REMOTE CLUSTER
SWITCH CONTROL PHOTO
PHOTO 53 SWITCH 49
1 M57 (W/O Cruise) 1 M58 (W/O Cruise) 2 M01B
M59 (With Cruise) M60 (With Cruise)
18 19 20 JM01 PHOTO 53
0.3L 0.3P 0.3P 0.3P 0.3P 0.3P 0.3P 0.3P

AUX & 1 M05A (Auto A/C)
6 M22 6 M71 1 M13 1 M34 2 M54A 6 M77 5 M76 USB 1 M06B (Manual A/C) 2 MM01
ESP ISG ATM HEAD AUDIO NAVI AUDIO JACK A/C MULTIFUNCTION
OFF OFF SHIFT LAMP PHOTO PHOTO CONTROL CLOCK SWITCH
SWITCH SWITCH LEVER LEVELING 62 62 MODULE SPRING PHOTO
PHOTO PHOTO ILL. DEVICE PHOTO 59 50/53
116 116 SWITCH
2 M22 2 M71 2 M13 2 M34 PHOTO 7 M54A 11 M77 13 M76 13 M05A (Auto A/C) 2 M02R
PHOTO 65 PHOTO
60 0.3B 0.3B
0.5Gr 0.3Gr 0.3Gr 0.3Gr 0.3Gr 0.3Gr 0.3Gr 0.3Gr
9 6 10 7 JM01
JOINT
To Rheostat CONNECTOR
B
(SD9411) PHOTO 4
D01 D01R D21 D41
3 2 1 3 2 1
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 16 15 14 13 12 11 10 9 8 7 6 5 4 8 7 6 5 4
D51 M02L M02R
3 2 1 BLANK
8 7 6 4
13 12 11 10 9
* 7 6 5 4 3 2 1 6 5 4 3 2
*
* 12 11 10 9 8
*
M04A M04C M05A
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3
* 1 13
* * 10 9 8 7 6
** * 2 1
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21 16 15 14 13 12 11 10 9
26 25 24 23 22 21 20 19 18 17 16
* 14
M06B M13 M18 M22
2 1
14 13 12 11 10 9 8 7 6 5 4 3 2 1 2 1 *6 5 4 3
*
28 27 26 25
*23 22 21 20 19 18 17 16 15 6 5
* 3
M27 M34 M54A M57
2
* 1
4 3 2 1
1 2
* * 5 6 7 8
8 7 6 5
* * 4 3 5 4 3 2
M58 M59 M60 M61A
1 2
* * * 6 7 8 1 2
* * 5 6 7 8 1 2
* * * 6 7 8
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
M62 M71 M74 M75
2 1
12 11 10 9 8
* * 5 4 * 2 1 2 1 2 1
24 23 22 21 20 19 18 17 16 15
* 13 6 5 4 3
M76 M77 M80
7 6 5 4 3 2 1 BLANK
16 15 14 13
* 11
* 9
*
6
* 4 3 2 1
2 1
12 11 10
* 8 7
2012 > D 2.0 TCID > Immobilizer Control > Schematic Diagrams
Immobilizer System (1) SD9541
HOT WITH ENGINE CONTROL RELAY ON HOT AT ALL TIMES
See Power Distribution EMS See Power I/P
(SD1103) (SD1104) BOX Distribution JUNCTION
(SD1105) (SD1106) PHOTO (SD11010) BOX
(SD1107) 114 PHOTO
POWER 45
SNSR2 SNSR1 CONNECTOR
15A 10A ROOM
LP
See Power Distribution 15A
(SD1103) (SD1104) See Power Distribution
(SD1105) (SD1106) (SD1107)
See Passenger
9 E/RCGG2 4 E/RCUD2 Compartment
9 E/RCBG2 4 E/RCDD2 Fuse Details
(SD1203)
0.5L/O 0.5L/O
12 I/PC
G4FA/G4FC, G4GC D4FB/D4EA
31 MC11 0.5R
PHOTO 75
8 M01C
0.3P 0.5L/O INSTRUMENT
CLUSTER
2 M19 1 4 M09 PHOTO 49
IMMO.
IGNITION KEY IMMOBILIZER
Transponder ILL. & DOOR Antenna(+) Memory
ANTENNA MODULE
WARNING Power
COIL PHOTO 46
SWITCH
PHOTO 51
Antenna() Ground PCM
12 M01C
1 M19 2 3 5 M09
0.3W 0.5B 0.3L/B 0.3Y
17 16 6 MC11
PHOTO 75
0.5L/B(G4FA/G4FC, With ETC) 0.5Y
0.5L(G4FA/G4FC/W/O ETC,D4FB, G4GC)
0.5G(D4EA)
G4FA/G4FC G4GC/D4FB/D4EA
0.5B 0.5B 80 54 CGGK (G4FA/G4FC, With ETC)

18 48 CGGMK (G4FA/G4FC, M/T / W/O ETC)
44 32 CGGAA (G4FC, A/T / W/O ETC)
12 CBGK (G4GC) 75 69 CBGK (G4GC)
30 CUDK(D4FB) 44 70 CUDK(D4FB)
16 CDDK(D4EA) 47 92 CDDK(D4EA)
ECM/
Ground Signal IMMO. PCM
IND.
PHOTO
36/37/38
GGG11 PHOTO 36
2012 > D 2.0 TCID > Immobilizer Control > Schematic Diagrams
Immobilizer System (2) SD9542
CBGK CDDK
94 93 92
*90 89 88 87
* * * * 82 81 80 5779 78 77 * 5375 74 73 6 5
94 93 92
*90 89
* 87 86 * 84 83 * * 80 79 * 77 * 75 * * 6 5
** * 70 69 67 66 65 64
** **** *** * * 4 3
72 71 70 69 68
* * 65 64 * * * * * * 57 * * * * * 51 4 3
* 4927 26* 4725 * 23* 22* 21* 42 41 1840 1739 3816 1537 14* 1*3 12* * 10* *9 *8 297 2 1 * * * 4725 2446 45 4422 * * 19* 40 * 1638 3715 1436 1335 1234 1133 1032 319 308 297 2 1
28
* ** * 28
** * ** **
CGGAA CGGMK
* 44* 5843 57 56 5540 * 38* 3752 5136 50 3449 4833 32* * 94 93 92 91 90

* 66* 87 8664 6385 6284 8361 6082 8159 80 * * 77 54* * * 7351 6 *
* ** * * * 72 71 70 69 68
* * ** * * * *
* 3
28 27 26 25 24 23 22 21 * 19 18 17 16 15 * 36 3513 12* 3311 32 319 * 297 2 1
50 49 48 47 46 45 44 43 41 40 39 38
30
* * 27
* * * 23 22 21
* * * 17 16
15
* * 12 11 * 9 8 * 6 * * * 2 1 * * * *
CGGK CUDK
94
* 92 91 90 89 88 87 86 85 * 83 * 81 80 79 78 77 76 75 74 73 6 5 94 93 92
*90 89
*
87 86 85 84 83
* * 7856 7755 76 5375 52* 5173
81 80
6 5
* 71 70 69 68 67 66 65 * 63 62 61 * 59 58 57 56 * 54 53 52 51 4 3
72 71 70 69 68 67 66
*
64 63 62 61 60 59 58
* * 4 3
50 49
* 25* 24* 23* 4422 4321 4220 4119 4018 3917 38 15* 36 3513 3412 3311 32 319 308 297 2 1
50
* 26* 47 2446 * 4422 * 20* 1941 40 17* 38 15* 14* 1335 12* 1133 1032 *9 30 *7 2 1
28 27 26
* * * 28 27
* * * * * *
M01C M09 M19
8 7 6 5 4 3 2 1 1 1 2 BLANK
16 15 14 13 12 11 10 9 5 4 3 2 3 4 5 6
2012 > D 2.0 TCID > Indicators & Gauges > Schematic Diagrams
Indicators & Gauges (1) SD9401
I/P
(SD11010) BOX
POWER
CONNECTOR PHOTO
ROOM 45 See Tail, Parking
CLUSTER & License Lamps
10A LP
See Vehicle 15A (SD9281)
Speed System See Head Lamps/
See Passenger See Supplemental Auto Lights
(SD4361) Compartment Fuse Details
(SD4362) Restraint System (SRS) (SD9211) (SD9212)
(SD1201) (SD1203) (SD5691) (SD5692) (SD9511) (SD9512)
3 12 I/PC
0.3Gr/O 0.3R/O 0.5R 0.3R/O 0.5R/O 0.5G
0.3R/O
1 7 8 14 M01C 9 10 M01A
INSTRUMENT
To
Speed CLUSTER
B Indicators
Signal PHOTO
(SD9404)
49
To
Indicators
A (SD9402)
(SD9403)
(SD9404)
ESP
CRUISE IMMO. DOOR
SET 5V TAIL
POWER OPEN LAMP
SET SUPPLY
ESP DSL
CRUISE OFF GLOW
MIL.
TRUNK AIR HIGH
OPEN BAG BEAM
CHECK Seat
M I C O M
P.GND S.GND
16 10 M01C 12 6 1 M01A 4 12 11 M01C 11 M01B 13 M01C
0.3Br/O 0.3W 0.3Y 0.3G/B 0.5B 0.5B 0.3Y 0.5G/B 0.3B 0.3Y
(G4GC) (G4GC)
10 JM02
See Immobilizer See Supplemental
See MFI Control System See Auto JOINT System See Courtesy & Restraint System (SRS)
Cruise System See Ground
(SD3135) (SD31315) Distribution CONNECTOR (SD9541) Trunk Lamps
(SD9641) (SD9292) (SD9293) (SD5691) (SD5692)
(SD31323) (SD31331) (SD1301) PHOTO 47
(SD31341) (SD31351)
6 JM02
1.25B
GM21 PHOTO 46 GM31 PHOTO 119

See Turn & See Front Fog
Hazard Lamps & Rear Fog Lamps
See MFI Control System (SD9251) (SD9241) (SD9242)
(SD31339) (SD31349)
0.3Y 0.5Y/O 0.5L 0.5O 0.3Y/O
15 M01C 10 9 M01B 7 8 M01A

INSTRUMENT
From CLUSTER
CLUSTER
10A A PHOTO
(SD9401) 49
DSL
WASHER EBD/ WATER
SEAT LOW PARKING PARKING SEPARA LEFT RIGHT FRONT REAR
BELT ABS BRAKE BRAKE TOR TURN TURN FOG FOG
( )ABS ( )! ( )P ( )! ( )P
BRAKE BRAKE
SEAT
BRAKE EBD
M I C O M
BRAKE
6 M01B 5 M01A 4 8 M01B
0.3O 0.3R 0.3W/B 0.3L/B
20 MC11
PHOTO
75 7 I/PC 0.3L
0.3R I/P
CGG76 (G4FA/G4FC) JUNCTION
BOX 1 MC11
CBG76 (G4GC) PHOTO 75
CUD76 (D4FB) PHOTO 45
1 CDD76 (D4EA )
See Charging System 8 I/PC 0.3L(G4FA/G4FC, D4FB)
WASHER (SD3731) (SD3732) 0.3Y(G4GC, D4EA) CGG45 (G4FA/G4FC)
LEVEL (SD3733) (SD3734) CBG45 (G4GC)
SWITCH (SD3735) (SD3736) 0.3L 0.3L CUD45 (D4FB)
PHOTO 10 2 CDD45 (D4EA )
39 MC11
PHOTO 75 BRAKE
FLUID LEVEL
2 CGG76 (G4FA/G4FC) 0.3L(G4FA/G4FC, D4FB) SENSOR
CBG76 (G4GC) 0.3Y(G4GC, D4EA)
CUD76 (D4FB) PHOTO 7/13
CDD76 (D4EA )
0.3B 12 CGG70 (G4FA/G4FC) 1 CGG45 (G4FA/G4FC)
12 CBG70 (G4GC) CBG45 (G4GC)
1 M26 12 CUD70 (D4FB) 0.5B CUD45 (D4FB)
11 M04C 13 CDD70 (D4EA ) CDD45 (D4EA )
PARKING
BCM BRAKE ESP
PHOTO GGG15 (G4FA/G4FC) SWITCH CONTROL
MODULE GGG14 (G4FA/G4FC)
57 GBG15 (G4GC) PHOTO GBG14 (G4GC)
67 PHOTO
GUD14 (D4FB) PHOTO 7/13 GUD13 (D4FB) PHOTO
GDD14 (D4EA ) 69 GDD13 (D4EA ) 7/13
See Body Control
Module (BCM) System
(SD9521)
0.3R/B
9 M01C
INSTRUMENT
From From From Over Super CLUSTER
CLUSTER 10A A CLUSTER 10A A ROOM LP 15A B DC_12V Speed Vision
Out PHOTO 49
(SD9401) (SD9401) (SD9401)
Pointer Illumination
LCD Illumination
Moodring Illumination
Dial Illumination
OIL SPEED
BATTERY PRESSURE LIMIT
ISG
AUTO
STOP
M I C O M
Analog
Pointer Illumination
LCD Illumination
Dial Illumination
Vision
From ROOM
LP 15A B
(SD9401)
Driver Hood Oil ALT_L
Pressure DC_12V
Door Open Alternator (OUT)
3 2 M01C 5 4 M01B 4 M01A 12 M01B

With With W/O With With
ISG ISG ISG ISG ISG
0.3R 0.3G 0.3L/O 0.3W/B 0.3W 0.3W
30 MC11
See Courtesy & PHOTO 75 See Charging System See Audio
Trunk Lamps G4GC/D4FB (SD9617)
(SD9293) /D4EA G4FA/G4FC (SD3731) (SD3732)
(SD3733) (SD3734)
0.5L 0.5L (SD3735) (SD3736)
9 MC11 PHOTO 5 EC11
75
0.5L PHOTO 115
0.3G 0.5G CGG74 (G4FA/G4FC)
CBG74 (G4GC) 4 EB11
CUD74 (D4FB) CBG15 (G4GC) PHOTO 5
24 M04A 1 CDD74 (D4EA ) CUD15 (D4FB) 0.5L
1 CDD15 (D4FB) 1 E57
BCM HOOD
SWITCH OIL OIL
PHOTO PRESSURE PRESSURE
57 PHOTO SWITCH SWITCH
8
PHOTO PHOTO
20/25/106 96
INSTRUMENT
From CLUSTER
CLUSTER 10A A PHOTO 49
(SD9401)
LOW TPMS SPEEDO TACHO TEMP. FUEL

EPS FUEL TREAD TPMS METER METER GAUGE GAUGE
EPS ! TPMS
EPS Low Fuel Tread TPMS

IND. IND. IND. IND.
M I C O M CAN
Mode Fuel
Switch ILL(+) ILL() MTR High Low Input
F.Supply
F.Supply CAN
TRANSCEIVER
High Low F.GND
7 1 2 M01B 11 2 3 M01A 6 5 M01C

0.3Br/O 0.3P 0.3Gr 0.5G/B 0.5Y 0.5W 0.3P 0.3Gr/B
25 22 MF12
See Illuminations See BackUp PHOTO 43
(SD9412) Lamps See Data 0.3P 0.3B
(SD9261) Link Details
(SD9262) (SD2001)
F01 (G4FA/G4FC, G4GC)
1 F47 (D4EA/D4FB)
8 9 M02R PHOTO 50 0.3B
FUEL
MULTI Fuel SENDER &
CLOCK FUNCTION Level Fuel FUEL PUMP
SPRING SWITCH 3 JM02 FULL Float Sender MOTOR
See Ground JOINT PHOTO
CONNECTOR EMPTY 90
8 9 MM01 PHOTO 53 Distribution
(SD1301) PHOTO 47
3 F01 (G4FA/G4FC, G4GC)
1 JM02 2 F47 (D4EA/D4FB)
STEERING
5 6 M86 WHEEL
AUDIO 1.25B
TRIP REMOTE
CONTROL
SWITCH RH
(Trip Voice)
PHOTO 53 GM21 PHOTO 46
CBG15 CBG45 CBG74 CBG76
1 2
1 2 1 2 1
CBG70 CDD15 CDD45
13
12
***** 6 5 * 3 * 1
* * 22 * 20 19 18 17 16 * 14 1 2 1
38
* * * 34 33 32 31 30 * * 27 26 25
CDD70 CDD74 CDD76
1 2 3 4
5 6
* 8 9 10 11
* 13 14 * * * * * * * * * * * 1 2
26 27 28 29 30 31
* * * 35 * * * * * * * * * * * 2 1
CUD15 CGG45 CGG70
13
12
***** 6 5 * 3 * 1
1 2 1
* * 22 * 20 19 18 17 16 * 14
38
* * * 34 33 32 31 30 * * 27 26 25
CGG74 CGG76 CUD45
1 2 BLANK
2 1 2 1
CUD70 CUD74 CUD76
13
12
***** 6 5 * 3 * 1 1 2
* * 22 * 20 19 18 17 16 * 14 2 1
38
* * * 34 33 32 31 30 * * * 26 25
E57 F01 F47 M01A
3
* 1
6 5 4 3 2 1
1 6 5
* * * 4 3 2 1
12 11 10 9 8 7
M01B M01C M02R
BLANK
6 5 4
* 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2
*
12 11 10 9 8 7 16 15 14 13 12 11 10 9 12 11 10 9 8
*
M04A M04C M26
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3
* 1 1
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21 16 15 14 13 12 11 10 9
2012 > D 2.0 TCID > Keyless Entry & Burglar Alarm System > Schematic Diagrams
Keyless Entry & Burglar Alarm System (1) SD8141
HOT AT ALL TIMES HOT IN ON OR START HOT IN ON HOT AT ALL TIMES
E/R See Power Distribution See Power Distribution I/P
FUSE & (SD11010) (SD11010) JUNCTION
RELAY POWER BOX
BOX CONNECTOR
HORN CLUSTER A/CON ROOM LP PHOTO 45
15A 10A 10A 10A
0.85R (SD1201) (SD1202) (SD1203)
7 EM31 PHOTO 43 3 I/PC 21 I/PB 14 I/PC
See Courtesy PHOTO 48 See Turn &
0.85R 0.3R/B 0.5R
11 M08A & Trunk Lamps DATA LINK Hazard Lamps
(SD9292) (SD9293) 0.3R/O 0.3R/B 11 JM03 CONNECTOR (SD9251)
ICM PHOTO 54
RELAY JOINT 12 M10
30 85 BOX 0.5G/B CONNECTOR 0.3Br 0.3G
BURGLAR PHOTO 46 23 2 13 1 16 M04A 9 M04C
ALARM BCM
HORN T/GATE ON/START Input ON Input Memory Code Hazard Relay
RELAY Switch Power Save Control PHOTO
Burglar 57
Alarm Horn Driver Door Driver Door Driver/Passenger Passenger Passenger Rear Door Unlock Switch
Relay Lock/Unlock Key Unlock Door Key Door Key Door Unlock Hood
87 86 Control Switch Switch Lock Switch Unlock Switch Switch RH LH Switch
8 M04C 8 26 25 34 9 M04A 3 M04B 6 24 M04A
12 3 M08A
0.3G/O 0.3B/O(LHD) 0.3Y 0.3G 0.3L 0.3W(LHD) 0.3W 0.3L 0.3G
0.3W(RHD) 0.3G(RHD) PHOTO 5 MF22 3 MF12 PHOTO 43 9 MC11 PHOTO 75
2.0B 0.3B/O(LHD) PHOTO 43/75 0.3W PHOTO 75
43/75 With 3DR W/O 3DR
With 0.3W(RHD) 27 26 MF22 (LHD) With W/O
A/V 2 6 MF12 (LHD) 6 2 MF12 (RHD) 3DR 3DR LHD RHD
26 27 MF22 (RHD)
28 MF12 0.3L 0.3W(LHD) RHD LHD
0.3B/O(LHD) 0.3L(LHD) 0.3G(RHD)
0.5W 0.3L(RHD) 0.3Y(RHD) PHOTO 43
6 M54C1 0.3G 0.3W 0.3W 0.3L 0.3L 0.3L 0.5G
AUDIO
PHOTO 0.3B/O(LHD) 3 FD11
59 0.3L(RHD) 0.3G 0.3G 0.3W(LHD) 0.3W PHOTO 85 CGG74 (G4FA/G4FC)
0.3G(RHD) 3 FD21 PHOTO 85 0.3W CBG74 (G4GC)
38 MC11 20 7 19 FD12 16 17 10 FD22 0.3W CUD74 (D4FB)
PHOTO 75 0.3L(LHD) PHOTO 41 PHOTO 41 7 D57 1 D47 1 CDD74 (D4EA)
0.3P 0.3Y(RHD) 0.3G 0.3L 0.3G 0.3W
0.5W CGG46 (G4FA/G4FC) REAR REAR HOOD
1 2 4 D07 (LHD) 6 4 7 D27 (LHD) SWITCH
CBG46 (G4GC) 7 6 4 D07R (RHD) 2 4 1 D27R (RHD) DOOR LOCK DOOR LOCK
CUD46 (D4FB) ACTUATOR ACTUATOR PHOTO
1 CDD46 (D4EA) DRIVER PASSEN RH LH 8
DOOR GER PHOTO 86 PHOTO 86
BURGLAR Key LOCK
ALARM Door Door Key Key Key Door Door DOOR 5 D57 3 D47 2 CGG74 (G4FA/G4FC)
Unlock Lock Unlock Lock ACTUA Unlock Lock Unlock Lock LOCK
HORN TOR CBG74 (G4GC)
ACTUATOR CUD74 (D4FB)
2 CGG46 (G4FA/G4FC) PHOTO PHOTO 82 CDD74 (D4EA)
CBG46 (G4GC) 3 D07 (LHD) 80
CUD46 (D4FB) 5 D27 (LHD)
5 D07R (RHD) 3 D27R (RHD) 0.5B 0.5B 0.5B
CDD46 (D4EA)
0.5B 2.0B 0.5B 0.5Y
PHOTO 8 34 FD12 1 4 JD01
PHOTO 41 11 FD22 13 FD21 14 FD11
See Ground JOINT PHOTO 41
2.0B Distribution CONNECTOR PHOTO PHOTO 85
(SD1303) PHOTO 81 0.5B 0.3B 85 0.3B
GGG15 (G4FA/G4FC) GGG15 (G4FA/G4FC)
GBG15 (G4GC) GBG15 (G4GC)
GUD14 (D4FB) PHOTO GF11 (LHD) PHOTO GF21 (LHD) PHOTO GUD14 (D4FB) PHOTO
GDD14 (D4EA) 69 GF21 (RHD) 42/63 GF11 (RHD) 42/63 GF41 PHOTO 85 GF31 PHOTO 85 GDD14 (D4EA) 69
2012 > D 2.0 TCID > Keyless Entry & Burglar Alarm System > Schematic Diagrams
Keyless Entry & Burglar Alarm System (2) SD8142
CBG46 / CDD46 CBG74 / CDD74 CGG46 CGG74
2 1 2 1 2 1 2 1
CUD46 CUD74 D07 D07R
2 1 2 1 * 6 5 4 3 2 1 7 6 5 4 3 2 1
D27 D27R D47 D57
7 6 5 4 3 2
* 7 6 5 4 3 2 1 7 6 5
* 3
* 1 7
* 5
* 3 2 1
M04A M04B M04C
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1 10
* * 7 6 5 4 3 2 1 8 7 6 5 4 3
* 1
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
M08A M10 M54C1
2 1
* 7 6 5 4 3 2 1
9 8 7
* 5
*
3 2 1
18 17 16 15 14 13 12 11 10 * 15 * 13 12 11 * 9 * 3 BLANK
6 5
2012 > D 2.0 TCID > MFI Control System > Schematic Diagrams
MFI Control System (D4EA : D 2.0L) (1) SD31345
ECM Terminal Information
60 59 58
* * * 53 37* * 50 4934 33* 47 4631
56 94 93 92
* * 87 86 * 84 83 * * 80 79 * 77 * 75 * *
90 89
6 5
45 44 43 42 41 40
** * * * * * 65 64 * * * * * * 57 * * * * * 51
72 71 70 69 68
4 3
30
* 1328 1227 26 * * 238 *7 *6 20 194 * 172 161 * * * 47 46 45 44
* * * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* * *** * *
28
* * 25 24 * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
CDDA CDDK
PIN COLOR DESCRIPTION PIN COLOR DESCRIPTION PIN COLOR DESCRIPTION PIN COLOR DESCRIPTION PIN COLOR DESCRIPTION
1 R Injector #3 Control 32 1 W Engine Control Relay 'ON' Input 33 W Ground 65 L Lambda Sensor Current Pump
2 G Injector #2 Control 33 P/B Injector #4 Control 2 B Ground 34 L Signal 66
3 34 L/B Ground 3 P Engine Control Relay 'ON' Input 35 B Ground 67
4 W Power 35 4 B Ground 36 L/B Signal 68 Br/O MIL. Indicator Control
5 36 5 P Engine Control Relay 'ON' Input 37 B Ground 69 W Glow Time Ind. Lamp
6 B Ground 37 G Reference Frequency 6 B Ground 38 G/O Brake Switch Signal 70 L A/Con Relay Control
7 B Sensor Shield 38 7 L Fan Relay Control (High) 39 71 Y/O Fan Relay Control (Low)
8 B/O Ground 39 8 L Ground #2 40 Y Signal 72 G Engine Control Relay Control
9 40 L BPS Signal 9 O Signal #1 41 73
10 41 B/O Ground 10 B Ground 42 74
11 42 W AFS Signal 11 L Signal 43 75 Gr Vehicle Speed Input
12 W Sensor Signal 43 Y/O Signal 12 B Ground 44 P Power 76
13 R Power 44 L Ground 13 L Signal 45 Y Power #1 77 L Feedback Status Signal
14 45 L/O Fuel Pump Relay Control 14 B Cruise Ground 46 Br Power #2 78
15 46 W Injector #3 Control 15 L Cruise Switch 47 G IMMO. Interface 79 W Clutch Switch Signal
16 P Injector #1 Control 47 W Injector #1 Control 16 B IMMO. Ground 48 80 L Redundant Brake Switch
17 G Injector #4 Control 48 17 49 81
18 49 L/B Ground 18 50 82 W
19 W Power 50 Br Sensor Signal 19 B ESP/FTCS Auto Recognition 51 Y Heater Lambda Sensor 83 L CANLow
20 O Sensor Ground 51 20 52 84 CANHigh
21 52 21 53 85
22 53 O BPS Temp. Signal 22 W Power 54 86 W Lambda Sensor Virtual Ground
23 B Ground 54 23 55 87 Y Lambda Sensor Current Adjust
24 55 24 R Cruise Switch Power 56 88
25 56 L Feed Back Signal 25 G KLine 57 R Neutral Switch 89 L/O Temperature Output
26 P Power 57 26 58 90 Y Throttle Valve Actuator
27 G Sensor Signal 58 W Signal 27 59 91
28 G Power 59 L EGR Actuator 28 W ON/START Input 60 92 Y IMMO.IND.Lamp
29 60 W MTR(+) 29 L VGT Actuator 61 93 W Glow Plug Relay Control
30 B/O MTR() 30 Gr Ground #1 62 94 L Auxiliary Electric heater
31 W Injector #2 Control 31 G Signal #2 63
32 Gr Signal 64 G Lambda Sensor 'NERNST' Power
Full Circuit Diagrams
CAMSHAFT
POSITION INJECTOR INJECTOR
HOT IN OR START HOT AT ALL TIMES B SENSOR #1 #3
R W
U
EMS E/R I/P FUSIBLE
BOX FUSE & JUNCTION LINK
MULTI BOX 1 1 2 3 CDD13
FUSE RELAY BOX
STOP GLOW 1 2 CDD241 1 2 CDD243
ECU1 F/PUMP SNSR BOX 15A
ALT 10A PLUG W
30A 15A 80A
150A 1 CDD27
Blower & BOOSTER INJECTOR INJECTOR
A/C Control
AIR PRESSURE
FLOW #4 #2
1 System (Auto) SENSOR
ENGINE SENSOR
CONTROL P
U
RELAY
W Y 1 2 3 4 CDD39 1 2 CDD 1 2 CDD
3 2 5 4 CDD27 244 242
1 4 CDD90
BATTERY
GLOW W P W G P/B R W G W
PLUG
RELAY
ECU 4 ECU 2 SNSR2 SNSR1 FUEL
20A 10A 15A 10A PUMP 5 2 CDD90
RELAY
5
2
B 5 4 B 2 3
W P W G G R 1 CDD86 R
BODY W
GROUND 3 W 2 CDD31
LAMBDA 3 CDD83
2 CDD36 SENSOR 3 2 CDD77 ELECTRICAL EGR
4 F47 STOP
DIFFERENTIAL FUEL THROTTLE CONTROL
PRESSURE LAMP GLOW ACTUATOR ACTUATOR
SENDER & SWITCH
SENSOR PLUG
M FUEL
1 2 4 CDD83
PUMP 4 1 CDD77 1 CDD31
5 6 4 3 1 CDD36 2 CDD37 MOTOR
See Cooling L Y B
VGT 3 F47 See
ACTUATOR System Vehicle Speed 4
2 3 1 CDD79 Sensor
1 CDD37 B GDD21
L/B B P P P W G Y L Y W G L W L G/O L Y/O Gr W L/O L W G L L/O Br O L R O B P W G P/B R W G W
GF71
36 37 44 5 3 1 72 51 65 87 86 64 29 28 80 38 7 71 75 93 77 90 89 44 42 37 59 45 50 20 40 13 53 23 16 47 17 33 1 46 2 31
ECM (CDDK) ECM (CDDA)
4 19 6 34 35 33 32 57 2 94 70 40 25 84 83 69 92 68 16 47 15 14 24 45 9 30 46 31 8 11 10 79 12 13 22 60 30 26 6 56 27 12 7 41 58 28 43 8 19 49 4 34
B B B L B W Gr R B L/O L Y G W Y W Y Br/O B G L B R Y O Gr Br G L L B W B L W W B/O P B L G W B B/O W G Y/O B/O W L/B W L/B
With
ESP
See Blower & See Cruise
1 CDD64 A/C Control System Control System
1 2 CDD62 NEUTRAL
SWITCH
1 2 1 CDD32 1 2 3 CDD72
3 5 M09
EXHAUST GAS 2 CDD64 See Data
P
TEMPERATURE Link Details W L/B W L/B

#1 A/C
IMMOBILIZER PRESSURE
B R Y MODULE TRANSDUCER
FUEL 1 2 3 CDD33 1 2 CDD34
3 1 2 CDD84 TEMPE G W B
2 CDD71 U
RATURE
B Y SENSOR CLUTCH P
1 2 3 5 4 CDD40
SWITCH RAIL PRESSURE
3 2 1 CDD14 SENSOR RAIL
M
PRESSURE
1 CDD71
FUEL FILTER 15 10 12 16 M01C 5 3 4 6 1 2 CDD44 3 1 CDD11 REGULATOR
1 2 M67 WARNING 1 2 CDD38
SWITCH B
EXHAUST GAS
TEMPERATURE INSTRUMENT CLUSTER ACCELERATOR VARIABLE SWIRL CRANKSHAFT ENGINE FUEL
GDD11 #2 GDD21 GDD12 GDD13
PEDAL SENSOR CONTROL ACTUATOR POSITION COOLANT PRESSURE
SENSOR TEMPERATURE REGULATING
SENSOR VALVE
EMS See Power I/P
BOX Distribution JUNCTION
PHOTO (SD11010) BOX
ECU 1 114 PHOTO
30A STOP 45
15A
ENGINE
CONTROL 15 I/PB
RELAY
See Power
Distribution 0.5R
(SD1107)
SNSR2 SNSR1 ECU 4 ECU 2
15A 10A 20A 10A
24 MC11
To Fuel PHOTO 75
A Pump Relay
(SD31348)
A : Closed with brake
11 E/RCDD1 9 6 13 11 2 1 16 17 E/RCDD2 pedal depressed
B : Open with brake
0.5G 0.5P 0.5W 0.5W 0.85R 2.5P 2.5P 2.5W 0.5W 0.5R pedal depressed
2 CDD36 3 CDD95 3 2 CDD77
ELECTRICAL STOP
LAMBDA A S I C THROTTLE
PUMP SENSOR B A LAMP
ACTUATOR SWITCH
PHOTO PHOTO
105 102 PHOTO
55
4 1 CDD77
6 4 3 1 5 CDD36 2 1 4 CDD95 0.5P/B
1 CDD13 2 CDD31
ABS ESP
CAM EGR
SHAFT CONTROL
POSITION ACTUATOR 0.5G/O 0.5G/O 0.5P/B
SENSOR 0.5L 0.5G/O
PHOTO
PHOTO 103 20 CDD41 30 CDD70
101 1 CDD31
4 CF11
2 3 CDD13
0.5W PHOTO
75
0.5L 0.5Y 0.5W 0.5G 0.75Y 0.5Br 0.5O 0.5Y 0.5L 0.5B 0.75L
ABS ESP
CONTROL CONTROL
MODULE MODULE
GDD21 PHOTO 38 PHOTO 7 PHOTO 7
72 65 87 86 64 51 CDDK 50 20 CDDA 90 77 CDDK 59 CDDA 5 3 1 80 38 CDDK
See Stop Lamps
Engine Current Current Virtual 'Nernst' Heater Sensor Sensor Throttle Feedback EGR Redundant Brake ECM (SD9272)
Control Pump Adjust Ground Power Signal Ground Valve Status Actuator Engine Control Brake Switch PHOTO
Relay Actuator Signal Relay 'ON' Input Switch Signal 38
Control Lambda Sensor
FUSIBLE EMS
PTC LINK BOX BOX
HEATER PHOTO
GLOW RELAY #1
PLUG F/PUMP 114
80A PHOTO 11 15A
5 CDD91
8.0W From SNSR1 10A
(SD31347) FUEL
1 4 CDD90 PUMP
GLOW A RELAY
PLUG
RELAY
PHOTO
11
14 3 E/RCDD2 9 20 3 E/RCDD1
5 2 CDD90
0.5W 0.5G 0.5L/O 1.25G

8.0B 0.75W 0.75W
1 CDD86 2 CDD37 21 EC11

VGT PHOTO 115
ACTUATOR
GLOW PHOTO 105 1.25G
PLUG
PHOTO 14 I/PG
103
1 CDD37 I/P
JUNCTION
1.25L BOX
PHOTO 45
93 29 CDDK 45 CDDA
27 I/PF
ECM
Glow Plug VGT Fuel Pump
Relay Control Actuator Relay PHOTO
Control 38 1.25R/B
Signal Ground Ground Signal Signal Ground Power 4 F47

FUEL
34 35 33 32 36 37 44 CDDK SENDER
FUEL
PUMP & FUEL
M MOTOR PUMP
0.5L 0.5B 0.5W 0.5Gr 0.5L/B 0.5B 0.5P MOTOR
PHOTO
90
MC21 3 F47
22 21
PHOTO 57
0.5W 0.5Gr
1.25B
1 2 CDD62 1 2 M67 2 3 1 CDD79
EXHAUST GAS EXHAUST GAS DIFFERENTIAL
TEMPERATURE TEMPERATURE PRESSURE
SENSOR #1 SENSOR #2 SENSOR
P
With C.P.F With C.P.F With C.P.F
GF71 PHOTO 90
PHOTO 105 PHOTO 64 PHOTO 99
HOT IN ON OR START
See Power Distribution E/R
(SD1109) FUSE &
RELAY
SNSR BOX
10A
1.25R
1 JE01
JOINT
CONNECTOR
PHOTO 114
3 2 4 JE01
1.25R 1.25R 1.25R
37 29 18 EC11 PHOTO 115
0.5W 0.5W 0.5R
1 CDD27 1 CDD84
AIR INSTRUMENT FUEL FILTER
FLOW Power
CLUSTER WARNING
SENSOR SWITCH
PHOTO See Vehicle See Data Link Details
PHOTO 49 PHOTO
38 Speed System (SD2001) (SD2003)
Signal Ground 104 (SD4361)
15 M01C 2 3 CDD84
0.3Y 0.5Y 0.5B
2 MC21
4 5 2 3 CDD27 PHOTO 57
0.5Gr 0.5B 0.5W 0.5G
0.5G 0.5W 0.5L 0.5L/O 0.5Y
GDD12 PHOTO 7
37 42 44 CDDA 89 28 40 75 83 84 25 CDDK
Reference AFS Ground Temperature ON/START Signal Vehicle Low High KLine ECM
Frequency Signal Output Input Speed Input PHOTO
CAN 38
BPS
Temp. BPS Sensor Signal Sensor ESP/FTCS Ground
Ground Signal Power Signal Shield Ground Power Signal Ground
23 53 13 40 27 12 7 8 28 43 CDDA 19 4 2 6 CDDK
0.5G 0.5W 0.5B
With
ESP
0.5B 0.5O 0.5R 0.5L 0.5B/O 0.5G 0.5Y/O 0.5B 2.5B 2.5B 2.5B
0.5G 0.5W 0.5B

4 3 2 1 CDD39 3 1 2 CDD33
3 2 1 CDD14
BOOSTER RAIL
PRESSURE CRANKSHAFT PRESSURE
P P SENSOR
SENSOR POSITION
U PHOTO 12 SENSOR PHOTO
S
PHOTO 101
N 106 GDD11 GDD21
PHOTO 38 PHOTO 38
ENGINE INJECTOR INJECTOR INJECTOR INJECTOR VARIABLE

SENSOR COOLANT #1 #2 #3 #4 SWIRL
TEMPERATURE PHOTO PHOTO PHOTO PHOTO CONTROL
SENSOR M ACTUATOR
101 101 101 101
PHOTO PHOTO
101 102
1 3 CDD11 2 1 CDD241 1 2 CDD242 2 1 CDD243 1 2 CDD244 5 4 3 2 1 CDD40
0.5W 0.5B/O 1.25W 1.25P 1.25G 1.25W 1.25W 1.25R 1.25G 1.25P/B 0.5B 0.5L 0.5P 0.5B/O 0.5W
1.25W 1.25P 1.25G 1.25W 1.25W 1.25R 1.25G 1.25P/B
58 41 47 16 2 31 46 1 17 33 6 56 26 30 60 CDDA
Signal Ground Ground Feed Back Power MTR() MTR(+) ECM

Injector #1 Injector #2 Injector #3 Injector #4 Signal PHOTO
Control Control Control Control 38
Neutral IMMO. IMMO.

Switch Signal Ground lnterface Ground Ground Signal Power Power #1 Signal #1 Ground #1 Power #2 Signal #2 Ground #2
57 11 10 47 16 12 13 22 45 9 30 46 31 8 CDDK
0.5R 0.5L 0.5B 0.5B 0.5L 0.5W 0.5Y 0.5O 0.5Gr 0.5Br 0.5G 0.5L
0.5G 0.5B
1 CDD64
NEUTRAL
SWITCH
PHOTO
106
16 17 MC11
2 CDD64 PHOTO
75
0.3L/B 0.5B
2 1 CDD32 5 3 M09 1 2 3 CDD72 5 3 4 6 1 2 CDD44

0.5B
FUEL IMMOBILIZER ACCELERATOR
TEMPERATURE MODULE PEDAL SENSOR
P
SENSOR PHOTO PHOTO 55
PHOTO 46 PHOTO
103 8
GDD21
PHOTO 38
I/P
(SD11010) JUNCTION
POWER BOX
CONNECTOR PHOTO
ROOM 45
CLUSTER LP
10A 15A STEERING
See Passenger CRUISE WHEEL
Compartment Fuse Details REMOTE
(SD1201) (SD1203) CONTROL
ILL. SWITCH
3 12 I/PC PHOTO
0.3R/O 0.5R CRUISE RES COAST 53
CANCEL
MAIN ACCEL SET
0.3R/O
7 8 M01C
INSTRUMENT (+) ()
CLUSTER
2 1 7 6 8 M60
PHOTO 49
DSL
CRUISE MIL. IMMO.
CRUISE GLOW 3 2 11 12 10 MM01
SET
SET CHECK MULTIFUNCTION
SWITCH
CLOCK PHOTO
SPRING 50/53
CAN
MICOM
High Low
3 2 11 12 10 M02R
0.3P 0.3Gr 0.3L 0.3B 0.3R/O
CAN 10 16 12 M01C
TRANSCENER 0.3W 0.3Br/O 0.3Y
High Low 1 MC21 14 6 MC11 See Illuminations 9 6 MC21 37 MC11
PHOTO 57 PHOTO 75 (SD9412) PHOTO 57 PHOTO 75
2 3 M01A
0.5W 0.5Br/O 0.5Y 0.5L 0.5B 0.5R
69 68 92 15 14 24 CDDK
0.5Y 0.5W ECM
Glow Time MIL. Ind. IMMO. Cruise Cruise Cruise Switch
Ind. Lamp Control Ind. Lamp Switch Ground Power PHOTO
38
See Data Clutch Switch Fan Relay Fan Relay A/Con Relay Auxiliary
Link Details Power Ground Power Ground Signal Control (High) Control (Low) Control Electric Heater
(SD2001)
19 49 4 34 CDDA 79 7 71 70 94 CDDK
1.25W 1.25L/B 1.25W 1.25L/B 0.5W 0.3L 0.3Y/O 0.3L 0.75L
2 CDD71
CLUTCH
SWITCH
PHOTO 4 See Cooling System See Blower &
(SD2532) A/C Control System
1.25W 1.25L/B (SD9713) (SD9714)
1 2 CDD38 1 2 CDD34 1 CDD71 (SD97111) (SD97112)
FUEL RAIL 0.5B
PRESSURE PRESSURE
REGULATING REGULATOR
VALVE PHOTO
PHOTO 103 102 GDD13 PHOTO 7
CDDA CDDK
60 59 58
* * * 53 37* * 50 4934 33* 47 4631
56 94 93 92
*90 89
* 87 86 * 84 83 * * 80 79 * 77 * 75 * * 6 5
45 44 43 42 41 40
** * * * 72 71 70 69 68
* * 65 64 * * * * * * 57 * * * * * 51 4 3
30
* 1328 1227 26 * * 238 *7 *6 20 194 * 172 161 * * * 4725 2446 45 4422 * * 19* 40 * 1638 3715 1436 1335 1234 1133 1032 319 308 297 2 1
* * *** * *
28
** * ** **
3 1 3 2 1 3 2 1 2 1
*
2 1 2 1 2 1 5 4 3 2 1
2 1 3 2 1 2 1
2 1
3 2 1 4 3 2 1
2 1 2 1
6 5 4
2 1
1 2 3 4
5 6
*8 9 10 11
* * * 15 6 5 4 3 2 1
5 4 3 2 1 16 17 18 19 20
* * * * * 26 3
CDD62 CDD64 CDD70
1 2 3 4
5 6
*8 9 10 11
* 13 14 * * * * * * * * * * *
2 1 2 1 * * * 35 * * * * * * * * * * *
26 27 28 29 30 31
1 3 2 1
3 2 1
3 2 1
2
CDD86 CDD90 CDD95 F01
1
4
* 2 4 3 2 1
3
* 1
1 5
6 5
*
M01C M02R M09 M60
8 7 6 5 4 3 2 1 6 5 4 3 2
*
1 1 2
* * * 6 7 8
5 4 3 2
16 15 14 13 12 11 10 9 12 11 10 9 8
*
M67
BLANK BLANK BLANK

1 2
2012 > D 2.0 TCID > Main Harness > Schematic Diagrams
2012 > D 2.0 TCID > Main Harness > Schematic Diagrams
2012 > D 2.0 TCID > Motor Driven Power Steering (MDPS) System > Schematic Diagrams
Motor Driven Power Steering (MDPS) System (1) SD5631
E/R See Power Distribution I/P
MULTI FUSE & (SD11010) JUNCTION
FUSE RELAY BOX
BOX PHOTO
MDPS MDPS CLUSTER 45
80A 15A 10A
120 1%
See Passenger
(SD1201)
8 I/PB 3 4 5 I/PC
0.3R/O
8.0W 0.5P 0.3R/O 0.5Y 0.5Y 0.5W 0.5W
7 M01C
11 3 M10
INSTRUMENT
CLUSTER DATA LINK
PHOTO CONNECTOR
49 PHOTO 48
EPS
EPS
MIC OM
CAN TRANSCEIVER
Low High
2 3 M01A
0.5Y 0.5W
12 2 JM01
See Data JOINT
Link Details CONNECTOR
(SD2001) PHOTO 4
11 1 JM01
0.5Y 0.5W
20 12 19 11 JM02
JOINT
CONNECTOR
PHOTO 47
18 13 JM02
8.0B 0.5Y 0.5W

1 E79 1 E78 4 5 6 M49
Low High EPS
Ground Battery ON/START CONTROL
Power Input MODULE
CAN
GE13 PHOTO 47
PHOTO 44
2012 > D 2.0 TCID > Motor Driven Power Steering (MDPS) System > Schematic Diagrams
Motor Driven Power Steering (MDPS) System (2) SD5632
E78 E79 M01A M01C
6 5 4 3 2 1 8 7 6 5 4 3 2 1
1 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
M10 M49
* 7 6 5 4 3 2 1
* * BLANK
* 15 * 13 12 11 * 9 6 5 4
*
2012 > D 2.0 TCID > Multi Display > Schematic Diagrams
Multi Display (1) SD9421
HOT IN ON OR START HOT IN ACC OR ON HOT AT ALL TIMES
I/P
See Power Distribution See Power Distribution JUNCTION
(SD11010) (SD11010) BOX
POWER PHOTO 45
CLUSTER CLOCK CONNECTOR
10A 10A AUDIO
15A
See Passenger
(SD1201)
2 I/PC 1 I/PB 1 I/PA

0.3Br 0.3Y 0.5R
See Data See Vehicle See Stop Lamps
5 JM03 Link Details See Supplemental Speed System (SD9271) (SD9272)
JOINT (SD2001) Restraint System (SRS) (SD4361)
CONNECTOR (SD5691) (SD5692) (SD4362)
PHOTO 54
6 JM03
0.5W 0.5Y 0.5Y 0.3L 0.3W/O 0.3W/B
0.3R/O
24 10 12 2 1 22 13 19 20 M62
High Low MULTI
IGN ACC BATT PAB OFF Speed Stop Lamp Stop Lamp DISPLAY
Input Fail_LH IND. Fail_RH IND.
CAN PHOTO
59
Ambient DC
S.GND ILL(+) ILL() Sensor (+) P.GND ILL.
11 4 5 8 23 9 M62
0.3B 0.3P 0.3Gr 0.3L/O 0.3B 0.5B 0.5W

With
ISG
20 19 EM31 9 JM04
PHOTO 43 See Ground JOINT See DCDC
See Illuminations Distribution CONNECTOR Converter
0.3L/O 0.3B
(SD9411) (SD1302) PHOTO 68 (SD9617)
10 9 EE12 1 JM04
PHOTO 1
0.3L/O 0.3B 1.25B
1 2 E842
AMBIENT
SENSOR #2
PHOTO 2
GM31 PHOTO 119 GM41 PHOTO 120
MULTI
DISPLAY
Door Switch PHOTO
59
FL FR RR RL Tail Gate
15 16 18 17 21 M62
0.3G/O 0.3W 0.5G/B

LHD RHD RHD LHD See Courtesy
& Trunk Lamps
(SD9292)
(SD9293)
0.3R 0.3L/O 0.3R 0.3L/O 0.3W 0.5G/B
16 11 MF12
PHOTO 43
See Courtesy & See Courtesy & 0.5G/B
Trunk Lamps Trunk Lamps
(SD9292) (SD9293) (SD9292) (SD9293)
10 FR12
PHOTO 66/88
0.3R 0.3R 0.3L/O 0.3L/O 0.3G/O 0.3W
5DR/WGN 3DR
0.5G 0.5G
31 MF12 3 MF22 31 MF12 3 16 MF22 8 RR11
PHOTO 43 PHOTO PHOTO 43 PHOTO 75 PHOTO
75 0.5G
61/97
R28 (5DR/WGN)
0.3R 0.3R 0.3L/O 0.3L/O 0.3G/O 2 R31 (3DR)
TAIL GATE
SWITCH ACTUATOR
PHOTO
61/97/109
1 R28 (5DR/WGN)
LHD RHD RHD LHD R31 (3DR)
5DR/WGN 3DR
2 F04 2 F03 2 F06 2 F05

DRIVER PASSENGER REAR DOOR REAR DOOR 0.5B 0.5B
DOOR DOOR SWITCH RH SWITCH LH
SWITCH SWITCH
PHOTO PHOTO
PHOTO PHOTO 89
85 88
85 PHOTO PHOTO
GR11 61/97 GR12 109
E842 F03 F04 F05
2 1
* 2
* * 2
* * 2
*
F06 M62 R28 R31
* 2
*
12 11 10 9 8
* * 5 4
* 2 1 4 3 2 1 4 3 2 1
24 23 22 21 20 19 18 17 16 15
* 13
2012 > D 2.0 TCID > Outside Mirror Folding > Schematic Diagrams
Outside Mirror Folding (1) SD8781
HOT AT ALL TIMES
(SD11010) JUNCTION
BOX
T/LID PHOTO 45
15A
See Passenger
(SD1204)
25 I/PF
0.85R
36 FD12
PHOTO 41
0.85R
4 D11
POWER
OUTSIDE
MIRROR
MIRROR SWITCH
FOLDING PHOTO 80
SWITCH
5 3 2 D11
0.5B
0.5L 0.5G
5 JD01
JOINT 4 3 FD12
Distribution PHOTO 41
(SD1303) PHOTO 81
0.5L 0.5G 0.85L 0.85G
1 JD01
19 18 FD22
PHOTO 41
2.0B 0.5L 0.5G
34 FD12 4 3 D10 4 3 D30

PHOTO 41 DRIVER PASSENGER
2.0B POWER POWER
DRIVER OUTSIDE OUTSIDE PASSENGER OUTSIDE OUTSIDE
M MIRROR FOLDING MIRROR M MIRROR FOLDING MIRROR
MOTOR PHOTO 81 MOTOR PHOTO 82
GF11 (LHD) PHOTO
GF21 (RHD) 42/63
2012 > D 2.0 TCID > Outside Mirror Folding > Schematic Diagrams
Outside Mirror Folding (2) SD8782
D10 D11 D30
6 5 4 3 2 BLANK
4 3 2 1 * 4 3 2 1
12 11 10 9 8
8 7 6 5 * 8 7 6 5
2012 > D 2.0 TCID > Passenger Compartment Fuse Details > Schematic Diagrams
Passenger Compartment Fuse Details (1) SD1201
HOT IN ACC OR ON HOT IN ON OR START
I/P
JUNCTION
BOX
CLOCK C/LIGHTER P/OUTLET A/BAG

MDPS A/BAG T/SIG CLUSTER
10A 15A 15A IND
15A 15A 10A 10A
10A
9 I/PF 1 2 6 7 4 8 I/PB 5 I/PE 3 I/PA 3 1 I/PC 23 I/PF 2 I/PC
0.5P
With ISG W/O ISG
With
TPMS
0.3Y 0.3Y 0.3R 0.5Y 0.3Y 0.5O 0.85Y 0.85W 0.3R/O 0.5P 0.5P 0.5P 0.5R/O 0.3R/O 0.3R/O 0.3R 0.5P 0.5Y 0.5R/B 0.3Br
6 M54A 10 M12 2 M04A 2 F37 1 F38
24 MC21
AUDIO ATM BCM FRONT STOP
32 FD12 KEY LOCK SEAT LAMP
0.5L 0.5Y 0.5L CONTROL WARMER FAILURE
MODULE CONTROL MODULE
A/T A/T MODULE 5 JM03
RH JOINT
CONNECTOR
0.5L CGG01 (G4FC) 0.3R/O 0.3R/O
CBG01 (G4GC)
10 M62 7 M12 1 CUD01 (D4FB) 2 1 M18 4 M22 13 M82A 7 M01C 18 M46 7 6 JM03
Cigarette Front
Lighter Power
0.5L Outlet 0.3R/O
24 M62
MULTI ATM KEY TRANSAXLE CIGARETTE LIGHTER & ESP OFF SRS INSTRUMENT TIRE 0.5R

DISPLAY LOCK RANGE FRONT POWER OUTLET SWITCH CONTROL CLUSTER PRESSURE
CONTROL SWITCH MODULE MONITORING 3 MC11
MODULE MODULE
0.3Y 0.3R 0.5R MULTI
12 CGGA (G4FC,A/T,With ETC)
67 CGGAK (G4FC,A/T,W/O ETC) DISPLAY
CGG60 (G4FA/G4FC) 6 CBGA (G4GC) CGG45 (G4FA/G4FC)
6 D11 1 M74 8 CUD60 (D4FB) 24 CUDAT (D4FB) 14 M01C 4 M49 6 M61A 1 M65 2 F36 2 M12 6 CUD45 (D4FB)
POWER GLOVE DCDC PCM/ INSTRUMENT EPS SWITCH PRE FRONT ATM DCDC
OUTSIDE BOX CONVERTER TCM CLUSTER CONTROL MODULE EXCITATION SEAT KEY LOCK CONVERTER
MIRROR LAMP MODULE RESISTOR WARMER CONTROL
SWITCH CONTROL MODULE
MODULE
LH
HOT IN ON
I/P
JUNCTION
BOX
SEAT HTR A/CON HEAD FR RR
15A 10A LAMP WIPER WIPER
10A 25A 15A
12 13 21 I/PB 10 I/PF 5 I/PG 9 I/PD 13 I/PG 20 I/PB 18 I/PF

A/C
CONTROL D4FB/D4EA
BCM MODULE 0.5P 0.5R/B 0.3R/O 0.85R
1 FR11 22 EC11 2.0R 0.85R 0.85R

20 M08B
0.5P 37 MF12
ICM 2.0L
13 M04A 15 M06B RELAY
16 JR01 BOX
0.85R/O 0.85R/O 0.3R/B 0.3R/B 0.5O 0.5R 0.5R 0.3R/B
0.85R
Manual JOINT 8 M08B
A/C CONNEC
TOR 0.3R/O 0.3R/O
11 14 JM03 17 18 19 JR01 19 M04B 12 10 M02W 1 F35
36 9 MF12 JOINT 21 EM31
CONNEC 0.85R
TOR
0.3R/O
12 13 JM03
BCM MULTIFUNCTION REAR
SWITCH WIPER
0.85R/O 0.85R/O 0.3R 0.3R/B 0.5P 0.5P 0.5W RELAY
Auto 2 E41
5 R17 3 R07 1 R01
A/C 5 FR12
8 JE01 5DR/
1 F37
JOINT 3DR WGN
CONNECTOR
RAIN SUNROOF ELECTRO BLOWER 0.85R 0.85R

SENSOR CONTROL CHROMIC RELAY 6 5 7 JE01
FRONT MODULE MIRROR
2.0L 2.0L 2.0L
SEAT 4 RR11
WARMER 17 EC11
CONTROL
MODULE RH CGG07 (G4FA/G4FC)
0.5R
18 M08A 2.0L CBG07 (G4GC)
CUD92 (D4FB) CUD93 (D4FB) CUD94 (D4FB) 5 E47 5 E43 2 5 E46
4 CDD92 (D4EA) 4 CDD93 (D4EA) 5 CDD94 (D4EA) CUD07 (D4FB) 0.85R
1 F36 14 M05A 3 CDD07 (D4EA) 4 R30 4 R27
85
RAIN
SENSOR
RELAY
HEAD HEAD WIPER RELAY
FUEL FILTER LAMP LAMP
FRONT A/C PTC HEATER PTC HEATER HEATER RELAY RELAY RELAY FRONT REAR REAR
SEAT CONTROL RELAY #2 RELAY #3 (LOW) (HIGH) WIPER WIPER WIPER
WARMER ICM RELAY BOX MODULE MOTOR MOTOR MOTOR
CONTROL FUSIBLE LINK BOX E/R FUSE & RELAY BOX
MODULE LH
I/P
To STOP 15A JUNCTION
A BOX
REAR (SD1204)
DEFOGGER
RELAY POWER
CONNECTOR
ROOM
AUDIO
LP
15A
15A
HTD
MIRR
10A
16 11 I/PB 4 2 I/PF 1 I/PA 7 8 I/PF 14 13 12 I/PC

TIRE
PRESSURE
W/O With ROOM PIEZO MONITORING
ISG ISG LAMP BUZZER MODULE
0.3R 0.3G 0.5R 0.5R 3.0R 0.5R 0.5R 0.5R 0.5R 0.5R
2 MC21 5 FD22 6 FD12 7 FR12 3 FR11

Auto A/C Manual A/C 0.85R 2 R06 5 M64 3 M46
0.5R 0.5R 3.0R 0.85R 0.5R 0.5R 0.5R 0.5R 0.5R 0.5L
21 MC21 8 M01C 9 M10
11 14 JR01 DATA LINK
CONNECTOR
0.85R JOINT
0.3G 0.3G CONN
ECTOR
INSTRUMENT
15 12 13 JR01 CLUSTER
0.5R 0.5R 0.5R 1 JM03
1 R08 JOINT
3 M04C 10 M06B 1 D30 1 R23 4 M54A 2 F48 1 M04A CONNECTOR
0.5G 2 4 3 JM03
BCM A/C PASSENGER REAR AUDIO LUGGAGE VANITY BCM 0.5R 0.5R/O 0.5R
CONTROL POWER DEFOGGER LAMP LAMP
MODULE OUTSIDE (+) SWITCH
G4FA/ MIRROR RH
G4FC
13 CGGK (With ETC) 0.5R
31 CGGMK (M/T, W/O ETC) CGG60 (G4FA/G4FC) M05A (Auto A/C)
9 M05A 22 CGGAK (A/T, W/O ETC) 1 D10 12 M62 1 CUD60 (D4FB) 1 R12 6 4 M19 4 M66 2 M06B (Manual A/C)
3 R16
A/C ECM/ DRIVER MULTI DCDC SUNROOF VANITY IGNITION KEY SECURITY A/C
CONTROL PCM POWER DISPLAY CONVERTER SWITCH LAMP ILL. & DOOR INDICATOR CONTROL
MODULE OUTSIDE SWITCH WARNING MODULE
MIRROR LH SWITCH
I/P
JUNCTION
From HOT AT BOX
ALL TIMES A
(SD1203)
DR RR
STOP DEICER T/LID
LOCK P/OUTLET
15A 15A 15A
20A 15A
TRUNK
LID
RELAY
15 14 I/PB 6 I/PA 3 12 I/PF 14 I/PD 25 28 I/PF 2 I/PD
0.5R
0.85W 0.85W 0.85R 0.85R 1.25W 0.85R 0.5R/O 0.85R 0.85R 0.3B
0.5R 0.5R 0.5R RHD
5 M90 WGN
24 MC11
5 FR11 36 FD12 11 FR12
G4FA/G4FC
D4FB/D4EA G4GC 3DR 5DR/WGN
STOP
SIGNAL 0.85R 0.85R 0.85R 0.85R
10 14 M08A
RELAY
12 RR11
30 85 1 R07 1 F34 2 M68 3 R31 18 M04A
87 85
0.5R 0.5R 0.85R
SUNROOF REAR SOUND TAIL GATE BCM

FRONT DEICER DEAD LOCK CONTROL POWER RELAY ACTUATOR
5 CF11 MODULE OUTLET
RELAY RELAY (RHD)
0.5R 0.5R 15 M08B
With
TPMS CGG77 (G4FA/G4FC)
CUD77 (D4FB) CBG58 (M/T, W/O Auto Cruise & ESP)
5 M45 6 F38 2 CDD77 (D4EA) 2 CBG77 (A/T, With Auto Cruise & ESP) 87 85 85 87 3 M61B 4 D11 3 R28
ATM STOP STOP STOP DOOR LOCK DOOR UNLOCK SWITCH POWER TAIL GATE

LEVER LAMP LAMP LAMP RELAY RELAY MODULE OUTSIDE ACTUATOR
SWITCH FAILURE SWITCH SWITCH MIRROR
MODULE ICM RELAY BOX SWITCH
HOT IN START HOT AT ALL TIMES
I/P
To Tail Lamp JUNCTION
B Relay BOX
START (SD1206)
A/CON 10A
SW POWER
10A WINDOW
RELAY SAFETY
RR SAFETY
P/WDW RH
FOG P/WDW LH
25A
10A 25A
P/WDW P/WDW
LH RH
25A 25A
7 I/PA 5 3 19 17 I/PB 17 16 20 21 1 I/PF

W/O
3.0P Safety
0.3W 0.5L 0.3Gr 2.0Y 2.0R 2.0R 2.0R
2.0R
See Blower & See Starting 12 M04B 11 JF01
A/C Control System System
(SD9711) (SD3601) JOINT
(SD9719) (SD3602) CONNEC
TOR
13 12 14 JF01
BCM
W/O
Safety
0.3R(Auto A/C) 2.0R 2.0Y 2.0Y 2.0R 0.5B(With Safety) 2.0R 2.0R
0.3Gr(Manual A/C) 2.0R(W/O Safety)
5 FD11 13 38 FD12 21 FD22 34 FD22 21 FD12 15 FD11

5 15 FD21
11 M08B
2.0R 2.0Y 2.0Y 2.0R 2.0R 2.0R 2.0R 2.0R 2.0R
85 30
10 M05B (Auto A/C) D01 (LHD)
16 M06B (Manual A/C) 6 D41 16 9 D01R (RHD) 6 D21 6 D51 4 D53 4 D23 4 D03 4 D43
REAR FOG
A/C LAMP RELAY REAR POWER WINDOW PASSENGER REAR POWER REAR PASSENGER DRIVER REAR
CONTROL POWER MAIN SWITCH POWER WINDOW SAFETY SAFETY SAFETY SAFETY
MODULE ICM RELAY BOX POWER POWER POWER POWER
WINDOW WINDOW SWITCH RH
SWITCH LH SWITCH WINDOW WINDOW WINDOW WINDOW
MODULE RH MODULE MODULE MODULE LH
I/P
JUNCTION
From HOT AT BOX
B ALL TIMES
TAIL (SD1205) RHEOSTAT
LAMP RELAY
RELAY (WITH DRL)
SHUNT
CONNECTOR
TAIL LH TAIL RH
10A 10A With DRL W/O DRL
6 I/PD 15 I/PG 22 6 I/PF 11 I/PC 4 I/PG 10 I/PC 18 I/PB

0.3L
3DR/5DR WGN 0.3L 0.3L

0.3L 0.5Y 0.5P 0.5R/O 0.5P 0.85P
W/O 3DR With 3DR 3DR 5DR

0.5Br/O
0.5G/O 0.5G/O See Illuminations

27 MC11 (SD9411)
0.5Br/O 0.5Br/O
6 E77 6 E111 5 F10 4 F49 28 M04A 1 M02L 9 M01A
HEAD HEAD REAR REAR BCM MULTI INSTRUMENT
LAMP LAMP COMBI COMBI FUNCTION CLUSTER
LH LH NATION NATION SWITCH
(3DR) LAMP RH LAMP RH
(5DR)
8 JF01
JOINT W/O 3DR With 3DR
CONNECTOR
10 9 JF01
3DR/5DR WGN
5DR/WGN 3DR 3DR 5DR 0.5P 0.5P

0.5Y
0.5Y 0.5Y
3 FR12
0.5Y
0.5Y 0.5Y
6 RR11 CGG75 (G4FA/G4FC) CGG96 (G4FA/G4FC)
0.5Y 0.5Br/O
0.5Y CBG75 (G4GC) CBG96 (G4GC)
5 E44 CUD75 (D4FB) CUD96 (D4FB)
4 F50 2 F32
4 M04C 3 R26 1 F25 5 F08 2 F31 5 F07 5 F09
FRONT 6 CDD75 (D4EA) 6 CDD96 (D4EA)
FOG
LAMP
RELAY
BCM LICENSE LICENSE REAR REAR REAR REAR REAR REAR E/R FUSE & HEAD HEAD
LAMP LAMP COMBINATION COMBINATION COMBINATION COMBINATION COMBINATION COMBINATION RELAY BOX LAMP LAMP
LAMP LH LAMP LH (5DR) LAMP LH (UP) LAMP LH (LOW) LAMP RH (UP) LAMP RH (LOW) RH RH(3DR)
2012 > D 2.0 TCID > Power Distribution > Schematic Diagrams
Power Distribution (1) SD1101
5.0W To EMS Box
G (SD1103) (SD1104)
(SD1105) (SD1106) (SD1107)
E/R
To HORN MULTI FUSE FUSE &
15A A To ABS1 RELAY
(SD1102) B 40A BOX
ALT RR (SD1102)
B+ 1 IGN1 150A IGN2 C/FAN BLOWER HTD MDPS
50A 30A 40A 40A 40A 40A 80A
3.0P 3.0L 3.0L 3.0W

3.0P 0.5O
1 E42 1 2 E48 1 2 E49 1 E41
START CONDENSER CONDENSER BLOWER

RELAY FAN RELAY FAN RELAY RELAY
(HIGH) (LOW)
20B 5.0W 3.0R 3.0P 0.5O 3.0W 8.0W 15B 20B(W/O D4EA)

(W/O D4EA) 20R(D4EA)
20R E
(With D4EA) 9 27 EM31 13 EC11
3.0R 3.0B 0.5O To I/P E50 (G4FA/G4FC)
Junction Box E60 (G4GC)
BATTERY F C D (SD11010) E90 (D4FB)
I 1 E100 (D4EA)
1 E78
From SNSR1 10A EPS ALTERNATOR
To I/P
Junction Box To Ignition Switch (SD1103) (SD1104) CONTROL
(SD11010) (SD11010) (SD1105) (SD1106) MODULE
(SD1107)
D4FB/D4EA
With ISG W/O ISG FUSIBLE
LINK
BOX
GLOW PTC PTC PTC FUEL
PLUG HEATER HEATER HEATER FILTER
80A #1 #2 #3 HEATER
50A 50A 50A 30A
30B 20B 20B(W/O D4EA)

(With D4EA) 30R(D4EA) 8.0W 8.0W 5.0R 5.0R 5.0R 3.0W
20B (D4FB) CUD90 (D4FB) CUD91 (D4FB) CUD92 (D4FB) CUD93 (D4FB) CUD94 (D4FB)
(W/O D4EA) 1 CUD78 (D4FB) 1 CDD90 (D4EA) 5 CDD91 (D4EA) 5 CDD92 (D4EA) 5 CDD93 (D4EA) 1 CDD94 (D4EA)
E55 (G4FA/G4FC)
E65 (G4GC) G4FAGSL 1.4L
E59 (G4FA/G4FC) E95 (D4FB) GAMMA
1 E99 (D4FB) 1 E105 (D4EA) G4FCGSL 1.6L
START START BETA G4GCGSL 2.0L
MOTOR MOTOR AIR GLOW PTC PTC PTC FUEL FILTER U/U IIENG D4FBDSL 1.6L
HEATER PLUG HEATER HEATER HEATER HEATER
BATTERY RELAY RELAY RELAY #1 RELAY #2 RELAY #3 RELAY DENG D4EADSL 2.0L
GROUND
E/R
FUSE &
From From Battery RELAY
Multi Fuse B Power A BOX
(SD1101) (SD1101) See Head Lamp
ABS1 F/FOG ABS2 BATT HORN H/LP System B+ 2
40A 15A 20A SNSR 15A 20A (SD9211) 50A
10A (SD9212)
0.3R/O
0.85R 0.85R 0.85L 0.3R/O
1 5 E43 5 1 E47
HEAD HEAD
LAMP LAMP
1 E44 RELAY RELAY
FRONT (HIGH) (LOW)
FOG 0.85R
LAMP 2 E47
RELAY 3 1 E45
HORN
RELAY 0.5R 0.5R
H/LP H/LP
LO LH LO RH
10A 10A
3.0W 2.0R 0.5R 0.85R 0.5Y 5.0W

HEAD LAMP HEAD LAMP
With W/O LEVELING LEVELING
3DR 3DR DEVICE DEVICE H
ACTUATOR ACTUATOR
1 2 EC11 0.5Y RH (3RD) RH To I/P Junction Box
ESP ABS ABS ESP 7 EM31 2 CGG97 (G4FA/G4FC) 2 CGG73 (G4FA/G4FC) (SD11010)
CDD97 (D4EA) CDD73 (D4EA)
3.0R 3.0R 2.0R 2.0R 0.85R 0.5Y
(W/O D4EA) (W/O D4EA) 0.5O 0.5O 0.5O
3.0W 3.0W 28 EC11
(D4EA) (D4EA) 2 E83 3 E111 3 E77
With 3DR W/O 3DR
BATTERY HEAD HEAD
SENSOR LAMP LAMP
LH LH
(3DR) With 3DR W/O 3DR
25 EM31 With 3DR W/O 3DR 0.5O
1 25 CGG41 (G4FA/G4FC)
1 25 CBG41 (G4GC)
1 25 CUD41 (D4FB)
2 3 CDD41 (D4EA) 11 M08A 0.3R/O 0.5Y 0.5Y 0.5O CGG96 (G4FA/G4FC) CGG75 (G4FA/G4FC)
ABS ICM CUD96 (D4FB) CUD75 (D4FB)
CONTROL RELAY 4 M34 3 E112 3 E76 3 CDD96 (D4EA) 3 CDD75 (D4EA)
30 85 BOX
MODULE
1 25 CBG70 (G4GC)
1 25 CUD70 (D4FB)
2 3 CDD70 (D4EA)
ESP HEAD LAMP HEAD LAMP HEAD LAMP HEAD HEAD
CONTROL LEVELING LEVELING LEVELING LAMP LAMP
MODULE BURGLAR ALARM DEVICE DEVICE DEVICE RH RH
HORN RELAY SWITCH ACTUATOR ACTUATOR (3DR)
LH(3DR) LH
From Battery
Power G
(SD1101) 5.0W G4FA/G4FC(With ETC)
1 E/REMS
EMS
BOX
ECU 3 ECU 1 F/PUMP A/CON

10A 30A 15A 10A
ENGINE
CONTROL
RELAY
SNSR2 ECU 4 ECU 2 SNSR1 INJ

15A 20A 10A 10A 15A
FUEL A/CON
PUMP RELAY
RELAY
Not used
6 16 11 E/RCGG1 8 9 6 5 7 16 17 13 4 15 3 E/RCGG2 9 7 8 18 19 E/RCGG1

0.5L/O 0.5G
Except With
31 MC11 Euro II ISG A/T A/T A/T
1.25W 0.5R 0.5O 0.5R 0.5L/O 0.5R 0.5R 0.5R 0.5R 0.5R 0.75R 0.75R 0.75R 2.0R 2.0R 0.5O 0.5R 0.5R 0.5R 0.5R
11 EC11
0.5R
12 CGG47 1 CGG21 2 CGG05 3 CGG22 6 5 CGGK 1 CGG242 1 CGG244
MULTIPURPOSE 2 E42
CHECK
CONNECTOR
PURGE OIL OXYGEN PCM INJECTOR INJECTOR

CONTROL CONTROL SENSOR START #2 #4
SOLENOID VALVE (DOWN) RELAY I
VALVE
E/R FUSE &
RELAY BOX To
3 CGG16 39 54 55 CGGAA Condenser
50 CGGA 30 CGGK 4 M09 1 CGG13 Fan Relay 1 CGG241 1 CGG243
(Low)
(SD1101)
PCM PCM IMMOBILIZER OXYGEN CAMSHAFT PCM INJECTOR INJECTOR

MODULE SENSOR POSITION #1 #3
(UP) SENSOR
From Battery
Power G
(SD1101) 5.0W
G4FA/G4FC(W/O ETC)
1 E/REMS
EMS
BOX
ECU 1 F/PUMP A/CON ECU 3

30A 15A 10A 10A
ENGINE
CONTROL
RELAY

15A 10A 20A 10A 15A
Not used FUEL A/CON

PUMP RELAY
RELAY
11 E/RCGG1 9 8 6 5 7 1 10 11 12 15 3 E/RCGG2 9 7 8 18 19 16 6 E/RCGG1

0.5L/O 0.5O 0.5G
31 MC11 Except
Euro II I
0.5B/O 0.5L/O 0.5R 0.5R 0.5R 0.5R 0.5R 2.5W 2.5W 2.5W 2.0R 0.5R 0.5R 0.5R 0.5R 0.5R 0.5R
To Condenser
Fan Relay (Low)
(SD1101)
6 CGGMK (M/T)
4 M09 2 CGG05 1 CGG13 6 CGGAK (A/T) 2 CGG26 1 CGG242 1 CGG244 56 CGGAA (A/T)
IMMOBILIZER OIL CAMSHAFT ECM(M/T)/ IDLE SPEED INJECTOR INJECTOR PCM(A/T)

MODULE CONTROL POSITION PCM(A/T) CONTROL #2 #4
VALVE SENSOR ACTUATOR
22 CGGMK (M/T)
9 CGGAK (A/T) 1 CGG21 3 CGG16 3 CGG22 5 4 CGGAK (A/T) 1 CGG241 1 CGG243 12 CGG47
MULTIPURPOSE
CHECK
CONNECTOR
ECM(M/T)/ PURGE OXYGEN OXYGEN PCM(A/T) INJECTOR INJECTOR

PCM(A/T) CONTROL SENSOR SENSOR #1 #3
SOLENOID (UP) (DOWN)
VALVE
From Battery
Power
(SD1101)
G
5.0W
G4GC
1 E/REMS
EMS
BOX
ECU 1 F/PUMP A/CON

30A 15A 10A
ENGINE FUEL A/CON

CONTROL PUMP RELAY
RELAY RELAY
SNSR2 ECU 2 SNSR1 INJ

15A 10A 10A 15A
1 11 E/RCBG1 6 5 8 7 9 18 16 17 14 15 4 13 3 E/RCBG2 9 7 19 8 18 E/RCBG1
Except
Euro II 0.5G
2.0R 0.5L 0.5W 0.5W 0.5W 0.5W 0.5L/O 2.0G 0.75P 0.75P 0.5W 0.5O 0.5W 0.5W 0.5W 0.5W 0.5W 0.5W
31 MC11 I
4 5 6 CBGINJ
0.5L/O To
Condenser
Fan Relay
(Low) 0.85 0.85 0.85
(SD1101)
3 CBG31
6 64 CBGK 1 CBG13 1 CBG29 4 CBG16 3 CBG22 4 M09 4 73 CBGK 2 CBG26 2 CBG05 1 CBG21 1 CBG241 2 CBG242 2 CBG243 2 CBG244
PCM CAM CRANK OXYGEN OXYGEN IMMO IGNITION PCM IDLE SPEED OIL PURGE INJECTOR INJECTOR INJECTOR INJECTOR
SHAFT SHAFT SENSOR SENSOR BILIZER COIL CONTROL CONTROL CONTROL #1 #2 #3 #4
POSITION POSITION (UP) (DOWN) MODULE ACTUATOR VALVE SOLENOID
SENSOR SENSOR VALVE
From Battery
Power G
(SD1101) 5.0W D4FB
1 E/REMS
EMS
BOX
ECU 1 A/CON ECU 3

30A 10A 10A
ENGINE A/CON
CONTROL RELAY
RELAY

15A 20A 10A 10A 15A
11 E/RCUD1 7 5 6 2 1 10 17 4 14 13 15 E/RCUD2 8 19 7 6 16 E/RCUD1
0.5L/O
W/O Except
C.P.F Euro V A/T
31 MC11 Not used
0.5G 0.5R 0.5P 1.25W 2.5P 2.5P 2.5P 0.5W 0.5L/O 0.5Y 0.5R 0.5O 0.5W 0.5R 0.5W 0.5R
2 CUD36
47 CUDK 5 3 1 CUDK 4 M09 3 CUD78 2 CUD35 2 CUD37
ECM LAMBDA ECM IMMOBILIZER AIR THROTTLE VGT

SENSOR MODULE HEATER FLAP ACTUATOR
RELAY ACTUATOR
4 CUD90 4 CUD91
1 CUD13 1 CUD38 3 CUD77 2 CUD31 12 CUDAT

I
To Condenser
GLOW PTC Fan Relay(Low)
PLUG HEATER (SD1101)
CAMSHAFT FUEL PRESSURE STOP EGR TCM
RELAY RELAY #1 CONTROL
POSITION REGULATING LAMP
SENSOR VALVE SWITCH FUSIBLE LINK BOX ACTUATOR
From Battery
Power G
(SD1101) 5.0W D4EA
1 E/REMS
EMS
BOX
ECU 3 ECU 1 A/CON F/PUMP

10A 30A 10A 15A
ENGINE
CONTROL
RELAY

15A 20A 10A 10A 15A
A/CON FUEL
RELAY PUMP
RELAY
6 11 E/RCDD1 9 6 11 2 1 16 17 4 13 15 14 3 E/RCDD2 9 E/RCDD1
0.5L 0.5G 0.5P 0.5W 0.85R 2.5P 2.5P 2.5W 0.5W 0.5L/O 0.5W 0.5O 0.5Y 0.5W 0.5G
31 MC11 I
5 EC11
To Condenser
Fan Relay(Low)
0.5L 0.5L/O (SD1101)
4 EB11
4 CDD90 4 CDD91
0.5L
2 CDD36
1 E101 72 CDDK 1 CDD13 2 CDD31 5 3 1 CDDK 3 CDD77 4 M09 3 CDD95 2 CDD37
GLOW PTC
PLUG HEATER
RELAY RELAY #1
ALTERNATOR ECM LAMBDA CAMSHAFT EGR ECM STOP IMMOBILIZER ELECTRICAL FUSIBLE LINK BOX VGT
SENSOR POSITION CONTROL LAMP MODULE THROTTLE ACTUATOR
SENSOR ACTUATOR SWITCH CONTROL
ACTUATOR
From Ignition
Switch (IG1)
(SD11010)
J
3.0R
E/R
K To SNSR 10A FUSE &
(SD1109) RELAY
BOX
B/UP ABS START ECU
10A 10A RELAY 10A
2 E42
0.5R
G4FA/G4FC
M/T, W/O ETC & With ISG
0.5R 0.5W 2.0W
30 34 3 EC11
M/T A/T ESP ABS G4FA/G4FC G4GC
1.25O 1.25R
0.5R 0.5R 0.5W 0.5W 0.5W 5 CGGIG
1.25B/W
0.85B/W 1.25B/W 0.85B/W 0.85B/W
CGG50 (G4FA/G4FC) CGG10 (G4FA/G4FC) 32 CGG70 (G4FA/G4FC) 32 CGG41 (G4FA/G4FC)

CBG50 (G4GC) CGG01 (G4FC) CBG10 (G4GC) 32 CBG70 (G4GC) 32 CBG41 (G4GC)
CUD50 (D4FB) CBG01 (G4GC) CUD10 (D4FB) 32 CUD70 (D4FB) 32 CUD41 (D4FB)
2 CDD50 (D4EA) 8 CUD01 (D4FB) 1 CDD10 (D4EA) 28 CDD70 (D4EA) 18 CDD41 (D4EA) 2 CGG184 2 CGG181 2 CGG182 2 CGG183 1 CBGA
BACKUP TRANSAXLE YAW ESP ABS IGNITION IGNITION IGNITION IGNITION PCM
LAMP RANGE RATE CONTROL CONTROL COIL #4 COIL #1 COIL #2 COIL #3
SWITCH SWITCH SENSOR MODULE MODULE
E/R FUEL
From HOT IN FUSE & FILTER STOP PULSE
ON OR START K RELAY WARNING LAMP GENERATOR
(SD1108) BOX SWITCH SWITCH 'A' TCM CONDENSER
SNSR
10A
3
1 CUD84 (D4FB) 3 CGG77 (G4FA/G4FC) CBG02A (G4GC) 2 CUDAT 2 CGG19
CDD84 (D4EA) CBG77 (G4GC) (D4FB) (G4FA/G4FC)
0.5R 0.5R 0.5R 1.25R 1.25O
1.25R 1.25R A/T
18 EC11
1.25R
1 4 JE01
JOINT
CONNECTOR
2 3 JE01
1.25R 1.25R
33 29 37 EC11
D4FB/ D4FB/ W/O

G4FC G4GC D4EA D4EA D4EA
A/T
A/T M/T
0.5R A/T
D4FB D4FB D4EA
G4FC/
G4GC D4FB 0.5R 0.5R 0.5R 0.5R 1.25R 0.5W 0.5R 0.5R 0.5R
(D4FB)
37 MC11 0.5W
2 CGG52 (G4FA/G4FC) (D4EA)
1.25R 0.5R 0.5R 2 CBG52 (G4GC) 0.3R/O
2 CUD52 (D4FB) 5 CUD27 (D4FB)
3 CGG02B (G4FC) 1 CDD52 (D4EA) 3 CGG02A 7 CBG59 28 CDDK(D4EA) 1 CDD27 (D4EA)
PULSE VEHICLE PULSE AUTO ECM AIR

GENERATOR SPEED GENERATOR CRUISE FLOW
'B' SENSOR 'A' CONTROL SENSOR 18 CGGK (G4FA/G4FC, With ETC)
MODULE 83 CGGMK (G4FA/G4FC, M/T, W/O ETC)
11 CGGAA (G4FC, A/T, W/O ETC)
2 CBGK (G4GC)
2 CBGA 3 CUD02A (D4FB) 3 CUD02B 10 M02R 1 CUDAT (D4FB) 3 CBG02B (G4GC) 46 CUDK(D4FB)
PCM PULSE PULSE MULTIFUNCTION TCM PULSE ECM/

GENERATOR GENERATOR 'B' SWITCH GENERATOR PCM
'A' (REMOCON) 'B'
From IGN1 30A From IGN2 40A
(SD1101) (SD1101)
C D
3.0R 3.0B
2 5 M35
IGNITION
AM AM SWITCH
START
START
LOCK LOCK
ACC ON ACC ON
4 6 3 1 M35
To E/R Fuse
From RR HTD 40A From B+ 1 50A & Relay Box From B+ 2 50A
(SD1101) (SD1101) (SD1108) (SD1102)
E F H
ACC IG1 J IG2 START
3.0W 5.0W 2.0Y 3.0L 3.0R 3.0P 3.0W 5.0W

3 I/PG 2 I/PH 4 2 I/PA 4 I/PH 5 8 I/PA 3 I/PH
I/P
JUNCTION
REAR BOX
DEFOGGER START
P/OUTLET C/LIGHTER CLOCK 10A
RELAY 15A 15A 10A
See Starting System
See Passenger (SD3601) (SD3602)
HTD (SD1201)
MIRR
10A
MDPS A/BAG A/BAG T/SIG CLUSTER
15A 15A IND 10A 10A POWER
10A CONNECTOR
See Passenger
Compartment Fuse Details AUDIO ROOM
(SD1203) 15A LP
See Passenger 15A
(SD1201)
TAIL POWER See Passenger

LAMP WINDOW Compartment Fuse Details
RELAY RELAY (SD1203)
TAIL TAIL P/WDW P/WDW SAFETY SAFETY RR HEAD RR FR SEAT DR RR

P/WDW P/WDW A/CON DEICER T/LID STOP
LH RH LH RH FOG LAMP WIPER 10A WIPER HTR 15A 15A 15A LOCK P/OUTLET
10A 10A 25A 25A LH RH 10A 10A 15A 25A 15A 20A 15A
25A 25A

(SD1205) (SD1206) (SD1202) (SD1204)
2012 > D 2.0 TCID > Power Door Locks > Schematic Diagrams
Power Door Locks (1) SD8131
HOT AT ALL TIMES
(SD11010) JUNCTION
BOX * Note
T/LID DR LOCK PHOTO
45 A B
15A 20A C D
and
See Passenger The arrows indicate the direction of
Compartment Fuse Details current flow with the door lock relay
TRUNK (SD1204) in operation. Current will flow in the
LID opposite direction when the door
RELAY 6 I/PA unlock relay is in operation.
0.85W
RHD 0.85R
14 M08A 15 M08B
28 I/PF 2 I/PD
ICM
0.85R 0.3B RELAY
87a 87 85 87a 87 85 85 87 87a BOX
11 FR12 PHOTO
DEAD DOOR DOOR 46
PHOTO 18 M04A LOCK LOCK UNLOCK
88/66 RELAY RELAY RELAY
Trunk BCM (RHD)
3DR 5DR/WGN Lid PHOTO
Relay 57
0.85R Control
30 86 30 86 86 30
12RR11
PHOTO
0.85R 0.85R 61/97 7 15 5 13 M08A 13 5 16 17 12 4 14 M08B
0.85G/O 0.85G 0.3L 0.85B 0.85B 0.85Gr 0.85Gr 0.3Y/O 0.3Y 0.85G 0.85G
3DR 5DR/WGN 6 M04C 15 M04B
BCM 35 MF12 22 MF22
Door Lock Door Unlock PHOTO PHOTO
R28 (5DR/WGN) Relay Control Relay Control 43 75
3 R31 (3DR) 24 23 MF12 38 MF12 33 MF22 0.85G 0.85G
PHOTO PHOTO PHOTO C/DR Lock/ C/DR Lock/ Hazard Relay
TAIL GATE 43 43 75 Unlock SW Unlock IND. Control
ACTUATOR
0.85G 0.85G 0.85Gr 0.85Gr C D
M MOTOR PHOTO 35 M04A 15 9 M04C
61/97/109
0.3W 0.3B/O 0.3G PHOTO 57
From Door Lock Actuator
9 8 3 M61A (SD8132) (SD8133)
PTC E F A B
CTR SWITCH
CTR D/Lock RKE DR MODULE
D/Lock IND. Lock/Unlock
Select PHOTO
4 R28 (5DR/WGN) To Door To Door Lock Actuator C/DR 59
R31 (3DR) Lock Actuator (SD8132) (SD8133) Lock
(SD8133)
3DR 5DR/WGN
10 9 JM02 18 M61A
JOINT 0.5B
See Ground
Distribution CONNECTOR 3 JM04
0.85B 0.85B
(SD1301) PHOTO 47 JOINT
See Ground Distribution
7 M04C (SD1302) CONNECTOR
6 JM02
PHOTO 68
Dead BCM 1.25B 1 JM04
Lock PHOTO
1.25B
Relay 57
GR12 GR11 Control
PHOTO PHOTO
109 61/97 GM21 PHOTO 46 GM41 PHOTO 120
AUDIO
LHD
BCM
Driver Driver/
Door Key Passenger Passenger Passenger Rear Door Rear Door PHOTO
Driver Door Unlock Door Key Door Door Key Unlock Unlock 57
Unlock Switch Switch Lock Switch Unlock Switch Unlock Switch Switch LH Switch
6 M54C1 8 26 25 9 34 6 M04A 3 M04B
With PHOTO
A/V 59
0.3Br 0.3B/O 0.3Y 0.3G 0.3W 0.3L 0.3L 0.3W
0.3B/O
From Door From Door From Door From Door
Lock Relay Lock Relay Lock Relay Lock Relay
(SD8131) (SD8131) 3 MF12 (SD8131) 5 MF22
(SD8131)
PHOTO 43 PHOTO 75
2 6 28 MF12 B 26 27 MF22 A B
A With With
0.3G PHOTO 43 PHOTO 75 3DR W/O 3DR 3DR W/O 3DR
0.85Gr 0.3B/O 0.3L 0.3G 0.85Gr 0.3W 0.3L 0.3G 0.85Gr 0.3L 0.3L 0.85Gr 0.3W 0.3W
0.3B/O
0.3W
11 20 7 19 FD12 9 10 16 17 FD22 8 3 FD11 8 3 FD21
PHOTO PHOTO PHOTO 85 PHOTO 85
41 41
0.85Gr 0.3P 0.3L 0.3G 0.85Gr 0.3W 0.3L 0.3G 0.85Gr 0.3W 0.85Gr 0.3W
5 1 2 4 D07 3 7 6 4 D27 5 1 D47 3 7 D57
DRIVER PASSENGER REAR REAR
Door Door Key Key DOOR Door Door Key Key DOOR Door Door DOOR Door Door DOOR
Unlock Lock Unlock Lock LOCK Unlock Lock Unlock Lock LOCK Lock Unlock LOCK Lock Unlock LOCK
ACTUATOR ACTUATOR ACTUATOR ACTUATOR
M LH M RH
M PHOTO M PHOTO
80 82 PHOTO PHOTO
86 86
6 3 D47 2 5 D57
6 3 D07 2 5 D27
0.85G 0.5B 0.85G 0.5Y 0.85G 0.5B 0.85G 0.5B
4 JD01
See Ground JOINT
(SD1303) PHOTO 81
8 11 FD22 9 14 FD11 9 13 FD21
1 JD01
2.0B
8 34 FD12
0.85G 2.0B PHOTO 41 0.85G 0.5B 0.85G 0.3B 0.85G 0.3B
C D C D
To Door To Door To Door To Door

Unlock Relay Unlock Relay Unlock Relay Unlock Relay
(SD8131) GF11 PHOTO 42 (SD8131) GF21 PHOTO 63 (SD8131) GF31 PHOTO 85 (SD8131) GF41 PHOTO 85
AUDIO
RHD
BCM
Passenger Driver/ PHOTO
Driver Door Driver Door Passenger Door Key Passenger Rear Door Rear Door 57
Unlock Key Unlock Door Unlock Door Key Lock/Unlock Unlock
Switch Switch Unlock Switch Switch Lock Switch Switch LH Switch
6 M54C1 8 26 9 34 25 6 M04A 3 M04B
With PHOTO From Dead From Dead From Dead
A/V 59 Lock Relay Lock Relay Lock Relay
0.3W 0.3Y (SD8131) 0.3G 0.3L 0.3G (SD8131) 0.3L (SD8131) 0.3W
0.3Br
E F E
0.3W
From Door From Door From Door From Door
Lock Relay Lock Relay Lock Relay Lock Relay
(SD8131) (SD8131) (SD8131) 3 MF12 (SD8131) 5 MF22
PHOTO 43 PHOTO 75
B A A With B With
From Dead 26 27 MF22 2 6 28 MF12 3DR W/O 3DR 3DR W/O 3DR
Lock Relay PHOTO 75 PHOTO 43
(SD8131) 0.3L 0.3G 0.3G
0.3L 0.3W
F
0.85G 0.85Gr 0.3L 0.3Y 0.3G 0.85G 0.85Gr 0.3G 0.3L 0.3G 0.85G/O 0.85Gr 0.3L 0.85G/O 0.85Gr 0.3W
29 11 20 7 19 FD12 29 9 10 16 17 FD22 13 8 3 FD11 12 8 3 FD21

PHOTO PHOTO PHOTO 85 PHOTO 85
41 41
0.85G/O 0.85Gr 0.3P 0.3Y 0.3G 0.85G/O 0.85Gr 0.3W 0.3L 0.3G 0.85G/O 085Gr 0.3W 0.85G/O 0.85Gr 0.3W
1 3 7 6 4 D07R 7 5 1 2 4 D27R 7 5 1 D47 1 3 7 D57
DRIVER PASS REAR REAR
Dead Door Door Key Key DOOR Dead Door Door Key Key ENGER Dead Door Door DOOR Dead Door Door DOOR
Lock Unlock Lock Unlock Lock LOCK Lock Unlock Lock Unlock Lock DOOR Lock Lock Unlock LOCK Lock Lock Unlock LOCK
ACTUA LOCK ACTUA ACTUA
M M TOR ACTUA M M TOR M M TOR
M M TOR LH RH
2 5 D07R 6 3 D27R 6 3 D47 2 5 D57

PHOTO PHOTO
0.85G 0.5B 0.85G 0.5Y 0.85G 0.5B 86 0.85G 0.5B 86
4 JD01
See Ground JOINT
(SD1303) PHOTO 81
8 FD12 11 FD22 9 14 FD11 9 13 FD21
1 JD01 8
0.85G 2.0B 0.85G 0.5B 0.85G 0.3B 0.85G 0.3B
34 FD12
D PHOTO 41 C D
2.0B C
To Door To Door To Door To Door

Unlock Relay GF21 PHOTO 63 Unlock Relay Unlock Relay Unlock Relay
(SD8131) (SD8131) GF11 PHOTO 42 (SD8131) GF31 PHOTO 85 (SD8131) GF41 PHOTO 85
D07 D07R D27 D27R
* 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2
* 7 6 5 4 3 2 1
D47 D57 M04A
7 6 5
* 3
* 1 7
* 5
* 3 2 1
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21
M04B M04C M08A M08B
8
* * 5 4
* 2
*
10
* * 7 6 5 4 3 2 1 8 7 6 5 4 3
* 1 9 8 7
* 5
*
3 2 1
18 17 16 15 14 13 12 11 10
20
* * 17 16 15 14 13 12 11 10 9
20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
M54C1 M61A R28 R31
2 1
3
* 12 11 10 9 8 7 6 5 4 3 2 1 4 3 2 1 4 3 2 1
6 5 24 23 22 21 20 19 18 17 16 15 14 13
2012 > D 2.0 TCID > Power Outside Mirror > Schematic Diagrams
Power Outside Mirrors (1) SD8761
TABLE
HOT IN ACC OR ON PIN NO.(RHD)
SELECTOR
See Power Distribution I/P SWITCH POSITION 6 5 8 9 10 11 12
(SD11010) JUNCTION POSITION (6) (5) (12) (11) (10) (9) (8)
BOX
UP
CLOCK PHOTO 45
10A DOWN
DRIVER OFF
See Passenger LEFT
Compartment Fuse Details MIRROR
See Outside (SD1201) SELECT RIGHT
Mirror Folding SWITCH UP
(SD8781) 9 I/PF
DOWN
0.3Y
PASSENGER OFF
32 FD12
0.85R LEFT
0.3Y PHOTO 41
RIGHT
4 6 D11
POWER
OUTSIDE
MIRROR
MIRROR SWITCH
FOLDING LEFT RIGHT LEFT/ PHOTO
DOWN UP UP DOWN RIGHT
SWITCH RIGHT LEFT 80
SELECTOR SWITCH
DRIVER PASSENGER
3 2 5 10 8(LHD) 9(LHD) 12(LHD) 11(LHD) D11

0.5B 12(RHD) 11(RHD) 8(RHD) 9(RHD)
0.5L 0.5G
5 JD01
0.3Br 0.3O 0.3W PHOTO 41
(SD1303) CONNECTOR 18 28 15 FD12
See Outside
Mirror Folding 0.3Br 0.3O 0.3W PHOTO 41
(SD8781) 1 JD01 PHOTO 81 See Rear See Rear
Glass & See Outside 2 3 4 FD22 See Outside Glass &
See Turn & Mirror Defogger Mirror Folding Mirror Folding Mirror Defogger See Turn &
Hazard Lamps (SD8791) (SD8781) (SD8781) (SD8791) Hazard Lamps
(SD9252) (SD9251)
2.0B 0.5Y/O 0.5B 0.5R 0.5G 0.5L 0.3Br/B 0.3O 0.3P 0.3Br 0.3O 0.3W 0.5G 0.5L 0.5R 0.5B 0.5L
5 2 1 3 4 6 8 7 D10 6 8 7 3 4 1 2 5 D30
34 FD12
PHOTO
41 UP UP
M L R M L R
2.0B M M
DOWN DOWN
M M
TURN LAMP DEFOGGER OUTSIDE MIRROR OUTSIDE MIRROR DEFOGGER TURN LAMP
FOLDING MOTOR FOLDING MOTOR
OUTSIDE MIRROR MOTOR OUTSIDE MIRROR MOTOR
PHOTO GF11 (LHD)
42/63 GF21 (RHD) DRIVER POWER OUTSIDE MIRROR PHOTO 81 PASSENGER POWER OUTSIDE MIRROR PHOTO 82
2012 > D 2.0 TCID > Power Outside Mirror > Schematic Diagrams
Power Outside Mirrors (2) SD8762
D10 D11 D30
6 5 4 3 2 BLANK
4 3 2 1 * 4 3 2 1
12 11 10 9 8
8 7 6 5 * 8 7 6 5
2012 > D 2.0 TCID > Power Windows > Schematic Diagrams
Power Windows (1) SD8241
WITH SAFETY POWER WINDOW See Illuminations
(SD9412)
0.3P
D01 (LHD)
4 D01R (RHD)
POWER
WINDOW
From Window MAIN
G Switch SWITCH
(SD8242)
PHOTO
80
WINDOW
AUTO AUTO LOCK
DOWN UP
HOT AT ALL TIMES UL SWITCH
OFF OFF L
See Passenger I/P ILL.
JUNCTION MANUAL MANUAL
Compartment
Fuse Details BOX
(SD1205) PHOTO 45
6 7 8 5 13 D01 (LHD)
SAFETY SAFETY 3 1 2 D01R (RHD)
P/WDW P/WDW
RH LH 0.5Gr 0.5Br 0.5O 2.0B 0.3B
25A 25A 5 2 1 D03
DRIVER
Hall SAFETY
Effect M RLY AUTO UP DOWN POWER
SNSR WINDOW
MODULE
20 21 1 I/PF See Illuminations
Shunt Resistor SIG & Filter PHOTO (SD9412)
2.0R 2.0R 2.0R 80
ECU
Reverse Protection & Filter SIG Filter
2.0R 2.0R
21 FD12 4 6 3 D03
A B
PHOTO 41 2.0R 0.5P 2.0B
To Rear Safety To Passenger Safety 2 FD12
Power Window 2 3 JD01
Power Window 0.5P PHOTO 41
Module RH Module JOINT
(SD8242) See Ground Distribution CONNECTOR
(SD8243) (SD1303)
0.5P PHOTO 81
32 MF12 1 JD01
0.5P PHOTO 43
0.3P/B 2.0B
0.3P/B 34 FD12
0.3P/B PHOTO 41
C 11 M04B
D 2.0B
E Safety BCM
Power PHOTO
To Passenger Safety Window 57
To Rear Safety Power
Window Module LH Power Window Module GF11 (LHD) PHOTO
(SD8243) (SD8242) GF21 (RHD) 42/63
WITH SAFETY POWER WINDOW
POWER
PASSENGER WINDOW SWITCH WINDOW
To Power Window
Main Switch From Rear MAIN
G H Window Switch SWITCH
(Window lock switch)
(SD8241) (SD8243) PHOTO
80
AUTO AUTO
0.5O 0.5L 0.5G DOWN UP
5 2 1 D23 OFF OFF
PASSENGER MANUAL MANUAL
Hall SAFETY
Effect M RLY AUTO UP DOWN POWER
SNSR WINDOW
MODULE
Shunt Resistor SIG & Filter PHOTO 2 3 1 D01 (LHD)
82 8 6 7 D01R (RHD)
ECU
2.0G 0.5O 2.0L
Reverse Protection & Filter SIG Filter
39 9 22 FD12
4 6 3 D23 PHOTO 41
0.5G 0.5O 0.5L
2.0R 0.5P 2.0B
12 24 13 FD22
PHOTO 41
2.0B See Illuminations
(SD9412)
34 23 22 FD22
PHOTO 41 0.5G 0.5O 0.5L 0.3P
0.5P/B
4 5 1 8 D21
PASSENGER
2.0R 0.5P/B 0.5P/B 2.0B POWER
OFF OFF WINDOW
F SWITCH RH
UP DOWN UP DOWN PHOTO
ILL.
82
To Rear Safety
Power Window
Module RH 24 MF22
(SD8243) PHOTO 75
6 3 D21
0.3P/B
0.5B 0.3B
B E
From SAFETY From Driver Safety
P/WDW RH Power Window Module GF21 PHOTO 63 See Illuminations
25A (SD8241) (SD9412)
(SD8241)
POWER WINDOW
WITH SAFETY To Power Window Main Switch
(Window lock switch) H
MAIN SWITCH
POWER WINDOW (SD8242)
PHOTO 80
REAR WINDOW SWITCH LH REAR WINDOW SWITCH RH
From Driver From SAFETY From Passenger From SAFETY
Safety Power P/WDW LH OFF OFF OFF OFF Safety Power P/WDW RH
Window Module 25A Window Module 25A
(SD8241) (SD8241) (SD8242) (SD8241)
UP DOWN UP DOWN UP DOWN UP DOWN
D C F A
0.5P 2.0R 2.0B

PHOTO 0.5P/B 2.0R 2.0B
85
12 15 14 FD11 15 16 14 9 11 12 10 D01 (LHD) 14 15 13 FD21
D01R (RHD)
PHOTO
GF31 85 GF41
0.5P 2.0R 2.0B 0.5P 0.5Y 0.5L 2.0Y 0.5W 0.5G 0.5Br 0.5P 2.0R 2.0B
PHOTO 85 PHOTO 85
6 4 3 D43 23 10 12 38 35 25 26 FD12 6 4 3 D53
REAR PHOTO REAR
SAFETY 41 SAFETY
SIG Filter Reverse Protection & Filter POWER 0.5Y 0.5L 2.0Y 0.5W 0.5G 0.5Br SIG Filter Reverse Protection & Filter POWER
WINDOW WINDOW
ECU 13 JF01 ECU MODULE
MODULE
LH JOINT RH
SIG & Filter Shunt Resistor PHOTO CONN SIG & Filter Shunt Resistor PHOTO
Hall 86 ECTOR Hall 86
DOWN UP AUTO RLY M Effect 11 14 JF01 DOWN UP AUTO RLY M Effect
SNSR SNSR
PHOTO
0.5P 2.0B 0.5B 43
1 2 5 D43 1 2 5 D53
0.5P 0.5L 0.5Y 6 2 7 5 FD11 5 6 2 7 FD21 0.5W 0.5Br 0.5G
PHOTO PHOTO 85
85
(SD9412) (SD9412)
0.3P 0.5P 0.5Y 0.5L 0.5W 0.5G 0.5Br 0.3P

8 4 5 1 D41 4 5 1 8 D51
REAR REAR
POWER POWER
OFF OFF WINDOW OFF OFF WINDOW
SWITCH SWITCH
ILL. UP DOWN UP DOWN LH UP DOWN UP DOWN
ILL. RH
PHOTO PHOTO
86 86
3 6 D41 6 3 D51
0.3B 2.0R 2.0R 0.3B
(SD9412) (SD9412)
HOT AT ALL TIMES W/O SAFETY POWER WINDOW
E/R
FUSE &
(Front & Rear Power Window)
RELAY
BOX
B+ 1
50A
See Illuminations
(SD9412)
2.0Y 0.3P
0.5W
D01 (LHD)
2 I/PH 16 3 D01R (RHD)
I/P POWER
JUNCTION Rear Window From Window WINDOW
BOX A Switch LH Switch MAIN
POWER D
WINDOW PHOTO 45 (SD8245) (SD8245) SWITCH
RELAY DRIVER PHOTO
OFF OFF WINDOW 80
WINDOW
SWITCH LOCK
UP DOWN UP DOWN
UL SWITCH
P/WDW P/WDW L
AUTO DOWN ILL.
RH LH CONTROL UNIT
25A 25A
17 I/PB 16 17 I/PF 8 7 12 5 D01 (LHD)

2 1 D01R (RHD)
0.3Gr 2.0R 2.0Y 13 FD12
2.0O 2.0Br 2.0B 0.3B
PHOTO 41
2.0Y 2.0R See Illuminations

(SD9412)
3 JD01
C B JOINT
See Ground
To Joint To Rear Power (SD1303) PHOTO 81
Connector Window Switch LH
(SD8245) (SD8245) 1 JD01
2.0B
34 FD12
PHOTO 41
12 M04B 1 2 D02 2.0B
Power BCM DRIVER
Window PHOTO POWER
Relay 57 WINDOW
Control M MOTOR
GF11 (LHD) PHOTO
PHOTO 80 GF21 (RHD) 42/63
W/O SAFETY POWER WINDOW
(Front & Rear Power Window)
POWER
WINDOW
From P/WDW MAIN SWITCH
LH 25A A
(SD8244) PHOTO 80
PASSENGER WINDOW SWITCH REAR WINDOW SWITCH RH
REAR WINDOW
OFF OFF SWITCH LH OFF OFF OFF OFF
From P/WDW
UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN RH 25A
To Window (SD8244)
Lock Switch D
(SD8244) C
2.0R
15 14 2 1 9 11 10 D01 (LHD)
8 7 D01R (RHD) 11 JF01
JOINT
2.0P 2.0L 2.0G 2.0L 2.0Y 2.0W 2.0Br CONNECTOR
PHOTO 43
23 12 39 22 38 35 26 FD12 13 12 14 JF01
From P/WDW PHOTO 41
LH 25A 2.0Y
(SD8244)
B
(SD9412) (SD9412) 2.0G 2.0R 2.0L 2.0W 2.0R 2.0Br See Illuminations
2.0P 2.0R 2.0L
(SD9412)
6 5 7 FD11 12 21 13 FD22 6 5 7 FD21
0.3P 2.0P 2.0R 2.0L PHOTO 85 PHOTO 41 PHOTO 85
0.3P 2.0G 2.0R 2.0L 2.0W 2.0R 2.0Br 0.3P
8 7 6 2 D41 8 7 6 2 D21 7 6 2 8 D51
REAR PASSENGER REAR
POWER POWER POWER
OFF OFF WINDOW OFF OFF WINDOW OFF OFF WINDOW
SWITCH LH SWITCH SWITCH RH
UP DOWN UP DOWN PHOTO UP DOWN UP DOWN PHOTO UP DOWN UP DOWN
ILL. ILL. ILL. PHOTO
86 82 86
3 4 1 D41 3 4 1 D21 4 1 3 D51

0.3B 2.0O 2.0Gr 0.3B 2.0O 2.0Gr 2.0O 2.0Gr 0.3B
1 2 D42 1 2 D22 1 2 D52
REAR PASSENGER REAR See Illuminations
POWER POWER POWER (SD9412)
(SD9412) WINDOW (SD9412) WINDOW WINDOW
M MOTOR LH M MOTOR M MOTOR RH
W/O SAFETY POWER WINDOW HOT AT ALL TIMES
(Front Power Window) E/R
FUSE &
See Illuminations
(SD9412) RELAY
BOX
B+ 1
0.3P 50A
D01 (LHD)
3 9 D01R (RHD)
POWER
DRIVER WINDOW SWITCH PASSENGER WINDOW SWITCH WINDOW
MAIN 5.0W
SWITCH
PHOTO 2 I/PH
OFF OFF OFF OFF 80
I/P
ILL. WINDOW
UP DOWN UP DOWN UP DOWN UP DOWN JUNCTION
LOCK
BOX
SWITCH 2.0Y PHOTO
L UL POWER 45
See Passenger WINDOW
38 FD12 Compartment RELAY
PHOTO 41 Fuse Details
2.0Y (SD1205)
5 8 7 12 2 1 D01 (LHD)
2 1 8 7 D01R (RHD) 13 JF01
0.3B 2.0B 2.0G 2.0L JOINT
CONNECTOR P/WDW
PHOTO 43 RH
39 22 FD12 25A
See Illuminations 3 JD01 12 11 JF01
PHOTO 41
(SD9412) JOINT
See Ground CONNECTOR 2.0R
Distribution 16 I/PF 17 I/PB
(SD1303) PHOTO 81
2.0G 2.0R 2.0L
1 JD01 See Illuminations
12 21 13 FD22 (SD9412)
PHOTO 41
2.0O 2.0Br 2.0B 2.0G 2.0R 2.0L 0.3P 0.3Gr
7 6 2 8 D21
PASSENGER
POWER
OFF OFF WINDOW
SWITCH
34 FD12 UP DOWN UP DOWN PHOTO
ILL.
PHOTO 41 82
4 1 3 D21
2.0B 2.0O 2.0Gr 0.3B
1 2 D02 1 2 D22 12 M04B
DRIVER PASSENGER Power BCM
See Illuminations Window PHOTO
POWER POWER (SD9412)
WINDOW WINDOW Relay 57
M MOTOR M MOTOR Control
GF11 (LHD) PHOTO
PHOTO 80 GF21 (RHD) 42/63 PHOTO 82
D01 D01R D02 D03
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
6 5 4 3 2 1
16 15 14 13 12 11 10 9 16 15 14 13 12 11 10 9 2 1
D21 D22 D23 D41
3 2 1 3 2 1
6 5 4 3 2 1
8 7 6 5 4 2 1 8 7 6 5 4
D42 D43 D51 D52
3 2 1
6 5 4 3 2 1
2 1 8 7 6 5 4 2 1
D53 M04B
BLANK BLANK
6 5 4 3 2 1 10
* * 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
2012 > D 2.0 TCID > Rear Glass & Mirror Defogger > Schematic Diagrams
Rear Glass & Mirror Defogger (1) SD8791
HOT AT ALL TIMES
E/R
FUSE &
RELAY
RR HTD BOX
40A
3.0W
3 I/PG
I/P
JUNCTION
REAR BOX
DEFOGGER PHOTO 45
RELAY
HTD
MIRR See Charging System
10A (SD3731) (SD3732) (SD3733)
(SD3734) (SD3735) (SD3736)
2 4 I/PF 11 16 I/PB 0.3W/B(W/O ISG)

0.3R 0.3W(With ISG)
3.0R 0.5R 0.5R
3 M04C 3 M04A
6 FD12 PHOTO 41 5 FD22 PHOTO 41
7 FR12 Rear Defogger Engine Running BCM
0.5R 0.5R 0.3G Relay Control Input PHOTO
PHOTO
3.0R 66/88 1 D10 1 D30 Defogger 57
Switch
DRIVER PASSENGER 2 MC21
DEFOGGER POWER DEFOGGER POWER PHOTO 57 4 M04B
1 R23 OUTSIDE OUTSIDE
MIRROR MIRROR 0.3G 0.3L
REAR See Front Wiper Deicer
DEFOGGER PHOTO PHOTO (SD8611)
0.3L
PHOTO 81 82
61/97/109 9 10 M05A (Auto A/C)
2 D10 2 D30
1 F24 A/C
0.5B DEFOGGER CONTROL
6 JD01 SWITCH MODULE
0.5B 0.5G IND.
JOINT PHOTO
See Ground G4FA/ 59
G4FC
(SD1303) PHOTO 81 11 FD22
PHOTO 41 25 M05A (Auto A/C)
1 JD01
28 M06B (Manual A/C)
3.0B 2.0B 0.5B
0.5B
34 FD12 PHOTO 41 4 JM04
13 CGGK (G4FA/G4FC, With ETC)
31 CGGMK (G4FA/G4FC, M/T, W/O ETC) See Ground Distribution JOINT
(SD1302) CONNECTOR
2.0B 22 CGGAK (G4FC, A/T, W/O ETC) PHOTO 68
ECM(M/T)/ 1 JM04
PCM(A/T) 1.25B
PHOTO
PHOTO GF11 (LHD) PHOTO GF21 (LHD) PHOTO 36
GF81 61/97/109 GF21 (RHD) 42/63 GF11 (RHD) 42/63 GM41 PHOTO 120
2012 > D 2.0 TCID > Rear Glass & Mirror Defogger > Schematic Diagrams
Rear Glass & Mirror Defogger (2) SD8792
CGGAK CGGMK
94 93
*
91 90 89 88
* 86 * * 8361 6082 * 80 5779 * 77 * 75 * 7351 6 5
94 93 92 91 90
* 66* 87 8664 6385 6284 8361 6082 8159 80 * * 77 54* * * 7351 6 *
72 71 70
*68 67 66
**** ** ***** 72 71 70 69 68
* * ** * * * *
4 3
* 3
* 4927 26* 25* 24* * 22* * 20* 41 * 17* 38 * * 3513 * * 1032 319 308 * 28 27 26 25 24 23 22 21 * 19 18 17 16 15 * 36 3513 12* 3311 32 319 * 297 2 1
50 49 48 47 46 45 44 43 41 40 39 38
2 1
* * * * * *** ** * * * * *
CGGK D10 D30
94
* 92 91 90 89 88 87 86 85 * 83 * 81 80 79 78 77 76 75 74 73 6 5
* 71 70 69 68 67 66 65 * 63 62 61 * 59 58 57 56 * 54 53 52 51 4 3 4 3 2 1 4 3 2 1
50 49
* 25* 24* 23* 4422 4321 4220 4119 4018 3917 38 15* 36 3513 3412 3311 32 319 308 297 2 1
28 27 26
* * * 8 7 6 5 8 7 6 5
F24 M04A M04B
1
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1 10
* * 7 6 5 4 3 2 1
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11
M04C M05A M06B R23
8 7 6 5 4 3
* 1 13
* * 10 9 8 7 6
** * 2 1
14 13 12 11 10 9 8 7 6 5 4 3 2 1 1
16 15 14 13 12 11 10 9
26 25 24 23 22 21 20 19 18 17 16
* 14 28 27 26 25
* 23 22 21 20 19 18 17 16 15
2012 > D 2.0 TCID > Rear Parking Assist System > Schematic Diagrams
Rear Parking Assist System (1) SD9571
HOT AT ALL TIMES
(SD11010) JUNCTION
POWER BOX
CONNECTOR PHOTO 45
ROOM
LP
15A
See Passenger
(SD1203)
13 I/PC
0.5R
1 JM03
JOINT
CONNECTOR
PHOTO 54
2 JM03
0.5R
5 M64 See BackUp Lamps
(SD9261) (SD9262)
PIEZO
BUZZER
2 M64 0.5R
PHOTO 46
0.5O
18 MF22
PHOTO 75
0.5O
3 8 F22
REAR PARKING
Piezo Buzzer Backup ASSIST CONTROL
Signal MODULE
LH Sensor RH LC RC
PHOTO
74/89
GND RX TX 8V GND RX TX RX TX RX TX
9 4 15 2 1 13 6 11 14 12 5 F22
0.3P 0.3Gr 0.3Y 0.3B 0.3W 0.3L/B 0.3Y 0.3G 0.3Y/O 0.3G/B
0.5B 6 5 1 2 4 3 7 8 9 10 FF11
PHOTO 95
0.3Y 0.3B
0.3P 0.3Gr 0.3B 0.3Y PHOTO 95 0.3Y 0.3B 0.3W 0.3L/B PHOTO 95 0.3Y/B 0.3Gr/O 0.3B 0.3Y PHOTO 95 0.3Y 0.3B 0.3G 0.3G/B PHOTO 95
4 3 2 1 F30L 1 2 4 3 F30R 4 3 2 1 F30LC 1 2 4 3 F30RC
LIN VABT GND 8V REAR 8V GND VABT LIN REAR LIN VABT GND 8V REAR 8V GND VABT LIN REAR
GF61 PARKING PARKING PARKING PARKING
ASSIST ASSIST ASSIST ASSIST
PHOTO SENSOR SENSOR SENSOR SENSOR
89/111 LH RH CENTER LH CENTER RH
2012 > D 2.0 TCID > Rear Parking Assist System > Schematic Diagrams
Rear Parking Assist System (2) SD9572
F22 F30L F30LC F30R
* 156 145 13 12 114 3 2 1

2 1 2 1 2 1
* * 9 8
4 3 4 3 4 3
F30RC M64
BLANK BLANK
2 1
*
4 3 5 2
* *
2012 > D 2.0 TCID > Rear Wiper & Washer > Schematic Diagrams
Rear Wiper & Washer (1) SD9821
HOT IN ON
(SD11010) JUNCTION
BOX
RR PHOTO
WIPER 45
WASHER
15A MOTOR
M PHOTO
10
18 I/PF
0.85R
0.85R
37 MF12 PHOTO 43
0.85R 3 1 2 CGG67 (G4FA/G4FC)
CBG67 (G4GC)
0.85R 10 M02W CUD67 (D4FB)
CDD67 (D4EA)
5 2 FR12 MULTIFUNCTION
REAR SWITCH
PHOTO
66/88 WIPER & PHOTO
WASHER 51
5DR/ 5DR/ WASHER WASHER
3DR WGN 3DR SWITCH 1.25G/O 1.25B 1.25Y/O
WGN
(W/O D4EA)
0.85R 0.85R 0.85Y 0.85Y WIPER 1.25L(D4EA)
OFF
4 2 RR11 22 MC11
PHOTO PHOTO
0.85R 0.85Y 61/97 2 9 M02W 1.25G/O 75
See Front Wiper
& Washer
0.85Y 0.85R 0.5L/O 0.5G/O (SD9811)
10 17 M04A (SD9812)
R27 (5DR/WGN) Rear Rear BCM
4 2 R30 (3DR) Wiper Rear Washer PHOTO
REAR Switch Wiper Switch 57
WIPER Relay
MOTOR Control
PHOTO 18 M04B
M 61/97/109
0.3W
10 MF12 PHOTO 43
0.3W
5 1 2 F35
3 1 R27 (5DR/WGN) REAR
R30 (3DR) WIPER
RELAY
5DR/WGN 3DR PHOTO
66/73/88
0.85L 0.85L 0.85B
3 RR11
PHOTO 3 4 F35
0.85L 61/97
PHOTO 0.85L 0.3B
61/97/109 GGG13 (G4FA/G4FC)
4 FR12
GR11 (5DR/WGN) GBG13 (G4GC)
PHOTO PHOTO GUD12 (D4FB) PHOTO
GR12 (3DR) 66/88
GF31 85 GDD12 (D4EA) 7/13
2012 > D 2.0 TCID > Rear Wiper & Washer > Schematic Diagrams
Rear Wiper & Washer (2) SD9822
2 1 2 1 2 1 2 1
3 3 3 3
F35 M02W M04A
1
4 3 2 7 6 5 4 3 2
* 20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1
5
14 13 12 11 10 9
* * 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21
KET_250_05F_W_RLY
M04B R27 R30
BLANK
10
* * 7 6 5 4 3 2 1
4 3 2 1 4 3 2 1
20 19 18 17 16 15 14 13 12 11
2012 > D 2.0 TCID > Roof & Tail Gate Harness > Schematic Diagrams
2012 > D 2.0 TCID > Roof & Tail Gate Harness > Schematic Diagrams
2012 > D 2.0 TCID > Seat Warmer > Schematic Diagrams
Seat Warmer (1) SD8891
HOT IN ON HOT IN ON OR START
(SD11010) JUNCTION
BOX
SEAT PHOTO 45
CLUSTER
HTR See Illuminations
10A
15A (SD9411)
See Passenger
(SD1201)
12 13 I/PB 23 I/PF 0.3Gr 0.3P
19 17 M61A
S/Warmer S/Warmer SWITCH

ILL() ILL(+) MODULE
PHOTO
S/Warmer S/Warmer S/Warmer S/Warmer S/Warmer S/Warmer 59
S/Warmer IND IND IND S/Warmer IND IND IND
SW LH HI LH MID LH LO LH SW RH HI RH MID RH LO RH
22 20 21 10 M61A 2 13 1 14 M61A
0.85R/O 0.3Y/O 0.3Br 0.3W 0.3Gr 0.5P 0.85R/O 0.3Y 0.3O 0.3L 0.3G
36 MF12 20 6 2 1 MF22 9 MF12 19 14 13 12 MF22

PHOTO PHOTO PHOTO PHOTO
43 75 43 75
0.85B 0.85R/O 0.3Y/O 0.3Br 0.3W 0.3Gr 0.5P 0.5Y 0.85R/O 0.3Y 0.3O 0.3L 0.3G 0.85B
GF31 GF41 PHOTO
PHOTO 85 85
7 1 3 4 5 6 2 F36 2 1 3 4 5 6 7 F37
1.25B/Y 1.25R 0.5G/B 0.5R 0.5L 0.5L 1.25G 1.25G 1.25R 0.5G/B 0.5R 0.5L 0.5L 1.25B/Y
FRONT FRONT
SEAT SEAT
WARMER WARMER
GND IG 2 SW HI MID LOW IG 1 CONTROL IG 1 IG 2 SW HI MID LOW GND CONTROL
Signal MODULE Signal MODULE
LH RH
PHOTO PHOTO
NTC() NTC(+) Heater(+) Heater() 83 NTC() NTC(+) Heater(+) Heater() 84
0.5Br 0.5W 1.25Y 1.25B 1.25B 0.5Br 0.5W 1.25Y 1.25B 1.25B
HEATER HEATER
CUSHION BACK CUSHION BACK

HEATER HEATER HEATER HEATER
NTC NTC
2012 > D 2.0 TCID > Seat Warmer > Schematic Diagrams
Seat Warmer (2) SD8892
F36 F37 M61A
3 2 1 3 2 1
BLANK
12 11 10 9 8 7 6 5 4 3 2 1
* 7 6 5 4
* 7 6 5 4
24 23 22 21 20 19 18 17 16 15 14 13
2012 > D 2.0 TCID > Shift & Key Lock System > Schematic Diagrams
Shift & Key Lock System (1) SD4521
HOT AT ALL TIMES HOT IN ON OR START HOT IN ACC OR ON HOT IN ON OR START
See Power I/P See Power Distribution E/R
See Power Distribution JUNCTION FUSE &
Distribution (SD1108)
(SD11010) BOX RELAY
(SD11010)
PHOTO BOX
B/UP
STOP CLUSTER CLOCK 45 10A
15A 10A 10A
See Passenger
Compartment
Fuse Details 0.5R
(SD1201) 30 EC11
15 I/PB 2 I/PC 2 I/PB 0.5R PHOTO 115
CGG01 (G4FC)
CBG01 (G4GC)
8 CUD01 (D4FB)
TRANSAXLE
0.5Y 0.3Br 0.5O RANGE SWITCH
PHOTO 33
5 JM03 D
P
5 M45 JOINT
CONNECTOR R N
ATM PHOTO 54
LEVER 1 6 2 CGG01 (G4FC)
SHIFT SWITCH 7 JM03 CBG01 (G4GC)
PHOTO 0.5L 0.5P 0.5Y CUD01 (D4FB)
LOCK
SOLENOID 64 See Stop Lamps
(SD9271) (SD9272)
0.5Br 0.5L 0.5P 0.5Y 0.5P(G4FC/G4GC) 0.5Y 0.5L

6 M45 0.5B(D4FB)
11 24 23 19 MC21
PHOTO 57
See Automatic
0.5G/B 0.3R 0.5Br 0.5L 0.5P 0.5Y Transaxle Control System
(SD4501) (SD4502)
5 2 10 4 7 8 1 M12
(SD4505) (SD4507)
ATM KEY
Shift Lock ON/START ACC/ON Stop Lamp 'P' 'N' 'D' LOCK
Solenoid Input Input Switch Input Input Input CONTROL
Vehicle Speed MODULE
Ground Signal PHOTO 63
11 13 M12
0.5B 0.3L/O
5 JM04
See Ground JOINT
(SD1302) PHOTO 68
See Vehicle
1 JM04 Speed System
(SD4361)
1.25B (SD4362)
GM41 PHOTO 120
2012 > D 2.0 TCID > Shift & Key Lock System > Schematic Diagrams
Shift & Key Lock System (2) SD4522
CBG01 CGG01 CUD01 M12
5 4 2 1
6 5
10 9
* 3 2 1
8 7
6 5
10 9
* 3 2 1
8 7
6 5
10 9
* 3 2 1
8 7
* *
* 13
* 11 10
* 8 7
M45
3
* * BLANK BLANK BLANK
8 6 5
* *
2012 > D 2.0 TCID > Starting System > Schematic Diagrams
Starting System (1) SD3601
E/R
W/O ISG 1 M35
IGNITION
3.0W
FUSE & SWITCH 8 I/PA
RELAY PHOTO 50
20B(W/O D4EA) BOX ON ACC I/P
20R(With D4EA) JUNCTION
IGN2 START LOCK BOX
40A START PHOTO
AM 10A 45
5 M35
BATTERY
3.0P 3.0B 3 I/PB
27 EM31
0.3W
PHOTO 43
3.0P
8 MC11 PHOTO 75
W/O D4FB With D4FB
3.0P
1 2 E42
M/T A/T
START
RELAY
0.5B 0.5B(G4FC/ 0.5B 0.5B
PHOTO G4GC)
31 52 CUDK
20B(W/O D4EA) 20B(W/O D4EA)
30B(With D4EA) 30R(With D4EA) Start ECM
5 4 E42 Input PHOTO
38
2.0R 0.5R Start
PHOTO 115 Relay
24 EC11 Control
BODY
GROUND W/O With W/O With 68 CUDK
1 EB11
D4FB D4FB D4FB D4FB
PHOTO 5
FLY WHEEL MAGNETIC A/T M/T
2.0R 0.85B 0.5L
LEVER
START 20 EC11 PHOTO 115 0.5L(D4FB)
E55 (G4FA/G4FC) E56 (G4FA/G4FC) MOTOR
E65 (G4GC) E66 (G4GC)
E95 (D4FB) E96 (D4FB) M/T A/T A/T M/T
1 E105 (D4EA) 1 E106 (D4EA) 9 CGG01 (G4FC)
START 9 CBG01 (G4GC)
SOLENOID 9 CUD01 (D4FB)
PHOTO TRANSAXLE
25/34/96/107 0.5B 0.5L 0.5B RANGE
(D4FB) (G4FC/G4GC) SWITCH
P PHOTO
L
2 33
R
N D
With W/O
D4FB D4FB 10 CGG01 (G4FC)
PINION MOTOR 10 CBG01 (G4GC)
GEAR 10 CUD01 (D4FB)
GE11
OVERRUNNING
CLUTCH PHOTO 1
3.0W
HOT IN ON OR START
M/T Only With ISG E/R
1 M35
EMS 8 I/PA
(G4FA/G4FC/D4FB ) FUSE &
RELAY ON ACC
IGNITION
SWITCH
BOX
PHOTO
I/P
JUNCTION
20B BOX PHOTO 114 BOX
ISG : Idle Stop & Go START LOCK 50 ECU 2 START
IGN2 10A PHOTO
40A 10A 45
AM
See Power
Distribution
3.0P 5 M35 (SD1103)
BATTERY 3.0B 3 I/PB
27 EM31 16 E/RCGG2
3.0P 3.0P 0.3W
PHOTO 43
HOT AT ALL TIME
See Power 8 MC11
1 2 E42 PHOTO 31 Distribution PHOTO 75
(SD1108)
START
RELAY
20B 20B D4FB, ECU
G4FA/G4FC, G4FA/G4FC, 10A 0.5Gr
With ETC W/O ETC
5 4 E42
2.0R 0.5L 0.5R

0.3L
1 EB11 38 20 11 EC11 12 CGGK (G4FA/G4FC, With ETC)
BODY PHOTO 0.5R PHOTO 115 26 CGGMK (G4FA/G4FC, W/O ETC)
GROUND 0.3L 52 CUDK(D4FB)
5 CGG60 (G4FA/G4FC)
7 CUD60 (D4FB) Starting ECM(M/T),
DCDC Signal PCM
CONVERTER PHOTO
Clutch Neutral 36/38
PHOTO Switch Switch
52
FLY WHEEL MAGNETIC 33 35 CGGK (G4FA/G4FC, With ETC)
9 27 CGGMK (G4FA/G4FC, W/O ETC)
LEVER 2.0R 55 75 CUDK(D4FB)
START 0.5Br/B(G4FA/G4FC, With ETC) G4FA/G4FC D4FB
MOTOR 0.5L(G4FA/G4FC, W/O ETC)
0.5Br/O(D4FB) 0.5G 0.5G
E59 (G4FA/G4FC) E56 (G4FA/G4FC) G4FA/
1 E99 (D4FB) 1 E96 (D4FB) D4FB G4FC CGG71 (G4FA/G4FC)
2 CUD71 (D4FB) 1 CB11 1 CB21
START 0.5G PHOTO 14 0.5G PHOTO 27
SOLENOID CLUTCH
W/O ETC With ETC SWITCH
PHOTO 1 E58 1 E98
25/96 PHOTO
4 NEUTRAL NEUTRAL
SWITCH SWITCH
0.3L 0.3L 0.3L 0.3L 0.3L 1 CGG71 (G4FA/G4FC) PHOTO PHOTO
CUD71 (D4FB) 35 35
51 CUDA 45 61 CGGMK 89 52 CGGK
2 E58 2 E98
Start ECM(M/T)/
Relay PCM 0.5B 0.5B 0.5B
Start Start
PINION MOTOR Control Relay Relay PHOTO
36/38 2 CB11 2 CB21
GEAR Control Control
0.5B PHOTO 14 0.5B PHOTO 27
GGG14 (G4FA/G4FC)
OVERRUNNING CUD13 (D4FB) PHOTO PHOTO
CLUTCH PHOTO 7/13 GGG11 36 GUD21 38
CBG01 CGGMK
94 93 92 91 90
* 66* 87 8664 6385 6284 8361 6082 8159 80 * * 77 54* * * 7351 6 *
6 5
* 3 2 1
72 71 70 69 68
* * ** * * * * BLANK
* 3
28 27 26 25 24 23 22 21 * 19 18 17 16 15 * 36 3513 12* 3311 32 319 * 297 2 1
10 9 8 7 50 49 48 47 46 45 44 43 41 40 39 38
* * * *
CGGK CGG01 CGG60
94
* 92 91 90 89 88 87 86 85 * 83 * 81 80 79 78 77 76 75 74 73 6 5
* 71 70 69 68 67 66 65 * 63 62 61 * 59 58 57 56 * 54 53 52 51
50 49
* 25* 24* 23* 4422 4321 4220 4119 4018 3917 38 15* 36 3513 3412 3311 32 319 308 297
4
2
3
1
6 5
10 9
* 3 2 1
8 7
4
* * 1
* * * * 10 9 8 7 6
*
28 27 26
CGG71 CUDA
60
* 58 57 56 55 54 53 52 51 50 49 * 47 46
1 * 44 * 42 41 40 39 38 37 36 35 34 33 32 31 BLANK
2 * 1429 1328 12* * 10* * * 227 *6 * 194 * 172 161
* * ** * *
CUDK CUD01 CUD60
94 93 92
*
90 89
*
87 86 85 84 83
* * 7856 7755 76 5375 52* 5173
81 80
6 5
72 71 70 69 68 67 66
*
64 63 62 61 60 59 58
* *
50
* 26* 47 2446 * 4422 * 20* 1941 40 17* 38 15* 14* 1335 12* 1133 1032 *9 30 *7
4
2
3
1
6 5
10 9
* 3 2 1
8 7
4
* * 1
28 27
* * * * * * * 10 9 8 7 6
*
CUD71 E42 E55 E56
1
1 4 2 1
* 1
2 5
E58 E59 E65 E66
2 1 1 1
1
E95 E96 E98 E99
1 2 1 1
1
E105 E106 M35
1 3 2 1 BLANK
1
6 5 4
2012 > D 2.0 TCID > Stop Lamps > Schematic Diagrams
Stop Lamps (1) SD9271
E/R
FUSE &
G4FA/G4FC/G4GC (1/2) See Power Distribution I/P
(SD11010) JUNCTION
RELAY BOX
BOX PHOTO
SNSR
10A STOP 45
15A
(SD1109)
15 I/PB
1.25R 0.5R
1 JE01 0.5R
JOINT 24 MC11 PHOTO 75
CONNECTOR
PHOTO 114 G4FA/G4FC G4GC
0.5R
4 JE01 With ESP, A/T W/O ESP, M/T
1.25R A : Closed with brake /Auto Cruise /Auto Cruise C
18 EC11 pedal depressed 0.5R
B : Open with brake 0.5R 0.5R
0.5R PHOTO 115 pedal depressed 2 CBG58 To Stop
CGG77 (G4FA/G4FC) Lamp Failure
3 2 CBG77 (G4GC) STOP Module
LAMP (SD9272)
STOP SWITCH
B A LAMP
SWITCH PHOTO
55
PHOTO
55 1 CBG58
CBG77 (G4GC)
0.5Br 0.5G 0.5G 0.5Gr/O

A/T
With ESP, A/T W/O ESP, M/T
/Auto Cruise /Auto Cruise
G4FA/G4FC G4GC
4 MC11 0.5R
PHOTO 75
0.5P
2 5 M90
11 MC21 STOP
SIG Input Supply
PHOTO 57 SIGNAL
RELAY
Output Output PHOTO
0.5Br 0.5L 0.5Br(G4GC) (SIG) (Lamp) GND. 122
3 1 4 M90
0.5Y 0.5O 0.5B
4 JM02
15 5 MC11
PHOTO 75 JOINT
0.5G/O 0.5P/B See Ground CONNECTOR
Distribution
(SD1301) PHOTO 47
4 M12 38 CGGK (With ETC) 1 CBG59 D E
ATM KEY PCM AUTO 1 JM02
LOCK CRUISE 1.25B
PHOTO To Rear To Rear
CONTROL 36 CONTROL Combination Lamp Combination Lamp
MODULE MODULE (SD9272) (SD9272)
PHOTO 63 PHOTO 9 GM21 PHOTO 46
HOT IN ON OR START
G4FA/G4FC/G4GC (2/2) See Power Distribution
(SD11010)
I/P
JUNCTION
BOX
PHOTO
CLUSTER 45
10A
See Passenger
(SD1201)
From From 23 I/PF

From
Stop Signal Relay Stop Signal Relay STOP 15A
(SD9271) (SD9271) (SD9271)
D E C
0.5R 0.3R/B
5 CF11
PHOTO
0.5R 75
0.5G(G4GC) 0.5G/O 0.5G/O

6 1 F38
Power IGN1 STOP

LAMP
Trip_COM. FAILURE
MODULE
34 CGGK (G4FA/G4FC, With ETC) 0.5P/B Fail Fail (With TPMS)
9 CGGA (G4FA/G4FC, With ETC) Stop IND. IND. PHOTO
86 CGGAK (G4FA/G4FC, W/O ETC) 13 MC21 4 CF11 PHOTO 75 SW GND. LH RH 74/89
38 CBGA (G4GC) PHOTO 57
0.5W 5 4 8 7 F38
PCM/
ECM Not Used
PHOTO 6 FR12 PHOTO 66/88 0.3W/O 0.3W/B
36/37 ESP ABS
3DR 5DR/WGN W/O 9 8 MF22
TPMS PHOTO
0.85W 0.85W 0.5W 0.5Y/O 0.5B 0.3W/O 0.3W/B 75
0.5G/O 0.5G/O
1 R24 1 R21
HIGH HIGH
MOUNTED MOUNTED
STOP STOP W/O With
LAMP LAMP TPMS TPMS 19 20 M62
PHOTO PHOTO
93 2 R21 93 MULTI
2 R24 DISPLAY
0.85B 0.85B 0.5W PHOTO
59
B A
30 CGG70 (G4FA/G4FC) 30 CGG41 (G4FA/G4FC)
5 CBG59 30 CBG70 (G4GC) 30 CBG41 (G4GC) 15 FR12 PHOTO 66/88
AUTO ESP ABS 0.5B To Rear
CRUISE CONTROL CONTROL Combination Lamp
CONTROL MODULE MODULE (SD9275)
MODULE PHOTO PHOTO
PHOTO 13 PHOTO 13
PHOTO 9 GF51 66/88 GF61 89/111
E/R
FUSE &
D4FB/D4EA (1/2) See Power Distribution
(SD11010)
I/P
JUNCTION
(SD1106) (SD1107) BOX
RELAY
BOX PHOTO
STOP 45
ECU 2
10A 15A
17 E/RCUD2 A : Closed with brake 15 I/PB

E/RCDD2 pedal depressed 0.5R
B : Open with brake 0.5R
0.5W pedal depressed 24 MC11 PHOTO 75
0.5R
CUD77 (D4FB) 0.5R
3 2 CDD77 (D4EA)
STOP
B A LAMP C
SWITCH
PHOTO
55 To Stop
4 1 CUD77 (D4FB) Lamp Failure
CDD77 (D4EA) Module
(SD9274)
0.5G
4 MC11
0.5Br PHOTO 75
0.5P 0.5R
2 5 M90
11 MC21
SIG Input Supply STOP
PHOTO 57 SIGNAL
RELAY
Output Output PHOTO
(SIG) (Lamp) GND. 122
0.5Br 0.5L
3 1 4 M90
A/T
0.5Y 0.5O 0.5B
4 JM02
15 5 MC11
PHOTO 75 JOINT
0.5G/O 0.5P/B See Ground CONNECTOR
Distribution
(SD1301) PHOTO 47
78 CUDK(D4FB) 1 JM02
4 M12 80 CDDK(D4EA) 1.25B
ATM KEY ECM
LOCK PHOTO D E
CONTROL 38 GM21 PHOTO 46
MODULE
PHOTO 63 To Rear To Rear
Combination Lamp Combination Lamp
(SD9274) (SD9274)
HOT IN ON OR START
D4FB/D4EA (2/2) See Power Distribution
(SD11010)
I/P
JUNCTION
BOX
PHOTO
CLUSTER 45
10A
See Passenger
(SD1201)
23 I/PF
From
STOP 15A
(SD9273)
C
0.5R 0.3R/B
5 CF11
PHOTO
From From 0.5R 75
Stop Signal Relay Stop Signal Relay
(SD9273) (SD9273)
D E 6 1 F38
Power IGN1 STOP

LAMP
Trip_COM. FAILURE
MODULE
0.5G/O Fail Fail (With TPMS)
0.5P/B
Stop IND. IND. PHOTO
13 MC21 4 CF11 PHOTO 75 SW GND. LH RH 74/89
PHOTO 57
0.5W 5 4 8 7 F38
Not Used
6 FR12 PHOTO 66/88 0.3W/O 0.3W/B
ESP ABS
3DR 5DR/WGN W/O 9 8 MF22
TPMS PHOTO
0.85W 0.85W 0.5W 0.5Y/O 0.5B 0.3W/O 0.3W/B 75
0.5G/O 0.5G/O 0.5G/O
1 R24 1 R21
HIGH HIGH
MOUNTED MOUNTED
STOP STOP W/O With
LAMP LAMP TPMS TPMS 19 20 M62
PHOTO PHOTO
93 2 R21 93 MULTI
2 R24 DISPLAY
0.85B 0.85B 0.5W PHOTO
59
38 CUDK(D4FB) B A
30 CUD70 (D4FB) 30 CUD41 (D4FB)
38 CDDK(D4EA) 30 CDD70 (D4EA) 20 CDD41 (D4EA) 15 FR12 PHOTO 66/88
ECM ESP ABS 0.5B To Rear
PHOTO CONTROL CONTROL Combination Lamp
38 MODULE MODULE (SD9275)
PHOTO 7 PHOTO 7 PHOTO PHOTO
GF51 66/88 GF61 89/111
STOP
LAMP
FAILURE
MODULE
Stop Stop (With TPMS)
Lamp LH Lamp RH
PHOTO
3 2 F38 74/89
5DR 3DR WGN 3DR WGN 5DR
From Stop Lamp Switch
From Stop Lamp Switch (SD9272) (SD9274)
(SD9272) (SD9274) B
A
0.5W/O 0.5W 0.5W 0.5W 0.5W/O 0.5W 0.5W 0.5W 0.5W/O 0.5W/O 0.5W 0.5W/O
With W/O With W/O With W/O With W/O W/O With W/O With
TPMS TPMS TPMS TPMS TPMS TPMS TPMS & TPMS & TPMS & TPMS & TPMS TPMS
& 5DR & 5DR & 3DR & 3DR & 3DR & 3DR WGN WGN WGN WGN & 5DR & 5DR
See Tail, Parking See Tail, Parking
See Tail, Parking & License Lamps & License Lamps See Tail, Parking
& License Lamps (SD9281) (SD9282) (SD9281) (SD9282) & License Lamps
(SD9282) (SD9281)
0.5Y 0.5Y 0.5Br/O 0.5Y 0.5Br/O 0.5Br/O
1 5 F08 2 5 F07 4 2 F49

REAR REAR REAR
COMBINATION COMBINATION COMBINATION
STOP TAIL LAMP LH STOP TAIL LAMP LH STOP TAIL LAMP RH
PHOTO (LOW) (5DR)
66 PHOTO 73 PHOTO 89
4 2 F50 3 F08 5 1 F10 5 2 F09
3 F07 6 F49
REAR REAR REAR
COMBINATION COMBINATION COMBINATION
TAIL STOP LAMP LH TAIL STOP LAMP RH TAIL STOP LAMP RH
PHOTO PHOTO (LOW)
88 111 PHOTO 74
6 F50 3 F10 3 F09
0.85B 0.85B 0.85B 0.85B 0.85B 0.85B
See Ground See Ground
5DR 3DR Distribution WGN Distribution
0.85B (SD1304) 0.85B (SD1304) 0.85B
3DR WGN 5DR
PHOTO PHOTO
GF51 66/88 GF61 89/111
CBGA CBG41
* * 58 57 56 55 3954 3853 52 * 5035 3449 48 * 46

* ***** ** *** 13 * * 22* * 20* 19* 186 17* * * 14* 1
** * **
* 14* * 12* 11* 10* *9 *8 *7 *6 20 194 18 172 161
15
* * * 38
* * * 34 33 32 31 30 * * 27 26 25
CBG58 CBG59 CBG70
1 6 5 4 3 2 1
13
12
***** 6 5 * 3 * 1
* * 22 * 20 19 18 17 16 * 14
2 * 11 10 9 8 7
38
* * * 34 33 32 31 30 * * 27 26 25
CBG77 CDDK CDD41
94 93 92
*90 89
* 87 86 * 84 83 * * 80 79 * 77 * 75 * * 6 5
72 71 70 69 68
* * 65 64 * * * * * * 57 * * * * * 51 4 3 1 2 3 4
5 6
* 8 9 10 11
* * * 15
2 1
* * * 4725 2446 45 4422 * * 19* 40 * 1638 3715 1436 1335 1234 1133 1032 319 308 297 2 1
16 17 18 19 20
* * * * * 26
4 3
28
** * ** **
CDD70 CDD77
1 2 3 4
5 6
* 8 9 10 11
* 13 14 * * * * * * * * * * * 2 1 BLANK
26 27 28 29 30 31
* * * 35 * * * * * * * * * * *
4 3
CGGA CGGAK
60 59 58 57
* 55 54 53 * * 50 49 * 47 46 94 93
*91 90 89 88
* 86 * * 8361 6082 * 80 5779 * 77 * 75 * 7351 6 5
45
* * * * * 39 * * * * * * 32 * 72 71 70
*68 67 66
**** ** ***** 4 3
30
* * * * * * * * * * * 18 17 16 * 4927 26* 25* 24* * 22* * 20* 41 * 17* 38 * * 3513 * * 1032 319 308 * 2 1
* 14 13 12 11 * 9 8 7 6 * * * 2 1 * * * * * *** ** *
CGGK CGG41
94
* 92 91 90 89 88 87 86 85 * 83 * 81 80 79 78 77 76 75 74 73 6 5
13 * * 22* * 20* 19* 186 17* * * 14* 1
* 71 70 69 68 67 66 65 * 63 62 61 * 59 58 57 56 * 54 53 52 51 4 3 ** * **
50 49
* 25* 24* 23* 4422 4321 4220 4119 4018 3917 38 15* 36 3513 3412 3311 32 319 308 297 2 1 38
* * * 34 33 32 31 30 * * 27 26 25
28 27 26
* * *
CGG70 CGG77
13
12
***** 6 5 * 3 * 1 BLANK
* * 22 * 20 19 18 17 16 * 14 2 1
38
* * * 34 33 32 31 30 * * 27 26 25 4 3
CUDK CUD41
94 93 92
*
90 89
*
87 86 85 84 83
* * 7856 7755 76 5375 52* 5173
81 80
6 5
* * 22* * 20* 19* 186 17* * * 14* 1
72 71 70 69 68 67 66
*
64 63 62 61 60 59 58
* * 4 3
13
** * **
50
* 26* 47 2446 * 4422 * 20* 1941 40 17* 38 15* 14* 1335 12* 1133 1032 *9 30 *7 2 1
28 27
* * * * * * 38
* * * 34 33 32 31 30 * * * 26 25
CUD70 CUD77 F07
13
12
***** 6 5 * 3 * 1
* * 22 * 20 19 18 17 16 * 14 2 1 * 2
3 4 5 6
38
* * * 34 33 32 31 30 * * * 26 25 4 3
F08 F09 F10 F38
2 1 2 1
* 2 3 2 1
6 5
* 3 3 4 5 6 6 5
* 3 8 7 6 5 4
F49 F50 M12 M62
1 2 1 2
5 4 2 1
3 4
* 6 3 4
* 6 * * 12 11 10 9 8
* * 5 4
* 2 1
* 13
* 11 10
* 8 7 24 23 22 21 20 19 18 17 16 15
* 13
M90 R21 R24
4 3 2 BLANK
5 2 1 1 2
2012 > D 2.0 TCID > Sunroof > Schematic Diagrams
Sunroof (1) SD8161
HOT AT ALL TIMES HOT IN ON
I/P
(SD11010) BOX
PHOTO
DR LOCK A/CON 45
20A 10A
See Passenger See Passenger
Compartment Fuse Details Compartment Fuse Details
(SD1204) (SD1202)
3 10 I/PF
SUNROOF
SWITCH
PHOTO
77 0.85R 0.5P
OPEN TILT CLOSE/
See Courtesy & UP TILT
Trunk Lamps DOWN
(SD9291)
5 1 FR11
4 1 5 6 R16 PHOTO 42
0.5B 0.5Y 0.5L/O 0.5Gr 0.85R 0.5P
6 JR01
JOINT 16 JR01
Distribution JOINT
See Passenger CONNECTOR
(SD1303) PHOTO 78 Compartment
8 1 JR01 (SD1202)
18 JR01
1.25B 0.85B 0.5P
2 4 6 5 1 3 R07
SUNROOF
6 FR11 Ground Open Tilt Up Close/Tilt Down Battery ON Input CONTROL
PHOTO 42 Power MODULE
1 5 10 4 6 3 R14
PHOTO
SUNROOF 78
HALL MOTOR
1.25B
SENSOR PHOTO
AUTHORIZATION USER POWER 78
SIGNAL SWITCHES INPUTS ASIC MOTOR CONTROL
GF11 PHOTO 42
2012 > D 2.0 TCID > Sunroof > Schematic Diagrams
Sunroof (2) SD8162
R07 R14 R16
2 1 10
* * * 6 2 1 BLANK
6 5 4 3
5 4 3
* 1
6 5 4 3
2012 > D 2.0 TCID > Supplemental Restraint System(SRS) > Schematic Diagrams
Supplemental Restraint System (SRS) (1) SD5691
HOT IN ON OR START
See Power I/P
LHD (SD11010) BOX
A/BAG PHOTO
STEERING A/BAG 45
DRIVER 15A IND
WHEEL 10A
AIR
BAG See Passenger
Compartment
Fuse Details 4 I/PB
(SD1201)
0.3R/O
14 M01C
AIR INSTRUMENT
PASSENGER MULTIFUNCTION BAG CLUSTER
AIR BAG CLOCK SWITCH PHOTO 49
ON/OFF SPRING PHOTO 50
PAD SWITCH
Ground Switch
PHOTO
2 72
1 M84 13 M01C
2 1 M81 0.3Y
8 I/PD
0.5B 0.5R 0.5L/B 0.5Y/O
5 7 I/PE
0.5P 0.3W
24 5 6 13 1 M82A
PAD High Low ON/START Air Bag SRS
Switch Input IND. CONTROL
MODULE
PAD PHOTO
Ground Low High High Low IND. Crash Output KLine 67
2 20 21 23 22 18 17 14 M82A
0.5B 0.5O 0.5Y/O 0.5G 0.5L 0.5Y 0.3W 0.3G
9 12 10 11 1 6 8 I/PE
11 19 20 21 I/PG 7 3 4 I/PD
0.5O 0.5Y 0.5G 0.5L 0.5Y 0.3G
0.5B 0.5Y 0.5G 0.3L 0.3L 0.3G 0.3L

14 13 11 12 EE12 Auto
PHOTO 1 A/C
0.5O 0.5Y 0.5G 0.5L
2 1 E17 1 2 E73 22 M62 1 M04A 14 M04C 6 M05A 13 M10

PASSENGER DRIVER MULTI BCM A/C DATA LINK
FRONT FRONT DISPLAY PHOTO CONTROL CONNECTOR
IMPACT IMPACT PHOTO 57 MODULE
GM51 GE11 PHOTO 48
SENSOR SENSOR 59 PHOTO
PHOTO 119 PHOTO 1 59
PHOTO 2 PHOTO 2
HOT IN ON OR START
See Power I/P
RHD (SD11010) BOX
A/BAG PHOTO
STEERING A/BAG 45
DRIVER 15A IND
WHEEL 10A
AIR
BAG See Passenger
Compartment
Fuse Details 4 I/PB
(SD1201)
0.3R/O
14 M01C
AIR INSTRUMENT
PASSENGER MULTIFUNCTION BAG CLUSTER
AIR BAG CLOCK SWITCH PHOTO 49
ON/OFF SPRING PHOTO 50
PAD SWITCH
Ground Switch
PHOTO
2 72
1 M84 13 M01C
2 1 M81 0.3Y
8 I/PD
0.5B 0.5R 0.5L/B 0.5Y/O
5 7 I/PE
0.5P 0.3W
24 5 6 13 1 M82A
PAD High Low ON/START Air Bag SRS
Switch Input IND. CONTROL
MODULE
PAD PHOTO
Ground Low High High Low IND. Crash Output KLine 67
2 22 23 21 20 18 17 14 M82A
0.5B 0.5L 0.5G 0.5Y/O 0.5O 0.5Y 0.3W 0.3G
9 12 10 11 1 6 8 I/PE
11 19 20 21 I/PG 7 3 4 I/PD
0.5O 0.5Y 0.5G 0.5L 0.5Y 0.3G
0.5B 0.5Y 0.5G 0.3L 0.3L 0.3G 0.3L

14 13 11 12 EE12 Auto
PHOTO 1 A/C
0.5O 0.5Y 0.5G 0.5L
2 1 E17 1 2 E73 22 M62 1 M04A 14 M04C 6 M05A 13 M10

PASSENGER DRIVER MULTI BCM A/C DATA LINK
FRONT FRONT DISPLAY PHOTO CONTROL CONNECTOR
IMPACT IMPACT PHOTO 57 MODULE
GM51 GE11 PHOTO 48
SENSOR SENSOR 59 PHOTO
PHOTO 119 PHOTO 1 59
PHOTO 2 PHOTO 2
COMMON
PASSENGER DRIVER PASSENGER DRIVER P AS S ENGER
AIR BAG SIDE SIDE CURTAIN CURTAIN
PHOTO 68 AIR BAG AIR BAG AIR BAG AIR BAG
1 2 M83 2 1 F53 1 2 F59 2 1 F52 1 2 F58
0.5L 0.5Y 0.5O/B 0.5P/B 0.5W/B 0.5Gr 0.5G/R 0.5Y 0.5L 0.5Br
4 3 M82A 16 15 14 13 9 10 11 12 F82B
High Low Low High High Low Low High High Low SRS
CONTROL
MODULE
PHOTO
67
High Low Low High Low High Low High
27 28 26 25 4 3 1 2 F82B
0.5B/O 0.5G 0.5O 0.5L 0.5Y 0.5R 0.5Br 0.5G
1 2 F54 2 1 F55 2 1 F51 2 1 F57

DRIVER P AS S ENGER DRIVER P AS S ENGER
LO HI S EAT BELT LO HI
S IDE IMP ACT S IDE IMP ACT S EAT BELT
S ENS OR S ENS OR P RETENS IONER P RETENS IONER
E17 E73 F51 F52
2 1 2 1
2 1 2 1
F53 F54 F55 F57
2 1
2 1 2 1 2 1
F58 F59 F82B M01C
2 1
****4 3 21
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
2 1
* * * * 28 27 26 25 * * * * * * * * 16 15 14 13 12 11 10 9
M04A M04C M05A
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3
* 1 13
* * 10 9 8 7 6
** * 2 1
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21 16 15 14 13 12 11 10 9
26 25 24 23 22 21 20 19 18 17 16
* 14
M10 M62 M81 M82A
* * * * * * 6 5 4 3 2 1
* 157 6 135 124 113 2 1
9
12 11 10 9 8
* * 5 4
* 2 1
* * * 24 23 22 21 20 19 18 17 16 15
* 13 24 23 22 21 20
* 18 17
* * 14 13
* * 2 1
M83 M84
2 1
BLANK BLANK
2 1
* *
2012 > D 2.0 TCID > Switch Module System > Schematic Diagrams
Switch Module System (1) SD9341
See Power Distribution See Power Distribution I/P
(SD11010) (SD11010) JUNCTION
BOX
PHOTO
RR T/SIG 45
P/OUTLET 10A
15A
See Passenger
(SD1204)
14 I/PD 3 I/PA
0.85R 0.5R/O
See Charging System See Vehicle
(SD3731) (SD3732) Speed System See BCM System See Turn & Hazard Lamps
2 M68 (SD3733) (SD3734) (SD4361) (SD9523) (SD9251) See Illuminations
(SD3735) (SD3736) (SD4362) (SD9411)
B+ SOUND
RELAY
PHOTO
Signal 4
1 M68
0.5Gr 0.3W/B(W/O ISG) 0.5R/O 0.3L 0.3O 0.3L 0.3G 0.5L 0.5Y/O 0.5Y/O 0.5O 0.3G 0.3P
0.3W(With ISG)
3 M61B 7 5 6 24 12 11 23 15 16 M61A 2 1 M61B 3 17 M61A
B+ Sound Relay ALTL IG1 Speed CTR LH RH M_F RH M_F LH Turn Signal Turn Signal PKE DR SWITCH
Signal Sensor Lamp LH Lamp RH Lock/Unlock MODULE
CTR DR
LOCK Rear SBR IND. Flasher MICOM PHOTO
ILL. 59
S/Warmer S/Warmer S/Warmer S/Warmer S/Warmer S/Warmer
ASS SBR CTR DR S/Warmer IND IND IND S/Warmer IND IND IND
IND. Lock IND. SW LH HI LH MID LH LO LH SW RH HI RH MID RH LO RH
4 8 9 18 22 20 21 10 2 13 1 14 19 M61A
0.3Y 0.3B/O 0.3W 0.5B 0.3Y/O 0.3Br 0.3W 0.3Gr 0.3Y 0.3O 0.3L 0.3G 0.3Gr
3 JM04
See Ground JOINT
Distribution CONNECTOR See Illuminations
(SD1302) PHOTO 68 See Seat Warmer (SD9411)
(SD8891)
1 JM04
20 M04B 15 M04C 35 M04A
ASS SBR CTR DR C/DR Lock/ BCM 1.25B
IND. Lock Unlock PHOTO
IND. Switch 57
GM41 PHOTO 120
2012 > D 2.0 TCID > Switch Module System > Schematic Diagrams
Switch Module System (2) SD9342
M04A M04B M04C
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1 10
* * * 6 5 4 3 2 1 8 7 6 5 4 3
* 1
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21
20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
M61A M61B M68
1 BLANK
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 3 2 1 * 2
2012 > D 2.0 TCID > Tail, Parking & License lamps > Schematic Diagrams
Tail, Parking & License Lamps (1) SD9281
HOT AT ALL TIMES
E/R
FUSE &
RELAY
B+ 1 BOX
50A
5.0W
2 I/PH
I/P
(SD11010) BOX
TAIL
LAMP PHOTO
RELAY 45
To TAIL LH
A 10A
(SD9282)
6 I/PD
TAIL RH
0.3L 10A
4 M04C
See Passenger
Tail Lamp BCM Compartment Fuse Details
Relay Control PHOTO (SD1206)
57
6 I/PF 10 I/PC
Tail Lamp 5DR/3DR WGN
Switch Input 0.5R/O 0.5P
28 M04A See Stop Lamps 0.5Br/O 9 M01A
5DR 3DR (SD9273)
0.3L INSTRUMENT 27 MC11
See DRL CLUSTER PHOTO 75
(Daytime Running Lights) PHOTO 49
0.3L (SD9581) 0.5Br/O 0.5Br/O 0.5W 0.5W/O TAIL
LAMP
1 M02L 5 1 F10 2 F32 With 3DR W/O 3DR
MULTI REAR 0.5Br/O REAR 0.5P 0.5P
LIGHT FUNCTION COMBI COMBI
SWITCH TAIL STOP NATION TAIL NATION CGG96 (G4FA/G4FC) CGG75 (G4FA/G4FC)
PARK HEAD SWITCH
PHOTO LAMP LAMP CBG96 (G4GC) CBG75 (G4GC)
RH RH(UP) 1 M01A CUD96 (D4FB) CUD75 (D4FB)
50 4 F49 2 5 F09
6 CDD96 (D4EA) 6 CDD75 (D4EA)
OFF AUTO 3 F10 F32 PHOTO
REAR REAR 1 74 HEAD HEAD
COMBI PHOTO 111 COMBI
TAIL NATION STOP TAIL NATION 0.5B PAR LAMP PAR LAMP
LAMP RH LAMP KING RH KING RH
2 M02L PHOTO PHOTO
(5DR) RH(LOW) 10 JM02 6 6
0.3B 6 F49 PHOTO 89 JOINT 5 CGG96 (G4FA/G4FC) 5 CGG75 (G4FA/G4FC)
3 F09 See Ground
2 JM02 CONNEC CBG96 (G4GC) CBG75 (G4GC)
0.85B PHOTO 74 Distribution TOR
JOINT 0.85B 0.85B 0.5B (SD1301) 1.25B CUD96 (D4FB) 1.25B CUD75 (D4FB)
See Ground CONNEC See Ground See Ground CDD96 (D4EA) CDD75 (D4EA)
Distribution TOR Distribution Distribution 6 JM02
(SD1301) (SD1304) (SD1304)
PHOTO 0.85B 0.85B 0.85B PHOTO 47
1 JM02 47 1.25B
1.25B
GGG15 (G4FA/G4FC)
GBG15 (G4GC)
PHOTO PHOTO GUD14 (D4FB) PHOTO
GM21 PHOTO 46 GF61 89/111 GM21 46 GDD14 (D4EA) 69
I/P
From Tail JUNCTION
Lamp Relay A BOX
(SD9281) PHOTO
TAIL LH 45
10A
15 I/PG 22 I/PF
0.5Y
8 JF01
JOINT
CONNECTOR
PHOTO 43
9 10 JF01
With 3DR W/O 3DR 5DR/3DR WGN 3DR 5DR/WGN
See Front Fog & 0.5Y
5DR 3DR See Stop Lamp
(SD9273) 0.5Y Rear Fog Lamps
(SD9242) 3 FR12
PHOTO
0.5G/O 0.5G/O 0.5Y 0.5Y 0.5W 0.5W 0.5Y 0.5W/B 0.5Y 0.5Y 66/88
2 1 F25
6 E111 4 F50 2 5 F07
LICENSE
HEAD REAR REAR REAR LICENSE LAMP &
LAMP COMBI COMBI FOG LAMP REAR
LAMP 6 RR11
PARKING LH TAIL NATION STOP TAIL NATION FOG
LH RH LAMP PHOTO
(3RD) LAMP LH LAMP 61/97
(5DR) LH(LOW) PHOTO
5 E111 PHOTO 3 95
6 F50 3 F07
PHOTO 88 PHOTO 73 0.5Y
3 F25
6 E77 5 1 F08 2 F31 3 R26
HEAD REAR REAR LICENSE
LAMP COMBI COMBINATION LAMP
PARKING LH TAIL STOP NATION TAIL LAMP LH PHOTO
LAMP (UP) LH RH 61/97
LH PHOTO 73
5 E77 PHOTO 3
3 F08 1 F31
PHOTO 66 2 R26
1.25B 1.25B 0.85B 0.85B 0.85B 0.5B 0.5B 0.5B
3DR
PHOTO PHOTO PHOTO

GE11 PHOTO 1 GF51 66/88 GF61 89/111 GR11 61/97
3 2 1 3 2 1 3 2 1 3 2 1
6 5 4 6 5 4 6 5 4 6 5 4
3 2 1 3 2 1 3 2 1 3 2 1
6 5 4 6 5 4 6 5 4 6 5 4
E77 E111 F07 F08
3 2 1 3 2 1 2 1
6 5 4 6 5 4 * 2
3 4 5 6 6 5
* 3
F09 F10 F25 F31
2 1
* 2
3 2 1 1 2
3 4 5 6 6 5
* 3
F32 F49 F50 M02L
1 2 1 2
1 2
3 4
* 6 3 4
* 6
13 12 11 10 9
* 7 6 5 4 3 2 1
M04A M04C R26
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3
* 1
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21
16 15 14 13 12 11 10 9
* 2 3
2012 > D 2.0 TCID > Tire Pressure Monitoring System (TPMS) > Schematic Diagrams
Tire Pressure Monitoring System (TPMS) (1) SD9561
(SD11010) JUNCTION
BOX
POWER PHOTO
CONNECTOR 45
ROOM LP CLUSTER
15A 10A
See Passenger 0.5W 0.5Y
Compartment 13 3 JM01 8 18 JM03
Fuse Details
(SD1201) See Data JOINT See Data JOINT
Link Details CONNECTOR Link Details CONNECTOR
13 1 3 I/PC (SD2001) PHOTO 4 (SD2001) PHOTO 54
0.5R 0.3R 0.3R/O 12 2 JM01 10 20 JM03
0.3R/O 0.5Y 0.5W 0.5W 0.5Y
7 M01C 2 3 M01A 11 20 JM04
INSTRUMENT See Data JOINT
CLUSTER Link Details CONNECTOR
PHOTO 49 (SD2003) PHOTO 68
TPMS
TREAD 12 19 JM04
TPMS
1 JM03
JOINT
! TPMS CAN TRANSCEIVER 0.5W 0.5Y
See Passenger CONNECTOR
Compartment 15 14 MC21
0.5L (SD1203) PHOTO
0.5W 0.5Y 57
Tread TPMS Low High
IND. IND.
CAN 0.3W 0.3Y
MIC OM See Data
Link Details
(SD2003)
3 18 5 6 M46
Battery ON/START High Low TIRE
Voltage Input PRESSURE
CAN MONITORING
MODULE
GND. VABT LIN Ground PHOTO 58
1 7 8 9 M46
0.5B/O 0.5Y 0.5W 0.5B
0.5W 0.5Y 0.5B/O 0.5B/O 0.5Y 0.5W 0.5B/O 0.5Y 0.5W

4 JM04
4 3 5 MC21 31 29 30 EM31 17 4 7 MF22
See Ground JOINT
PHOTO 57 PHOTO 43 PHOTO 75 CONNECTOR
0.5W 0.5Y 0.5B/O 0.5B/O 0.5Y 0.5W 0.5B/O 0.5Y 0.5W Distribution
CGG66 (G4FA/G4FC) (SD1302) PHOTO 68
CBG66 (G4GC)
0.5B/O 0.5B/O CUD66 (D4FB) 0.5B/O 0.5B/O 0.5B/O 0.5B/O 1 JM04
2 1 3 5 CDD66 (D4EA) 4 3 1 2 E110 3 6 1 2 F39
1.25B
LIN VABT GND CODE FRONT CODE GND VABT LIN FRONT GND CODE TPMS
VABT LIN REAR
TPMS TPMS LFI FR TPMS
INITIATOR INITIATOR PHOTO INITIATOR
RH LH 37 RH
GM41 PHOTO 120
2012 > D 2.0 TCID > Tire Pressure Monitoring System (TPMS) > Schematic Diagrams
Tire Pressure Monitoring System (TPMS) (2) SD9562
* 5
* 3 2 1
* 5
* 3 2 1
* 5
* 3 2 1
* 5
* 3 2 1
E110 F39 M01A M01C
6 5 4 3 2 1 8 7 6 5 4 3 2 1
* * 4 3 2 1 6
* * 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
M46
BLANK BLANK BLANK

* 9 188 7 6 5 * 3 * 1
** ** ** ** *
2012 > D 2.0 TCID > Turn & Hazard Lamps > Schematic Diagrams
Turn & Hazard Lamps (1) SD9251
See Power Distribution I/P See Power Distribution I/P
(SD11010) JUNCTION (SD11010) JUNCTION
BOX BOX
RR PHOTO PHOTO
P/OUTLET 45 T/SIG 45
15A SOUND BCM 10A
RELAY PHOTO
See Passenger
Compartment Fuse Details PHOTO 57
(SD1204) B+ Signal 4
See Illuminations 3 I/PA
(SD9411) 14 I/PD 2 1 M68 9 M04C
0.3R/O 0.5Gr
0.3P 0.85R 0.3G 0.5R/O
17 M61A 3 M61B 7 3 6 M61A
B+ Sound Relay RKE Door IG1 SWITCH

Signal Lock/Unlock MODULE
Flasher Micom
PHOTO
ILL. 59
M_F M_F Turn Signal Turn Signal
LH RH Lamp LH Lamp RH
19 16 15 M61A 2 1 M61B
0.3Gr 0.5Y/O 0.5L 0.5Y/O 0.5O
9 I/PB 16 I/PC
See Illuminations
(SD9411) To Lamp LH To Lamp RH
(SD9252) A B (SD9252)
22 I/PB 6 11 I/PF
0.5Y/O 0.5L With O/S Mirror,

S/Repeater
10 9 M01B 3DR/WGN 5RD
11 13 M02L
INSTRUMENT
MULTI CLUSTER 0.5L
3DR WGN
FUNCTION PHOTO 49 6 FD22
TURN SWITCH LEFT RIGHT PHOTO 41
LAMP TURN TURN 0.5L 0.5L 0.5L 0.5L
LEFT RIGHT PHOTO 50
SWITCH
5 D30 2 F10 4 F09 1 F49
PASSEN REAR REAR REAR
GER COMBI COMBI COMBI
12 M02L TURN POWER TURN NATION TURN NATION TURN NATION
1 M01A LAMP OUTSIDE LAMP LAMP LAMP LAMP LAMP LAMP
0.5B 0.5B MIRROR RH RH(LOW) RH(5DR)
PHOTO 3 F10 PHOTO PHOTO 6 F49 PHOTO
8 10 JM02 2 D30 82 111 3 F09 74 89
See Ground JOINT 0.5B

CONNECTOR 0.85B 0.85B 0.85B
Distribution 11 FD22
(SD1301) PHOTO 47 See Ground See Ground
PHOTO 41 Distribution Distribution
6 JM02 (SD1304) (SD1304)
0.5B 0.85B 0.85B 0.85B
1.25B
GF21 (LHD) PHOTO PHOTO

GM21 PHOTO 46 GF11 (RHD) 42/63 GF61 89/111
I/P
From Switch From Switch JUNCTION
A Module(T/S Lamp LH) B Module(T/S Lamp RH) BOX
(SD9251) (SD9251) PHOTO 45
6 I/PG 26 I/PF 18 I/PC
0.5L
25 MC11
PHOTO 75
3DR/WGN 5RD
0.5L
3DR WGN W/O
With W/O W/O With O/S Mirror,
3DR 3DR O/S Mirror, O/S Mirror, With 3DR W/O 3DR S/Repeater
S/Repeater S/Repeater
0.5Y/O 0.5Y/O 0.5Y/O 0.5Y/O 0.5Y/O 0.5Y/O 0.5Y/O 0.5L 0.5L CGG75 (G4FA/G4FC)
CBG75 (G4GC)
1 E81 CUD75 (D4FB)
1 E111 2 F08 1 F50 1 CDD75 (D4EA)
HEAD SIDE REAR REAR HEAD
LAMP REPEATER COMBI COMBI LAMP RH
TURN LH LAMP LH TURN NATION TURN NATION TURN
LAMP (3DR) 2 E81 LAMP LAMP LAMP LAMP LAMP PHOTO
6
PHOTO LH LH(5DR)
40 PHOTO
4 E111 PHOTO 16 FD12 3 F08 PHOTO 6 F50 4 CGG75 (G4FA/G4FC)
3 66 88 CBG75 (G4GC)
PHOTO 41 CUD75 (D4FB)
0.5Y/O CGG96 (G4FA/G4FC) CDD75 (D4EA)
CBG96 (G4GC) CGG65 (G4FA/G4FC)
CUD96 (D4FB) CBG65 (G4GC)
1 E77 5 D10 4 F07 1 CDD96 (D4EA) CUD65 (D4FB)
HEAD DRIVER REAR 1 CDD65 (D4EA)
HEAD
LAMP POWER COMBI LAMP RH SIDE
TURN LH TURN OUTSIDE TURN NATION TURN (3DR) REPEATER
LAMP LAMP MIRROR LAMP LAMP LAMP LAMP RH
PHOTO
PHOTO LH(LOW) 6 2 CGG65 (G4FA/G4FC)
4 E77 PHOTO 2 D10 81 PHOTO 4 CGG96 (G4FA/G4FC) CBG65 (G4GC)
3 F07
3 73 CBG96 (G4GC) CUD65 (D4FB)
CUD96 (D4FB) CDD65 (D4EA)
0.5B CDD96 (D4EA) PHOTO 40
6 JD01
See Ground JOINT
(SD1303) PHOTO 81
1 JD01
0.85B 0.85B
1.25B 1.25B 0.5B 2.0B 0.85B 1.25B 1.25B 0.85B
GGG15 (G4FA/G4FC)
GE11 PHOTO 1 GF11 (LHD) PHOTO GF51 PHOTO GBG15 (G4GC)
GF21 (RHD) 42/63 88/66 GUD14 (D4FB) PHOTO
GDD14 (D4EA) 69
CBG65 CBG75 CBG96 CDD65
3 2 1 3 2 1
2 1 2 1
6 5 4 6 5 4
CDD75 CDD96 CGG65 CGG75
3 2 1 3 2 1 3 2 1
2 1
6 5 4 6 5 4 6 5 4
CGG96 CUD65 CUD75 CUD96
3 2 1 3 2 1 3 2 1
2 1
6 5 4 6 5 4 6 5 4
D10 D30 E77 E81
3 2 1
4 3 2 1 4 3 2 1 2 1
6 5 4
8 7 6 5 8 7 6 5
E111 F07 F08 F09
3 2 1 2 1
6 5 4
* 2
* 2
3 4 5 6 6 5
* 3 3 4 5 6
F10 F49 F50 M01B
2 1 1 2 1 2
3 4
* 6 3 4
* 6 6 5 4
* 2 1
6 5
* 3
12 11 10 9 8 7
M02L M04C M61A M61B
8 7 6 5 4 3 1
13 12 11 10 9
* 7 6 5 4 3 2 1 * 12 11 10 9 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 16 15 14 13 3 2 1
2012 > D 2.0 TCID > Vehicle Speed System > Schematic Diagrams
Vehicle Speed System (1) SD4361
HOT IN ON OR START
See Power E/R
FUSE &
G4FA/G4FC, G4GC
Distribution
(SD1109) RELAY
BOX
SNSR
10A
ECM(M/T)/
Vehicle Vehicle PCM(A/T)
Speed Speed PHOTO
1.25R Output Input 36/37
53 CGGA (G4FC, A/T, With ETC) 39 CGGK (G4FA/G4FC, With ETC)

49 CGGAK (G4FC, A/T, W/O ETC) 64 CGGMK (G4FA/G4FC, M/T, W/O ETC)
53 CBGA (G4GC) 20 CGGAK (G4FA/G4FC, A/T, W/O ETC)
33 EC11 53 CBGK (G4GC)
PHOTO
115
0.5R 0.5Gr ATM KEY AUDIO MULTI INSTRU
LOCK PHOTO DISPLAY MENT
CONTROL PHOTO 48
60 PHOTO CLUSTER
MODULE DATA LINK PHOTO
CGG52 (G4FA/G4FC) 59
PHOTO CONNECTOR 49
2 CBG52 (G4GC)
VEHICLE 13 M12 63 1 M54A 6 M10 13 M62 1 M01C
SPEED
SENSOR
+ PHOTO 0.3L/O 0.3Gr/O 0.3Gr/O 0.3L 0.3Gr/O
35
HALL IC A/T
_
14 15 JM02
JOINT
CONNECTOR
1 3 CGG52 (G4FA/G4FC) PHOTO 47
CBG52 (G4GC)
0.5Gr
16 17 JM02
M/T A/T Except For

Euro II Euro II
0.3Gr/O 0.3L 0.3L
11 MC11
ABS ESP PHOTO
0.5Gr
75
0.5B 0.5Gr 0.5Gr 0.5O 0.5O
G4GC
CGG41 (G4FA/G4FC) CGG70 (G4FA/G4FC) 30 M04A 24 M61A
6 CBG59 27 CBG41 (G4GC) 27 CBG70 (G4GC)
BCM SWITCH
AUTO ABS ESP MODULE
CRUISE CONTROL CONTROL PHOTO
CONTROL MODULE MODULE 57 PHOTO
MODULE 59
PHOTO PHOTO
GGG11 (G4FA/G4FC) PHOTO PHOTO 9 13 13
GBG11 (G4GC) 36/37
HOT IN ON OR START
See Power E/R D4FB/D4EA
Distribution FUSE &
(SD1109) RELAY
BOX
SNSR
10A INSTRUMENT MULTI AUDIO SWITCH BCM
CLUSTER DISPLAY PHOTO 48 PHOTO MODULE PHOTO 57
PHOTO 49 PHOTO 58 60 PHOTO
DATA LINK 59
CONNECTOR
1 M01C 13 M62 6 M10 1 M54A 24 M61A 30 M04A
1.25R 0.3Gr/O 0.3L 0.3Gr/O 0.3Gr/O 0.3L 0.3L

33 EC11
PHOTO 115
0.5R
2 CUD52 (D4FB)
1 CDD52 (D4EA)
VEHICLE
SPEED
SENSOR
15 14 17 JM02
+ PHOTO
35/106 JOINT
HALL IC CONNECTOR
_ PHOTO 47
16 JM02
1 3 CUD52 (D4FB)
2 3 CDD52 (D4EA)
R
TCM
Vehicle PHOTO
Speed 110
Output
53 CUDAT
0.5B 0.5G 0.5Gr 0.3Gr/O 0.3L/O
M/T A/T
0.5Gr
19 CUDK(D4FB) 11 MC11
75 CDDK(D4EA) 13 M12
PHOTO 75
ATM KEY
Vehicle ECM LOCK
Speed PHOTO CONTROL
GUD21 (D4FB) PHOTO Input 38 MODULE
GDD21 (D4EA) 38 PHOTO 63
CBGA CBGK
* * 58 57 56 55 3954 3853 52 * 5035 3449 48 * 46 94 93 92

*90 89 88 87
* * * * 82 81 80 5779 78 77 * 5375 74 73 6 5
* ***** ** *** ** * 70 69 67 66 65 64
** **** *** * * 4 3
*15 14* * 12* 11* 10* *9 *8 *7 *6 20 194 18 172 161 * 4927 26* 4725 * 23* 22* 21* 42 41 1840 1739 3816 1537 14* 1*3 12* * 10* *9 *8 297 2 1
* * *
28
* ** *
CBG41 CBG52 CBG59
13 * * 22* * 20* 19* 186 17* * * 14* 1 2 1

** * ** 6 5 4 3 2 1
38
* * * 34 33 32 31 30 * * 27 26 25 3 * 11 10
9 8 7
CBG70 CDDK
12
***** 6 5 * 3 * 1
94 93 92
*90 89
* 87 86 * 84 83 * * 80 79 * 77 * 75 * * 6 5
13
* * 22 * 20 19 18 17 16 * 14
72 71 70 69 68
* * 65 64 * * * * * * 57 * * * * * 51 4 3
* * * 4725 2446 45 4422 * * 19* 40 * 1638 3715 1436 1335 1234 1133 1032 319 308 297 2 1
38
* * * 34 33 32 31 30 * * 27 26 25 28
** * ** **
CDD52 CGGA
60 59 58 57
* 55 54 53 * * 50 49 * 47 46
2 1 45
* * * * * 39 * * * * * * 32 * BLANK
3 30
* * * * * * * * * * * 18 17 16
* 14 13 12 11 * 9 8 7 6 * * * 2 1
CGGAK CGGMK
94 93
*
91 90 89 88
* 86 * * 8361 6082 * 80 5779 * 77 * 75 * 7351 6 5
94 93 92 91 90
* 66* 87 8664 6385 6284 8361 6082 8159 80 * * 77 54* * * 7351 6 *
72 71 70
*
68 67 66
**** ** ***** 72 71 70 69 68
* * ** * * * *
4 3
* 3
* 4927 26* 25* 24* * 22* * 20* 41 * 17* 38 * * 3513 * * 1032 319 308 * 2 1
28 27 26 25 24 23 22 21 * 19 18 17 16 15
50 49 48 47 46 45 44 43 41 40 39 38
* 36 3513 12* 3311 32 319 * 297 2 1
* * * * * *** ** * * * * *
CGGK CGG41
94
* 92 91 90 89 88 87 86 85 * 83 * 81 80 79 78 77 76 75 74 73 6 5
* * 22* * 20* 19* 186 17* * * 14* 1
* 71 70 69 68 67 66 65 * 63 62 61 * 59 58 57 56 * 54 53 52 51 4 3
13
** * **
50 49
* 25* 24* 23* 4422 4321 4220 4119 4018 3917 38 15* 36 3513 3412 3311 32 319 308 297 2 1
28 27 26
* * * 38
* * * 34 33 32 31 30 * * 27 26 25
CGG70 CGG52 / CUD52
13
12
***** 6 5 * 3 * 1 2 1 BLANK
* * 22 * 20 19 18 17 16 * 14
3
38
* * * 34 33 32 31 30 * * 27 26 25
CUDAT CUDK
6 7 8 9 10 5 4
* 12 * 14 * * 36* 18
37
19 20 21 22 23 24
94 93 92
*
90 89
*
87 86 85 84 83
* * 7856 7755 76 5375 52* 5173
81 80
6 5
* * * * * * * * * * * * * * * * * 3
72 71 70 69 68 67 66
*
64 63 62 61 60 59 58
* * 4 3
44
* * * * * * * * 53 * * * * 58 59 * 61 62
50
* 26* 47 2446 * 4422 * 20* 1941 40 17* 38 15* 14* 1335 12* 1133 1032 *9 30 *7 2 1
28 27
* * * * * *
* * * * * * * * * * * 74 * * * 78 * * * 2 1
M01C M04A M10
8 7 6 5 4 3 2 1
* 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12
* 10 9 8 7 6 5 4 3 2 1
* 15 * 13 12 11 * 9
16 15 14 13 12 11 10 9
* 39 38 37 36 35 34 33 32 31 30 29 28
* 26 25 24 23 22 21
M12 M54A M61A M62
5 4 2 1 4 3 2 1
* * 12 11 10 9 8 7 6 5 4 3 2 1
* 13
* 11 10
* 8 7 8 7 6 5
12 11 10 9 8
* * 5 4
* 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15
* 13
2012 > D 2.0 TCID > Steering System > General Information > Specifications English
GENERAL
SPECIFICATIONS
Items Specification
Type Electric Power Steering (Columnassist type)
2.69 turns and over
Steering wheel rotation (Lock to lock)
Vehicles with D2.0 Engine or 225 tire (2.58 turns and over)
Type Rack & Pinion
Steering gear 140mm (5.51in.)
Rack stroke
Vehicles with D2.0 Engine or 225 tire (134mm (5.28in.))
SERVICE STANDARD
Steering wheel free play 30mm (1.18in.) and below
Tierod end starting torque 30kgf.cm (2.96Nm, 2.18lbft) and below
TIGHTENING TORQUE
Tightening torque
Items
Nm kgf.m lbft
Hub nuts 90 ~ 110 9.0 ~ 11.0 65 ~ 80
Steering wheel lock nut 40 ~ 50 4.0 ~ 5.0 29 ~ 36
Steering column mounting bolts and nuts 13 ~ 18 1.3 ~ 1.8 9.4 ~ 13.0
Bolt connecting universal joint to pinion 30 ~ 35 3.0 ~ 3.5 22 ~ 25
Bolt connecting steering column to universal joint 30 ~ 35 3.0 ~ 3.5 22 ~ 25
Tierod end castle nut 24 ~ 34 2.4 ~ 3.4 17 ~ 25
Lower arm ball joint bolts 100 ~ 120 10.0 ~ 12.0 72 ~ 87
Steering gear box mounting bolts 60 ~ 80 6.0 ~ 8.0 43 ~ 58
Stabilizer link nut 100 ~ 120 10.0 ~ 12.0 72 ~ 87
Front and Rear roll stopper bolt & nut 50 ~ 65 5.0 ~ 6.5 36 ~ 47
Rear roll stopper mounting bolts 50 ~ 65 5.0 ~ 6.5 36 ~ 47
Sub frame stay mounting bolts & nuts 45 ~ 55 4.5 ~ 5.5 33 ~ 40
Sub frame mounting bolts & nuts 160~ 180 16.0 ~ 18.0 116 ~ 130
2012 > D 2.0 TCID > Steering System > General Information > Special Service Tools English
SPECIAL TOOLS
Tool (Number and Name) Illustration USE
0956111001
Removal of the steering wheel
Steering wheel puller
0956834000
Removal of the tie rod end ball joint
Ball joint puller
2012 > D 2.0 TCID > Steering System > Electric Power Steering > Schematic Diagrams English
SCHEMATIC DIAGRAMS
MDPS Circuit Diagram
Harness Connector
English
Connector Pin no Pin name

1 Battery +
Battery
2 Battery
1 Igntion
2
3
4
Vehicle signal
5
6
7 CAN_High
8 CAN_Low
2012 > D 2.0 TCID > Steering System > Electric Power Steering > Description and Operation English
DESCRIPTION
EPS (Electric power steering, Column assist type) system uses an electric motor to assist the steering force and it is an engine operation
independent steering system.
EPS control module controls the motor operation according to information received from the each sensor and CAN (Controller Area
Network), resulting in a more precise and timely control of steering assist than conventional enginedriven hydraulic systems.
Components (Steering Angle Sensor, Torque Sensor, Failsafe relay, etc.) of the EPS system are located inside the steering column &
EPS unit assembly and the steering column & EPS unit assembly must not be disassemble to inspect or replace them.
NOTES WITH REGARD TO DIAGNOSIS
Trouble Check
Trouble symtom Explanation Note
factor item
Drop, Motor Abnormal noise – Visable or unvisable damage – Do not use the impacted EPS.
impact, and can occur.
overload ECU Circuit damage – Do not overload each parts.
The steering wheel could pull to
– Wrong welding one side by using the dropped
point parts.
– Broken PCB – Precise parts of motor/ECU are
– Damaged precise sensitive to vibration and
parts impact.
– Overload can cause
unexpected damage
Torque – Do not impact the connecting
sensor parts (When inserting and
torquing)
Insufficient steering Overload to INPUT shaft can cause
– Use the specified tool to
effort malfunction of the torque sensor
remove the steering wheel. (Do
not hammer on it)
– Do not use the impacted EPS
Shaft Insufficient steering Do not use the impacted EPS

effort (Uneven between
LH and RH)
Pull/Dent Harness – Malfunction Disconnection between harness Do not overload the harness
impossible power connecting portion and harness
operation
– Malfunction of
EPS
Abnormal Motor/ECU Abnormal steering effort – Waterproof at the normal – Keep the normal temperature

storage by improper operation of condition and proper moisture, while
temperature the motor/ECU storaging
– Even a little moisture can
cause malfunction of the – Avoid drowning
precise parts of the motor/ECU
1. Do not impact the electronic parts, if they are dropped or impacted, replace them with new ones.
2. Avoid heat and moisture to the electronic parts.
3. Do not contact the connect terminal to avoid deformation and static electricity. English
4. Do not impact the motor and torque sensor parts, if they are dropped or impacted, replace them with new ones.
5. The connector should be disconnected or connected with IG OFF.
2012 > D 2.0 TCID > Steering System > Electric Power Steering > Components and Components Location
English
COMPONENTS
2012 > D 2.0 TCID > Steering System > Electric Power Steering > Troubleshooting English
GENERAL INSPECTION
After or before servicing the EPS system, perform the troubleshooting and test procedure as follows. Compare the system condition with
normal condition in the table below and if abnormal symptom is detected, perform necessary remedy and inspection.
Normal condition: Motor must not supply steering assist.
Test condition
Perform the ASP calibration using a scan
Motor supplies ASP is not calibrated.
IG Off tool.
steering assist.
IG power supplies Inspect the IG power supply line.
Normal condition: Motor must not supply steering assist, Warning lamp is illuminated.
Test condition
Perform the ASP calibration using a scan
Motor supplies ASP is not calibrated.
tool.
steering assist.
IG On/Engine Off EMS CAN signal is not received. Inspect the CAN line.
Warning lamp is
Cluster fault Inspect the cluster and cluster harness
not illuminated.
Normal condition: Motor supplies steering assist, Warning lamp is not illuminated.
Test condition
Warning lamp is EPS (Hot at all times) and IG power supply Inspect the connector and harness for EPS
illuminated and fault (Hot at all times) and IG power supply line.
Motor dose not
supply steering Perform the self test using a scan tool and
DTC is detected by system.
assist. repair or replace.
IG On/Engine On
Warning lamp is Perform the ASP calibration using a scan
ASP is not calibrated.
illuminated and tool.
Motor supplies CAN communication between EPS and
steering assist. Inspect the CAN line.
cluster is fault.
ASP: Absolute Steering Position
CAN: Controller Area Network
EMS: Engine Management System

The following symptoms may be occurred during normal vehicle operation and if there is no EPS warning light
illumination, it is not malfunction of EPS system.
• After turning the ignition switch on, the steering wheel becomes heavier while it performs EPS system diagnostics,
for about 2 seconds, then it becomes normal steering condition.
• After turning the ignition switch on or off, EPS relay noise may occur but it is normal.
• When it is steered, while the vehicle is stopped or in low driving speed, motor noise may occur but it is normal
operating one.
Caution when ASP (Absolute Steering Position) calibration or EPS type recognition
• Check if the battery is fully charged before ASP calibration or EPS type recognition. English
• Be careful not to disconnect any cables connected to the vehicle or scan tool during ASP calibration or EPS type
recognition.
• When the ASP calibration or EPS type recognition is completed, turn the ignition switch off and wait for several seconds,
then start the engine to confirm normal operation if the vehicle.
Scan tool (HiScan Pro) installation
1. Attach the CAN interface module to the HiScan Pro main body and securely tighten the two bolts.
2. Install the CAN interface module to the Data Link Cable and securely tighten the two bolts.
ASP calibration procedure
1. Plug DLC cable from a scan tool into the vehicle's data link connector located under the instrument panel on the driver's
side.
2. Turn the ignition switch ON position.
3. Turn the steering wheel so that the front wheel can face straight ahead.
4. Select a model and ELECTRIC POWER STEERING.
5. Select the ASP CALIBRATION and press ENTER.
6. Check the massage on the screen and press ENTER'.
7. Confirm the vehicle condition (IG On) and then turn the steering wheel until massage changes to the next screen.
8. When the massage is displayed on the screen as follows, turn the steering wheel so that the front wheel can face straight
ahead and then press ENTER.
9. When the calibration is completed, the massage will be displayed on the screen as follows.
EPS type recognition procedure
1. Plug DLC cable from a scan tool into the vehicle's data link connector located under the instrument panel on the driver's
side.
2. Turn the ignition switch ON position.
3. Select a model and ELECTRIC POWER STEERING.
4. Select the EPS type recognition and press ENTER.
5. Select the affected area and press ENTER.
6. When the EPS type recognition is completed, the massage will be displayed on the screen as follows.
2012 > D 2.0 TCID > Steering System > Electric Power Steering > Steering Column and Shaft > Repair
English
procedures
REMOVAL
1. Disconnect the battery negative cable from the battery and then wait for 30 seconds.
2. Turn the steering wheel so that the front wheels can face straight ahead.
3. Loosen the torx bolts which are located on the both side of the steering wheel.
4. Disconnect the connector (A) from the airbag module and then remove the airbag module (B) from the steering wheel.
5. Disconnect the remote switch connector (A) and remove the steering wheel lock nut (B) and washer.
6. Remove the steering wheel from the steering column shaft by using a SST (0956111001).

Do not hammer on the steering wheel to remove it; it may damage the steering column & EPS unit.
English
7. Remove the steering column upper (A) and lower (B) shroud.
8. Disconnect the connectors (A) from the lower portion of the clock spring and then remove the clock spring (B) from the
steering column shaft.
9. Remove the multifunction switches (A) from the steering column with the portion indicated by the arrow pressed.
10. Remove the lower side panel (A) and crash pad (B).
11. Remove the reinforce panel (A).
12. Loosen the bolt (A) and then disconnect the universal joint assembly (B) from the pinion of the steering gear box.

Keep the neutralrange to prevent the damage of the clock spring inner cable when you handlethe steering wheel.
13. Disconnect the connectors (A, B, C).
14. Remove the steering column mounting bolts (B).
15. Remove the steering column & EPS unit assembly (C) by loosening the mounting nuts (A).
INSTALLATION

Apply the multipurpose grease to sliding surface of the each part before the installation.
1. Install the steering column & universal joint assembly by tightening the bolts (B) and nuts (A).
Tightening torque Nm (kgf.m, lbft):
13 ~ 18 (1.3 ~ 1.8, 9.4 ~ 13.0)
2. Connect the connectors (A, B, C).
3. Connect the universal joint assembly (B) to pinion of the steering gear box and then tighten the bolt (A).
30 ~ 35 (3.0 ~ 3.5, 22 ~ 25)

Tighten up with bolt after inserting Ujoint to the steering gear pinion shaft firmly.
4. Install the reinforce panel (A).
5. Install the lower crash pad (A) & side panel.
6. Install the multifunction switches (A) to steering column.
7. Install the clock spring (B) to steering column assembly and then connect the connectors (A).

When installing the clock spring, refer the RT group to prevent the damage of clock spring inner cable.
8. Install the steering column upper (A) and lower (B) shroud.
9. Connect the remote switch connector (A).
10. Install the steering wheel to the steering column shaft and then tighten the lock nut (B) and the washer together.
40 ~ 50 (4.0 ~ 5.0, 29 ~ 36)
11. Connect the connector (A) to air bag module and then install the airbag module (B) to steering wheel.
12. Tighten the torx bolts which are located on the both side of the steering wheel.
13. Connect the battery negative cable to the battery.
14. Check and adjust the front wheel alignment.
(Refer to SS group)
15. When the steering column & EPS unit assembly is replaced, perform EPS type recognition procedure using a scan tool.
(Refer to EPS type recognition)
16. Perform the ASP (Absolute Steering Position) calibration procedure. (Refer to ASP calibration)

If the ASP calibration procedure is not performed. EPS warning lamp will be turned on or flicker and vehicle may pull
to the left or the right.
DISASSEMBLY AND REASSEMBLY

Do not disassemble the steering column & EPS unit assembly.
1. Loosen the bolt (A) and then disconnect the universal joint assembly (B) from the steering column assembly.
30 ~ 35 (3.0 ~ 3.5, 22 ~ 25)
2. Make a groove the head of special bolts (A) by a punch.

Do not impact the steering column mounting bracket and EPS unit.
3. Loosen the special bolts by using screw driver and than remove the key lock assembly (B) from the steering column
assembly.
4. Reassembly is the reverse of the disassembly. When reassembling the key lock assembly, install the key lock assembly
to the steering column and then tighten new special bolts until its head (A) is cut off.
INSPECTION
1. Check the steering column for damage and deformation.
2. Check the connection for play, damage and smooth operation.
3. Check the join bearing for damage and wear.
4. Check the tilt bracket for damage and cracks.
5. Check the key lock assembly for proper operation and replace it if necessary.
2012 > D 2.0 TCID > Steering System > Electric Power Steering > Steering Gear box > Components and
English
Components Location
STEERING GEAR BOX
2012 > D 2.0 TCID > Steering System > Electric Power Steering > Steering Gear box > Repair procedures
English
REMOVAL
1. Remove the front wheel & tire.
2. Loosen the bolt (A) and then disconnect the universal joint assembly (B) with the pinion of the steering gear box.

3. Disconnect the stabilizer link (A) from the front strut assembly by loosening the nut.
4. Remove the split pin and castle nut and then disconnect the tie rod end (A) with the knuckle by using a SST (09568
34000).
5. Connect the lower arm with the ball joint and then remove the castle nut and the split pin.
English
6. Remove the muffler rubber hanger (A).
7. Loosen the wiring harness protector bolts (A).
8. Remove the front and rear roll stopper bolt and nut (A, B).
9. Remove the sub frame (E) and sub frame stay by loosening the mounting bolts (A, C) and nuts (B, D).
10. Remove the rear roll stopper (A) from the sub frame by loosening mounting bolts.
11. Remove the steering gear box (A) from the sub frame by loosening the mounting bolts.
INSTALLATION
1. Install the steering gear box (A) to the sub frame by tightening the mounting bolts.
60 ~ 80 (6.0 ~ 8.0, 43 ~ 58)
2. Install the rear roll stopper (A) to the sub frame by tightening the mounting bolts.
50 ~ 65 (5.0 ~ 6.5, 36 ~ 47)
3. Install the sub frame (E) and sub frame stay by tightening the mounting bolts (A, C) and nuts (B, D).
Tightening torque Nm (kgf.m, lbft)
Sub frame mounting bolts (C) and nuts (D):
160 ~ 180 (16.0 ~ 18.0, 116 ~ 130)
Sub frame stay mounting bolt (A) and nut (B):
45 ~ 55 (4.5 ~ 5.5, 33 ~ 40)
4. Tighten the front and rear roll stopper bolt and nut (A, B).
50 ~ 65 (5.0 ~ 6.5, 36 ~ 47)
5. Install the wiring harness protector to the subframe by tightening the bolts (A).
6. Install the muffler rubber hanger (A).
8. Connect the tie rod end with the knuckle and then install the castle nut and split pin.
24 ~ 34 (2.4 ~3.4, 17 ~ 25)
9. Connect the stabilizer link (A) with the front strut assembly and than tighten the nut.
100 ~ 120 (10.0 ~ 12.0, 72 ~ 87)
10. Connect the universal joint assembly (B) with the pinion of the steering gear box and then tighten the bolt (A).
30 ~ 35 (3.0 ~ 3.5, 22 ~ 25)

Tighten up with bolt after inserting Ujoint to the steering gear pinion shaft firmly.
11. Install the front wheel & tire.
90 ~ 110 (9.0 ~ 11.0, 65 ~ 80)
12. Check and adjust the front wheel alignment. (Refer to SS group)
13. Perform the ASP (Absoulte Steering Position) calibration procedure. (Refer to ASP calibration)

If the ASP calibration procedure is not performed, EPS warning lamp will be turned on or flicker and behicle may pull
to the left or the right.
DISASSEMBLY
1. Remove the dust packing & cap (A) from the pinion housing.
2. Loosen the lock nut and then remove the tie rod end (B) and lock nut (A) from the tie rod.
3. Remove the bellows clip (A) and band (B) and then pull the bellows (C) away from the end of the tie rod.
4. Remove the tie rod (B) from the rack bar (A) by unscrewing the tie rod inner ball joint.
5. Remove the plug (A) from the pinion housing.
6. Remove the oil seal (B) from the plug (A).
7. Remove the yoke plug (A) and spring (B) and then pull out the support yoke (C).
8. Remove the Orings (B) from the support yoke assembly (A).
9. Pull the pinion assembly (A) out of the pinion housing.
10. Pull the rack bar (A) out of the rack housing.
INSPECTION
1. Rack bar
– Check the rack gear for damage.
– Check the rack bar for bend and deformation.
2. Pinion assembly
– Check the pinion gear for damage.
– Check the surface contacting the oil seal for damage.
– Check the oil seal for damage.
3. Check the inside of rack housing for damage.
4. Check the bellows for being torn.
REASSEMBLY
1. Apply the grease to rack gear teeth and then insert the rack bar (A) into the rack hosing.
2. Insert the pinion assembly (A) into the pinion housing.
3. Tap the top of the pinion assembly with a plastic hammer to seat the pinion assembly thoroughly.
4. Assemble new Orings (B) to support yoke (A).
5. Insert the support yoke assembly (C) into the housing.
6. Apply the sealant to the thread of the yoke plug and then assemble the yoke plug (A) and the yoke spring (B) together.
7. Apply the grease to the edge of the new oil seal (B) and then assemble it to the pinion plug (A).
8. Apply the sealant to the thread of the plug and then assemble the pinion plug (A) to the housing.
60 ~ 80 (6.0 ~ 8.0, 43 ~ 58)
9. Apply loctite (Three bond1374) to the thread of the tie rod inner ball joint and then assemble the tie rod (A) to the rack bar
(B).
110 ~ 130 (11.0 ~ 13.0, 65 ~ 94)
10. Assemble new bellows band (A) to the bellows.
11. Apply the grease (Kyoto YushiOne Luber2128 to the portion (D) of the tierod.
12. Apply the sealant (Three bond1141E) to the bellows mating surface of therack housing.
13. Assemble the bellows (C) to rack housing and then tighten the bellows clip (A) and band (B).
14. Assemble the lock nut (A) and tie rod end (B) to tie rod.
2012 > D 2.0 TCID > Suspension System > General Information > Specifications English
GENERAL
SPECIFICATIONS
FRONT SUSPENSION
Item Specification
Suspension type McPherson strut
Type Gas pressurized
15", 16" wheel: 154.2mm (6.07in.)
Stroke
17" wheel: 149.0mm (5.87in.)
Shock absorber
15", 16" wheel
LH: Grey, RH: Brown
I.D. color
17" wheel
LH: Lilac, RH: Blue
White2: 296.3mm (11.67in.)
Pink2: 301.9mm (11.89in.)
Yellow2: 309.3mm (12.18in.)
Coil spring I.D. color/ Height
Blue2: 316.7mm (12.47in.)
Brown2: 324.1mm (12.76in.)
Violet2: 331.5mm (13.05in.)
REAR SUSPENSION
Item Specification
Suspension type Multilink coil spring
Type Gas pressurized
15", 16" wheel: 162.6mm (6.40in.)
Stroke
Shock absorber 17" wheel: 148.4mm (5.84in.)
15", 16" wheel: Yellow
I.D. color
17" wheel: Pink
Green2: 309.7mm (12.19in.)
Red2: 313.6mm (12.35in.)
Yellow2: 317.6mm (12.50in.)
Coil spring I.D. color/ Height
Blue2: 327.9mm (12.91in.)
Pink2: 331.8mm (13.06in.)
Violet2: 335.7mm (13.22in.)
WHEEL AND TIRE
Item Specification
185/65 R15
195/65 R15
Tire
205/55 R16
225/45 R17
5.5J × 15
Wheel 6.0J × 16
English
7.0J × 17
Front 2.4kg/cm² (34psi)
Tire pressure
Rear 2.6kg/cm² (37psi)
FRONT WHEEL ALIGNMENT
Item Specification
Total 0°±0.2°
Toein
Individual 0°±0.1°
Camber angle 0.6°±0.5°
Caster angle 4.43°±0.5°
Kingpin angle 13.65°±0.5°
REAR WHEEL ALIGNMENT
Item Specification
Total 0.1°±0.2°
Toein
Individual 0.05°±0.1°
Camber angle 1.15°±0.5°
TIGHTENING TORQUE
FRONT SUSPENSION
Tightening torque (kgf.m)
Item
Nm Kgf.m lbft
Hub nuts 90 ~ 110 9.0 ~ 11.0 65 ~ 80
Strut assembly to wheel housing penal bolts 45 ~ 60 4.5 ~ 6.0 33 ~ 43
Strut assembly to knuckle bolts 140 ~ 160 14.0 ~ 16.0 101 ~ 116
Strut assembly self locking nut 50 ~ 70 5.0 ~ 7.0 36 ~ 51
Stabilizer link to strut assembly nut 100 ~ 120 10.0 ~12.0 72 ~ 87
Lower arm to sub frame bolt & nut (Front) 140 ~ 160 14.0 ~ 16.0 101 ~ 116
Lower arm to sub frame bolt & nut (Rear) 100 ~ 120 10.0 ~ 12.0 72 ~ 87
Lower arm ball joint castle nut 80 ~ 90 8.0 ~ 9.0 58 ~ 65
Stabilizer bar to stabilizer link nut 45 ~ 55 4.5 ~ 5.5 33 ~ 40
Stabilizer bracket mounting bolts 100 ~ 120 4.5 ~ 5.5 33 ~ 40
Sub frame to body bolts and nuts 160 ~ 180 16.0 ~ 18.0 116 ~ 130
Sub frame stay mounting bolts & nut 45 ~ 55 4.5 ~ 5.5 33 ~ 40
Front & Rear roll stopper bolt & nut 50 ~ 65 5.0 ~ 6.5 36 ~ 47
Lower arm ball joint to knuckle bolts 100 ~ 120 10.0 ~ 12.0 72 ~ 87
Tierod end castle nut 24 ~ 34 2.4 ~ 3.4 17 ~ 25
Universal join to pinion of steering gear bolt 26 ~ 43 2.6 ~ 4.3 19 ~ 31
REAR SUSPENSION
Tightening torque (kgf.m)
Item
Nm Kgf.m lbft
Hub nuts 90 ~ 110 9.0 ~ 11.0 65 ~ 80
Shock absorber to wheel housing penal bolts 50 ~ 65 5.0 ~ 6.5 36 ~ 47
Shock absorber to carrier bolt& nut 140 ~ 160 14.0 ~ 16.0 101 ~ 116
Shock absorber self locking nut 20 ~ 25 2.0 ~ 2.5 14 ~ 18
Upper arm to carrier bolt & nut 100 ~ 120 10.0 ~ 12.0 72 ~ 87
Upper arm to cross member bolt 100 ~ 120 10.0 ~ 12.0 72 ~ 87
Lower arm to carrier bolt & nut 140 ~ 160 14.0 ~ 16.0 101 ~ 116
Lower arm to cross member bolt 140 ~ 160 14.0 ~ 16.0 101 ~ 116
Assist arm to carrier castle nut 45 ~ 55 4.5 ~ 5.5 33 ~ 40
Assist arm to cross member cam bolt & nut 100 ~ 120 10.0 ~ 12.0 72 ~ 87
Trailing arm to carrier bolts 35 ~ 55 3.5 ~ 5.5 25 ~ 40
Trailing arm to body bolts 140 ~ 160 14.0 ~ 16.0 101 ~ 116
Stabilizer link to trailing arm nut 45 ~ 55 4.5 ~ 5.5 33 ~ 40
Stabilizer bar to stabilizer link nut 45 ~ 55 4.5 ~ 5.5 33 ~ 40
Stabilizer bar bracket bolts 45 ~ 55 4.5 ~ 5.5 33 ~ 40
2012 > D 2.0 TCID > Suspension System > General Information > Special Service Tools English
Tool (Number and Name) Illustration Use

0954626000 Compression of coli spring
Strut spring compressor
0956834000 Remover of ball joint
Ball joint puller
2012 > D 2.0 TCID > Suspension System > General Information > Troubleshooting English
TROUBLESHOOTING

Hard steering Improper front wheel alignment Correct
Excessive turning resistance of lower Replace
arm ball joint
Low tire pressure Adjust
No power assist Repair and replace
Poor return of steering wheel to center Improper front wheel alignment Correct
Poor or rough ride Improper front wheel alignment Correct
Malfunctioning shock absorber Repair or replace
Broken or worn stabilizer Replace
Broken or worn coil spring Replace
Worn lower arm bushing Replace the lower arm assembly
Abnormal tire wear Improper front wheel alignment Correct
Improper tire pressure Adjust
Malfunctioning shock absorber Replace
Wandering Improper front wheel alignment Correct
Poor turning resistance of lower arm ball Repair
joint
Loose or worn lower arm bushing Retighten or replace
Vehicle pulls to one side Improper front wheel alignment Correct
Excessive turning resistance of lower Replace
arm ball joint
Bent lower arm Repair
Steering wheel shimmy Improper front wheel alignment Correct
Poor turning resistance of lower arm ball Replace
joint
Broken or worn stabilizer Replace
Worn lower arm bushing Replace
Bottoming Broken or worn coil spring Replace
Wheel /tire noise, vibration and harshness concerns are directly related to vehicle speed and are not generally affected by acceleration,
coasting or decelerating. Also, outofbalance wheel and tires can vibrate at more than one speed. A vibration that is affected by the
engine rpm, or is eliminated by placing the transmission in Neutral is not related to the tire and wheel. As a general rule, tire and wheel
vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the
rear tire and wheel assemblies. This can initially isolate a concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can be caused by damaged or worn tire and
wheels. Perform a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial
runout. Refer to the tire wear chart to determine the tire wear conditions and actions
WHEEL AND TIRE DIAGNOSIS
Rapid wear at the center Rapid wear at both shoulders Wear at one shoulder
English
• Centertread down to fabric due to • Underinflated tires • Toe adjustment out of specification

excessive over inflated tires
• Worn suspension components • Camber out of specification
• Lack of rotation
• Excessive cornering speeds • Damaged strut
• Excessive toe on drive wheels
• Lack of rotation • Damaged lower arm
• Heavy acceleration on drive
Partial wear Feathered edge Wear pattern
• Caused by irregular burrs on brake • Toe adjustment out of specification • Excessive toe on nondrive wheels

drums
• Damaged or worn tie rods • Lack of rotation
• Damaged knuckle
2012 > D 2.0 TCID > Suspension System > Front Suspension System > Components and Components
English
Location
COMPONENTS
2012 > D 2.0 TCID > Suspension System > Front Suspension System > Front Strut Assembly > English
COMPONENTS
2012 > D 2.0 TCID > Suspension System > Front Suspension System > Front Strut Assembly > Repair
English
procedures
REMOVAL

Be careful not to damage to the hub bolts when removing the front wheel & tire.
2. Remove the brake hose and the wheel speed sensor bracket from the front strut assembly by loosening the mounting bolts
(A).
3. Disconnect the stabilizer link (A) with the front strut assembly after loosening the nut.
4. Disconnect the front strut assembly (A) with the knuckle by loosening the bolt & nut.
5. Remove the front strut cap (A).
6. Remove the front strut assembly from the wheel housing panel by loosening the mounting nuts (B).
English
INSTALLATION
1. Install the front strut assembly to the wheel housing panel by tightening the mounting nuts (B).
45 ~ 60 (4.5 ~ 6.0, 33 ~ 43)
2. Install the front strut cap (A).
3. Connect the front strut assembly (A) with the knuckle by tightening the bolts & nuts.
140 ~ 160 (14.0 ~ 16.0, 101 ~ 116)
4. Install the stabilizer link (A) to the front strut assembly and then tighten the nut.
100 ~ 120 (10.0 ~ 12.0, 72 ~ 87)
5. Install the brake hose and wheel speed sensor bracket to front strut assembly by tightening the mounting bolts (A).
90 ~ 110 (9.0 ~ 11.0, 65 ~ 80)
DISASSEMBLY
1. Compress the coil spring (A) with a SST (0954626000). Do not compress the spring more than necessary.
2. Loosen the self locking nut (A).
3. Remove the insulator assembly (A) and the strut bearing (B).
4. Remove the spring upper seat (A) and pad (B).
5. Remove the dust cover (A) and the bumper rubber (B).
6. Remove the coli spring (A) and the spring lower pad (B).
7. Remove the shock absorber (A) from the special tool.
INSPECTION
1. Check the strut bearing for wear and damage.
2. Check the spring upper and lower seat for damage and deterioration.
3. Compress and extend the piston rod (A) and check that there is no abnormal resistance or unusual sound during operation.
REASSEMBLY
1. Install the front shock absorber to SST (0954626000).
2. Install the spring lower pad (C) so that the protrusions (A) fit in the holes (B) in the spring lower seat.
3. Put the coil spring (A) on the spring lower pad (B) correctly as illustration below.
4. Install the bumper rubber (B) and the dust cover (A) to piston rod.
5. Install the spring upper pad (B) and seat (A).
6. Compress the coil spring with the SST.
7. Fully extend the piston rod and then install the strut bearing (B) and the insulator (A).
8. Tighten a new self locking nut (A) to the specified torque.
50 ~ 70 (5.0 ~ 7.0, 36 ~51)
9. Remove the special service tool.
2012 > D 2.0 TCID > Suspension System > Front Suspension System > Front Lower Arm > RepairEnglish
procedures
REMOVAL

2. Remove the split pin and the castle nut (A) from the lower arm ball joint.
3. Separate the lower arm (A) from the lower arm ball joint by using SST (0956834000).
4. Loosen the bolts and nuts and then remove the lower arm (A) from the sub frame.
INSTALLATION
English
1. Install the front lower arm to the sub frame and then tighten the bolts (A, B) and nuts.
Bolt & nut (A): 140 ~ 160 (14.0 ~ 16.0, 101 ~ 116)
Bolt & nut (B): 100 ~ 120 (10.0 ~12.0, 72 ~ 87)
2. Connect the lower arm with the ball joint and then install the castle nut (A) and the split pin.
80 ~ 90 (8.0 ~ 9.0, 58 ~ 65)
90 ~ 110 (9.0 ~ 11.0, 65 ~ 80)
INSPECTION
1. Check the bushing for wear and deterioration.
2. Check the lower arm for deformation.
3. Check the all bolts and nuts
2012 > D 2.0 TCID > Suspension System > Front Suspension System > Front Stabilizer Bar > Repair
English
procedures
REMOVAL

2. Loosen the bolt (A) and then disconnect the universal joint assembly (B) from the pinion of the steering gear box.

3. Disconnect the stabilizer link (A) from the front strut assembly by loosening the nut.
34000).
English
6. Remove the muffler rubber hanger (A).
7. Loosen the wiring harness protector mounting bolts (A).
8. Remove the front and rear roll stopper bolts & nut (A, B).
9. Remove the sub frame (E) and the sub frame stay by loosening the mounting bolts (A, C) and nuts (B, D).
10. Remove stabilizer (B) from the sub frame by loosening the bracket mounting bolts (A).
11. Disconnect the stabilizer link (A) with the stabilizer bar by loosening the nut.
12. Remove the bushing (A) and the bracket (B) from the stabilizer bar.
INSTALLATION
1. Install the bushing (A) and the bracket (B) to the stabilizer bar.
2. Connect the stabilizer link (A) with the stabilizer bar by tightening the nut.
100~ 120 (10.0 ~ 12.0, 72 ~ 87)
3. Install the stabilizer (B) to the sub frame by tightening the bracket mounting bolts (A).
45 ~ 55 (4.5 ~ 5.5, 33 ~ 40)
4. Install the sub frame (E) and the sub frame stay by tightening the mounting bolts (A, C) and nuts (B, D).
Sub fame mounting bolts (C) and nuts (D):
160 ~ 180 (16.0 ~ 18.0, 116 ~ 130)
Sub frame stay mounting bolts (A) and nuts (B):
45 ~ 55 (4.5 ~ 5.5, 33 ~ 40)
5. Tighten the rear roll stopper through bolt(A).
50 ~ 65 (5.0 ~ 6.5, 36 ~ 47)
6. Tighten the front roll stopper through bolt & nut (A).
50 ~ 65 (5.0 ~ 6.5, 36 ~ 47)
7. Install the wire harness protector to sub frame by tightening the mounting bolts (A).
8. Install the muffler rubber hanger (A).
10. Connect the tie rod end with the knuckle and then install the castle nut and split pin.
24 ~ 34 (2.4 ~3.4, 17 ~ 25)
11. Connect the stabilizer link (A) with the front strut assembly and then tighten the nut.
100 ~ 120 (10.0 ~ 12.0, 72 ~ 87)
12. Connect the universal joint assembly (B) with the pinion of the steering gear box and then tighten the bolt (A).
30 ~ 35 (3.0 ~ 3.5, 22 ~ 25)
90 ~ 110 (9.0 ~ 11.0, 65 ~ 80)
INSPECTION
2. Check the front stabilizer bar for deformation.
3. Check the front stabilizer link ball joint for damage.
2012 > D 2.0 TCID > Suspension System > Rear Suspension System > Components and Components
English
Location
COMPONENTS
2012 > D 2.0 TCID > Suspension System > Rear Suspension System > Rear Shock Absorber > English
COMPONENTS
2012 > D 2.0 TCID > Suspension System > Rear Suspension System > Rear Shock Absorber > Repair
English
procedures
REMOVAL
1. Remove the rear wheel & tire.

Be careful not to damage to the hub bolts when removing the rear wheel & tire.
2. Support the lower portion of the rear lower arm (A) with the jack.
3. Remove the bolt & nut (B) holding the rear shock absorber (A) to the carrier assembly.
4. Remove the rear shock absorber (B) from the wheel housing by loosening the mounting bolts (A).
INSTALLATION
English
1. Install the rear shock absorber (B) to the wheel housing penal by tightening the bracket mounting bolts (A).
50 ~ 65 (5.0 ~ 6.5, 36 ~ 47)
2. Connect the rear shock absorber (A) with the carrier assembly and then tighten the bolt & nut (B).
140 ~ 160 (14.0 ~ 16.0, 101 ~ 116)
3. Install the rear wheel & tire.
90 ~ 110 (9.0 ~ 11.0, 65 ~ 80)
INSPECTION
1. Check the rubber parts for wear and deterioration.
2. Compress and extend the piston rod (A) and check that there is no abnormal resistance or unusual sound during operation.
2012 > D 2.0 TCID > Suspension System > Rear Suspension System > Rear Upper Arm > Repair English
procedures
REMOVAL

2. Remove the rear upper arm (C) by loosening the mounting bolts & nut (A, B).
INSTALLATION
1. Install the rear upper arm (C) between the rear cross member and the carrier assembly and then tighten the mounting bolts
and nut (A, B).
Bolt (A): 100 ~ 120 (10.0 ~ 12.0, 72 ~ 87)
Bolt & Nut (B): 100 ~ 120 (10.0 ~ 12.0, 72 ~ 87)

Install the rear upper arm so that the letter "R" can face the rear of vehicle.
90 ~ 110 (9.0 ~ 11.0, 65 ~ 80)
INSPECTION English
2. Check the rear upper arm or damage and deformation.
3. Check for all bolts and nut.
2012 > D 2.0 TCID > Suspension System > Rear Suspension System > Rear Lower Arm > Repair English
procedures
REMOVAL

2. Support the lower portion of the rear lower arm (A) with a jack.
3. Temporarily loosen the bolt (B) holding the cross member to the rear lower arm. Do not remove it.
4. Remove the bolt & nut (C) holding the rear lower arm to the carrier assembly.
5. Lower the jack and then remove the coil spring (A) and the spring pad.
6. Remove the rear lower arm (C) from the cross member by removing the bolt (B) completely.
INSTALLATION
1. Connect the rear lower arm (A) with the cross member and then temporarily tighten the bolt (B).
English
2. Install the coil spring (A) and support the lower portion of the rear lower arm with a jack.
3. Adjust height of the jack to place the bolt (B) holding rear lower arm and carrier assembly through the mating holes.
4. Tighten the bolt and nut (B, C) to the specified torque.
140 ~ 160 (14.0 ~ 16.0, 101 ~ 116)
90 ~ 110 (9.0 ~ 11.0, 65 ~ 80)
INSPECTION
2. Check the rear lower arm for deformation.
3. Check the coil spring and spring pad for deterioration and deformation.
4. Check for all bolts and nut.
2012 > D 2.0 TCID > Suspension System > Rear Suspension System > Rear Assist Arm > Repair English
procedures
REMOVAL

2. Remove the split pin and castle nut (A) from the rear assist arm.
3. Disconnect the rear stabilizer link with the trailing arm by loosening the nut (B).
4. Disconnect the ball joint of the rear assist arm (A) with the carrier assembly with the SST (0956834000).
5. Loosen the nut and then remove the cam bolt (B) rear assist arm (A) from the cross member.
INSTALLATION
1. Install the rear assist arm (A) and the cam bolt (B) to cross member and then tighten the nut.
100 ~ 120 (10.0 ~ 12.0, 72 ~ 87)
2. Connect the ball joint of the rear assist arm (A) with the carrier assembly.
3. Install the castle nut (C) and split pin to the ball joint of the rear assist arm.
45 ~ 55 (4.5 ~ 5.5, 33 ~ 40)
4. Connect the rear stabilizer link with the trailing arm and then tighten the nut (D). English
45 ~ 55 (4.5 ~ 5.5, 33 ~ 40)
90 ~ 110 (9.0 ~ 11.0, 65 ~ 80)
INSPECTION
2. Check the rear assist arm for deformation.
3. Check the ball joint for damage.
4. Check for the all bolts, nut, and washer.
2012 > D 2.0 TCID > Suspension System > Rear Suspension System > Trailing Arm > Repair procedures
English
REMOVAL

2. Disconnect the parking brake cable (A) with the rear brake assembly.
3. Remove the parking brake cable bracket from the trailing arm by loosening the mounting bolt (A).
4. Disconnect the rear stabilizer link with the trailing arm by loosening the nut (B).
5. Disconnect the trailing arm (B) with the carrier assembly by loosening mounting bolts (A).
6. Remove the rear trailing arm (B) by loosening the mounting bolts (A).
English
INSTLLATION
1. Install the rear trailing arm (B) to the body by tightening the mounting bolts (A).
140 ~ 160 (14.0 ~ 16.0, 101 ~ 116)
2. Connect the trailing arm (B) with the carrier assembly by tightening the bolts (A).
35 ~ 55 (3.5 ~ 5.5, 25 ~ 40)
3. Connect the parking brake cable (A) with the rear brake assembly.
4. Connect the rear stabilizer link with the trailing arm and then tightening the nut (B).
45 ~ 55 (4.5 ~ 5.5, 30 ~ 40)
5. Install the parking brake cable bracket to the trailing arm by mounting bolt (A).
90 ~ 110 (9.0 ~ 11.0, 65 ~ 80)
INSPECTION
2. Check the rear trailing arm for deformation.
3. Check for all bolts and nuts.
2012 > D 2.0 TCID > Suspension System > Rear Suspension System > Rear Stabilizer Bar > Repair
English
procedures
REMOVAL

2. Remove the stabilizer link (C) by loosening the nuts (A, B).
3. Remove the rear stabilizer bar (B) from the cross member by loosening the bracket mounting bolts (A).
4. Remove the mounting bracket (A) and bushing (B) from the rear stabilizer bar.
1. Install the mounting bracket (A) and bushing (B) to the rear stabilizer bar.
2. Install the rear stabilizer bar (B) to the cross member by tightening the bracket mounting bolts (A).
45 ~ 55 (4.5 ~ 5.5, 33 ~ 40)
3. Connect the rear stabilizer link (C) between the rear stabilizer bar and the trailing arm and then tighten the nut (A, B).
45 ~ 55 (4.5 ~ 5.5, 33 ~ 40)
90 ~ 110 (9.0 ~ 11.0, 65 ~ 80)
INSPECTION
1. Check the rear stabilizer bar for deformation.
2. Check the rear stabilizer link ball joint for damage.
2012 > D 2.0 TCID > Suspension System > Tire Pressure Monitoring System > Schematic Diagrams
English
SCHEMTIC DIAGRAM
2012 > D 2.0 TCID > Suspension System > Tire Pressure Monitoring System > Description and Operation
English
DESCRIPTION
1. SYSTEM DESCRIPTION

AL: Auto Learning
CAN: Controller Area Network
ECU: Electronic Control Unit
IC: Instrument Cluster
LF: Low Frequency
LFI: Low Frequency Initiator
MIL: Malfunction Indicator LED
RF: Radio Frequency
WE: Wheel Electronic
WU: Wheel Unit
The TPMS monitors the pressure and temperature of a vehicles tire to alert on pressure variations that may impact the driving conditions.
Messages deduced from processed data are displayed at the Instrument Cluster (IC) via 2 warning lamps and 4 tirerelated LEDs. In
parallel, the ECU executes error evaluation on input and output signals. Pressure monitoring during parking is provided.
The ECU processes data from the WE sensor, determines the state of the tires and communicates the required warning message via the
CAN line to the driver.
2. FUNCTIONAL DESCRIPTION
WARNING THRESHOLDS
Hard warning
One non temperature compensated hard warning threshold applies to front and rear axle of vehicle. If the pressure reported by the WE
sensor is below the tirespecific minimum pressure then the low pressure warning telltale and the telltale indicating position of the under
inflated tire is illuminated immediately. A warning is reset when tire pressure is reported to be at 211kPa (30.6psi).
FAST PRESSURE LOSS
Fast pressure loss function is deactivated during parking and only active while driving. So it is avoided that a warning is set when the
driver manually deflates the tire to a level above hard warning threshold.
Upon a rapid pressure decrease the WE emits a deltap telegram which triggers the fast pressure loss function to start. Including the first
dptelegram the function waits for a 2nd telegram of the same wheel electronic and calculates the pressure loss rate. If the pressure
drops by more than 20kPa/min, a "fast pressure loss" warning is generated and displayed with a maximum of 60s delay while driving.
INITIALIZATION
The initialization function determines which WE sensor identifier belongs to the vehicle.
The corresponding set of identifiers is stored in the ECU memory and used to determine if a received RF telegram comes from a wheel
unit, which belongs to the vehicle.
Only telegrams containing known (initialized) identifiers are being supervised in the warning algorithm.
The initialization function is implemented in two independent parts: as an auto learning function and as an auto location function.
INITIALIZATIONAuto Learning
AL starts every time, the vehicle was parked long enough to change or permute wheels (19min), and is traveling again at a speed that
ensures that the WE sensors are transmitting.
AL is automatically considering all WE identifiers received and extracts, based on statistical evaluation, IDs belonging to the WEs
mounted on the vehicle. If new (unknown) IDs are detected, their recurrence will be tracked by AL.
AI compares the acceleration reported by the wheel unit to the vehicle speed to rule out transmissions received from neighboring
vehicles traveling with different speeds.
A WE sensor identifier is assigned to the vehicle when 8 RF telegrams have been received while driving above 25km/h.
INITIALIZATIONAuto Location English
This function gives very reliable full localization information.
It relies on the physical properties of long wave emissions in the frequency range of 125 kHz. These emissions are inductively sensed in
the wheel unit.
The localization consists in a classification of the WU identifiers in the following order:
0. Left Front Wheel
1. Right Front Wheel
2. Right Rear Wheel
After activation of the initiators the system listens for wheel units reporting that their transmission was caused by an LF trigger signal. If
such a transmission is received, the respective identifier is assigned to the triggered wheel well.
The position of the WE, which belongs to the wheel well without LF initiator, is deduced by identifying the WE sensor, that never detected
LF, but assigned to the vehicle by auto learning.
SENSOR RRGISTRAION

If the sensor registration procedure is not performed by GDS after replacing the TPM sensor or Receiver, TPMS is not
operated.
1. Install GDS (Global Diagnostic System) and GDS TPMS module to vehicle.
2. Select the model and perform the sensor registration procedure according to instruction of the GDS as follows.
VIN AND VEHICLE NAME WRITING
1. Install GDS (Global Diagnostic System) and GDS TPMS module to vehicle.
2. Select the model and perform the VIN and vehicle name writing procedure according to instruction of the GDS as follows.
[VIN Writing]
2012 > D 2.0 TCID > Suspension System > Tire Pressure Monitoring System > Components and English
Components Location
COMPONENTS
2012 > D 2.0 TCID > Suspension System > Tire Pressure Monitoring System > TPMS Sensor > Repair
English
procedures
REMOVAL
REMOVING THE TIRE FROM THE RIM

During all the operations on the tire, the sensor must be correctly maintained and thus it is FORBIDDEN to unscrew the
nut and to force the sensor into the wheel. This could damage the sensor.
1. Take off the first side of the tire. The tool should not be used near the valve (no less than 30 cm).
2. Take off the second side of the tire. The tool should not be used near the valve (No less than 30 cm).
3. Dismount the first side of the tire: Place the shoe of the tool between 5 and 15 cm away from the sensor and use the tire
lever as shown in the picture.
4. By using the tire lever, extract the external side wall of the tire and engage on the shoe of the machine. The lever and the
tire must not come into contact with the sensor. Then remove the lever.
English
5. The wheel rotation allows the complete extraction of the first side of tire.
6. Raise the tire to prepare the introduction of the tire lever to aid extraction of the second side wall, the same
recommendations as for the first side wall will apply.
7. By using the tire lever, extract the external side wall of the tire and engage the shoe of the machine. The lever and the tire
must not come into contact with the sensor. Then remove the lever.
8. Extract entirely the second side wall of the tire.
PRESSURE SENSOR REMOVING
1. While supporting the sensor unit, unscrew the nut.
INSTALLATION
SENSOR REINSTALLATION
1. Hold the sensor and the seal washer, then extract it, this also extracts the seal. Take care to not damage the valve thread.
2. Clean the sensor and the valve stem holding the valve using a dry cloth as shown on the picture. Take care to support the
rear of the valve with a thumb so that there is no movement of the stem.
3. When removing the sensor, a new washer and seal must be used. Insert these up to the base of the sensor, making sure to
secure the valve base with a thumb, as shown. Wipe the seal and threading.
4. Insert the valve, in the valve hole, without modifying the angle of the stem (retain position of delivery). The laser marking
should be visible to the operator.
5. When the valve is completely inserted, maintain the sensor in contact with the rim (as shown on the picture), then screw
manually the nut until it is in contact with the wheel (without force).
6. While maintaining the sensor contact with the rim by applying pressure to the back of the valve, slightly press on the cap
towards the center of the wheel in order to adapt the angle of the valve/sensor to the profile of the rim. It is mandatory to
guarantee the contact of the housing unit on the rim drop center.
7. While maintaining the sensor unit and valve in position, screw the nut with a torque wrench.
Apply a torque of 7.5 ~ 8.5Nm (0.76 ~ 0.86kgf.m, 5.5 ~ 6.2lbft).
Take care that the wrench socket is correctly inserted on the nut.
8. Check the followings.
(1) It is normal that the seal washer becomes bent during the nut tightening.
(2) Check that the visible part of the antenna is not damaged or broken.
(3) The plastic bridge should neither be cracked nor broken. It is designed so that it will fracture due to an error in the
assembly process (too high torque, bad positioning……). Any defect must mean the rejection of the sensor.
MOUNTING OF TIRE

• Before any tire mounting operation, make sure that the sensor has been correctly mounted and tightened to the rim.
• No lubricant product or any other material may partially or completely cover the air pressure inlet hole of the sensor.
• The assembly tools have to never have a collision with the sensor.
• The tire cannot be in contact with the sensor only after it is engaged in the rim and after the exceeded peak of
traction. Therefore, generally at the end of the assembly.
1. Prepare the tire and fix the rim as usual.
2. Put the tire on the rim, so that the cross point of the belt with the rim is between 15 and 20 cm away from the valve (see
the picture).
3. Engage the shoe and make sure that 20cm is maintained between the cross point and the valve. The arrow shows the
direction of rotation of the wheel.
4. Turn the wheel in order to engage all the first side of the tire.

The standard shoes can pass over the sensor without damaging it.
5. Put the second side of the tire in position, so that the cross point of the belt with the rim is approximately 20 cm away from
the valve (see the picture). The curved arrow shows the direction of rotation of the wheel.
6. Turn the wheel in order to engage all of the second side of the tire.

The standard shoes can pass over the sensor without damaging it.
7. Perform the Register Sensor procedure.
(Refer to Register Sensor.)
2012 > D 2.0 TCID > Suspension System > Tire Pressure Monitoring System > TPMS Initiator > Repair
English
procedures
REPLACEMENT
1. Disconnect the battery negative cable from the battery.
2. Remove the wheel and the wheel cover.
3. Remove the malfunctioning part and fit new part.
4. Reinstall the wheel and wheel cover.
2012 > D 2.0 TCID > Suspension System > Tire Pressure Monitoring System > TPMS Receiver > Repair
English
procedures
REPLACEMENT
1. Disconnect the battery negative cable from the battery.
2. Put the SST (098401E100) (A) into the space between the center fascia and crash pad.

• Be care not to damage the center facia and crash pad.
3. Separate the center facia panel from the crash pad pulling the SST (098401E100) (A) as shown on the photo.

• Pull the SST (098401E100) (A) slowly not to damage the center fascia panel.
4. Pull the other side of center facia panel with the SST (098401E100) in the way of "step 2)".
5. Remove the center facia lower tray (A).
English
6. Remove the malfunctioning part and fit new part.
7. Reinstall the center facia lower tray.
9. Perform the VIN and Vehicle name writing procedure. (Refer to VIN and Vehicle name writing.)
10. Perform the sensor registration procedure.
(Refer to Sensor registration.)
2012 > D 2.0 TCID > Suspension System > Tires/Wheels > Tire > Repair procedures English
TIRE WEAR
1. Measure the tread depth of the tires.
Tread depth [limit] : 1.6 mm (0.063 in)
2. If the remaining tread depth (A) is less than the limit, replace the tire.

When the tread depth of the tires is less than 1.6 mm(0.063 in), the wear indicators (B) will appear.
TIRE ROTATION
Rotate the tires in the pattern illustrated.
CHECKING FOR PULL AND WANDER
If the steering pulls to one side, rotate the tires according to the following wheel rotation procedure.
1. Rotate the front right and front left tires, and perform a road test in order to confirm vehicle stability.
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2. If the steering pulls to the opposite side, rotate the front and rear tires, and perform a road test again.
3. If the steering continues to pull to one side, rotate the front right and left tires again, and perform a road test.
4. If the steering continues to pull to the opposite side, replace the front wheels with new ones.
2012 > D 2.0 TCID > Suspension System > Tires/Wheels > Wheel > Repair procedures English
HUB NUT TIGHTENING SEQUENCE
Tighten the hub nuts as follows.
90 ~ 110 (9.0 ~ 11.0, 65 ~ 80)

When using an impact gun, final tightening torque should be checked using a torque wrench.
Run out inspection
1. Jack up the vehicle.
2. Measure the wheel Runout by using a dial indicator as illustration below.
Runout Aluminum Steel

Radial mm(in) Below 0.3(0.012) Below 0.6(0.024)
Lateral mm(in) Below 0.3(0.012) Below 0.8(0.031)
3. If measured value exceeds the standard value, replace the wheel.
2012 > D 2.0 TCID > Suspension System > Tires/Wheels > Alignment > Repair procedures English
FRONT WHEEL ALIGNMENT

When using a commercially available computerized wheel alignment equipment to inspect the front wheel alignment,
always position the vehicle on a level surface with the front wheels facing straight ahead.
Prior to inspection, make sure that the front suspension and steering system are in normal operating condition and that
the tires are inflated to the specified pressure.
Toe
B A > 0: Toe in (+)
B A < 0: Toe out ()
Toe adjustment
1. Loosen the tie rod end lock nut.
2. Remove the bellows clip to prevent the bellows from being twisted.
3. Adjust the toe by screwing or unscrewing the tie rod. Toe adjustment should be made by turning the right and left tie rods
by the same amount.
Toein
Total : 0°±0.2°
Individual : 0°±0.1°
Tie rod Turning direction Toe

Decrease
Reward
LH (Toe in)
(Driver's side) Increase
Forward
(Toe out)
Increase
Reward
(Toe out)
RH
Decrease
Forward
(Toe in)
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4. When completing the toe adjustment, install the bellows clip and tighten the tie rod end lock nut to specified torque.
50 ~ 55 (5.0 ~ 5.5, 36 ~ 40)
Camber and Caster
Camber and Caster are preset at the factory, so they do not need to be adjusted. If the camber and caster are not within the standard
value, replace or repair the damaged parts and then inspect again.
Camber angle: 0.6°±0.5°
Caster angle : 4.43°±0.5°
REAR WHEEL ALIGNMENT

When using a commercially available computerized wheel alignment equipment to inspect the rear wheel alignment,
always position the vehicle on a level surface.
Prior to inspection, make sure that the rear suspension system is in normal operating condition and that the tires are
inflated to the specified pressure.
Toe
B A > 0: Toe in (+)
B A < 0: Toe out ()
Toe adjustment
1. Loosen the nut holding the assist arm cam bolt (A).
2. Adjust rear toe by turning the rear assist arm cam bolt (A) clockwise or counter clockwise. Toe adjustment should be made
by turning the right and left cam bolt by the same amount.
Toein
Total : 0.1°±0.2°
Individual : 0.05°±0.1°
Cam bolt Turning direction Toe
Decrease
Clockwise
LH (Toe in)
(Driver's side) Counter Increase
clockwise (Toe out)
Increase
Clockwise
(Toe out)
RH
Counter Decrease
clockwise (Toe in)
3. When completing the toe adjustment, tighten the nut to specified torque.
100 ~ 120 (10.0 ~ 12.0, 72 ~ 87)
Camber
Camber is preset at the factory, so it does not need to be adjusted. If the camber is not within the standard value, replace or repair the
damaged parts and then inspect again.
Camber: 1.15°±0.5°
Contents
2012 > D 1.6 TCIU2 > Automatic Transaxle System > General Information > Specifications (A4CF2)
English
Please rate this document after reviewing at the bottom of this page.
SPECIFICATIONS
Transaxle model A4CF2
Engine model Diesel 1.6L
Torque converter type 3 elements 2 phases 1 stage
Torque converter size (Φ) 236
Oil pump type Parachoid
T/M case type Separated
Clutch: 3EA
Friction elements Brake: 2EA
OWC : 1EA
Planetary gear 2EA
1st 2.919
2nd 1.551
Gear ratio 3rd 1.000
4th 0.713
Reverse 2.480
Final gear ratio 3.532
Fluid pressure balance piston 2EA
Stall speed 2000~2700 rpm
Accumulator 4EA
Solenoid valve 6EA (PWM:5EA, VFS:1EA)
Gear shift position 7 range (P,R,N,D,3,2,L)
Oil filter 1EA
Solenoid Valve Operation Table
Solenoid Valve
Range
*PCSVA *PCSVB *PCSVC *PCSVD *ON/OFF
N, P ● ● ●
1st ● ● ●
2nd ● ●
3rd ● ●
4th ● ●
Reverse ● ●
*PCSVA: Overdrive clutch, Reverse clutch, Low&Reverse brake control solenoid valve
*PCSVB: 24 brake control solenoid valve
*PCSVC: Underdrive clutch control solenoid valve
*PCSVD: Damper clutch control solenoid valve
*ON/OFF: ON/OFF solenoid valve
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Clutch & Brake Operation Table English
Clutch Brake

UD OD REV L&R 2ND
N, P ●
1 ● ●
2 ● ●
3 ● ●
4 ● ●
R ● ●
Tightening Torques
Item Nm kgf.m lbft
Control cable bracket 15~22 1.5~2.2 11~16
Input shaft speed sensor 10~12 1.0~1.2 7~8
Output shaft speed sensor 10~12 1.0~1.2 7~8
Manual control lever 17~21 1.7~2.1 13~15
Inhibitor switch 10~12 1.0~1.2 7~8
Oil pan 10~12 1.0~1.2 7~8
Valve body mounting bolt 10~12 1.0~1.2 7~8
Oil drain plug 35~45 3.5~4.5 25~32
Differential drive gear 130~140 13~14 94~101
Pressure check plug 8~10 0.8~1.0 6~7
Front roll stopper bracket bolt 50~65 5.0~6.5 36.2~47.0
Rear roll stopper bracket bolt 50~65 5.0~6.5 36.2~47.0
Transaxle stopper bracket bolt 60~80 6.0~8.0 43~58
LUBRICANTS
Item Specified lubricant Quantity

Transaxle fluid liter (US qt, lmp.qt) GENUINE DIAMOND ATF SPIII or SK ATF SP III 6.6 (6.9, 5.81)
Sealant
Item Specified sealant
Rear cover
Torque converter housing LOCTITE FMD546
Oil pan
* Thanks for your cooperation for the more quality. Please surely rate this document before closing.
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Automatic Transaxle System > Description and
English
Operation (A4CF2)
DESCRIPTION
The new small sized automatic transaxle (A4CF2) is for Diesel 1.6 engine.
The transaxle (A4CF2) is improved on the durability, fuel consumption and efficiency by the new main features as followed.
The new main features
1) The hydraulic centrifugal oil pressure balance piston.
2) The full line pressure variable control system.
3) The long travel damper clutch.
4) The disc type return spring.
5) The ultra flat torque converter.
Functions
Item Contents
Components The full line pressure variable control operates in the valve body to improve the fuel consumption.
The long travel damper clutch is applied to the torque converter to improve the engine revolution change
reduction capability and the fuel consumption. (17~20°)
The oil pump of the trochocentric type is changed to parachoid type to improve the processing and the
capacity efficiency at the low RPM range.
The disc type return spring is applied to the low&reverse brake to improve the durability and reduce the
length.
The hydraulic centrifugal oil pressure balance piston is applied to the inside of clutch to improve the
durability and the shift control capability.
The low noise gear and the gear teeth face grinding are applied to the transfer driven gear to improve the
noise and the durability.
Electronic control The oil pressure value set by TCM is coupled with the engine torque so that the stable shift feeling can
system be improved.
The engine torque reduction control operates effectively to improve the shift feeling and the durability.
It can be the skip shift of 1↔3 and 2↔4 when shifting.
The range of the damper clutch direct control expands to improve the fuel consumption.
The current control chip is installed into the TCM to regulate the solenoid control current and control the
oil pressure securely according to the change of the temperature and voltage.
The FPC(Flexible Printed Circuit) harness is composed of the thin and flat copper in the insulating film
like electric wire.
The tachometer is operated by the change of the frequency forwarded from the TCM to the instrument
cluster, not vehicle speed sensor.
Mechanical System
Function
Torque Converter
The torque converter, as the power plant which delivers the power of engine to the automatic transaxle, consists of 3 elements, 2
phases and 1 stage type.
– The flowing section form of the torque converter changes the round type to the flat type to reduce the length of the
torque converter.
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– The maximum operating degree of the damper clutch installed inside the transaxle increases from 11° to 18° to improve
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the engine revolution change reduction capability and the fuel consumption
Oil Pump
The oil pump is made of the aluminum (the reaction shaft support) to loose the weight and selects the parachoid type to
improve the processing and the capacity efficiency at the low RPM range.
Brakes
The automatic transaxle (A4CF2) uses the low and reverse brake and the second brake.
– The disc type return spring is applied to the low and reverse brake and it minimizes the slip of the friction material from
the uniform spring operation power to improve the durability and reduce the length.
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Clutch
The multiple clutches and the one way clutch are used as the transaxle device.
The retainer of each clutch is composed of the precision sheet metal parts to realize the productivity and the light weight.
The hydraulic centrifugal oil pressure balance device places inside the clutch assembly.
Generally the oil remained in the piston oil pressure chamber pushes the piston by the centrifugal force. But to prevent the piston from
being pushed, the oil filled in between the piston and the return spring retainer occurs the centrifugal force and both of the power is
offset so that the piston don't move. In result, it improves the durability and the shift control ability.
1. Underdrive Clutch
The driving force of input shaft is delivered to the underdrive sun gear.
The operating oil pressure in the underdrive clutch components operates between the piston and the retainer and pushes
the piston to the clutch discs to deliver the driving force from the retainer to the hub.
2. Reverse Clutch And Overdrive Clutch
The reverse clutch delivers the driving force of input shaft to the reverse sun gear.
The overdrive clutch delivers the driving force of input shaft to the overdrive planetary carrier and the low and reverse
annulus gear.
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The operating oil pressure of the reverse clutch operates between the reverse clutch retainer and overdrive clutch
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retainer and it has the whole overdrive clutch moved to deliver into the hub via retainer.
Structure Of The Reverse And The Overdrive Clutch
1. Snap ring 11. Dring
2. Clutch reaction plate 12. Return spring
3. Clutch disc 13. Overdrive clutch piston
4. Clutch plate 14. Dring
5. Snap ring 15. Reverse clutch piston
6. Clutch reaction plate 16. Dring
7. Clutch disc 17. Dring
8. Clutch plate 18. Dring
9. Snap ring 19. Reverse clutch retainer
10. Spring retainer
Parking System
The parking system for A4CF2 model is the cam type.
The roller type installed to the existing new generation AT needs the support to move the roller when operating the parking system
and is so complicated.
But the cam type for A4CF2 model doesn't need the support and the structure is simply. It only needs the guide to prevent from moving
the cam idly.
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OPERATION
Hydraulic Control System
Main Features
The VFS (Variable Force Solenoid) installed in the valve body is applied to transaxle(A4CF2). VFS varies the line pressure from
4.5bar to 10.5bar according to throttle open angle and shift range to improve the fuel consumption and shift ability.
And the reducing valve which is installed in the valve body makes the solenoid control pressure using the reducing pressure instead
of the line pressure like the HIVEC transaxle.
The material of spool valve in the valve body is changed from the steel to aluminum to reduce the oil leakage by the thermal
expansion between the valve body and spool valve at the high temperature.
The switch valve, the solenoid valve and the fail safe valve are operated to drive the vehicle at the 3rd speed and reverse even
thought the malfunction of the electronic control parts occur.
Electronic Control System
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Sensor And Actuator Function
Item Function
Input speed sensor Detect the input shaft rpm(TURBINE RPM) at the OD/RVS retainer
Output speed sensor Detect the output shaft rpm(T/F DRIVE GEAR RPM) at the T/F drive gear
Engine rpm signal Receive the engine rpm via CAN communication with ECM
Fluid temperature sensor Detect the temperature of ATF through the thermistor
Brake switch Detect the brake operation at the contact switch of the brake pedal
Inhibitor switch Detect the position of select lever through the contact switch
ON/OFF solenoid valve (SCSVA) Control the hydraulic passage for the shift control
Change the line pressure from 4.5 bar to 10.5 bar according to throttle open angle
VFS solenoid valve
and shift ranges
Control the OD or L/R hydraulic pressure to the pressure control valve for shift
PCSVA(SCSVB)
control
Control the 2/4 or REV hydraulic pressure to the pressure control valve for shift
PCSVB(SCSVC)
control
PCSVC(SCSVD) Control the UD hydraulic pressure to the pressure control valve for shift control
PCSVD(TCC) Control the hydraulic pressure for the damper clutch control
Receive the signal of engine reduction pressure operation from ECM via CAN
Torque reduction operation signal
communication
Send the signal of the current position of shift lever and vehicle speed and operate
Cluster
the lamp, distance meter and speed meter
TCM
The TCM which is adapted to the new small sized automatic transaxle (A4CF2) is integrated into the PCM and deliver information via
CAN communication.
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Item Bosch Tcm English
Hardware Integrated type
Duty driving Chopping method
Main oil pressure control components Turbin torque, Vehicle speed
ATF Temp. compensation control Independently
Direct control range Wide
● TLE6288 current control chip
The TLE6288 current control chip is installed into the TCM to regulate the solenoid control current and control the oil pressure
securely according to the change of the temperature and voltage. In this case, the control signal of solenoid valve is divided into the
Peak signal and the Hold signal.
1) Peak : The 12 voltage signal applied to move the solenoid plunger quickly.
2) Hold : The signal applied to keep holding the pulled solenoid valve.
FPC (Flexible Printed Circuit) Harness
The FPC (Flexible Printed Circuit) harness is composed of the thin and flat copper in the insulating film like electric wire.
Item Round Wire Type FPC Type

Weight (g) 96.6 72
Practical use of space Low High
TM installation capability Bad Good
Softness High Low
Drawing modification Normal Low
Quality occurring High Low
Tighten in solenoid valve Bad Good
Measurement Unstable Stable
CAN Communication
Layout
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ECM TCM CAN Communication Error Management
No. Item Error management
1 Engine rpm 3,000 RPM
2 Engine torque 80%
3 Vehicle speed 0 km/h
4 A/C Switch OFF
5 Engine coolant temperature 70°C
6 TPS 50%
7 Shift range hold signal OFF
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Automatic Transaxle System > Troubleshooting
English
(A4CF2)
TROUBLESHOOTING
Diagnostic Trouble Codes (Inspection Procedure)
Check the Diagnostic Trouble Codes
1. Turn the ignition switch to OFF.
2. Connect the Hiscan tool to the DLC connector for diagnosis.
3. Turn the ignition switch to ON.
4. Check the diagnostic trouble codes using the Hiscan tool.
5. Read the output diagnostic trouble codes. Then follow the remedy procedures according to the "DIAGNOSTIC
TROUBLE CODE DESCRIPTION" on the following pages.

• A maximum of 10 diagnostic trouble codes (in the sequence of occurrence) can be stored in the Random
Access Memory (RAM) incorporated within the control module.
• The same diagnostic trouble code can be stored one time only.
• If the number of stored diagnostic trouble codes or diagnostic trouble patterns exceeds 10, already stored
diagnostic trouble codes will be erased in sequence, beginning with the oldest.
• Do not disconnect the battery until all diagnostic trouble codes or diagnostic trouble patterns have been read
out, because all stored diagnostic trouble codes or diagnostic trouble patterns will be cancelled when the
battery is disconnected.
• All diagnostic trouble codes are deleted from memory the 200th time the ATF temperature reaches
50°C(122°F) after memorization of the most recent diagnostic code.
6. Delete the diagnostic trouble code.
7. Disconnect the Hiscan tool.

DTC cleaning should only be done with the scan tool.
Diagnostic Trouble Code Table
No Code Item MIL Remark
1 P0707 Transmission range sensor circuit low input ●
2 P0708 Transmission range sensor circuit high input ●
3 P0712 Transmission fluid temperature sensor "A" circuit low input ●
4 P0713 Transmission fluid temperature sensor "A" circuit high input ●
5 P0717 Input/turbine speed sensor "A" circuit no signal ●
6 P0722 Output speed sensor circuit no signal ●
7 P0731 Gear 1 incorrect ratio ●
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11 P0741 Torque converter clutch circuit performance or stuck off ●
12 P0742 Torque converter clutch circuit stuck on ●
13 P0743 Torque converter clutch circuit electrical ●
14 P0748 Pressure control solenoid valve(VFS) "A" Electrical X
15 P0750 Shift control solenoid valve "A" (ON/OFF control solenoid) ●
16 P0755 Shift control solenoid valve "B" (PCSVA) ●
17 P0760 Shift control solenoid valve "C" (PCSVB) ●
18 P0765 Shift control solenoid valve "D" (PCSVC) ●
19 U0001 High speed CAN communication bus off ●
20 U0100 Lost communication with ECM/PCM "A" X
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Automatic Transaxle System > Repair procedures
English
(A4CF2)
BASIC INSPECTION ADJUSTMENT
Transaxle Fluid Level
Inspection
1. Drive the vehicle until the fluid reaches normal operating temperature [70~80°C(158~176°F)].
2. Place the vehicle on a level surface.
3. Move the gear selector lever through all gear positions. This will fill the torque converter with trans fluid. Set the selector
lever to the "N" (Neutral) position.
4. Before removing the oil level gauge, wipe all contaminants from around the oil level gauge. Then take out the oil level
gauge and check the condition of the fluid.

If the fluid smells as if it is burning, it means that the fluid has been contaminated by fine particles from the
bushes and friction materials, a transmission overhaul may be necessary.
5. Check that the fluid level is in the "HOT" mark on the oil level gauge. If fluid level is low, add automatic transaxle fluid
until the level reaches the "HOT" mark.
Automatic transaxle fluid :
DIAMOND ATF SPIII, SK ATF SPIII
Automatic transaxle fluid capacity:
6.6liter(6.9 US qt, 5.81lmp.qt)

Low fluid level can cause a variety of abnormal conditions because it allows the pump to take in air along with
fluid. Air trapped in the hydraulic system forms bubbles, which are compressible. Therefore, pressures will be
erratic, causing delayed shifting, slipping clutches and brakes, etc. Improper filling can also raise fluid level too
high. When the transaxle has too much fluid, gears churn up foam and cause the same conditions which occur
with low fluid level, resulting in accelerated deterioration of automatic transaxle fluid. In either case, air bubbles can
cause overheating, and fluid oxidation, which can interfere with normal valve, clutch, and brake operation. Foaming
can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak.
6. Insert the oil level gauge securely.

When new, automatic transmission fluid should be red, The red dve is added so the assembly plant can identify it
as transmission fluid and distinguish it from engine oil or antifreeze. The red dve, which is not an indicator of fluid
quality, is not permanent. As the vehicle is driven the transmission fluid will begin to look darker. The color may
eventually appear light brown.
Replacement
If you have a fluid changer, use this changer to replace the fluid. If you do not have a fluid replace the fluid by the following procedure.
1. Disconnect the hose, which connects the transmission and the oil cooler (inside the radiator).
2. Start the engine and let the fluid drain out.
Running conditions : "N" range with engine idling
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The engine should be stopped within one minute after it is started. If the fluid has all drained out before then, the
engine should be stopped at that point.
3. Remove the drain plug(A) from the bottom of the transmission case to drain the fluid.
4. Install the drain plug via the gasket, and tighten it the specified torque.
Tightening torque :
35~45 Nm (3.5~4.5kgf.m, 25~32lbft)
5. Pour the new fluid in through the oil filler tube.

Stop pouring if the full volume of fluid cannot be poured in.
6. Repeat the procedure in step (2).

Check the old fluid for contamination. If it has been contaminated, repeat the steps (5) and (6).
7. Pour the new fluid in through the oil filler tube.
8. Reconnect the hose, which was disconnected in step (1) above, and firmly replace the oil level gauge.
(In case of this "replace", this means after wiping off any dirt around the oil level gauge, insert it into the filler tube.)
9. Start the engine and run it at idle for 1~2 minutes.
10. Move the select lever through all positions, and then move it to the "N" or "P" position.
11. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80°C(158~176°F)), and then check the
fluid level again. The fluid level must be at the HOT mark.
12. Firmly insert the oil level gauge into the oil filler tube.
Torque Converter Stall Test
This test measures the maximum engine speed when the select lever is at the "D" or "R" position and the torque converter stalls to test
the operation of the torque converter, starter motor and oneway clutch operation and the holding performance of the clutches and
brakes in the transmission.

Do not let anybody stand in front of or behind the vehicle while this test is being carried out.
1. Check the automatic transmission fluid level and temperature and the engine coolant temperature.
• Fluid level : At the HOT mark on the oil level gauge
• Fluid temperature : 80~100°C (176~212°F)
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• Engine coolant temperature : 80~100°C (176~212°F)
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2. Check both rear wheels (left and right).
3. Pull the parking brake lever on, with the brake pedal fully depressed.
5. Move the select lever to the "D" position, fully depress the accelerator pedal and take a reading of the maximum engine
speed at this time.

• The throttle should not be left fully open for any more than eight seconds.
• If carrying out the stall test two or more times, move the select lever to the "N" position and run the engine at
1,000 r/min to let the automatic transaxle fluid cool down before carrying out subsequent tests.
• Move the select lever to the "R" position and carry out the same test again.
Stall rpm : 2000~2700 RPM
Range Condition Passable cause

R range slip Reverse REV in D range normal
L/R in D range abnormal
D1 rang slip D range 1st/ Sports mode 1st L/R in reverse range abnormal
UD in reverse range normal
D3 range slip 3rd gear hold OD in 3rd gear slip
(1st and 2nd gear normal)
Forwarding, reverse slip D range, R range Torque converter
Oil pump, Manual valve in the valve
Driving device abnormal
Hydraulic Pressure Test
1. Warm up the engine until the automatic transaxle fluid temperature is 80~100°C(176~212°F).
2. Jack up the vehicle so that the wheels are free to turn.
3. Connect the special tools(0945221500, 0945221000, 0945221600) oil pressure gauge to each pressure discharge port.
4. Measure the hydraulic pressure at each port under the conditions given in the standard hydraulic pressure table, and
check that the measured values are within the standard value ranges.
5. If a value is outside the standard range, correct the problem while referring to the hydraulic pressure test diagnosis table.
a. Bottom side
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1. LUB pressure port 6. DA pressure port
2. RED pressure port 7. UD pressure port
3. OD pressure port 8. LR pressure port
4. 2/4 pressure port 9. DR pressure port
5. REV pressure port
Standard Hydraulic Pressure Table
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Automatic Transaxle System > AutomaticEnglish
Transaxle > Components and Components Location (A4CF2)
COMPONENTS(1)
1. Torque converter 20. Oil separate mounting bolt
2. Differential oil seal 21. Transfer driven gear
3. Converter housing 22. Output shaft speed sensor
4. Oil pump mounting bolt 23. Shift cable bracket
5. Oil pump assembly 24. Plug
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6. Thrust washer 25. Input shaft speed sensor
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7. Underdrive(U/D) clutch 26. Accumulator piston
8. Thrust bearing 27. Coil spring
9. Underdrive(U/D) clutch hub 28. Oring
10. Transfer drive gear mounting bolt 29. Oil filter
11. Transfer drive gear 30. Valve body assembly
12. Parking sprag shaft 31. Oil pan
13. Sprag spring 32. Drain plug
14. Parking sprag 33. Valve body cover bolt
15. Detent spring 34. Valve body connector
16. Manual control shaft 35. Valve body connector mounting clip
17. Spacer 36. Oil level gauge
18. Differential 37. Oil level gauge bracket bolt
19. Oil separate
COMPONENTS(2)
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38. Low & reverse brake piston 54. Dring
39. Low & reverse brake return spring 55. 2ND brake retainer
40. Low & reverse brake spring retainer 56. Snap ring
41. 2ND brake return spring 57. Low & reverse planetary gear set
42. Snap ring 58. Snap ring
43. Wave spring 59. Reverse sun gear
44. Low & reverse pressure plate 60. Thrust bearing
45. Low & reverse brake disc 61. Overdrive(O/D) hub
46. Snap ring 62. Thrust bearing
47. Reaction plate 63. Reverse & Overdrive(O/D) clutch
48. Snap ring 64. Thrust bearing
49. 2ND brake plate 65. Rear cover
50. 2ND brake disc 66. Rear cover bolt
51. 2ND brake pressure plate 67. One way clutch inner race
52. Dring 68. Low&reverse brake plate
53. 2ND brake piston 69. Transmission case
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Automatic Transaxle System > AutomaticEnglish
Transaxle > Repair procedures (A4CF2)
REMOVAL


1. Remove the engine cover.
(refer to Engine and Transaxle Assembly in EM group)
2. Remove the battery (A) after removing the battery terminal.
3. Remove the air duct (A).
4. Remove the air cleaner assembly (D) by disconnecting the AFS(Air Flow Sensor) connector (A), the clamp (B) and the
ECM connector (C).
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5. Remove the battery tray (A).
6. Remove the ground cable from transaxle (A).
7. Disconnect the inhibiter switch connector (A), solenoid valve connector (B) and the input speed sensor connector (C).
8. Disconnect the output speed sensor connector (A).
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9. Remove the control cable assembly (A).
10. Remove the oil cooler hoses (A).
11. Install the special tools (0920038001), the engine support fixture and the adapter on the engine assembly.
12. Remove the transaxle upper mounting bolts (A2ea) and the starter motor mounting bolts (B2ea).
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13. After removing the four bolts, take the transaxle insulator mounting bracket (A) off.
14. Remove the steering joint assembly bolt (A). (refer to Steering column/shaft in ST group)
15. Remove the front wheels and tires. (refer to removal in SS group)
16. Remove the side mud cover (A).
17. Remove the under shield cover (A).
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18. Drain the transaxle fluid by removing the oil drain plug (A).
19. Remove the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting nut from
the front knuckles. (refer to Front suspension system in SS group)
20. Remove the roll stopper mounting bolts (A, B).
21. Remove the muffler hanger rubber (A).
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22. Supporting the sub frame (A) with a jack and the Special tool (0962438000), remove the mounting bolts.(refer to
Stabilizer's removal in SS group)
23. Disconnect the drive shafts (A, B) from the transaxle.
24. Remove the oil pan protecting cover (A).
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25. Remove the intercooler hose (A).
26. Remove the transaxle housing guide (A).
27. Remove the torque converter assembly mounting bolts (A6ea).
28. Supporting the transaxle with a jack, remove the transaxle lower mounting bolts (B2ea, C2ea)
29. Lowering the jack slowly, remove the transaxle.

When removing the transaxle assembly, be careful not to damage any surrounding parts or body components.
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INSTALLATION
1. Install the transaxle lower mounting bolts (B2ea, C2ea) after fitting the transaxle assembly into the engine assembly.
Tightening torque :
[B] : 3550Nm (3.55.0kgf.m, 25.336.2lbft)
[C] : 4355Nm (4.35.5kgf.m, 31.139.8lbft)
2. Install the torque converter assembly mounting bolts (A6ea).
Tightening torque :
4653Nm (4.65.3kgf.m, 33.338.3lbft)
3. Install the transaxle housing guide (A).
Tightening torque :
3042Nm (3.04.2kgf.m, 21.730.4lbft)
4. Install the intercooler hose (A).
5. Install the oil pan protecting cover (A).
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6. Connect the drive shafts (A, B) to the transaxle.
7. Supporting the sub frame (A) with a jack and the Special tool(0962438000), install the mounting bolts. (refer to
Stabilizer's installation in SS group).
Tightening torque :
140160Nm (1416kgf.m, 101118lbft)
8. Install the muffler hanger rubber (A).
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9. Install the roll stopper mounting bolts (A, B).
Tightening torque :
5065Nm (56.5kgf.m, 36.247.0lbft)
10. Install the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting nut to the
front knuckles. (refer to Front suspension system in SS group)
11. Install the under shield cover (A).
12. Install the side mud cover (A).
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13. Install the front wheels and tires. (refer to installation in SS group)
14. Install the steering joint assembly bolt (A). (refer to Steering column/shaft in ST group)
15. Install the transaxle insulator mounting bracket bolts (A).
Tightening torque :
6080Nm (6.08.0kgf.m, 43.457.9lbft)
16. Install the transaxle upper mounting bolts (A2ea) the starter motor mounting bolts (B2ea).
Tightening torque :
[A] 6080Nm (6.08.0kgf.m, 43.457.9lbft)
[B] 3960Nm (3.96.0kgf.m, 28.243.4lbft)
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17. Remove the special tool (0920038001).
English
18. Connect the transaxle oil cooler hoses (A) to the tubes by fastening the clamps.
19. Install the control cable assembly (A).
20. Install the output speed sensor connector (A).
21. Connect the inhibiter switch connector (A), solenoid valve connector (B) and the input speed sensor connector (C).
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22. Install the ground cable (A) to transaxle.
23. Install the battery tray (A).
24. Install the air cleaner assembly (D) by connecting the AFS(Air Flow Sensor) connector (A), the clamp (B) and the ECM
connector (C).
25. Install the air duct (A).
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26. Install the engine cover.
(refer to Engine and Transaxle Assembly in EM group)
After completing the installation perform the following procedure;
• Adjust the shift cable.
• Refill the transaxle fluid.
• Clean the battery posts and cable terminals with sandpaper and grease them to prevent corrosion before
installing.

When replacing the automatic transaxle, reset the automatic transaxle’s values by using the High Scan Pro.
a. Connect the HiScan Pro connector to the data link connector under the crash pad and power cable to the cigar
jack under the center facia.
b. Turn the ignition switch on and power on the HiScan Pro.
c. Select the vehicle's name.
d. Select 'AUTOMATIC TRANSAXLE'.
e. Select 'RESETTING AUTO T/A VALUES' and perform the procedure
f. Perform the procedure by pressing F1 (REST).
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Valve Body System > Solenoid valve > English
Description and Operation (A4CF2)
DESCRIPTION
TCM calculates the best condition using the information from all kinds of sensors. If the solenoid valve receives the information on the
oil pressure, the solenoid valve actuates according to the driving signal. All kinds of regulators in the valve body are controlled to
change the oil passage and also the line pressure is controlled by TCM.
● PWM (Pulse Width Modulation) Solenoid Valve
Structure and functions
PWM solenoid valve is composed of five solenoid valves and the oil capacity in the solenoid valve is changed by the electric duty
value of TCM. The oil pressure of the valve body and the torque converter engages or disengages the damper clutch. The solenoid
valves send the operating oil pressure to the clutches and brakes at the each range and also control the strength and weakness of oil
pressure to reduce the shock when shifting the range.
PWM (Pulse Width Modulation) Solenoid
PWM solenoid valve
Range PCSVA PCSVB PCSVC PCSVD ON, OFF
(SCSVB) (SCSVC) (SCSVD) (TCC SV) (SCSVA)
N, P OFF ON ON OFF ON
1st ON ON OFF OFF ON
2nd ON OFF OFF ON OFF
3rd OFF ON OFF ON OFF
4th OFF OFF ON ON OFF
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Reverse OFF OFF ON OFF ON
English
LOW OFF ON OFF OFF ON
PWM (PULSE WIDTH MODULATION) SOLENOID VALVE CONTROL FEATURE
PWM solenoid valve is controlled linearly according to the duty ratio.
Oil pressure range:
0~4.3 kgf/cm² (0~422kpa, 0~61.2psi)
Type 3way & Normal High
Input voltage 12V
Coil resistance 3.2±0.2Ω (at 25°C, 77°F)
Cycle 50Hz
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Valve Body System > Solenoid valve > Repair
English
procedures (A4CF2)
REMOVAL
1. Remove the battery terminal.
2. Lift the vehicle.
3. Remove the under cover.
4. Loosen the drain plug and drain the transaxle oil.
5. Remove the oil pan. (Refer to Automatic transaxle's disassembly in 'A4CF2' overhaul manual)
6. Remove the oil filter.
7. Remove the valve body. (Refer to Valve body's disassembly in 'A4CF2' overhaul manual)
8. Disconnect the main harness(A) from valve body.
9. Remove the solenoid valve assembly(A).
INSTALLATION
1. Install the solenoid valve.

Apply the ATF oil or White Vaseline to the Oring not to be damaged.
2. Connect the solenoid valve connector to the valve body.
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English
When connecting the solenoid valve connector, check the connector for rust, dirt, or oil, then reconnect it.
3. Install the valve body. (Refer to Valve body's reassembly in 'A4CF2' overhaul manual)
Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lbft)
4. Install the oil filter.
Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lbft)
5. Continue to apply liquid gasket at application points at the oil pan with Ø2.5mm (0.098in) thickness.
Liquid gasket Part name : Threebond 1281B
6. Tighten the mounting bolt with the specified torque after installing the oil pan.
Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lbft)
7. Install the drain plug.
Tightening torque :
35~45Nm(3.5~4.5kgf.m, 25~32lbft)
8. Installation is the reverse of the removal.
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Valve Body System > VFS(Variable ForceEnglish
Solenoid) Valve > Description and Operation (A4CF2)
DESCRIPTION
VFS valve controls the regulator valve and varies the line pressure from 4.5bar to 10.5bar according to the throttle open angle and
the shift range. The holder is installed on the upper side of the case and the filter is installed to the two places on the holder outside
to prevent in the strange material from flowing in the VFS.
VFS (VARIABLE FORCE SOLENOID) VALVE CONTROL FEATURE
PWM solenoid valve is controlled linearly according to the current value.
type 3way & Normal High
Input voltage 12V
Coil resistance 3.5±0.2Ω(at 25°C, 77°F)
Operating current 0 ~ 1200 mA
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Valve Body System > VFS(Variable ForceEnglish
Solenoid) Valve > Repair procedures (A4CF2)
REMOVAL
8. Disconnect the VFS solenoid valve connector (A).
9. Remove the solenoid valve assembly (B).
INSTALLATION
1. Install the solenoid valve (B).

Apply the ATF oil or White Vaseline to the Oring not to be damaged.
2. Connect the solenoid valve connector (A).
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English
When connecting the solenoid valve connector, check the connector for rust, dirt, or oil, then reconnect it.
Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lbft)
Tightening torque :
5~7Nm(0.5~0.7kgf.m, 4~5lbft)
5. Continue to apply liquid gasket at application points at the oil pan with Ø2.5mm (0.098in) thickness.
Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lbft)
Tightening torque :
35~45Nm(3.5~4.5kgf.m, 25~32lbft)
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Automatic Transaxle Control System > Input
English
Speed Sensor > Description and Operation (A4CF2)
DESCRIPTION
1) Type : HALL SENSOR
Sensor type 2) Operating voltage : DC 12V
3) Current consumption : 22mA (Max)
1) Input speed sensor: Detect the input shaft rotation at the OD & REV retainer side to control oil
pressure when shifting.
Function
2) Feedback control, clutchclutch control, damper clutch control, shift range control, incorrect ratio
control and sensor trouble detection signal.
Connector
Item Inspection item Standard value

Air gap Input speed sensor 0.05in(1.3mm)
Sensor resistance Input speed sensor Over 1 MΩ
HIGH Over 4.8V
Output voltage
LOW Below 0.8V
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Automatic Transaxle Control System > Input
English
Speed Sensor > Repair procedures (A4CF2)
REMOVAL
2. Remove the battery and battery tray.
3. Remove the air duct.
4. Remove the air cleaner assembly. (Refer to Automatic transaxle's Removal)
5. Remove the input speed sensor connector (A).
6. Remove the input speed sensor(A).
INSTALLATION
1. Install the new Oring to the input speed sensor.
2. Install the input speed sensor (A).
Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lbft)

While installing the input speed sensor, do not allow dust or other foreign particles to enter the transaxle.
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3. Check the connector for dust, dirt, or oil, and then connect the input speed sensor connector (A) securely.
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Automatic Transaxle Control System > Output
English
Speed Sensor > Description and Operation (A4CF2)
DESCRIPTION
1) Type : HALL SENSOR
Sensor type 2) Output voltage : DC 12V
3) Current consumption : 22mA (Max)
1) Output speed sensor : Detect the output shaft rpm(T/F DRIVE GEAR RPM) at the T/F drive gear
Function 2) Feedback control, clutchclutch control, damper clutch control, shift range control, incorrect ratio
control and sensor trouble detection signal.
Connector
Item Inspection item Standard value

Air gap Output speed sensor 0.033in(0.85mm)
Sensor resistance Output speed sensor Over 1 MΩ
HIGH Over 4.8V
Output voltage
LOW Below 0.8V
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Automatic Transaxle Control System > Output
English
Speed Sensor > Repair procedures (A4CF2)
REMOVAL
5. Remove the output speed sensor connector(A).
6. Remove the output speed sensor(A).
INSTALLATION
1. Install the new Oring to the output speed sensor.
2. Remove the output speed sensor (A).
Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lbft)

While installing the output speed sensor, do not allow dust or other foreign particles to enter the transaxle.
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3. Check the connector for dust, dirt, or oil, then connect the output speed sensor connector (A) securely.
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Automatic Transaxle Control System > Transaxle
English
Oil Temperature Sensor > Description and Operation (A4CF2)
DESCRIPTION
1) Type : Thermister
Sensor type
2) Use available temperature :40~160°C(40~320°F)
1) Detect the temperature of ATF through the thermistor which is exposed outside.
Function and feature
2) When shifting the range, it is used as the oil pressure control information.
Connector
Temp.[°C(°F)] Resistance (KΩ) Temp.[°C(°F)] Resistance (KΩ)

40(40) 139.5 80(176) 1.08
20(4) 47.4 100(212) 0.63
0(32) 18.6 120(248) 0.38
20(68) 8.1 140(284) 0.25
40(104) 3.8 160(320) 0.16
60(140) 1.98
INSTALLATION LOCATION
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Automatic Transaxle Control System > Transaxle
English
Oil Temperature Sensor > Repair procedures (A4CF2)
REMOVAL
8. Disconnect the main harness connector (A) from the valve body.
INSTALLATION
1. Connect the main harness connector (A) to the valve body.

When connecting the oil temperature connector, check the connector for rust, dirt, or oil, then reconnect it.
Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lbft)
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Tightening torque :
5~7Nm(0.5~0.7kgf.m, 4~5lbft)
4. Continue to apply liquid gasket at application points at the oil pan with Ø0.098in(2.5mm) thickness.
Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lbft)
Tightening torque :
35~45Nm(3.5~4.5kgf.m, 25~32lbft)
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Automatic Transaxle Control System > Inhibiter
English
Switch > Description and Operation (A4CF2)
DESCRIPTION
1) Type : ROTARY
Sensor tyep 2) Available temperature range : 40~145°C(40~293°F)
3) Tightening torque : 10~12Nm(1.0~1.2kgf.m, 7~8lbft )
Function Detect the position of select lever through the contact switch. It makes starting possible in "P" and "N".
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2012 > D 1.6 TCIU2 > Automatic Transaxle System > Automatic Transaxle Control System > Inhibiter
English
Switch > Repair procedures (A4CF2)
REMOVAL
5. Disconnect the inhibitor switch connector (A).
6. Remove the control cable(A) from the manual control lever.
7. Remove the inhibitor switch and manual control lever.
INSTALLATION
1. Set the inhibitor switch to the "N" position.
2. Set the inhibitor switch control shaft to the "N" position.
3. Install the inhibitor switch and manual control lever.
Tightening torque
Shaft nut: 17~21Nm(1.7~2.1kgf.m, 12~15lbft)
Bolt(2EA): 10~12Nm(1.0~1.2kgf.m, 7~8lbft )
4. Install the control cable (A) to the manual control lever.
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5. Connect the inhibitor switch connector (A).
7. Turn the ignition switch ON after installation.
Move the shift lever from "P" range to "L" range, and verify that the A/T gear position indicator follows the transaxle
range switch.
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Contents
2012 > D 1.6 TCIU2 > Engine Electrical System > General Information > General Information English
THE MICRO 570 ANALYZER
The Micro 570 Analyzer provides the ability to test the charging and starting systems, including the battery, starter and alternator.

※ Because of the possibility of personal injury, always use extreme caution and appropriate eye protection when
working with batteries.
※ When charging battery by test result, Battery must be fully charged.
To get accurate test result, battery surface voltage must have subsided ahead before test when you test battery after
charged. (See following Battery Test Results)
Keypad
The Micro 570 button on the key pad provide the following functions :
Battery Test Procedure
1. Connect the tester to the battery.
– Red clamp to battery positive (+) terminal.
– Black clamp to battery negative () terminal.
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Connect clamps securely. If "CHECK CONNECTION" message is displayed on the screen, reconnect clamps
securely.
2. The tester will ask if the battery is connected "INVEHICLE" or "OUTOFVEHICLE". Make your selection by pressing
the arrow buttons; then press ENTER.
3. Select CCA and press the ENTER button.

CCA : Cold cranking amps, is an SAE specification for cranking batteried at 0.4°F (18°C).
4. Set the CCA value displayed on the screen to the CCA value marked on the battery label by pressing up and down
buttons and press ENTER.
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The battery ratings(CCA) displayed on the tester must be identical to the ratings marked on battery label.
5. The tester will conduct battery test.
6. The tester displays battery test results including voltage and battery ratings.
Battery Test Results
GOOD BATTERY No action is required.
GOOD RECHARGE Battery is in a good state.
Recharge the battery and use.
below.)
CHARGE & RETEST Battery is not charged properly.
– Charge and test the battery again.
below.)
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REPLACE BATTERY Replace battery and recheck the charging system. English
– Improper connection between battery and vehicle cables may cause "REPLACE
BATTERY". Retest the battery after removing cables and connecting the tester
to the battery terminal directly prior to replacing the battery.
BAD CELLREPLACE Charge and retest the battery.
– If the Micro 570 recommends "REPLACE BATTERY", replace the battery and
recheck the charging system.
[Charge and Retest method after battery charge]
Battery charge
Set battery charger to ‘Auto Mode’ (The Mode that charging current drops as the battery charges.) and charge battery
until charging current down close to zero or the charger alerts you with an alarm when charge is complete.
(Minimum charging time recommended: More than 3 hours with Auto Mode that explained above)
• If battery is not fully charged, battery surface voltage will be high while the amount of current charged (CCA) in
battery is low. If you measure the battery under this condition, tester may misjudge that battery sulfation occurred
because the amount of current in battery is too low in comparison with battery voltage.
* Surface voltage: When battery is charged electrolyte temperature increases and chemical reaction become
active resulting in an excessive increase of battery voltage.
It is known that it takes approximate one day to subside this increased surface voltage completely.
Battery Test after charge
Do not test battery right after the charge. Test battery after battery surface voltage has subsided as instructed in the
following procedure.
(1) When battery charge is complete, install the battery in the vehicle.
(2) Put IG key to ON position and turn on head lamp with low beam, and wait 5 minutes. (Discharge for 5 minutes)
(3) Turn off the head lamp and IG key, and wait 5 minutes. (Waiting for 5 minutes)
(4) Remove +, cable from the battery and test battery.

Whenever filing a claim for battery, the print out of the battery test results must be attached.
Starter Test Procedure
7. After the battery test, press ENTER immediately for the starter test.
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9. Cranking voltage and starter test results will be displayed on the screen.
Starter Test Results
CRANKING VOLTAGE System shows a normal starter draw.
NORMAL
CRANKING VOLTAGE LOW Cranking voltage is lower than normal level.
– Check starter.
CHARGE BATTERY The state of battery charge is too low to test.
– Charge the battery and retest.
REPLACE BATTERY Replace battery.
– If the vehicle is not started though the battery condition of "GOOD BATTERY" is
displayed, check wiring for open circuit, battery cable connection, starter and
repair or replace as necessary.
– If the engine does crank, check fuel system.

When testing the vehicle with old diesel engines, the test result will not be favorable if the glow plug is not heated.
Conduct the test after warming up the engine for 5 minutes.
Charging System Test Procedure
10. Press ENTER to begin charging system test.
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11. The tester displays the actual voltage of alternator.
Press ENTER to continue.
12. Turn off all electrical load and rev engine for 5 seconds with pressing the accelerator pedal. (Follow the instructions on
the screen)
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15. The tester will conduct charging system test during loads off.
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16. Turn on electrical loads (air conditioner, lamps, audio and etc). Press ENTER to continue.
17. The tester will conduct charging system test during loads on.
18. Rev engine for 5 seconds with pressing the accelerator pedal. (Follow the instructions on the screen)
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21. Turn off electrical loads (air conditioner, lamps, audio and etc). Turn the engine off.
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22. Charging voltage and charging system test results will be displayed on the screen.
Shut off engine end disconnect the tester clamps from the battery. Refer to the following table and take the appropriate
action as recommended by the Micro 570.
Charging System Test Results
CHARGING SYSTEM Charging system is normal.
NORMAL / DIODE RIPPLE
NORMAL
NO CHARGING VOLTAGE Alternator does not supply charging current to battery.
–
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Check belts, connection between alternator and battery and replace belts or
English
cable or alternator as necessary.
LOW CHARGING VOLTAGE Alternator does not supply charging current to battery and electrical load to system
fully.
– Check belts and alternator and replace as necessary.
HIGH CHARGING VOLTAGE The voltage from alternator to battery is higher than normal limit during voltage
regulating.
– Check connection and ground and replace regulator as necessary.
– Check electrolyte level in the battery.
EXCESS RIPPLE One or more diodes in the alternator is not functioning properly.
DETECTED – Check alternator mounting and belts and replace as necessary.
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2012 > D 1.6 TCIU2 > Engine Electrical System > General Information > Specifications English
SPECIFICATION
Starting System
Items Specification
Rated voltage 12 V, 1.7 kW
Starter Voltage 11 V
Noload characteristics Ampere 90A, MAX
Speed 2,600 rpm, MIN
Starter
(ISG System Equipped Voltage 11.5 V
Vehicle Only)
Charging System
Items Specification
Rate voltage 12 V, 120A
Speed in use 1,000 ~ 18,000 rpm
Alternator Voltage regulator IC Regulator builtin type
Regulator setting voltage 14.1 ± 0.3 V
Temperature compensation 3.5 ± 2 mV / °C
Type 54 26 GL
Cold cranking amperage [at 18°C(0.4°F)] 600 A
Battery
Reserve capacity 110 min
Specific gravity [at 20°C(68°F)] 1.280 ± 0.01
Type AGM Battery 70Ah
Battery
(ISG System Equipped Cold cranking amperage [at 18°C(0.4°F)] 760 (EN) / 760 (SAE)
Vehicle Only)

• COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminal
• RESERVE CAPACITY RATING is amount of time a battery can deliver 25A and maintain a minimum terminal
voltage of 10.5V at 26.7°C(80.1°F).
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English
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2012 > D 1.6 TCIU2 > Engine Electrical System > General Information > Troubleshooting English
TROUBLESHOOTING
Starting System
Symptom Suspect area Remedy
Battery cables loose, corroded or worn Repair or replace cables
out
Transaxle range switch (Vehicle with Refer to TR groupautomatic transaxle
automatic transaxle only)
Fuse blown Replace fuse
Starter motor faulty Replace
Ignition switch faulty Replace
Engine cranks slowly Battery charge low Charge or replace battery
out
Starter keeps running Starter motor Replace
Ignition switch Replace
Starter spins but engine will Short in wiring Repair wiring
not crank
Pinion gear teeth broken or starter motor Replace
Ring gear teeth broken Replace fly wheel or torque converter
Charging System
Charging warning indicator Fuse blown Check fuses
does not light with ignition
Light burned out Replace light
switch "ON" and engine off.
Wiring connection loose Tighten loose connection
Charging warning indicator Drive belt loose or worn Adjust belt tension or replace belt
does not go out with engine
Battery cable loose, corroded or worn Inspect cable connection, repair or replace
running. (Battery requires
cable
frequent recharging)
Fuse blown Check fuses
Electronic voltage regulator or alternator Replace voltage regulator or alternator
Wiring Repair or replace wiring
Overcharge Electronic voltage regulator Replace voltage regulator
Voltage sensing wire Repair or replace wiring
Discharge Drive belt loose or worn Adjust belt tension or replace belt
Wiring connection loose or short circuit Inspect wiring connection, repair or replace
wiring
Fuse blown Check fuses
Electronic voltage regulator or alternator Replace voltage regulator or alternator
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Poor grounding Inspect ground or repair English
Worn battery Replace battery
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2012 > D 1.6 TCIU2 > Engine Electrical System > Charging System > Description and Operation
English
DESCRIPTION
The charging system included a battery, an alternator with a builtin regulator, and the charging indicator light and wire.
The Alternator has eight builtin diodes, each rectifying AC current to DC current.
Therefore, DC current appears at alternator "B" terminal.
In addition, the charging voltage of this alternator is regulated by the battery voltage detection system.
The alternator is regulated by the battery voltage detection system. The main components of the alternator are the rotor, stator,
rectifier, capacitor brushes, bearings and Vribbed belt pulley. The brush holder contains a builtin electronic voltage regulator.
Alternator Management System
Alternator management system controls the charging voltage set point in order to improve fuel economy, manage alternator load
under various operating conditions, keep the battery charged, and protect the battery from overcharging. Battery sensor is mounted
on battery () terminal. It transmits battery voltage, current, temperature information to ECM. ECM controls generating voltage by duty
cycle based on the signals from battery sensor and vehicle operating conditions.
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2012 > D 1.6 TCIU2 > Engine Electrical System > Charging System > Repair procedures English
ONVEHICLE INPECTION

Check The Battery Terminals And Fuses
2. Check the fuses for continuity.
Visually Check Alternator Wiring And Listen For Abnormal Noises
Check Discharge Warning Light Circuit
3. Turn the ignition switch "ON". Check that the discharge warning light is lit.
4. Start the engine. Check that the light is lit.
If the light does not go off as specified, troubleshoot the discharge light circuit.
Inspect Charging System
Voltage Drop Test Of Alternator Output Wire
This test determines whether or not the wiring between the alternator "B" terminal and the battery (+) terminal is good by the voltage
drop method.
Preparation
2. Disconnect the output wire from the alternator "B" terminal. Connect the (+) lead wire of ammeter to the "B" terminal of
alternator and the () lead wire of ammeter to the output wire. Connect the (+) lead wire of voltmeter to the "B" terminal
of alternator and the () lead wire of voltmeter to the (+) terminal of battery.
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Test
2. Turn on the headlamps and blower motor, and set the engine speed until the ammeter indicates 20A.
And then, read the voltmeter at this time.
Result
Standard value : 0.2V max
2. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case check th
e wiring from the alternator "B" terminal to the battery (+) terminal. Check for loose connections, color change due to an
overheated harness, etc. Correct them before testing again.
3. Upon completion of the test, set the engine speed at idle.
Turn off the headlamps, blower motor and the ignition switch.
Output Current Test
This test determines whether or not the alternator gives an output current that is equivalent to the normal output.
Preparation
Check the battery installed in the vehicle to ensure that it is good condition. The battery checking method is described
in the section "Battery".
Check the tension of the alternator drive belt. The belt tension check method is described in the section "Inspect drive
belt".

6. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the alternator "B"
terminal and () lead wire to a good ground.
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Test
1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the open
circuit in the wire between alternator "B" terminal and battery (+) terminal or poor grounding is suspected.
2. Start the engine and turn on the headlamps.
3. Set the headlamps to high beam and the heater blower switch to HIGH, quickly increase the engine speed to 2,500 rpm
and read the maximum output current value indicated by the ammeter.

After the engine start up, the charging current quickly drops. Therefore, the above operation must be done quickly
to read the maximum current value correctly.
Result
Limit value (120A alternator) : 60A min.

• The output current value changes with the electrical load and the temperature of the alternator itself.
Therefore, the nominal output current may not be obtained. If such is the case, keep the headlamps on the
cause discharge of the battery, or use the lights of another vehicle to increase the electrical load.
The nominal output current may not be obtained if the temperature of the alternator itself or ambient
temperature is too high. In such a case, reduce the temperature before testing again.
2. Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch.
Regulated Voltage Test
Preparation
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Check that the battery installed on the vehicle is fully charged. The battery checking method is described in the section
English
"Battery".
Check the alternator drive belt tension. The belt tension check method is described in the section "Inspect drive belt".
4. Connect a digital voltmeter between the "B" terminal of the alternator and ground. Connect the (+) lead of the voltmeter
to the "B" terminal of the alternator. Connect the () lead to good ground or the battery () terminal.
6. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire.
Connect the () lead wire of the ammeter to the disconnected output wire.
Test
Voltage: Battery voltage
If it reads 0V, there is an open circuit in the wire between the alternator "B" terminal and the battery and the battery ()
terminal.
less
Result
1. If the voltmeter reading dosen't agree with the standard value, the voltage regulator or the alternator is faulty.
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2012 > D 1.6 TCIU2 > Engine Electrical System > Charging System > Alternator > Components and
English
Components Location
COMPONENTS
1. Overrunning Alternator Pulley(OAP) 4. Regulator
2. Front housing complete 5. Rectifier assembly
3. Rotor assembly 6. Cover
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2012 > D 1.6 TCIU2 > Engine Electrical System > Charging System > Alternator > Repair procedures
English
REPLACEMENT
1. Disconnect the battery negative terminal first, then the positive terminal.
2. Disconnect the alternator connector(A), and remove the cable(B) from alternator "B" terminal.
3. Remove the alternator(A).
Tightening torque :
38.2 ~ 58.8N.m (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lbf.ft)
DISASSEMBLY
1. Remove the B terminal mounting nut(A) and rear cover nut(B).
2. Remove the alternator cover(A) using a screw driver(B).
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English
3. Loosen the mounting bolts(A) and disconnect the brush holder assembly(B).
4. Remove the slip ring guide(A).
5. Remove the pulley(A) using the special tool.
6. Unsolder the 3 stator leads(A).
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English
7. Loosen the 4 through bolts(A).
8. Disconnect the rotor(A) and cover(B).
9. Reassembly is the reverse order of disassembly.
INSPECTION
Rotor
1. Check that there is continuity between the slip rings (C).
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2. Check that there is no continuity between the slip rings and the rotor (B) or rotor shaft (A). English
Stator
1. Check that there is continuity between each pair of leads (A).
3. If the coil fails either continuity check, replace the alternator.
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2012 > D 1.6 TCIU2 > Engine Electrical System > Charging System > DC DC converter > Components
English
COMPONENT LOCATION
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2012 > D 1.6 TCIU2 > Engine Electrical System > Charging System > DC DC converter > Schematic
English
Diagrams
CIRCUIT DIAGRAM

In case of IGN 2 with connecting battery, input the signal ‘ISG Start’ then BY PASS RELAY will be ON, after boosting
voltage (12±0.6V) of low battery, if the battery voltage is over 12±0.5V then BY PASS RELAY will be OFF.
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In the ISG mode, if the power of an audio system turns OFF by drawdown while “Auto Starting” or “Idle Starting”
English
function operates, replace the DC/DC converter.
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2012 > D 1.6 TCIU2 > Engine Electrical System > Charging System > DC DC converter > RepairEnglish
procedures
REPLACEMENT
1. Disconnect the battery negative terminal.
2. Remove the passenger’s crash pad side cover (A).
3. Remove the glove box (A) and housing (B). (Refer to glove box In BD group)
4. Disconnect the connector (A) and then remove the DC/DC converter (B).
Tightening torque :
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Nut :16.7 ~ 25.5Nm (1.7 ~ 2.6kgf.m, 12.3 ~ 18.8lbft)
English
Bolt : 19.6 ~ 29.4Nm (2.0 ~ 3.0kgf.m, 14.5 ~ 21.7lbft)
5. Installation is reverse order of removal.

After disconnecting then reconnecting the battery negative cable, the ISG function dose not operates until the
system is stabilized, about 4 hours.
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2012 > D 1.6 TCIU2 > Engine Electrical System > Charging System > Battery > Description andEnglish
Operation
DESCRIPTION
[NONISG Type]
1. The maintenancefree battery is, as the name implies, totally maintenance free and has no removable battery cell caps.
2. Water never needs to be added to the maintenancefree battery.
3. The battery is completely sealed, except for small vent holes in the cover.

After disconnecting then reconnecting the battery negative cable, reset some parts that require the reset procedures.
(Refer to BE group – General Information)
[ISG Type]
AGM battery is used for especially heavy load on the vehicle network depending on equipment and requirements. AGM stands for
Absorbent Glass Material Battery; that is absorbent glass fibre fleece. AGM batteries are fitted in models with electrical
loads/consumers which have a high energy demand.
The constantly increasing energy demand of modern vehicle electrical systems calls for ever more powerful battery solutions.
The power consumption is considerable even when the vehicle is parked.
The somewhat higher price compared with a battery of similar size is fully balanced by the following benefits:
– Significantly longer service life
– Increased starting reliability at low temperatures
– 100 % freedom from maintenance
– Low risk in event of an accident (reduced risk to the environment)
Recharging [ISG Type]
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Check the battery condition English
The battery condition cannot be determined solely on the basis of the battery charge state. If there is a suspicion of a damaged
battery, check the battery condition whit battery tester and investigate the cause by means of the test module. With a low battery
charge state, recharge the battery.
Recharging the AGM battery
The battery may be charged using the battery chargers at a constant charge voltage of 14.8V.
If possible, the battery temperature during charging should be between 20°C and 30°C.
Only chargers with voltage clamping (IU or WU curve) may be used or chargers with IUoU curve which have a trickle.
IU or WU charging technique
Optimized charging voltage for IU or WU: 14.7V (at 20°C ~ 30°C) about 24 hours
Min. charging voltage at 20°C: 14.4V
Max. charging voltage at 20°C: 14.8V
10% of capacity is recommended as charging current (e.g. 60Ah : 10 = 6,0A charging current).

Do not charge the AGM battery with>15.2V. No quickcharging routines.

If the battery is charged directly at the battery terminals on vehicles with battery sensor, misinterpretations of battery
condition and under certain circumstances also unwanted Check Control messages or fault memory entire can occur.
If the battery is charged directly at the battery (+),() terminals on vehicles with battery sensor, the battery sensor
should be reinstalled and then, battery sensor recalibration procedure should be performed.
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2012 > D 1.6 TCIU2 > Engine Electrical System > Charging System > Battery > Repair procedures
English
INSPECTION
Battery Diagnostic Flow
Vehicle parasitic current inspection
1. Turn the all electric devices OFF, and then turn the ignition switch OFF.
2. Close all doors except the engine hood, and then lock all doors.
(1) Disconnect the hood switch connector.
(2) Close the trunk lid.
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(3) Close the doors or remove the door switches. English
3. Wait a few minutes until the vehicle’s electrical systems go to sleep mode.

For an accurate measurement of a vehicle parasitic current, all electriacl systems should go to sleep mode. (It
takes at least one hour or at most one day.) However, an approximate vehicle parasitic current can be measured
after 10~20 minutes.
4. Connect an ammeter in series between the battery () terminal and the ground cable, and then disconnect the clamp
from the battery () terminal slowly.

Be careful that the lead wires of an ammeter do not come off from the battery () terminal and the ground cable to
prevent the battery from being reset. In case the battery is reset, connect the battery cable again, and then start
the engine or turn the ignition switch ON for more than 10 sec. Repeat the procedure from No. 1.
To prevent the battery from being reset during the inspection,
a. Connect a jump cable between the battery () terminal and the ground cable.
b. Disconnect the ground cable from the battery () terminal.
c. Connect an ammeter between the battery () terminal and the ground cable.
d. After disconnecting the jump cable, read the current value of the ammeter.
5. Read the current value of the ammeter.
• If the parasitic current is over the limit value, search for abnormal circuit by removing a fuse one by one and
checking the parasitic current.
• Check the parasitic current again, and search for suspected unit by removing a unit connected with the abnormal
circuit one by one.
Limit value (after 10~20 min.) : Below 50mA
CLEANING

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English
8. Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged or frayed cables
and broken terminal clamps.

batteries being charged or which have recently been charged. Do not break live circuit at the terminals of
batteries being charged.
A spark will occur when the circuit is broken. Keep open flames away from battery.
REPLACEMENT
[ISG Type]

ISG (Idle stop & go) system equipped vehicle always use the AGM battery only. If flooded battery has installed, this
can potentially lead to engine electrical trouble or ISG system error.
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1. Disconnect the battery terminals, negative first. English
2. Remove the battery bracket.
3. Replace same capacity of the AGM battery.
AGM battery60Ah
4. Install the battery bracket and connect the terminals.

Ensure the AGM battery is placed correctly on the battery tray.
In all cases, an AGM battery must be installed and the battery sensor calibrated for the ISG system to function.
After the battery has been changed or disconnected, the battery sensor must be recalibrated.
After connecting the battery, start the engine at least once.
Then park the car for at least 4 hours with the ignition off in the ignition switch OFF door closed, hood switch off state.
After the 4 hours, the engine should be started two times. At this time the battery sensor will be recalibrated. (Refer to
"Battery sensor recalibration procedure" in FL group)
But first 25 times, the ISG function can operates regardless of ISG system stability for ISG function operating check.

Do not open the AGM battery.
The AGM battery must not be opened under any circumstances as the introduction of oxygen from the air will cause
the battery to lose its chemical equilibrium and rendered nonoperational.
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2012 > D 1.6 TCIU2 > Engine Electrical System > Charging System > Battery Sensor > Description and
English
Operation
DESCRIPTION
Vehicles have many control units that use more electricity. These units control their own system based on information from diverse
sensors. It is important to have a stable power supply as there diverse sensors giving a variety of information. Battery sensor is
mounted on battery () terminal. It transmits battery voltage, current, temperature information to ECM. ECM controls generating
voltage by duty cycle based on these signals.

When battery sensor signal fault occurs, inspect the vehicle parasitic draw in advance after inspecting the sensor
because the sensor will behave abnormally when the parasitic draw is more than 100mA. (Refer to vehicle parasitic
current inspection)

Perform the following process after replace the battery sensor. (Refer to "Battery sensor recalibration procedure" in FL
group)
– Ignition switch ON/OFF.
– Park the vehicle about 4 hours.
– After 4 hours later, check the SOC (State of charge) of battery using GDS.
– After engine start ON/OFF 2 times or more, check the SOF (State of function) of battery using GDS.

For the vehicle equipped with a battery sensor, be careful not to damage the battery sensor when the battery is
replaced or recharged.
1) When replacing the battery, it should be same one (type, capacity and brand) that is originally installed on your
vehicle. If a battery of a different type is replaced, the battery sensor may recognize the battery to be abnormal.
2) When installing the ground cable on the negative post of battery, tighten the clamp with specified torque of
4.0~6.0N.m (0.4~0.6kgf.m, 3.0~4.4lbft). An excessive tightening torque can damage the PCB internal circuit of
battery sensor or the negative post of battery.
3) When recharging the battery, ground the negative terminal of the booster battery to the vehicle body.
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2012 > D 1.6 TCIU2 > Engine Electrical System > Starting System > Description and OperationEnglish
DESCRIPTION
[NONISG Type]
The starting system includes the battery, starter, solenoid switch, ignition switch, ignition lock switch, connection wires and the battery
cable.
The contacts close and the starter motor cranks. In order to prevent damage caused by excessive rotation of the starter armature
when the engine starts, the clutch pinion gear overruns.
[ISG Type]
In conjunction with the ISG function, the starter motor must do a great deal more work. The starter motor is therefore configured for a
significantly higher number of start cycles. The components of the starter motor have been adapted to the higher requirements.

There are two kinds of starter, ISG type starter and the other.
When replace the starter, confirm that the part number and connector shape.

ISG (Idle stop & go) system equipped vehicle always use the ISG type starter only. If the other starter has installed,
this can potentially lead to engine electrical trouble or ISG system error.

Do not disassemble the ISG type starter.
If the starter troubles occur, replace the starter.
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2012 > D 1.6 TCIU2 > Engine Electrical System > Starting System > Repair procedures English
TROUBLESHOOTING
Starter Circuit

If the starter normally cranks the engine, starting system is OK. If the starter will not crank the engine at all, go to next
step.
If the starter cranks normally the engine, repairing the loose connection repaired the problem. The starting system is
now OK.
4. Disconnect the connector from the Sterminal of solenoid. Connect a jumper wire from the Bterminal of solenoid to the
Sterminal of solenoid.
• Check the wire and connectors between the driver's underdash fuse/relay box and the ignition switch, and
between the driver's underdash fuse/relay box and the starter.
Stater Solenoid Test
1. Disconnect the field coil wire from the Mterminal of solenoid switch.
2. Connect a 12V battery between Sterminal and the starter body.
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English
3. Connect the field coil wire to the Mterminal.

This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
4. If the pinion moves out, the pullin coil of solenoid is working properly.
If the pinion does not move, replace the solenoid.
5. Diconnect the field coil wire from the Mterminal.
6. If the pinion has moved out, the holdin coil of the solenoid is working properly.
If the pinion moves in, replace the solenoid.
Free Running Test
1. Place the starter motor in a vise equipped with soft jaws and connect a fullycharged 12volt battery to starter motor as
follows.
2. Connect a test ammeter (100ampere scale) and carbon pile rheostats shown is the illustration.
5. Connect the battery cable from battery's negative post to the starter motor body.
6. Adjust until battery voltage shown on the voltmeter reads 11volts.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely.
Current : 90A max
Speed : 2,600 rpm
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2012 > D 1.6 TCIU2 > Engine Electrical System > Starting System > Starter > Components andEnglish
Components Location
COMPONENTS
1. Lever 6. Nut 11. Amature assembly

2. Lever packing 7. Front bracket 12. Washer
3. Plate 8. Stop ring 13. York assembly
4. Magnetic switch 9. Stopper 14. Rear bracket
5. Spring washer 10. Overrunning clutch
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2012 > D 1.6 TCIU2 > Engine Electrical System > Starting System > Starter > Repair procedures
English
REPLACEMENT
2. Disconnect the starter cable(A) from the B terminal on the solenoid then disconnect the connector(B) from the S
terminal.
Tighting torque :
38.2 ~ 58.8 Nm (3.9 ~ 6.0 kgf.m, 28.2 ~ 43.4 lbft)
DISASSEMBLY
1. Disconnect the Mterminal(A) on the magnet switch assembly(B).
2. After loosening the 2 screws(A), detach the magnet switch assembly(B).
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English
3. Loosen the brush holder mounting screw(A) and through bolts(B).
4. Remove the rear bracket(A) and brush holder assembly(B).
5. Remove the yoke(A) and armature(B).
6. Remove the lever plate(A) and planet shaft packing(B).
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English
7. Disconnect the planet gear(A).
8. Disconnect the planet shaft assembly(A) and lever(B).
9. Press the stopper(A) using a socket(B).
10. After removing the stop ring(A) using stop ring pliers(B).
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English
11. Disconnect the stopper(A), overrunning clutch(B), internal gear(C) and planet shaft(D).
12. Reassembly is the reverse of disassembly.

Using a suitable pulling tool(A), pull the overrunning clutch stopper(C) over the stop ring(B).
INSPECTION
Armature
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace
the armature.
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English
4. Check the commutator(A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the
following specifications, or recondition with #500 or #600 sandpaper(B).
5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.
Commutator diameter
Standard (New) : 29.4 mm (1.1575 in)
6. Measure the commutator(A) runout.
• If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between
the segments.
• If the commutator run out is not within the service limit, replace the armature.
Commutator runout
Standard (New) : 0.02mm (0.0008in.) max
Service limit : 0.05mm (0.0020in.)
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English
7. Check the mica depth(A). If the mica is too high(B), undercut the mica with a hacksaw blade to the proper depth. Cut
away all the mica(C) between the commutator segments. The undercut should not be too shallow, too narrow, or v
shaped(D).
Commutator mica depth
Standard (New) : 0.5 mm (0.0197 in.)
Limit : 0.2mm (0.0079 in.)
8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace
the armature.
9. Check with an ohmmeter that no continuity exists between the commutator(A) and armature coil core(B), and between
the commutator and armature shaft(C). If continuity exists, replace the armature.
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Inspect Starter Brush English
Brushes that are worm out, or oilsoaked, should be replaced.
Starter Brush Holder
Make sure there is no continuity between the (+) brush holder (A) and () plate (B). If there is continuity, replace the brush holder
assembly.
Overrunning Clutch
2. Rotate the overrunning clutch both ways.
Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction of it locks in both
3. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly. (the gear is not available
separately)
CLEANING
1. Do not immerse parts in cleaning solvent.
Immersing the yoke assembly and/or armature will damage the insulation wipe these parts with a cloth only.
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2. Do not immerse the drive unit in cleaning solvent.
English
The overrun clutch is prelubricated at the factory and solvent will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.
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2012 > D 1.6 TCIU2 > Engine Electrical System > Starting System > Starter Relay > Repair procedures
English
INSPECTION
2. Remove the starter relay(A).
3. Using an ohmmeter, check that there is continuity between each terminal.
Terminal Continuity
30 87 NO
85 86 YES
4. Apply 12V to terminal 85 and ground to terminal 86.
Check for continuity between terminals 30 and 87.
5. If there is no continuity, replace the starter relay.
6. Install the starter relay.
7. Install the fuse box cover.
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2012 > D 1.6 TCIU2 > Engine Electrical System > Preheating System > Components and Components
English
Location
COMPONENTS
1. Glow plug connector 3. Glow plug
2. Glow plug plate
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2012 > D 1.6 TCIU2 > Engine Electrical System > Preheating System > Repair procedures English
INSPECTION
Preheating System
Conditions before inspection :
Battery voltage : 12V
Cooling water temperature : Below 30°C (86°F)
(Disconnect the water temperature sensor connector).

Reconnect the water temperature sensor connector after inspection.
1. Connect voltmeter between glow plug plate and plug body (ground).
2. Check indicated value on voltmeter with ignition switch ON.
3. Check that preheat indication lamp lights for about 6 seconds and indicates battery voltage (about 9V or over) for about
36 seconds immediately after ignition switch is turned on. [At cooling water temperature 20°C (68.0°F)]

Continuity time varies depending upon cooling water temperature.
4. After checking 3, set ignition switch at START position.
5. The system is normal if battery voltage (about 9V or over) is generated for about 6 seconds during engine cranking and
after start operation. [at cooling water temperature 20°C (68.0°F)]
6. When the voltage or continuity time is not normal, check the terminal voltage in glow control unit, and single parts.
Glow Plug
1. Check the continuity between the terminal and body as illustrated. Replace if discontinuity or with large resistance.
Standard value : 0.25Ω

Remove oil from plug before measuring as glowplug resistance is very small.
2. Check for rust on glow plug plate.
3. Check glow plug for damage.
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English
Glow Plug Relay
1. Remove the glow plug relay.
2. Inspect the relay continuity.
– Check that there is no continuity between terminals 1 and 5.
If there is continuity, replace the relay.
3. Inspect the relay operation.
– Apply battery positive voltage across terminals 2 and 4.
4. Install the glow plug relay.
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2012 > D 1.6 TCIU2 > Engine Electrical System > Cruise Control System > Schematic Diagrams
English
SYSTEM BLOCK DIAGRAM
Component Parts And Function Outline
Component part Function
Vehiclespeed sensor Converts vehicle speed to pulse.
ECM Receives signals from sensor and control switches.
Cruise control indicator Illuminate when CRUISE main switch is ON (Built into
cluster)
Cruise Control switches ON/OFF switch Switch for automatic speed control power supply.
Speed limit control switches
Resume/Accel switch Controls automatic speed control functions by
Set/Coast switch Resume/Accel switch (Set/Coast switch)
Cancel switches Cancel switch Sends cancel signals to ECM.

Brakepedal switch
Transaxle range switch (A/T)
Injector Regulates fuel injection quantity by ECM.
* ETS : Electronic Throttle System
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2012 > D 1.6 TCIU2 > Engine Electrical System > Cruise Control System > Description and Operation
English
CRUISE CONTROL
The cruise control system is engaged by the cruise "ON/OFF" main switch located on right of steering wheel column. The system has
the capability to cruise, coast, accelerate and resume speed.
It also has a safety interrupt, engaged upon depressing brake or shifting select lever.
The ECM is the control module for this system. The main components of cruise control system are mode control switches,
transmission range switch, brake switch, vehicle speed sensor, ECM and injector.
The ECM contains a low speed limit which will prevent system engagement below a minimum speed of 40km/h (25mph).
The operation of the controller is controlled by mode control switches located on steering wheel.
Transmission range switch and brake switch are provided to disengage the cruise control system. The switches are on brake pedal
bracket and transmission. When the brake pedal is depressed or select lever shifted, the cruise control system is electrically
disengaged and the throttle is returned to the idle position.
Cruise main switch (ON/OFF)
The cruise control system is engaged by pressing the cruise "ON/OFF" main switch. Pressing the cruise "ON/OFF" main switch again
releases throttle, clears cruise memory speed, and puts vehicle in a noncruise mode.
Set/Coast switch (SET/–)
The "SET/–" switch located on right of steering wheel column has two functions.
The set function Push the "SET/–" switch and release it at the desired speed. The SET indicator light in the instrument cluster will
illuminate. Release the accelerator pedal. The desired speed will automatically be maintained.
The coast function Push the "SET/–" switch and hold it when the cruise control is on. The vehicle will gradually slow down. Release
the switch at the desired speed. The desired speed will be maintained.
Push the "SET/–" switch and release it quickly. The cruising speed will decrease by 2.0km/h (1.2mph).
Resume/Accel switch (RES/+)
The "RES/+" switch located on right of steering wheel column has two functions.
The resume function If any method other than the cruise “ON/OFF” main switch was used to cancel cruising speed temporarily and
the system is still activated, the most recent set speed will automatically resume when the "RES/+" switch is pushed. It will not
resume, however, if the vehicle speed has dropped below approximately 40km/h (25mph).
The accel function Push the "RES/+" switch and hold it when the cruise control is on. The vehicle will gradually accelerate. Release
the switch at the desired speed. The desired speed will be maintained.
Push the "RES/+" switch and release it quickly. The cruising speed will increase by 2.0km/h (1.2mph).
Cancel switch (CANCEL)
The cruise control system is temporarily disengaged by pushing the "CANCEL" switch.
Cruise speed canceled by this switch can be recovered by pushing the "RES/+" switch.
Speed Limit Control System
The speed limit control system operates by the speed limit ONOFF switch on the steering wheel, and limit speed can be set by
“RES/+” or “SET/“ switch. When activated the speed limit system illuminate on the instrument cluster. Drive over the preset speed
limit, the set speed limit will blink and chime will sound until return the vehicle speed within speed limit. While speed limit system in
operation, the cruise control system cannot be activated.
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2012 > D 1.6 TCIU2 > Engine Electrical System > Cruise Control System > Troubleshooting English
Trouble Symptom 1
Trouble Symptom 2
The set vehicle speed varies greatly
Malfunction of the vehicle speed sensor Repair the vehicle speed sensor
upward or downward
circuit system, or replace the part
"Surging" (repeated alternating
after setting Malfunction of ECM Check input and output signals at ECM
Trouble Symptom 3
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Trouble symptom Probable cause Remedy English
Damaged or disconnected wiring of the Repair the harness or replace the brake
The CC system is not canceled when brake pedal switch pedal switch
the brake pedal is depressed
Malfunction of the ECM signals Check input and output signals at ECM
Trouble Symptom 4
Damaged or disconnected wiring of
The CC system is not canceled when Repair the harness or repair or replace
inhibitor switch input circuit
the shift lever is moved to the "N" the inhibitor switch
position (It is canceled, however, when Improper adjustment of inhibitor switch
the brake pedal is depressed)
Trouble Symptom 5
Temporary damaged or disconnected Repair the harness or replace the
Cannot decelerate (coast) by using the wiring of "SET/–" switch input circuit "SET/–" switch
"SET/–" switch
Trouble Symptom 6
Damaged or disconnected wiring, or
Repair the harness or replace the
Cannot accelerate or resume speed by short circuit, or "RES/+" switch input
"RES/+" switch
using the "RES/+" switch circuit
Trouble Symptom 7
CC system can be set while driving at a Malfunction of the vehiclespeed sensor Repair the vehicle speed sensor
vehicle speed of less than 40km/h circuit system, or replace the part
(25mph), or there is no automatic
cancellation at that speed Malfunction of the ECM signals Check input and output signals at ECM
Trouble Symptom 8
The cruise main switch indicator lamp Damaged or disconnected bulb of
does not illuminate (But CC system is cruise main switch indicator lamp Repair the harness or replace the part.
normal) Harness damaged or disconnected
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2012 > D 1.6 TCIU2 > Engine Electrical System > Cruise Control System > Cruise Control Switch >
English
Schematic Diagrams
CIRCUIT DIAGRAM
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2012 > D 1.6 TCIU2 > Engine Electrical System > Cruise Control System > Cruise Control Switch >
English
Repair procedures
REMOVAL
1. Remove the air bag module assembly. (Refer to 'RT', 'ST' group)
INSPECTION
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Contents
2012 > D 1.6 TCIU2 > Engine Mechanical System > General Information > Specifications English
SPECIFICATIONS
Description Specifications (D4FB) Limit

General
Type Inline, DOHC
Bore 77.2mm (3.0394in)
Stroke 84.5mm (3.3268in)
Total displacement 1,582 cc (96.54 cu.in)
Firing order 1342
Valve timing
Opens (ATDC) 17°5' ±4°
Intake valve
Closes (ABDC) 14°6' ± 4°
Opens (BBDC) 23°25' ± 4°
Exhaust valve
Closes (ATDC) 20° ± 4°
Cylinder head
0.05mm (0.0020in) for all
Flatness of gasket surface
0.03mm (0.0012in) for each cylinder
0.025mm (0.0010in) for width
Flatness of Intake
0.160mm (0.0063in) for length
manifold mounting
surface 0.025mm (0.0010in) for width
Exhaust
0.160mm (0.0063in) for length
Camshaft
Intake 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)
LH camshaft
Exhaust 35.700 ~ 35.900mm (1.4055 ~ 1.4134in)
Cam height
Intake 35.537 ~ 35.737mm (1.3991 ~ 1.4070in)
RH camshaft
Exhaust 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)
Journal outer LH camshaft 20.944 ~ 20.960mm (0.8246 ~ 0.8252in)

Diameter RH camshaft 20.944 ~ 20.960mm (0.8246 ~ 0.8252in)
Bearing oil clearance 0.040 ~ 0.077mm (0.0016 ~ 0.0030in)
End play 0.10 ~ 0.20mm (0.00390.0079in)
Valve
Intake 93.0mm (3.6614in)
Valve length
Exhaust 93.7mm (3.6890in)
Stem outer Intake 5.455 ~ 5.470mm (0.2148 ~ 0.2154in)

diameter Exhaust 5.435 ~ 5.450mm (0.2140 ~ 0.2146in)
Face angle 45.5° ~ 45.75°
Thickness of Intake 1.1mm (0.0433in)
valve head
(margin) Exhaust 1.2mm (0.0472in)
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Valve stem to Intake 0.030 ~ 0.057mm (0.0012 ~ 0.0022in)
English
valve guide
clearance Exhaust 0.050 ~ 0.077mm (0.0020 ~ 0.0030in)
Valve guide
Intake 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Inner diameter
Exhaust 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Intake 31.3 ~ 31.7mm (1.2323 ~ 1.2480in)
Length
Exhaust 31.3 ~ 31.7mm (1.2323 ~ 1.2480in)
Valve seat
Width of seat Intake 0.8 ~ 1.4mm (0.0315 ~ 0.0551in)

contact Exhaust 1.2 ~ 1.8mm (0.0472 ~ 0.0709in)
Intake 45° ~ 45°30'
Seat angle
Exhaust 45° ~ 45°30'
Valve spring
Free length 44.9mm (1.7677in)
17.5±0.9kg/32.0mm(38.6±2.0 lb/1.2598in)
Load
31.0±1.6kg/23.5mm(68.3±3.5 lb/0.9252in)
Out of squareness Less than 1.5°
Cylinder block
Cylinder bore 77.200 ~ 77.230mm (3.0394 ~ 3.0405in)
Flatness of gasket surface Less than 0.05mm (0.0020in)
Piston
Piston outer diameter 77.130 ~ 77.160mm (3.0366 ~ 3.0378in)
Piston to cylinder clearance 0.060 ~ 0.080mm (0.0024 ~ 0.0031in)
No. 1 ring groove 1.83 ~ 1.85mm (0.0720 ~ 0.0728in)
Ring groove width No. 2 ring groove 1.82 ~ 1.84mm (0.0717 ~ 0.0724in)
Oil ring groove 3.02 ~ 3.04mm (0.1189 ~ 0.1197in)
Piston ring
No. 1 ring 0.09 ~ 0.13mm (0.0035 ~ 0.0051in)
Side clearance No. 2 ring 0.08 ~ 0.12mm (0.0031 ~ 0.0047in)
Oil ring 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
No. 1 ring 0.20 ~ 0.35mm (0.0079 ~ 0.0138in)
End gap No. 2 ring 0.35 ~ 0.50mm (0.0138 ~ 0.0197in)
Oil ring 0.20 ~ 0.40mm (0.0079 ~ 0.0157in)
Piston pin
Piston pin outer diameter 27.995 ~ 28.000mm (1.1022 ~ 1.1024in)
Piston pin hole inner diameter 28.004 ~ 28.010mm (1.1025 ~ 1.1028in)
Piston pin hole clearance 0.004 ~ 0.015mm (0.0002 ~ 0.0006in)
Connecting rod small end hole inner diameter 28.022 ~ 28.034mm (1.1032 ~ 1.1037in)
Connecting rod small end hole clearance 0.022 ~ 0.039mm (0.0009 ~ 0.0015in)
Connecting rod
Connecting rod big end inner diameter 49.000 ~ 49.018mm (1.9291 ~ 1.9298in)
Connecting rod bearing oil clearance 0.025 ~ 0.043mm (0.0010 ~ 0.0017in)
Side clearance 0.050 ~ 0.032mm (0.0020 ~ 0.0119in) 0.4mm (0.0157in)
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Crankshaft
English
Main journal outer diameter 53.972 ~ 53.990mm (2.1249 ~ 2.1256in)
Pin journal outer diameter 45.997 ~ 46.015mm (1.8109 ~ 1.8116in)
Main bearing oil clearance 0.024 ~ 0.042mm (0.0009 ~ 0.0017in)
End play 0.08 ~ 0.28mm (0.0031 ~ 0.110in)
Flywheel
Runout 0.1mm (0.0039in) 0.13mm (0.0051in)
Oil pump
Inner rotor 0.040 ~ 0.085mm (0.0016 ~ 0.0033in)
Side clearance
Outer rotor 0.040 ~ 0.090mm (0.0016 ~ 0.0035in)
Body clearance 0.120 ~ 0.185mm (0.0047 ~ 0.0073in)
Relief valve opening pressure 490±49.0kpa (5±0.5kg/cm², 71±7.1psi)
Engine oil
When replacing a short
Total 5.7 L (6.02 US qt, 5.01 lmp qt) engine or a block
assembly
Oil quantity
Oil pan 4.8 L (5.07 US qt, 4.22 lmp qt)
Drain and refill 5.3 L (5.60 US qt, 4.66 lmp qt) Including oil filter
With DPF : ACEA C2 or C3
Without DPF : ACEA B4
Recommended For information on SAE viscosity grades based
on ambient temperatures, refer to the
“Lubrication System”.
Oil grade
Chevron : KIXX D1 C2 5W30
ACEA C2
TOTAL : QUARTZ INEO HKS D 5W30
List of engine oil
Approved SK : ZIC LS 5W30 approved by KIA
ACEA C3 Chevron : KIXX D1 5W30
TOTAL : QUARTZ INEO MC3 5W30
Oil temperature in oil
Oil pressure (at idle) 78.45kPa (0.8kg/cm², 11.38psi) or above
pan : 80°C (176°F)
Cooling system
Cooling method Forced circulation with cooling fan
Coolant quantity 6.3 L (6.66 US qt, 5.54 lmp qt)
Type Wax pellet type
Thermostat Opening temperature 85±1.5°C (185.0±2.7°F)
Pull opening temperature 100°C (212°F)
Main valve opening 93.16 ~ 122.58kpa

pressure (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi)
Radiator cap
Vacuum valve
MAX. 6.86 kpa(0.07kg/cm², 1.00 psi)
openingpressure
Water temperature sensor
20°C (68°F) 2.45±0.14 kΩ
Resistance
80°C (176°F) 0.3222 kΩ
Tightening Torques
Item Quantity N.m kgf.m lbft
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Cylinder block English
Engine support bracket bolt 4 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Piston cooling oil jet bolt 4 8.8 ~ 12.7 0.9 ~ 1.3 6.5 ~ 9.4
Drive belt auto tensioner bolt 2 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Drive belt auto tensioner mounting bracket bolt 3 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Engine mounting
Engine mounting bracket and body fixing bolt 3 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Engine mounting insulator and engine mounting
1 63.7 ~ 83.4 6.5 ~ 8.5 47.0 ~ 61.5
support bracket fixing nut
Engine mounting support bracket and engine
2 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
support bracket fixing bolt
Engine mounting support bracket and engine
1 49.0 ~63.7 5.0 ~6.5 36.2 ~47.0
support bracket fixing nut
Transaxle mounting bracket and body fixing
4 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
bolt
Transaxle mounting insulator and transaxle
1 88.3 ~ 107.9 9.0 ~11.0 65.1 ~79.6
support bracket fixing bolt
Front roll stopper bracket and sub frame fixing
1 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
bolt (10 X 45)
Front roll stopper bracket and sub frame fixing
2 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
bolt (10 X 25)
Front roll stopper insulator and front roll stopper
1 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
support bracket fixing bolt,nut
Rear roll stopper bracket and sub frame fixing
1 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
bolt (10 X 60)
Rear roll stopper bracket and sub frame fixing
2 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
bolt (10 X 40)
Rear roll stopper insulator and rear roll stopper
1 49.0 ~63.7 5.0 ~6.5 36.2 ~47.0
support bracket fixing bolt,nut
Main moving system
Connecting rod cap bolt 8 12.7 + (87~93°) 1.3 + (87~93°) 9.4 + (87~93°)
(22.6~26.5) + (16.6~19.5) +
Crankshaft main bearing cap bolt (long) 10 (2.3~2.7) + (90~94°)
(90~94°) (90~94°)
Crankshaft main bearing cap bolt (short) 10 32.4 ~ 36.3 3.3 ~ 3.7 23.9 ~ 26.8
Flywheel bolt (M/T) 8 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9
Drive plate bolt (A/T) 8 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9
Timing chain
Timing chain cover bolt (8 X 70) 7 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain case bolt (8 X 22) 4 24.5 ~ 30.4 2.5 ~ 3.1 18.1 ~ 22.4
Engine hanger (front) 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Crankshaft pulley bolt 1 225.6 ~ 245.2 23.0 ~ 25.0 166.4 ~ 180.8
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Camshaft chain sprocket bolt 1 68.6 ~ 73.5 7.0 ~ 7.5 50.6 ~ 54.2
English
High pressure pump chain sprocket bolt 1 64.7 ~ 74.5 6.6 ~ 7.6 47.7 ~ 55.0
Timing chain guide (1) bolt 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain guide (2) bolt 1 9.8 ~ 13.7 1.0 ~ 1.4 7.2 ~ 10.1
Timing chain "A" auto tensioner bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain "C" auto tensioner bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Cylinder head
Engine cover bolt 5 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
Cylinder head cover bolt 13 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Camshaft bearing cap bolt (mark 10) 16 12.7 ~ 13.7 1.3 ~ 1.4 9.4 ~ 10.1
Camshaft bearing cap bolt (mark 9) 6 12.7 ~ 13.7 1.3 ~ 1.4 9.4 ~ 10.1
Engine hanger Front 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1

bolt Rear 1 47.1 ~ 51.0 4.8 ~ 5.2 34.7 ~ 37.6
(47.1~51.0) + (34.7~37.6) +
(4.8~5.2) + (88~92°) +
Cylinder head bolt 10 (88~92°) + (88~92°) +
(118~122°)
(118~122°) (118~122°)
Cooling system
Water pump pulley bolt 3 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt (8 X 50) 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Water pump bolt (8 X 70) 1 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Thermostat housing bolt 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Thermostat housing nut 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water return pipe assembly bolt 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Water temperature sensor 1 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3
Water inlet fitting nut 2 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Lubrication system
Oil filter assembly bolt 4 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil cooler assembly bolt 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil filter upper cap 1 24.5 2.5 18.1
Oil level gauge bolt 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil pan bolt (6 X 20) 16 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan bolt (6 X 65) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan bolt (6 X 85) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan and transaxle fixing bolt 3 29.4 ~ 41.2 3.0 ~ 4.2 21.7 ~ 30.4
Oil pan drain bolt 1 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Oil screen bolt 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil screen nut 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pressure switch 1 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Intake and exhaust system
Intake manifold and cylinder head fixing nut 2 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Intake manifold and cylinder head fixing bolt 7 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Exhaust manifold and cylinder head fixing nut 8 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
Exhaust manifold heat protector bolt 3 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
CPF assembly fixing nut 1 39.2 ~ 49.1 4.0 ~ 5.0 28.9 ~ 36.2
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CPF assembly fixing bolt 2 39.2 ~ 49.1 4.0 ~ 5.0 28.9 ~ 36.2
English
Air cleaner lower cover fixing bolt 2 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Throttle body and surge tank fixing nut 4 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8.0
Exhaust manifold and front muffler fixing bolt 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Front muffler fixing clip bolt 1 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9
Front muffler and center muffler fixing nut 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Center muffler and main muffler fixing nut 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
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2012 > D 1.6 TCIU2 > Engine Mechanical System > General Information > Repair procedures English
COMPESSION PRESSURE INSPECTION

• If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression
pressure.
• Whenever removing injectors for compression pressure inspection, replace the gaskets with new ones and
tighten them with the specified torque.
1. Warm up engine until the normal operating temperature.
2. Remove the injectors. (Refer to Injector in FL Group)
3. Check the cylinder compression pressure.
(1) Insert a compression gauge SST(0935127000, 093512A000) into the injector hole.
(2) Fully open the throttle.
(3) While cranking the engine, measure the compression pressure.

Always use a fully charged battery to obtain engine speed of 250rpm or more.
(4) Repeat step 1) though 3) for each cylinder.

This measurement must be done in as short a time as possible.
Compression pressure :
2,157.45kPa (22.0kg/cm², 312.91psi) (200 rpm)
Minimum pressure :
1,863.25kPa (19kg/cm², 270.24psi)
Difference between each cylinder :
294.20kPa (3.0kg/cm², 42.67psi) or less
(5) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat step 1) through 3) for cylinders with low compression.
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• If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.
English
• If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the
gasket.
4. Reinstall the injectors. (Refer to Injector in FL Group)
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2012 > D 1.6 TCIU2 > Engine Mechanical System > General Information > Troubleshooting English
TROUBLESHOOTING

Worn piston rings.
engine noises. Inspect the cylinder for a loss of compression.
(Oil consumption may or may not cause the
Repair or replace as required.
engine to misfire.)
Replace the crankshaft and bearings as
Worn crankshaft thrust bearings.
required.
Engine misfire with Stuck valves. Repair or replace as required.
abnormal valve train (Carbon buildup on the valve stem can cause
noise. the valve not to close properly.)
Replace the timing chain and sprocket as
Excessive worn or misaligned timing chain.
required.
Engine misfire with • Faulty cylinder head gasket and/or • Inspect the cylinder head and engine block
coolant consumption cracking or other damage to the cylinder for damage to the coolant passages and/or
head and engine block cooling system. a faulty head gasket.
• Coolant consumption may or may not • Repair or replace as required.
cause the engine to overheat.
Engine misfire with Worn valves, valve guides and/or valve stem oil
consumption
Worn piston rings.
Inspect the cylinder for a loss of compression
(Oil consumption may or may not cause the
engine to misfire)
Engine noise on start Incorrect oil viscosity. Drain the oil.
up, but only lasting a Refill with the correct viscosity oil.
few seconds.
Worn crankshaft thrust bearing. Inspect the thrust bearing and crankshaft.
Broken valve spring. Replace the valve spring.
speed.
Stretched or broken timing chain and/or Replace the timing chain and sprockets.
damaged sprocket teeth.
Worn timing chain tensioner, if applicable. Replace the timing chain tensioner as required.
Worn camshaft lobes. Inspect the camshaft lobes.
Replace the camshaft and valve lifters as
required.
Worn valve guides or valve stems. Inspect the valves and valve guides, then repair
as required.
Stuck valves. (Carbon on the valve stem or Inspect the valves and valve guides, then repair
valve seat may cause the valve to stay open.) as required.
Lower engine noise, Low oil pressure. Repair or replace damaged components as
regardless of engine required.
speed.
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Damaged oil pan, contacting the oil pump Inspect the oil pan.
English
screen. Inspect the oil pump screen.
Oil pump screen loose, damaged or restricted. Inspect the oil pump screen.
Excessive pistontocylinder bore clearance. Inspect the piston and cylinder bore.
Repair as required.
Excessive piston pintobore clearance. Inspect the piston, piston pin and the
connecting rod.
Excessive connecting rod bearing clearance. Inspect the following components and repair as
required.
• The crankshaft.
Excessive crankshaft bearing clearance. Inspect the following components and repair as
required.
Incorrect piston, piston pin and connecting rod Verify the piston pins and connecting rods are
installation. installed correctly.
Repair as required.
Engine noise under Low oil pressure. Repair or replace as required.
load.
Excessive connecting rod bearing clearance. Inspect the following components and repair as
required.
• The crankshaft.
Excessive crankshaft bearing clearance. Inspect the following components and repair as
required.
• The cylinder block crankshaft bearing
bore.
Engine will not crank. Hydraulically locked cylinder. Remove injectors and check for fluid.

(crankshaft will not • Coolant/antifreeze in cylinder. Inspect for broken head gasket.
rotate) Inspect for cracked engine block or cylinder
• Oil in cylinder. head.
• Fuel in cylinder. Inspect for a sticking fuel injector and/or leaking
fuel regulator.
Broken timing chain and/or timing chain gears. Inspect timing chain and gears.
Repair as required.
Foreign material in cylinder. Inspect cylinder for damaged components
• Broken valve. and/or foreign materials.
• Piston material.
• Foreign material.
Seized crankshaft or connecting rod bearings. Inspect crankshaft and connecting rod bearing.
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Bent or broken connecting rod. Inspect connecting rods. English
Broken crankshaft. Inspect crankshaft.
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Engine And Transaxle Assembly > Repair English
procedures
REMOVAL


1. Disconnect the battery terminals (A).
2. Remove the battery (B) and battery tray.
3. Remove the battery extention connector (A).
4. Remove the engine cover.
6. Drain the engine coolant. Remove the radiator cap to speed draining.
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7. Remove the radiator grill upper cover (A) and the air duct (B).
8. Remove the intercooler hoses (A).

Using a plier, take off the cap. After it removed, there will be another () cap which you can use a () driver.
9. Remove the air cleaner assembly.
(1) Disconnect the AFS (Air Flow Sensor) connector (A).
(2) Remove the air cleaner upper cover (B).
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(3) Remove the air hose (C). English
(4) Remove the air cleaner element.
(5) Disconnect the PCM connectors and remove the air cleaner lower part.
10. Remove the wiring (A) from fuse box.
11. Remove the ground cable from transaxle. (Refer to Transaxle in MT Group)
12. Remove the coolant reservoir tank hose (A).
13. Remove the radiator upper hose (A).
14. Remove the radiator lower hose (B).
15. Remove the fuel hose. (Refer to Fuel pump in FL Group).
16. Remove the brake vacuum hose (A).
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17. Remove the connector wiring (A) and the engine wiring (B) after remove the fuse box assembly.
18. Remove the heater hoses (A).
19. Remove the transaxle wire harness connectors and control cable from transaxle. (Refer to Transaxle in MT Group)
(1) Remove the clutch release cylinder.
(2) Remove the transaxle control cable.
20. Install the SST(0920038001, 092001C000), the engine support fixture and the adapter, on the engine and transaxle
assembly.
21. Disconnect the engine ground cable and then remove the engine mounting support bracket (A).
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Tightening torque :
English
Nut (D) :
68.6 ~ 93.2N.m (6.5 ~ 8.5kgf.m, 50.6 ~ 68.7lbft)
Bolt (B), Nut (C) :
49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lbft)
22. Remove the transaxle mounting bracket. (Refer to Transaxle MT or AT Groups)
Tightening torque :
Bolt (B) :
88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lbft)
23. Remove the front tires.
24. Remove the drive shaft lock pin and the lock nut with washer. (Refer to Front axle in DS Group)
25. Remove the lower arm ball joint mounting, the stabiliwer bar link mounting and the steering tie rod mounting. (Refer to
Front suspension system in SS Group)
26. Remove the steering ujoint mounting bolt. (Refer to Steering in ST Group).
27. Remove the front muffler (A).
Tightening torque :
39.2 ~ 58.8N.m (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lbft)
28. Using a floor jack, support the engine and transaxle assembly.

After removing the sub frame mounting bolt , the engine and transaxle assembly may fall downward, and so
support them securely with floor jack.
Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
29. Remove the sub frame bolts and nuts.
Tightening torque :
Bolt (A) : 44.1 ~ 53.9N.m (4.5 ~ 5.5kgf.m, 32.5 ~ 39.8lbft)
Nut (B), Bolt (C) : 156.9 ~ 176.5N.m (16.0 ~ 18.0kgf.m, 115.7 ~ 130.2lbft)
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30. Remove the engine support fixture and the adapter.
31. Remove the engine and transaxle assembly by lifting vehicle.

When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body
components.
INSTALLATION
Installation is in the reverse order of removal.
Perform the followings :
• Adjust shift cable.
• Adjust throttle cable.
• Refill engine with engine oil.
• Refill transaxle with fluid.
• Refill radiator and reservoir tank with engine coolant.
• Place heater control knob on "HOT" positon.
• Bleed air from the cooling system
– Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
– Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed
from the cooling system.
– Put radiator cap on tightly, then run the engine again and check for leaks.
• Clean battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent corrosion.
• Inspect for fuel leakage.
– After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for
approximately two seconds and fuel line pressurizes.
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– Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
English
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Timing System > Timing Chain > Components and
English
Components Location
COMPONENTS
1. Alternator 5. Key
2. Water pump pulley 6. Water pump
3. Drive belt tensioner 7. Timing chain cover
4. Crankshaft pulley 8. Idler
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English
1. Timing chain cover 6. Timing chain guide "2" 11. Timing chain "A" lever

2. Timing chain "C" 7. Timing chain "A" 12. Timing chain guide "1"
3. Timing chain "C" auto tensioner 8. High pressure pump sprocket 13. Timing chain case
4. Timing chain "C" lever 9. Crankshaft sprocket 14. Timing chain case gasket
5. Timing chain guide "1" 10. Timing chain "A" auto tensioner 15. Camshaft sprocket
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Timing System > Timing Chain > Repair procedures
English
REMOVAL
Engine removal is not required for this procedure.
1. Remove the drive belt.
2. Remove the injector. (Refer to Injector in FL Group).
3. Remove the cylinder head cover (A).
4. Remove the engine mounting support bracket.
(1) Set the jack to the engine oil pan
(2) Disconnect the engine ground cable and then remove the engine mounting support bracket (A).
5. Remove the alternator (A).
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6. Remove the water pump pulley (A).
7. Remove the drive belt auto tensioner (A).
8. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing chain cover. (No.1 cylinder
compression TDC position)
9. Remove the crankshaft pulley bolt (B) and crankshaft pulley (A).
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Use the SST(flywheel stopper, 092312A100)(A) to remove the crankshaft pulley bolt, after remove the starter.
10. Remove the oil gage guide.
11. Disconnect the fuel pressure regulator valve connector (A).
12. Remove the high pressure fuel pipe (B) connecting the high pressure fuel pump with the common rail.
13. Remove the engine mounting insulator (B).
14. Remove the idler (A) and the timing chain cover plug (B).
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15. Remove the high pressure fuel pump sprocket nut (C) after fixing the crank shaft. English

• Use flywheel stopper (SST No.: 092312A100) to remove the high pressure pump sprocket nut.
• Replace Oring of plug (B) with a new one when reinstalling the plug.
16. Disconnect the fuel feed tube (A) and the fuel return tube (B).
17. Unscrew the three high pressure fuel pump mounting bolts (C).
18. Install the high pressure fuel pump sprocket stopper (A) (SST No.: 093312A010) with rotating it clockwise.
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19. Lift the RH side of the engine with a jack. English
20. Install the high pressure fuel pump remover (SST No.:093312A010) (A) with three mounting bolts (B).
21. Fix the high pressure fuel pump remover (SST No.:093312A010) (A) and sprocket stopper (C) with two fixing bolts (D).
22. Rotate the bolt (E) of the high pressure fuel pump remover (SST No.:093312A010) (A) clockwise till the high pressure
fuel pump is pushed out.
23. Install the engine support fixture and the adapter (SST No.: 0920038001, 092001C000) on the engine hanger bracket.
24. Remove the intercooler pipe (A).
25. Remove the A/C compressor. (Refer to A/C compressor in HA group)
26. Remove the jack from oil pan.
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English
27. Remove the oil pan (A).

When removing the oil pan, use the SST(092153C000) in order not to damage the surface between the cylinder
block and the oil pan.

• Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction
of ① arrow.
• After tapping the SST with a plastic hammer along the direction of ② arrow around more than 2/3 edge of
the oil pan, remove it from the ladder frame.
• Do not turn over the SST abruptly without tapping. It be result in damage of the SST.
28. Remove the oil strainer (B).
29. Remove the timing chain cover (A)
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Remove thoroughly sealant and oil etc left at the sealing surface after remove the chain cover and oil pan. (If any
impurities are left at the sealing face, oil may leak after reassembly even with the sealant application.)
30. Remove the timing chain "C" auto tensioner(A).

Before removing autotensioner, install a set pin (B) (2.5 mm steel wire) after compressing the tensioner.
31. Remove the timing chain "C" lever (A) and the timing chain guide "1" (B).
32. Remove the timing chain guide "2" (A).
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33. Remove the timing chain "C" (A).
34. Remove the timing chain "A" auto tensioner (A).

Before removing autotensioner, install a set pin (B) (2.5 mm steel wire) after compressing the tensioner.
35. Remove timing chain "A" lever (A) and the timing chain guide "1" (B).
36. Remove the timing chain "A" (A)with high pressure pump sprocket (B) and crankshaft sprocket (C).
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37. Remove the water pump (A).
38. Remove the timing chain case (A).
(Engine removal is required for this procedure)
39. Remove the camshaft sprocket.
(1) Hold the portion (A) of the camshaft with a hexagonal wrench, and remove the bolt (C) with a wrench (B) and
remove the camshaft sprocket.

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Be careful not to damage the cylinder head and valve lifter with the wrench.
English
INSTALLATION
1. Install the camshaft sprocket and tighten the bolt to the specified torque.
(1) Temporarily install the camshaft sprocket bolt (C).
(2) Hold the portion (A) of the camshaft with a hexagonal wrench, and tighten the bolt (C) with a wrench (B).
Tightening torque :
68.6 ~ 73.5N.m (7.0 ~ 7.5kgf.m, 50.6 ~ 54.2lbft)
2. Install the timing chain case (A) with new gasket.
(Engine removal is required for this procedure)
Tightening torque :
Bolt (B) : 24.5 ~ 30.4N.m (2.5 ~ 3.1kgf.m, 18.1 ~ 22.4lbft)
Bolt (C) :18.6 ~ 27.5N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lbft)
Bolt (D) : 25.5 ~ 34.3N.m (2.6 ~ 3.5kgf.m, 18.8 ~ 25.3lbft)
3. Install the water pump (A).
Tightening torque :
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lbft)
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4. Install the high pressure fuel pump after connecting the fuel feed tube (A) and the fuel return tube (B).
Tightening torque :
19.6 ~ 25.5N.m (2.0 ~ 2.6kgf.m, 14.5 ~ 18.8lbft)

Install the high pressure fuel pump under installing the high pressure fuel pump remover (SST No. : 09331
2A010) (A) because of maintaining tension of the timing chain.
5. Connect the fuel pressure regulator valve and install the high pressure pipe (B).
Tightening torque :
24.5 ~ 28.4N.m (2.5 ~ 2.9kgf.m, 18.1 ~ 21.0lbft)
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English

Do not reuse the high pressure pipe.
6. Set the key of crankshaft sprocket to be aligned with the timing mark of timing chain case. As a result of this, place the
piston on No.1 cylinder at the top dead center on compression stroke.
7. After install timing chain "A" with high pressure pump sprocket (B) equipped at the crankshaft sprocket (C), and then
install high pressure pump sprocket at the high pressure pump shaft.

The timing mark of high pressure pump sprocket should be aligned with timing mark on the timing chain case.
8. Pretighten the high pressure fuel pump sprocket nut.
9. Install timing chain "A" lever (A) and the timing chain guide "1" (B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
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10. Install the timing chain "A" auto tensioner (A) and then remove set pin (B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
11. Align the timing mark (A) of camshaft sprocket on the vertical center line of crankshaft.
12. Install the timing chain "C" (A) as following procedure. High pressure pump sprocket → LH camshaft sprocket → RH
camshaft sprocket

The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing
timing chain as shown below illustration.
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English
13. Install the timing chain guide "2" (A).
Tightening torque :
9.8 ~ 13.7N.m (1.0 ~ 1.4kgf.m, 7.2 ~ 10.1lbft)
14. Install the timing chain "C" lever (A) and the timing chain guide "1" (B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
15. Install the timing chain "C" auto tensioner (A) and then remove set pin (B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
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16. Install the high pressure pump sprocket nut (A).
English
Tightening torque :
64.7 ~ 74.5N.m (6.6 ~ 7.6kgf.m, 47.7 ~ 55.0lbft)

Use the SST(flywheel stopper, 092312A100)(A) to tighten the high pressure pump sprocket nut, after remove the
starter.
17. Apply liquid gasket evenly to the mating surface of timing chain cover.

• Standard liquid gasket : LOCTITE 5900
• Check that the mating surfaces are clean and dry before applying liquid gasket.
• Assemble the timing chain cover in 5 minutes after applying the liquid gasket.
18. Install the timing chain cover (A).
Tightening torque :
Bolt (B, C, F) :
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lbft)
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Bolt (D, E) : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
English
Bolt (G) : 42.2 ~ 54.0N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lbft)
19. Install the front oil seal by using SST(092312A000, 09231H1100) (A).
20. Install the oil strainer (B).
Tightening torque :
Bolts : 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lbft)
Nuts : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
21. Apply liquid gasket evenly to the mating surface of oil pan.

• Apply liquid gasket in a 3mm wide bead without stopping.Assemble the oil pan in 5 minutes after applying
the liquid gasket.
• Apply liquid gasket to Tjoint before assembling oil pan.
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Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
23. Set the jack to the engine oil pan
24. Install the engine support fixture and the adapter (SST No.: 0920038001, 092001C000) on the engine hanger bracket.
25. Install the crankshaft pulley (A) and crankshaft pulley bolt (B).
Tightening torque :
225.6 ~ 245.2N.m (23.0 ~ 25.0kgf.m, 166.4 ~ 180.8lbft)
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Use the SST(flywheel stopper, 092312A100) to Install the crankshaft pulley bolt, after remove the starter.
26. Install the drive belt tensioner (A).
Tightening torque :
25.5 ~ 30.4N.m (2.6 ~ 3.1kgf.m, 18.8 ~ 22.4lbft)
27. Install the water pump pulley (A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
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28. Install the alternator (A). (Refer to Alternator in EEB group)
English
Tightening torque :
38.2 ~ 58.8N.m (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lbft)
29. Install the drive belt (A) after releasing tension of the tensioner (B) with a wrench.
30. Install the engine mounting support bracket (A) and connect the engine ground cable.
Tightening torque :
Nut (D) : 68.6 ~ 93.2N.m (6.5 ~ 8.5kgf.m, 50.6~ 68.7lbft)
Bolt (B), Nut (C) : 49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lbft)
31. Remove the jack from oil pan
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32. Install the cylinder head cover (A) with new head cover gasket.
English
Tightening torque :
1st : 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lbft)
2st : 8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 8.0lbft)

• Apply liquid gasket in a 7mm (0.28in) wide bead without stopping.
• Assemble the cylinder head cover in 5 minutes after applying the liquid gasket.
• Apply liquid gasket to Tjoint before assembling cylinder head cover.
33. Install the injectors. (Refer to Injector in FL Group)
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Cylinder Head Assembly > Cylinder Head >English
COMPONENTS
1. Common rail 5. Thermostat housing
2. Glow plug connector 6. Vacuum pump
3. Glow plug plate 7. Cylinder head
4. Glow plug
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English
1. Camshaft bearing cap 5. Valve spring retainer lock 9. Valve

2. Camshaft 6. Valve spring retainer 10. HLA(Hydraulic Lash Adjuster)
3. Camshaft sprocket 7. Valve spring 11. Cylinder head
4. Cam follwer 8. Valve stem seal 12. Cylinder head gasket
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Cylinder Head Assembly > Cylinder Head >English
COMPONENTS
1. Common rail 5. Thermostat housing
2. Glow plug connector 6. Vacuum pump
3. Glow plug plate 7. Cylinder head
4. Glow plug
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English
1. Camshaft bearing cap 5. Valve spring retainer lock 9. Valve

2. Camshaft 6. Valve spring retainer 10. HLA(Hydraulic Lash Adjuster)
3. Camshaft sprocket 7. Valve spring 11. Cylinder head
4. Cam follwer 8. Valve stem seal 12. Cylinder head gasket
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Cylinder Head Assembly > Cylinder Head > Repair
English
procedures
REMOVAL
Engine removal is required for this procedure.

• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature
before removing it.
• When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.

• Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
2. Remove the timing chain. (Refer to Timing system in this group)
3. Remove the intake and exhaust manifold. (Refer to Intake and exhaust system in this group)
4. Remove the common rail (A).
5. Remove the glow plug (A).
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6. Disconnect the water hose (A) from thermostat housing.
7. Remove the thermostat housing (A).
8. Remove the vacuum pump (A).

Do not disassemble the vacuum pump.
9. Remove the camshaft bearing caps (A).
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English
Mark the camshaft bearing caps to be able to reassemble in the original position and direction.
10. Remove the camshaft (A).
11. Remove the cam follower (A).
12. Remove the HLA (Hydraulic Lash Adjust).
13. Remove the cylinder head bolts, then remove the cylinder head.
(1) Using bit socket (12PT), uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the
sequence shown.Remove the 10 cylinder head bolts.
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Head warpage or cracking could result from removing bolts in an incorrect order.
(2) Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on wooden blocks on a
bench.

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
DISASSEMBLY
1. Remove the valves.
(1) Using the SST (0922228000, 0922228100)(A), compress the valve spring and remove the retainer lock.
(2) Remove the spring retainer.
(3) Remove the valve spring.
(4) Remove the valve.
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(5) Using a needlenose pliers, remove the stem oil seal.
English
INSPECTION
Cylinder Head
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the
manifolds for warpage.
Flatness of cylinder head gasket surface :
Less than 0.05mm (0.0020in) for all
Less than 0.03mm (0.0012in) for each cylinder
Flatness of manifold mating surface :
Less than 0.025mm (0.0010in) for width
Less than 0.160mm (0.0063in) for length
2. Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace
the cylinder head.
Valve And Valve Spring
1. Inspect the valve stems and valve guides.
(1) Using a caliper gauge, measure the inner diameter of valve guide.
Valve guide inner diameter :
Intake : 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Exhaust : 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
(2) Using a micrometer, measure the outer diameter of valve stem.
Valve stem outer diameter
Intake : 5.455 ~ 5.470mm (0.2148 ~ 0.2154in)
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Exhaust : 5.435 ~ 5.450mm (0.2140 ~ 0.2146in)
English
(3) Subtract the valve stem outer diameter measurement from the valve guide inner diameter measurement.
Valve stem toguide clearance
Intake : 0.030 ~ 0.057mm (0.0012 ~ 0.0022in)
Exhaust : 0.050 ~ 0.077mm (0.0020 ~ 0.0030in)
If the clearance is greater than specification, replace the valve and valve guide.
2. Inspect the valves.
(1) Check the valve is ground to the correct valve face angle.
(2) Check that the surface of valve for wear.
If the valve face is worn, replace the valve.
(3) Check the valve head margin thickness. If the margin thickness is less than specification, replace the valve.
Margin
Intake : 1.1mm (0.0433in)
Exhaust : 1.2mm (0.0472in)
(4) Check the valve length.
Length
Intake : 93.0mm (3.6614in)
(5) Check the surface of valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect the valve seats.
(1) Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
(2) Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then
recondition the seat.
(3) Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within
specifications and centered on the valve face.
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4. Inspect the valve springs.
(1) Using a steel square, measure the outofsquare of valve spring.
(2) Using a vernier calipers, measure the free length of valve spring.
Valve spring
Standard
Free height : 44.9mm (1.7677in)
Load : 17.5±0.9kg/32.0mm (38.6±2.0lb/1.2598in)
31.0±1.6kg/23.5mm (68.3±3.5lb/0.9252in)
Out of square : Less than 1.5°
If the loads is not as specified, replace the valve spring.
Camshaft
1. Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
LH camshaft
Intake : 35.432 ~ 35.652mm (1.3957 ~ 1.4306in)
Exhaust : 35.700 ~ 35.900mm (1.4055 ~ 1.4134in)
RH camshaft
Intake : 35.537 ~ 35.737mm (1.3991 ~ 1.4070in)
Exhaust : 35.432 ~ 35.652mm (1.3957 ~ 1.4036in)
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If the cam lobe height is less than specification, replace the camshaft.
2. Inspect the camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journal.
(4) Install the bearing caps and tighten the bolts with specified torque.
Tightening torque :
12.7 ~ 13.7N.m (1.3 ~ 1.4kgf.m, 9.4 ~ 10.1lbft)

Do not turn the camshaft.
(5) Remove the bearing caps.
(6) Measure the plastigage at its widest point.
Bearing oil clearance
0.040 ~ 0.077mm (0.0016 ~ 0.0030in)
If the oil clearance is greater than specificaiton, replace the camshaft. If necessary, replace the bearing caps and
cylinder head as a set.
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(7) Completely remove the plastigage.
English
(8) Remove the camshafts.
3. Inspect the camshaft end play.
(1) Install the camshafts.
(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play
Standard : 0.1 ~ 0.2mm (0.0039 ~ 0.0079in)
If the end play is greater than specification, replace the camshaft. If necessary, replace the bearing caps and
HLA (Hydraulic Lash Adjuster)
With the HLA filled with engine oil, hold A and press B by hand.
If B moves, replace the HLA.
Problem Possible cause Action

This noise will disappear after the oil in
1. Temporary noise when starting a cold
Normal the engine reaches the normal
engine
pressure.
2. Continuous noise when the engine is
Oil leakage of the high ressure chamber
started after parking more than 48
on the HLA, allowing air to get in.
hours.
3. Continuous noise when the engine is Noise will disappear within 15 minutes
Insufficient oil in cylinder head oil when engine runs at 20003000 rpm.
first started after rebuilding cylinder
gallery. If it doesn’t disappear, refer to step 7
head.
below.
4. Continuous noise when the engine is
started after excessively cranking the
engine by the starter motor or band.
Oil leakage of the highpressure
chamber in the HLA, allowing air to get
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in.
5. Continuous noise when the engine is English
Insufficient oil in the HLA.
running after changing the HLA.
Do not run engine at a speed higher
than 3000 rpm, as this may damage
the HLA.
Check oil level.
Engine oil level too high or too low.
Drain or add oil as necessary.
Excessive amount of air in the oil at
6. Continuous noise during idle after Check oil supply system.
high engine speed.
high engine speed.
Check oil quality.
Deteriorated oil. If deteriorated, replace with specified
type.
Check oil pressure and oil supply
Low oil pressure.
system of each part of engine.
7. Noise continues for more than 15
minutes. Remove the cylinder head cover and
Faulty HLA. press HLA down by hand.
If it moves, replace the HLA.
REASSEMBLY

• Thoroughly clean all parts to be assembled.
• Before installing the parts, apply fresh engine oil to all sliding and rotating surface.
• Replace oil seals with new ones.
1. Install the valves.
(1) Using the SST (092222A000)(A), push in a new stem oil seal.

Do not reuse old valve stem oil seals.
Incorrect installation of the seal could result in oil leakage past the valve guides.
(2) Install the valve, valve spring and spring retainer.

Place the valve springs so that the side coated with enamel faces toward the valve spring retainer and then
installs the retainer.
(3) Using the SST(092222A100, 092223K000)(A), compress the spring and install the retainer locks.
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After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring
English
compressor.
(4) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper
seating of the valve and retainer lock.
INSTALLATION

• Always use a new cylinder head and manifold gasket.
• Always use a new cylinder head bolt.
• The cylinder head gasket is a metal gasket. Take care not to bend it.
• Rotate the crankshaft, set the No.1 piston at TDC.
1. Cylinder head dowel pins must be aligned.
2. Select the cylinder head gasket.
(1) Measure the piston protrusion from the upper cylinder block face (I) on 8 places (A ~ H) at T.D.C.
Measure on the crankshaft center line considering the piston migration.
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English
(2) Select the gasket in the table below using the average value of piston protrusions. Although even the only 1 point
is over than the each rank limit, use 1 rank upper gasket than specified in the table below.
Displacement 1.6 L
Average of piston 0.035 ~ 0.105mm 0.105 ~ 0.175mm 0.175 ~ 0.245mm
protrusion (0.0014 ~ 0.0041in) (0.0041 ~ 0.0069in) (0.0069 ~ 0.0096in)
1.00 ~ 1.15mm 1.05 ~ 1.20mm 1.10 ~ 1.25mm
Gasket thickness
(0.0394 ~ 0.0453in) (0.0413 ~ 0.0472in) (0.0433 ~ 0.0492in)
Limit of each rank extant 0.14mm (0.0055in) 0.21mm (0.0083in)
Identification code
Gasket grade A B C
(3) Install the gasket so that the identification mark faces toward the timing chain side.
3. Install the cylinder head gasket (A) on the cylinder block.

Be careful of the installation direction.
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4. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
5. Install the cylinder head bolts.
(1) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
(2) Using bit socket (12PT), install and tighten the 10 cylinder head bolts, in several passes, in the sequence shown.
Tightening torque :
47.1~51.0Nm (4.8~5.2kgf.m, 34.7~37.6lbft) + (88~92°) + (118~122°)

Do not reuse the cylinder head bolts.
6. Istall the HLA (Hydraulic Lash Adjust).
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(1) Until installing HLA shall be held upright so that diesel oil in HLA should not spill and assured that dust does not
adhere to HLA.
(2) HLA should be inserted carefully to the cylinder head not to spill engine oil.
If engine oil has spilled out of the lash adjuster, HLA bleeding should be performed according to the below
procedure.
HLA bleeding procedure
Stroke the lash adjuster in engine oil by pushing its cap 4 to 5 times while pushing the ball down slightly using a
hard steel wire. Be careful not to give the ball a hard push because the ball weighs just several grams.
If installing with engine oil spilling out of the lash adjuster and air in it, it might make an abnormal noise.
7. Install the cam follower (A).
8. Install the camshaft (A).
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9. Install the camshaft bearing caps (A).
Tightening torque :
12.7 ~ 13.7N.m (1.3 ~ 1.4kgf.m, 9.4 ~ 10.1lbft)
10. Install the vacuum pump (A) with new gasket (B).
Tightening torque :
10.8 ~ 14.7N.m (1.1 ~ 1.5kgf.m, 8.0 ~ 10.8lbft)

Apply engine oil to the Oring(A) of vacuum pump shaft before assembling vacuum pump.
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11. Install the thermostat housing (A).
English
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
12. Reconnect the water hose (A) to thermostat housing.
13. Install the glow plug (A) and glow plug plate.
Tightening torque :
Glow plug: 15 ~ 20N.m (1.5 ~ 2.0kgf.m, 11 ~ 14lbft)
Plate nut : 0.8~1.5N.m (0.08 ~ 0.15kgf.m, 0.6 ~ 1.1lbft)
14. Install the common rail (A).
Tightening torque :
14.7 ~ 21.6N.m (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lbft)
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English
15. Install the intake and exhaust manifold. (Refer to Intake and exhaust system)
16. Install the timing chain. (Refer to Timing system in this group)
17. Install the drive belt.
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Cylinder Block > Cylinder Block > Components and
English
Components Location
COMPONENTS
1. Oil filter cap 7. Flywheel 12. Bed plate

2. Oil filter 8. Crankshaft rear oil seal 13. Crankshaft main bearing
3. Oil filter housing & oil cooler assembly 9. Piston & connecting rod 14. Crankshaft
4. Water pipe 10. Connecting rod bearing 15. Oil jet
5. Clutch disk cover 11. Connecting rod cap 16. Cylinder block
6. Clutch disk
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Cylinder Block > Cylinder Block > Repair English
procedures
DISASSEMBLY
1. Remove the engine and transaxle assembly.
(Refer to Engine And Transaxle Assembly in this group)
2. Remove the automatic or manual transaxle assembly.
(Refer to Transaxle in MT or AT group)
3. Remove the clutch cover and disk. (MT only)
(Refer to Clutch Cover And Disk in CH group)
4. MT : Remove the flywheel (A).
AT : Remove the drive plate adapter (A) and the drive plate (B).
5. Install the engine to engine stand for disassembly.
6. Remove the timing chain. (Refer to Timing system in this group)
7. Remove the intake manifold and exhaust manifold. (Refer to Intake and exhaust system in this group)
8. Remove the cylinder head. (Refer to Cylinder head in this group)
9. Remove the water pipe (A).
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10. Remove the oil filter and oil cooler assembly (A).
11. Remove the bed plate (A).
12. Remove the rear oil seal (A).
13. Remove the connecting rod cap (A).

Mark the connecting rod caps to be able to reassemble in the original position and direction.
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14. Remove the piston and connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

• Keep the bearings, connecting rod and cap together.
• Arrange the piston and connecting rod assemblies in the correct order.
15. Lift the crankshaft (A) out of the engine, being careful not to damage journals.

Arrange the main bearings and thrust bearings in the correct order.
16. Remove the oil jet.
17. Check fit between piston and piston pin.
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
18. Remove the piston rings.
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(1) Using a piston ring expender, remove the 2 compression rings.
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(2) Remove the 2 side rails and oil ring by hand.

Arrange the piston rings in the correct order only.
19. Remove the connecting rod from the piston.
Using a press, remove the piston pin from piston.
INSPECTION
Connecting Rod
1. Check the end play between piston and connecting rod.
End play
Standard : 0.05 ~ 0.302mm (0.0020 ~ 0.0119in)
• If outoftolerance, install a new connecting rod.
• If still outoftolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
(1) Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove the 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and lower bearing.
(4) Clean the crankshaft pin journal and bearing.
(5) Place a plastigage across the crankshaft pin journal.
(6) Reinstall the lower bearing and cap, and tighten the nuts.
Tightening torque :
12.7Nm (1.3kgf.m, 9.4lbft) + (87~93°)

Do not turn the crankshaft.
Do not reuse the connection rod cap bolts.
(7) Remove the 2bolts, connecting rod cap and lower bearing .
Standard oil clearance
0.025 ~ 0.043mm (0.0010 ~ 0.0017in)
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(9) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new
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bearings with the same color mark.
Recheck the oil clearance.

Do not file, shim, of scrape the bearings or the caps to adjust clearance.
(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the
crankshaft and start over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire
brush or scraper. Clean them only with solvent or detergent.
Connecting rod mark location
Discrimination of connecting rod
Connecting rod bigend
Mark
inner diameter
A 49.000 ~ 49.006mm (1.9291 ~ 1.9294in)
B 49.006 ~ 49.012mm (1.9294 ~ 1.9296in)
C 49.012 ~ 49.018mm (1.9296 ~ 1.9298in)
Crankshaft pin journal mark location
Discrimination of crankshaft pin journal
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Mark Crankshaft pin journal
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outer diameter
A 46.009 ~ 46.015mm (1.8114 ~ 1.8116in)
B 46.003 ~ 46.009mm (1.8111 ~ 1.8114in)
C 45.997 ~ 46.003mm (1.8109 ~ 1.8111in)
Connecting rod bearing mark location
Color Connecting rod bearing thickness
Blue 1.477 ~ 1.480mm (0.0581 ~ 0.0583in)
Black 1.480 ~ 1.483mm (0.0583 ~ 0.0584in)
None 1.483 ~ 1.486mm (0.0584 ~ 0.0585in)
Green 1.486 ~ 1.489mm (0.0585 ~ 0.0586in)
Yellow 1.489 ~ 1.492mm (0.0586 ~ 0.0587in)
(11) Select the bearing by using selection table.
Connecting rod bearing selection table
Connecting rod mark
Connecting rod bearing
A B C
A Blue Black None
Crank shaft pin journal
B Black None Green
mark
C None Green Yellow
3. Check the connecting rods.
(1) When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match.
When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the
same side.
(2) Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough
surface of the inside diameter of the small end is apparent, the rod must be replaced as well.
(3) Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair
limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced.
Allowable bend of connecting rod :
0.05mm / 100mm (0.0020in / 3.94in ) or less
Allowable twist of connecting rod :
0.1mm / 100mm (0.0039in / 3.94in) or less
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Crankshaft English
1. Check the crankshaft bearing oil clearance.
(1) To check main bearingtojournal oil clearance, remove the bed plate and lower bearings.
(2) Clean each main journal and lower bearing with a clean shop towel.
(3) Place one strip of plastigage across each main journal.
(4) Reinstall the lower bearings and bed plate, then tighten the bolts.
Tightening torque :
Long bolts : 22.6~26.5Nm (2.3~2.7kgf.m, 16.6~19.5lbft) + 90~94°
Short bolts : 32.4~36.3N.m(3.3~3.7kgf.m, 23.9~26.8lbft)

(5) Remove the bed plate and lower bearing again, and measure the widest part of the plastigage.
Standard oil clearance :
0.024 ~ 0.042mm (0.0009 ~ 0.0017in)
bearings with the same color mark.

Do not file, shim, or scrape the bearings or the cap to adjust clearance.


CYLINDER BLOCK CRANKSHAFT JOURNAL BORE MARK LOCATION
Letters have been stamped on the front face of block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct
bearings.
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Discrimination of cylinder block crankshaft journal bore
Mark Cylinder block crankshaft journal bore inner diameter
A 58.000 ~ 58.006mm (2.2835 ~ 2.2837in)
B 58.006 ~ 58.012mm (2.2837 ~ 2.2839in)
C 58.012 ~ 58.018mm (2.2839 ~ 2.2842in)
Crankshaft main journal mark location
Discrimination of crankshaft main journal
Mark Crankshaft main journal outer diameter
A 53.984 ~ 53.990mm (2.1254 ~ 2.1256in)
B 53.978 ~ 53.984mm (2.1251 ~ 2.1254in)
C 53.972 ~ 53.978mm (2.1249 ~ 2.1251in)
Crankshaft main bearing mark location
Color Crankshaft main bearing thickness
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Blue 1.990 ~ 1.993mm (0.0783 ~ 0.0785in)
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Black 1.993 ~ 1.996mm (0.0785 ~ 0.0786in)
None 1.996 ~ 1.999mm (0.0786 ~ 0.0787in)
Green 1.999 ~ 2.002mm (0.0787 ~ 0.0788in)
Yellow 2.002 ~ 2.005mm (0.0788 ~ 0.0789in)
Crankshaft main bearing selection table
Cylinder block crankshaft
Crankshaft main bearing journal bore mark
A B C
A Blue Black None
Crank shaft main journal
B Black None Green
mark
C None Green Yelllow
2. Check the crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
End play
Standard : 0.08 ~ 0.28mm (0.0031 ~ 0.110in)
Limit : 0.30mm (0.0118in)
If the end play is greater than specification, replace the center main bearings as a set.
Thrust washer thickness of center main beaing :
2.335 ~ 2.385mm (0.0919 ~ 0.0939in)
3. Inspect the crankshaft main journals and pin journals.
Using a micrometer, measure the diameter of each main journal and pin journal.
Main journal diameter :
53.972 ~ 53.990mm (2.1249 ~ 2.1256in)
Pin journal diameter :
45.997 ~ 46.015mm (1.8109 ~ 1.8116in)
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Cylinder Block
1. Remove the gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean the cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
Flatness of cylinder block gasket surface
Less than 0.05mm (0.0020in)
4. Inspect the cylinder bore.
Visually check the cylinder for vertical scratchs.
If deep scratchs are present, replace the cylinder block.
5. Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.
Standard diameter :
77.200 ~ 77.230mm (3.0394 ~ 3.0405in)
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6. Check the cylinder bore size code on the cylinder block front face. English
Discrimination of cylinder bore size
Mark Cylinder bore inner diameter
A 77.200 ~ 77.210mm (3.0394 ~ 3.0398in)
B 77.210 ~ 77.220mm (3.0398 ~ 3.0402in)
C 77.220 ~ 77.230mm (3.0402 ~ 3.0405in)
7. Check the piston size mark(A) on the piston top face.
Discrimination of piston outer diameter
Mark Piston outer diameter
A 77.130 ~ 77.140mm (3.0366 ~ 3.0370in)
B 77.140 ~ 77.150mm (3.0370 ~ 3.0374in)
C 77.150 ~ 77.160mm (3.0374 ~ 3.0378in)
8. Select the piston related to cylinder bore class.
Pistontocylinder clearance :
0.060 ~ 0.080mm (0.0024 ~ 0.0031in)
Boring Cylinder
1. Oversize pistons should be selected according to the largest bore cylinder.

The size of piston is stamped on top of the piston.
2. Measure the outside diameter of the piston to be used.
3. According to the measured O.D(Outer Diameter), calculate the new bore size.
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New bore size = piston O.D + 0.060 to 0.080mm (0.0024 to 0.0031in) (clearance between piston and
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cylinder) 0.01mm (0.0004in) (honing margin.)
4. Bore each of the cylinders to the calculated size.

To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing order.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard : 0.060 ~ 0.080mm (0.0024 ~ 0.0031in)

When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to the
oversize.
Piston And Piston Rings
1. Clean the piston.
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.

Do not use a wire brush.
2. The standard measurement of the piston outside diameter is taken 10mm (0.39in) from bottom land of the piston.
Standard diameter :
77.13 ~ 77.16mm (3.0366 ~ 3.0378in)
3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.
0.06 ~ 0.08mm (0.0024 ~ 0.0031in)
4. Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove.
Piston ring side clearance
No.1 : 0.09 ~ 0.13mm (0.0035 ~ 0.0051in)
No.2 : 0.08 ~ 0.12mm (0.0031 ~ 0.0047in)
Oil ring : 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
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If the clearance is greater than maximum, replace the piston.
5. Inspect the piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the
cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the
service limit, replace the piston rings. If the gap is too large, recheck the cylinder bore inner diameter. If the bore is over
the service limit, the cylinder block must be rebored.
Piston ring end gap
No.1 : 0.20 ~ 0.35mm (0.0079 ~ 0.0138in)
No.2 : 0.35 ~ 0.50mm (0.0138 ~ 0.0197in)
Oil ring : 0.20 ~ 0.40mm(0.0079 ~ 0.0157in)
Piston Pins
1. Measure the outer diameter of piston pin.
Piston pin diameter :
27.995 ~ 28.000mm (1.1022 ~ 1.1024in)
2. Measure the piston pintopiston clearance.
Piston pintopiston clearance :
0.004 ~ 0.015mm (0.0002 ~ 0.0006in)
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3. Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter.English
Piston pintoconnecting rod interference :
0.022 ~ 0.039mm (0.0009 ~ 0.0015in)
Oil Pressure Switch
1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity, replace the oil
pressure switch.
2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even when
the fine wire is pushed, replace the switch.
3. If there is no continuity when a 49.0kpa (0.5kg/cm², 7.1psi) vacuum is applied through the oil hole, the switch is
operating properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.
REASSEMBLY

• Thoroughly clean all parts to assembled.
• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
• Replace all gaskets, Orings and oil seals with new parts.
1. Assemble the piston and connecting rod.
(1) Use a hydraulic press for installation
(2) The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
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(1) Install the oil ring expander and 2 side rails by hand.
(2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.
3. Install the connecting rod bearings.
(1) Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2) Install the bearings(A) in the connecting rod and connecting rod cap(B).
4. Install the crankshaft main bearings.

Upper 1, 2, 4, 5 bearings have an oil groove of oil holes ; Lower bearings do not.
(1) Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings(A).
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(2) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
5. Install the oil jet.
Tightening torque :
8.8 ~ 12.7N.m (0.9 ~ 1.3kgf.m, 6.5 ~ 9.4lbft)
6. Place the crankshaft on the cylinder block.
7. Place the bed plate on the cylinder block.

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• Standard liquid gasket : FD 20, HYLOMAR3000, Dreibond 5105
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• Assemble the bed plate in 5 minutes after applying the liquid gasket.
8. Install the bed plate bolts.

• The bed plate bolts are tightened in 2 progressive steps.
• If any of the bed plate bolts in broken or deformed, replace it.
(1) Apply a light coat of engine oil on the threads and under the bed plate bolts.
(2) Tighten the bolts (11, 17, 20) in nunerical order.
(3) Tighten the main bearing cap bolts (1~10) in nunerical order.
(4) Loosen the bolts (11. 17, 20).
(5) Tighten the bolts (11~20) in nunerical order.
(6) Tighten torque of main bearing cap bolts.
Tightening torque :
Long bolts(1~10) : 22.6~26.5Nm (2.3~2.7kgf.m, 16.6~19.5lbft) + 90~94°
Short bolts(11~20) : 32.4~36.3N.m (3.3~3.7kgf.m, 23.9~26.8lbft)

Always use new main bearing cap bolts.
(7) Check that the crankshaft turns smoothly.

Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.
(1) Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting
rod bolts.
(2) Install the ring compressor, check that the rings are securely in place, then position the piston in the cylinder, and
tap it in using the wooden handle of a hammer.
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(3) Stop after the ring compressor pops free, and check the connecting rodtocrank journal alignment before pushing
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the piston into place.
(4) Apply engine oil to the bolt threads. install the rod caps with bearings, and tighten the bolts.
Tightening torque :
12.7Nm (1.3kgf.m, 9.4lbft) + (87~93°)

• Always use new connecting rod bearing cap bolts.
• Maintain downward force on the ring compressor to prevent the rings from expending before entering
the cylinder bore.
11. Install the rear oil seal.
(1) Apply engine oil to a new oil seal lip.
(2) Using the SST(092142A100, 09231H1100) and a hammer, tap in the oil seal until its surface is flush with the rear
oil seal retainer edge.
12. Install the oil filter and oil cooler assembly(A).
Tightening torque :
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lbft)
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13. Install the water pipe(A).
Tightening torque :
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lbft)
14. Install the cylinder head. (Refer to Cylinder head in this group)
15. Install the intake manifold and exhaust manifold. (Refer to Intake and exhaust system in this group)
16. Install the timing chain. (Refer to Timing chain in this group)
17. Remove the engine stand.
18. MT : Install the flywheel (A).
Tightening torque :
68.6 ~ 78.5 N.m (7.0 ~ 8.0 kgf.m, 50.6 ~ 57.9 lbft)
AT : Install the drive plate (B) and the drive plate adapter (A).
Tightening tor Tightening torque :
68.6 ~ 78.5 N.m (7.0 ~ 8.0 kgf.m, 50.6 ~ 57.9 lbft)
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19. Install the clutch cover and disk. (MT only)
(Refer to Clutch Cover And Disk in CH group)
20. Install the automatic or manual transaxle assembly.
(Refer to Transaxle in MT or AT group)
21. Install the engine and transaxle assembly.
(Refer to Engine And Transaxle Assembly in this group)
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Cooling System > Troubleshooting English
Inspection Remedy
coolant.
coolant.
Be careful when removing radiator cap from overheated
vehicle.
Inspect for leakage and loose coolant hoses (radiator hose, heater
reinstalling hoses and
hose, oil cooler hose, etc.).
clamps.
replacing Oring.
torque.
Visual inspection Adjust drive belt tension or
replace.
replacing gasket.
torque.
Inspect for loose coolant temperature sensor, cooling fan
connector and pin. Replace relevant part if
A/C.
ground cable.
Diagnostic device Inspect selfdiagnostic code using KDS/GDS. sensor, wiring, connector,
etc.
Inspect water pump impeller. Replace water pump.
foreign materials.
Inspect for stuck thermostat valve.
Immerse thermostat in water heated to over 95°C (203°F), then
Unit inspection heat for at least 3 minutes to check valve lift.
Check valve lift.
Replace thermostat if valve

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lift is below specification or
• Do not use water below 95°C (203°F). English
valve is stuck.
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Cooling System > Coolant > Repair procedures
English
REPLACEMENT AND AIR BLEEDING

Never remove the radiator cap when the engine is hot.
Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.

When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts of the
paint. If any coolant spills, rinse it off immediately.
1. Slide the heater temperature control lever to maximum heat. Make sure the engine and radiator are cool to the touch.
2. Remove the radiator cap (A).
3. Loosen the drain plug (A), and drain the coolant.
4. Tighten the radiator drain plug (A) securely.
5. Remove the coolant reservoir tank. Drain the coolant and reinstall the coolant reservoir tank. Fill the coolant reservoir
tank to the MAX mark with the coolant.
6. Fill fluid mixture (coolant 5: water 5) with coolant and water slowly through the radiator cap. Gently squeeze the upper/
lower hoses of the radiator so as to bleed air easily.

• Use only genuine antifreeze/coolant.
• For best corrosion protection, the coolant concentration must be maintained yearround at 50% minimum.
Coolant concentrations less than 50% may not provide sufficient protection against corrosion of freezing.
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• Coolant concentrations greater then 60% will impair cooling efficiency and are not recommended.
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• Do not mix different brands of antifreeze/coolants.
• Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.
7. Start the engine and allow coolant to circulate. When the cooling fan operates and coolant circulates, refill coolant
through the radiator cap.
8. Repeat 7 until the cooling fan 3 ~ 5times and bleed air sufficiently out of the cooling system.
9. Fill the reservoir to the "MAX" line with coolant.
10. Stop the engine and allow coolant to be cool.
11. Repeat step 6 to 10 until the coolant level stays constant and all air is bleed out of the cooling system.

Recheck the coolant level in the reservoir tank for 2 ~ 3 days after replacing coolant.
Coolant capacity : 6.3 liters(6.66 US qt, 5.54 lmp qt)
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Cooling System > Thermostat > Components and
English
Components Location
COMPONENTS
1. Water pump 7. Thermostat cover
2. Water pump Oring 8. Bypass hose connector
3. Thermostat cover gasket 9. Thermostat assembly
4. Thermostat housing gasket 10. Engine coolant temperature sensor (ECTS)
5. Heater connector 11. Return pipe assembly
6. Thermostat housing
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Cooling System > Thermostat > Repair procedures
English
REMOVAL

Disassembly of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.
1. Drain the engine coolant so its level is below thermostat.
2. Remove the water inlet fitting (A), gasket and thermostat.
INSPECTION

2. Check the valve opening temperature.
Valve opening temperature : 85±1.5°C (185±34.7°F)
Full opening temperature : 95°C (203°F)
If the valve opening temperature is not as specified, replace the thermostat.
3. Check the valve lift.
Valve lift : 8mm(0.3in) or more at 95°C (203°F)
If the valve lift is not as specified, replace the thermostat.
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1. Place the thermostat in thermostat housing with new gasket.
2. Install the water inlet fitting(A).
Tightening torque :
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lbft)
3. Fill with engine coolant.
4. Start engine and check for leaks.
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Cooling System > Water pump > Repair procedures
English
REMOVAL

System is under high pressure when the engine is hot.
To avoid danger of releasing scalding engine coolant, remove the cap only when the engine is cool.
3. Remove the water pump pulley (A).
4. Remove the water pump (A).
INSPECTION
1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if
necessary.
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3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump assembly.

A small amount of "weeping" from the bleed hole is normal.
INSTALLATION
1. Install the water pump(A) and a new Oring.
Tightening torque :
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lbft)
2. Install the water pump pulley(A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
6. Recheck engine coolant level.
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Cooling System > Radiator > Repair procedures
English
REMOVAL
1. Drain the engine coolant. Remove the radiator cap to speed draining.
2. Remove the radiator upper grill (A) and the air duct (B).
3. Remove the radiator upper hose (A).
4. Remove the radiator lower hose (B).

Remove the clamp on the cooling fan cover.
5. Disconnect the fan motor connector (A).
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6. Disconnect the hose (A) between the reservoir and the radiator.
7. Remove the radiator upper mounting brackets.
8. Remove the blower assembly from the radiator.
9. Remove the condenser from the radiator.
INSPECTION
Radiator Cap
1. Remove the radiator cap, wet its seal with engine coolant, then install it no pressure tester.
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2. Apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi).
3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.
Radiator Leakage
1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant, then install it on
the pressure tester.
2. Apply a pressure tester to the radiator and apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~
17.78psi).
3. Inspect for engine coolant leaks and a drop in pressure.
4. Remove the tester and reinstall the radiator cap.

Check for engine oil in the coolant and/or coolant in the engine oil.
INSTALLATION
1. Install the radiator to vehicle with mounting brackets and then tighten the bolts.
Tightening torque :
6.9 ~ 10.8Nm (0.7 ~ 1.1kgf.m, 5.1 ~ 8.0 lbft)
2. Install the cooling fan to the radiator.
Tightening torque :
8.8 ~ 10.8Nm (0.9 ~ 1.1kgf.m, 6.5 ~ 8.0 lbft)
3. Install the radiator to the air conditioning condenser and the radiator upper bracket.
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4. Connect the hose (A) between the radiator and the reservoir. English
5. Connect the fan motor connector (A).
6. Install the upper (A) and the lower radiator hoses (B) and the automatic transaxle fluid (ATF) cooler hose.
7. Fill with engine coolant and install the air duct (B), the radiator upper grill (A).
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Lubrication System > Components and English
Components Location
COMPONENTS
1. Bolt 5. Oil pressure switch assembly 9. Oil drain plug

2. Engine oil filter assembly 6. Oil pan assembly 10. Oil level gauge guide
3. Oring 7. Baffle plate 11. Oil screen assembly
4. Oil cooler assembly 8. Oil drain plug gasket 12. Oil pan acoustic shield
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Lubrication System > Engine Oil > Repair English
procedures
ENGINE OIL AND FILTER REPLACEMENT

• Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to
dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which
may cause skin cancer.
• Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear
protective clothing and gloves. Wash your skin thoroughly with soap and water, or use waterless hand cleaner,
to remove any used engine oil. Do not use gasoline, thinners, or solvents.
• In order to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal
sites.
(1) Remove the oil filler cap.
(2) Loosen the oil filter cap slowly until its Oring(C)'s coming out.
Be cautious of oil's overflowing at this moment.
(3) Remove the oil drain plug, and drain the oil into a container.
2. Replace the oil filter(B).
(1) Remove the oil filter upper cap(A).
(2) Replace the Oring(C, D) of oil filter cap with a new one.
Inspect the threads and Oring(C, D). Wipe off the seat on the oil filter cap, then apply a light coat of oil to the oil
filter upper cap Oring(C, D).
(3) Install the new oil filter by hand to the upper cap.
(4) After the rubber seal seats, tighten the oil filter clockwise.
Tightening torque :
24.5N.m(2.5kgf.m, 18.1lbft)
3. Refill with engine oil.
(1) Clean and install the oil drain plug with a new gasket.
Tightening torque :
34.3 ~ 44.1N.m (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lbft)
(2) Fill with fresh engine oil.
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English
Fill half amount of total oil first and then do the rest after 1 minute or more.
Oil Capacity
When replacing a short engine or a block assembly 5.7L(6.02US qt, 5.02lmp qt)
When replacing oil pan only 4.8L (5.07US qt, 4.22lmp qt)
Drain and refill including oil filter 5.3L (5.60US qt, 4.66lmp qt)
(3) Install the oil filler cap.
4. Start engine and check for oil leaks.
5. Recheck the engine oil level.
INSPECTION
Engine Oil
1. Check the engine oil quality.
Check the oil deterioration, entry of water, discoloring of thinning.
If the quality is visibly poor, replace the oil.
2. Check the engine oil level.
After warming up the engine and then 5 minutes after the engine stop, oil level should be between the "L" and "F" marks
in the dipstick.

Do not fill with engine oil above the "F" mark.
Selection Of Engine Oil
Recommendation For Europe
ACEA C2 or C3 (with DPF), ACEA B4 (without DPF)
Approved Engine Oil (With DPF)
Chevron : KIXX D1 C2 5W30
ACEA C2
TOTAL : QUARTZ INEO HKS D 5W30
SK : ZIC LS 5W30
ACEA C3 Chevron : KIXX D1 5W30
TOTAL : QUARTZ INEO MC3 5W30
SAE viscosity grade
Refer to the recommended SAE viscosity number
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English

1) Satisfy the requirement of the ACEA classification.
2) Have proper SAE grade number for expected ambient temperature range.
• Lubricants that do not have both an SAE grade number and ACEA service classification on the container should
not be used.
• For the vehicle equipped with DPF, the service engine oil quality should meet the ACEA C3 grade. However, oil
refill with small amount of ACEA B4 grade between oil change intervals is possible.
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Lubrication System > Oil Pump > Repair English
procedures
REMOVAL
3. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing chain cover.
4. Remove the timing chain cover.
5. Remove the oil pump cover(A) from the timing chain cover.
6. Remove the inner rotor and outer rotor.
DISASSEMBLY
Relief Plunger
1. Remove the relief plunger.
Remove the plug(A), spring(B) and relief plunger(C).
INSPECTION
1. Inspect the relief plunger.
Coat the plunger with engine oil and check that it falls smoothly into the plunger hole by its own weight.
If it does not, replace the relief plunger. If necessary, replace the front case.
2. Inspect the rotor side clearance.
Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge.
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0.04 ~ 0.09mm English
Outer rotor
(0.0016 ~ 0.0035in)
Side clearance
0.04 ~ 0.085mm
Inner rotor
(0.0016 ~ 0.0033in)
If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front case.
REASSEMBLY
Relief Plunger
1. Install the relief plunger.
Install relief plunger(C) and spring(B) into the front case hole, and install the plug(A).
Tightening torque :
25.5 ~ 34.3N.m (2.6 ~ 3.5kgf.m, 18.8 ~ 25.3lbft)
INSTALLATION
1. Install the oil pump.
(1) Place the inner and outer rotors into front case with the marks facing the oil pump cover side.
(2) Install the oil pump cover(A) to timing chain cover with the screws.
Tightening torque :
5.9 ~ 8.8N.m (0.6 ~ 0.9kgf.m, 4.3 ~ 6.5lbft)
2. Check that the oil pump turns freely.
3. Install the timing chain cover.
5. Fill with engine oil.
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English
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Intake And Exhaust System > Intake Manifold >
English
COMPONENTS
1. Intake manifold assembly 4. Intake manifold gasket
2. Bolt 5. Nut
3. Variable swirl control actuator
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Intake And Exhaust System > Intake Manifold >
English
Repair procedures
REPLACEMENT
1. Remove the reservoir hose (A), disconnect the swirl valve actuator connector (B).
2. Remove the intercooler hose (A) and the throttle body (B). For the vehicles equipped with the Catalyzed Particulate
Filter (CPF), remove the air heater (C) after removing the electrical throttle control assembly (D) by disconnecting its
connector (E).
3. Remove the EGR cooler pipe (A).
Tightening torque :
Nut (B) : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lbft)
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English
4. Disconnect the throttle flap control solenoid connector (A) and VGT solenoid valve connector (B) and remove the
bracket. For the vehicles equipped with the Catalyzed Particulate Filter (CPF), there is no throttle flap control solenoid
but VGT solenoid only.
5. Disconnect the fuel return hose (A), the high pressure pipe (B) and the fuel temperature sensor mounting.
Tightening torque :
14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lbft)
7. Remove the intake manifold gasket (A).
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English
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold >
English
COMPONENTS
[1.6 VGT]
1. Exhaust manifold assembly 8. Oil return pipe gasket 14. EGR valve assembly

2. Turbocharger oil drain gasket 9. Turbocharger outlet gasket 15. EGR cooler
3. Turbocharger inlet gasket 10. Exhaust manifold gasket 16. EGR valve gasket
4. Oil return pipe 11. Heat protector 17. EGR pipe
5. Oil feed pipe 12. EGR cooler inlet hose 18. Catalytic converter (CPF)
6. Turbocharger 13. Clamp 19. Bracket
7. EGR pipe gasket
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[1.6 WGT] English
1. Exhaust manifold assembly 8. Oil return pipe gasket 14. EGR valve assembly

2. Turbocharger oil drain gasket 9. Turbocharger outlet gasket 15. EGR cooler
3. Turbocharger inlet gasket 10. Exhaust manifold gasket 16. EGR valve gasket
4. Oil return pipe 11. Heat protector 17. EGR pipe
5. Oil feed pipe 12. EGR cooler inlet hose 18. Catalytic converter (WGT)
6. Turbocharger 13. Clamp 19. Bracket
7. EGR pipe gasket
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold >
English
Repair procedures
REMOVAL
1. Disconnect the exhaust gas temperature sensor #1 (A).
2. Disconnect the lambda sensor connector (A), the exhaust gas temperature sensor #2 (B) and the difference pressure
sensor connector (C) and its hoses.
3. Remove the intercooler hose (A) after loosening the clamp (B).
Tightening torque :
Hose clamp (B) : 4.9 ~ 6.9N.m (0.5 ~ 0.7kgf.m, 3.6 ~ 5.1lbft)
4. Remove the heat protector (A).
Tightening torque :
14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lbft)
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English
5. Disconnect the heater hoses (A).
6. Remove the water hose (A) from the EGR cooler and the thermostat housing.
7. Remove the EGR cooler (A).
Tightening torque :
Bolt (B) : 21.6 ~ 27.5N.m (2.2 ~ 2.8kgf.m, 15.9 ~ 20.3lbft)
Nut (C) : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lbft)
8. Remove the EGR valve assembly (A) and the EGR pipe (B).
Tightening torque :
Bolt (C, D) : 21.6 ~ 27.5N.m (2.2 ~ 2.8kgf.m, 15.9 ~ 20.3lbft)
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Bolt (E) : 29.4 ~ 34.3N.m (3.0 ~ 3.5kgf.m, 21.7 ~ 25.3lbft)
English
9. Remove the CPF mounting brackets and then remove the CPF assembly (A).
Tightening torque :
39.2 ~ 49.0N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lbft)
10. Remove the catalytic converter bracket (A, B).
Tightening torque :
39.2 ~ 49.1N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lbft)
[1.6 WGT]
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English
11. Remove the catalytic converter (B).
Tightening torque :
39.2 ~ 49.1N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lbft)
[1.6 WGT]
12. Remove the eye bolt (A) from the turbocharger oil return pipe (B).
Tightening torque :
Bolt (A) : 13.7 ~ 18.6N.m (1.4 ~ 1.9kgf.m, 10.1 ~ 13.7lbft)
Bolt (C) : 9.8 ~ 14.7N.m (1.0 ~ 1.5kgf.m, 7.2 ~ 10.9lbft)
Bolt (D) : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.9 ~ 14.5lbft)
Bolt (E) : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbft)
[1.6 VGT]
[1.6 WGT]
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English
13. Remove the turbocharger (B) first and then exhaust manifold assembly (A).
Tightening torque :
Bolt (C), Nut (E) : 44.1 ~ 49.1N.m (4.5 ~ 5.0kgf.m, 32.6 ~ 36.2lbft)
Nut (D) : 29.4 ~ 34.3N.m (3.0 ~ 3.5kgf.m, 21.7 ~ 25.3lbft)
[1.6 VGT]
[1.6 WGT]
14. Remove the exhaust manifold gasket (A).
15. Installation is reverse order of removal.
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English
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Intake And Exhaust System > Turbo Charger >
English
COMPONENTS
[VGT]
5. Compressor inlet
[WGT]
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English
5. Compressor inlet
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English
Repair procedures
If any problem related with turbocharger, such as lack of engine power, poor acceleration, abnormal engine noise or oil leaks,
may occur, check the turbocharger according to the procedure as follows.
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– Check if a gasket is installed. English
If the cause of the problem is detected, retighten the mounting bolts (or nuts) as the specified torque or replace the
gasket or damaged parts with new ones if necessary.
If the cause of the problem is detected, retighten the mounting bolts (or nuts) as the specified torque or install a new
gasket if necessary.
turbocharger. If the oil drain pipe & hose is damaged and clogged, engine oil is not drained smoothly then it may cause
oil leaks from the turbocharger.
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English
If the setting marks are not aligned in line, the engine performance is changed by an arbitrary tuneup of the
turbocharger after delivery.
If the vacuum pipes & hoses are damaged or disconnected, the actuator does not work properly then it may cause lack
of engine power and poor acceleration.
– Positive pressure type actuator: Check for movement of the actuator rod when a compressed air of 98kPa
(1kgf/cm², 14.2psi) is applied to the actuator.
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– Check if the compressor wheel rotates smoothly. English
EX)
EX)
If any problem is not detected in the turbocharger, check the turbochargerrelated parts according to the procedure as follows
.
If a crosssection of the hose diminishes as the air intake hose is bent or crushed, intake air to the turbocharger
reduces and the pressure in front of turbocharger drops. So it may cause damage of the turbocharger and oil leaks. If
the air intake hose is detached or torn, a foreign substance goes into the turbocharger and causes damage of it.
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English


turbocharger.


– Engine oil pressure: Check the oil pressure using an oil pressure gauge after removing the oil pressure switch on
the cylinder block.
– Check the engine oil screen in the oil pan if the engine oil level is low. Then check the injectors for gas leaks if
foreign substances are accumulated on the oil screen.
If the cause of the problem is detected, add or change engine oil. If foreign substances are accumulated on the oil
screen, wash the oil screen and replace the injector’s washer with a new one after checking the injectors for gas leaks.
Check the engine oilrelated parts, such as oil pump, if necessary.

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English
As the turbocharger rotates at high speed of 100,000 rpm or above, deterioration of engine oil can cause damage
of the turbocharger bearings. Check engine oil for discoloration, water influx, viscosity degradation and oil
pressure lowering.
from max. duty (95%) to min. duty (5%) by GDS. (If the solenoid valve filter is clogged, the vacuum won’t be
released or it will take a long time to be released.)
acceleration. If the solenoid valve filter is clogged, vacuum is not released then it may cause damage of the
turbocharger by overrunning.
– Check if the sensors, such as the mass air flow sensor (MAFS), intake air temperature sensor (IATS), boost
pressure sensor (BPS), operate properly.
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English
Repair procedures
If any problem related with turbocharger, such as lack of engine power, poor acceleration, abnormal engine noise or oil leaks,
may occur, check the turbocharger according to the procedure as follows.
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– Check if a gasket is installed. English
If the cause of the problem is detected, retighten the mounting bolts (or nuts) as the specified torque or install a new
gasket if necessary.
turbocharger. If the oil drain pipe & hose is damaged and clogged, engine oil is not drained smoothly then it may cause
oil leaks from the turbocharger.
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English
If the setting marks are not aligned in line, the engine performance is changed by an arbitrary tuneup of the
turbocharger after delivery.
If the vacuum pipes & hoses are damaged or disconnected, the actuator does not work properly then it may cause lack
of engine power and poor acceleration.
– Positive pressure type actuator: Check for movement of the actuator rod when a compressed air of 98kPa
(1kgf/cm², 14.2psi) is applied to the actuator.
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– Check if the compressor wheel rotates smoothly. English
EX)
EX)
If any problem is not detected in the turbocharger, check the turbochargerrelated parts according to the procedure as follows
.
If a crosssection of the hose diminishes as the air intake hose is bent or crushed, intake air to the turbocharger
reduces and the pressure in front of turbocharger drops. So it may cause damage of the turbocharger and oil leaks. If
the air intake hose is detached or torn, a foreign substance goes into the turbocharger and causes damage of it.
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English


turbocharger.


– Engine oil pressure: Check the oil pressure using an oil pressure gauge after removing the oil pressure switch on
the cylinder block.
– Check the engine oil screen in the oil pan if the engine oil level is low. Then check the injectors for gas leaks if
foreign substances are accumulated on the oil screen.
If the cause of the problem is detected, add or change engine oil. If foreign substances are accumulated on the oil
screen, wash the oil screen and replace the injector’s washer with a new one after checking the injectors for gas leaks.
Check the engine oilrelated parts, such as oil pump, if necessary.

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As the turbocharger rotates at high speed of 100,000 rpm or above, deterioration of engine oil can cause damage
of the turbocharger bearings. Check engine oil for discoloration, water influx, viscosity degradation and oil
pressure lowering.
from max. duty (95%) to min. duty (5%) by GDS. (If the solenoid valve filter is clogged, the vacuum won’t be
released or it will take a long time to be released.)
acceleration. If the solenoid valve filter is clogged, vacuum is not released then it may cause damage of the
turbocharger by overrunning.
– Check if the sensors, such as the mass air flow sensor (MAFS), intake air temperature sensor (IATS), boost
pressure sensor (BPS), operate properly.
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Intake And Exhaust System > Intercooler > Repair
English
procedures
REMOVAL
1. Remove the battery assembly with its tray.
2. Disconnect the boost pressure sensor connector (A).
3. Disconnect the intercooler hoses (B).
Tightening terque :
Hose clamp (E) :
4.9 ~ 6.9N.m (0.5 ~ 0.7kgf.m, 5.1 ~ 6.6 lbft)
4. Remove the intercooler assemlby mounting bolts (C).
Tightening terque :
6.9 ~ 8.8N.m (0.7 ~ 0.9kgf.m, 5.1 ~ 6.6 lbft)
5. Take off the intercooler assemlby (D).
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2012 > D 1.6 TCIU2 > Engine Mechanical System > Intake And Exhaust System > Muffler > Repair
English
procedures
REPLACEMENT
1. Remove the front muffler assembly (A).
Tightening torque :
39.2 ~ 58.8N.m (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lbft)
2. Remove the main muffler (A).
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Contents
2012 > D 1.6 TCIU2 > Fuel System > General Information > Specifications English
SPECIFICATIONS
Fuel Delivery System
Items Specification
Fuel Injection System Type Common Rail Direct Injection (CRDI)
Fuel Return System Type Return type
Fuel Pressure Max. Pressure 1,600 bar
Fuel Tank Capacity 55 lit. (14.5 U.S.gal., 12.1 Imp.gal.)
Fuel Filter Type High pressure type (Built in engine room)
Type Mechanical, Plunger Pumping Type
High Pressure Fuel Pump
Driven by Drive Belt
Type Mechanical, Gear Pumping Type
Low Pressure Fuel Pump
Driven by Involved in High Pressure Fuel Pump
Sensors
Mass Air Flow Sensor (MAFS)
▷ Type: HotFilm Type
▷ Specification
* At intake air temperature = 20°C(68°F)
8 1.96 ~ 1.97
10 2.01 ~ 2.02
40 2.50 ~ 2.52
105 3.18 ~ 3.23
220 4.26 ~ 4.35
480 7.59 ~ 7.94
560 9.08 ~ 9.89
* At intake air temperature = 15°C(5°F) or 80°C(176°F)
10 2.00 ~ 2.01
40 2.49 ~ 2.53
105 3.16 ~ 3.25
480 7.42 ~ 8.12
Intake Air Temperature Sensor (IATS) #1 [BUILT IN MAFS]
▷ Specification
40(40) 35.14 ~ 43.76
20(4) 12.66 ~ 15.12
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0(32) 5.12 ~ 5.89
English
20(68) 2.29 ~ 2.55
40(104) 1.10 ~ 1.24
60(140) 0.57 ~ 0.65
80(176) 0.31 ~ 0.37
Boost Pressure Sensor (BPS)
▷ Specification
32.5 0.5
70 1.02 ~ 1.17
140 2.13 ~ 2.28
210 3.25 ~ 3.40
270 4.20 ~ 4.35
284 4.5
Intake Air Temperature Sensor (IATS) #2 [BUILT IN BPS]
▷ Specification
40(40) 40.93 ~ 48.35
20(4) 13.89 ~ 16.03
0(32) 5.38 ~ 6.09
20(68) 2.31 ~ 2.57
40(104) 1.08 ~ 1.21
60(140) 0.54 ~ 0.62
80(176) 0.29 ~ 0.34
▷ Specification
40(40) 48.14
20(4) 14.13 ~ 16.83
0(32) 5.79
20(68) 2.31 ~ 2.59
40(104) 1.15
60(140) 0.59
80(176) 0.32
Camshaft Position Sensor (CMPS)
▷ Specification
High 5
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Low 0
English
Items Specification
Air Gap (mm) 0.5 ~ 1.5
Crankshaft Position Sensor (CKPS)
▷ Type: Variable reluctance type
▷ Output Voltage (V): 0 ~ 5V
Items Specification
Coil Resistance (Ω) 774 ~ 946 [20°C(68°F)]
Accelerator Position Sensor (APS)
▷ Type: Potentiometer type
▷ Specification
[With Kickdown switch]
Output Voltage (V) [Vref=5V]
Test Condition
APS 1 APS 2
Idle 0.7 ~ 0.8 0.275 ~ 0.475
Fully depressed 3.75 ~ 4.15 1.87 ~ 2.07
Specification
Items
APS 1 APS 2
[Without Kickdown switch]
Output Voltage (V) [Vref=5V]
Test Condition
APS 1 APS 2
Idle 0.7 ~ 0.8 0.275 ~ 0.475
Fully depressed 3.85 ~ 4.35 1.92 ~ 2.17
Specification
Items
APS 1 APS 2
Fuel Temperature Sensor (FTS)
▷ Specification
30(22) 27.00
20(4) 15.00
10(14) 9.45
0(32) 5.89
20(68) 2.27 ~ 2.73
40(104) 1.17
50(122) 0.83
60(140) 0.60
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70(158) 0.43
English
80(176) 0.30 ~ 0.32
Rail Pressure Sensor (RPS)
▷ Specification
Test Condition Rail pressure (bar) Output Voltage(V)

Idle 220 ~ 320 Below 1.7
Fully depressed 1,600 Approx. 4.5
Lambda Sensor
▷ Specification
0.65 2.22
0.70 1.82
0.80 1.11
0.90 0.50
1.01 0.00
1.18 0.33
1.43 0.67
1.70 0.94
2.42 1.38
Item Specification
Heater Resistance (Ω) 2.4 ~ 4.0 [20°C(68°F)]
Exhaust Gas Temperature Sensor (EGTS) #1 FOR Turbo charger [With CPF]
▷ Specification
100(212) 289.0 ~ 481.0
300(572) 5.30 ~ 6.61
600(1,112) 0.35 ~ 0.38
900(1,652) 0.08 ~ 0.09
Exhaust Gas Temperature Sensor (EGTS) #2 FOR CPF [With CPF]
▷ Specification
100(212) 289.0 ~ 481.0
300(572) 5.30 ~ 6.61
600(1,112) 0.35 ~ 0.38
900(1,652) 0.08 ~ 0.09
Differential Pressure Sensor (DPS) [With CPF]
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English
▷ Specification: Vout = (4.5 1.0) / 100 * ΔP + 1.0 (V)
Differential Pressure [ΔP] (kPa) Output Voltage (V)
0 1.00
10 1.35
20 1.70
30 2.05
40 2.40
50 2.75
60 3.10
70 3.45
80 3.80
90 4.15
100 4.50
Water Sensor
▷ Specification
Item Specification
Warning Level (cc) 40 ~ 60
Vehicle Speed Sensor (VSS)
▷ Type: Inductive type
Actuators
Injector
▷ Number: 4
▷ Specification
Items Specification
Coil Resistance (Ω) 0.215 ~ 0.295 [20°C(68°F)]
Fuel Pressure Regulator Valve
▷ Specification
Air Control Valve [With CPF]
▷ Type : Duty control motor type
▷ Specification
5 Open
94 Closed
Electric EGR Control Valve [Euro 5 only]
▷ Specification
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[Position Sensor]
English
Items Specification
Coil Resistance (kΩ) 2.4 ~ 5.6 [20°C(68°F)]
[Solenoid Valve]
Item Specification
Electric EGR Control Valve [Except Euro 5]
▷ Specification
Item Specification
WGT/VGT Control Solenoid Valve
▷ Specification
Items Specification
Throttle Flap Control Solenoid Valve [Without CPF]
▷ Specification
Items Specification
Coil Resistance (Ω) 28.3 ~31.1 [20°C(68°F)]
Variable Swirl Control Actuator
▷ Type: Motor Driven (including Position Sensor)
▷ Specification
Motor
Items Specification
Position Sensor
Items Specification
Coil Resistance (kΩ) 3.44 ~ 5.16 [20°C(68°F)]
SERVICE STANDARD
A/C OFF
Basic Idle rpm Drange 800 ± 100 rpm
(After warm up) Neutral,N,Prange 800 ± 100 rpm
A/C ON
TIGHTENING TORQUES
Engine Control System
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Item Kgf.m N.m lbft
English
Mass air flow sensor clamp installation bolts 0.3 ~ 0.5 2.9 ~ 4.9 2.2 ~ 3.6
Boost pressure sensor installation bolts 0.7 ~ 1.1 6.9 ~ 10.8 5.1 ~ 8.0
Rail pressure sensor installation 6.6 ~ 7.6 65.0 ~ 75.0 47.9 ~ 55.3
Lambda sensor installation 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
Electric EGR control valve installation bolts 2.2 ~ 2.8 21.6 ~ 27.5 15.9 ~ 20.3
Variable swirl control actuator installation bolts 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Exhaust gas temperature sensor (For CPF) installation 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
Exhaust gas temperature sensor (For VGT) installation 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
Differential pressure sensor bracket installation nuts 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Air control valve [With CPF] installation nuts 0.7 ~ 1.1 6.9 ~ 10.8 5.1 ~ 8.0
Throttle body [Without CPF] installation nuts 0.7 ~ 1.1 6.9 ~ 10.8 5.1 ~ 8.0
WGT/VGT control solenoid valve bracket installation bolt 0.7 ~ 1.1 6.9 ~ 10.8 5.1 ~ 8.0
Air heater relay installation bolt 0.6 ~ 1.2 5.9 ~ 11.8 4.3 ~ 8.7
Glow plug installation 1.5 ~ 2.0 14.7 ~ 19.6 10.9 ~ 14.5
Pipe (DPS ↔ CPF) installation (CPF side) 3.5 ~ 5.1 34.3 ~ 50.0 25.3 ~ 36.9
Fuel Delivery System
Item Kgf.m N.m lbft
Injector clamp installation bolt 2.9 ~ 3.1 28.4 ~ 30.4 21.0 ~ 22.4
Common rail installation bolt 1.5 ~ 2.2 14.7 ~ 21.6 10.9 ~ 15.9
High pressure fuel pump installation bolt 2.0 ~ 2.6 19.6 ~ 25.5 14.5 ~ 18.8
High pressure fuel pipe (Injector ↔ Common Rail) installation nut 2.5 ~ 2.9 24.5 ~ 28.4 18.1 ~ 21.0
High pressure fuel pipe (Common RaiI ↔ High Pressure Fuel
2.5 ~ 2.9 24.5 ~ 28.4 18.1 ~ 21.0
Pump) installation nut
Fuel tank band installation bolt 4.0 ~ 5.5 39.2 ~ 54.0 28.9 ~ 39.8
Fuel Sender installation bolt 0.2 ~ 0.3 2.0 ~ 2.9 1.4 ~ 2.2
Accelerator pedal module installation bolt 1.3 ~ 1.6 12.8 ~ 15.7 9.4 ~ 11.6
Fillerneck assembly installation bolt 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
Fillerneck bracket installation bolt 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
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2012 > D 1.6 TCIU2 > Fuel System > General Information > Troubleshooting English
Basic Troubleshooting Guide
Customer Problem Analysis Sheet
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English
Basic Inspection Procedure
Measuring Condition Of Electronic Parts' Resistance
The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be measured at
ambient temperature (20°C, 68°F), unless stated otherwise.

Intermittent Problem Inspection Procedure
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English
should thoroughly make out a "CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and condition
which occurred when the vehicle was having the issue.

● SIMULATING HEAT


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English
Connector Inspection Procedure
side.
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English
harness side.


Wire Harness Inspection Procedure
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4. Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part. English
Electrical Circuit Inspection Procedure
● Check Open Circuit
• Voltage Check
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity Check Method) or Step
3 (Voltage Check Method) as shown below.

In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1MΩ and below 1 Ω respectively. Specifically
the open circuit is line 1 (Line 2 is normal). To find exact break point, check sub line of line 1 as described in next
step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1) and between (B2) and (A)
as shown in [FIG. 3].
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English
The measured voltage of each connector is 5V, 5V and 0V respectively. So the open circuit is between connector
(C) and (B).
● Check Short Circuit
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing Step 2 (Continuity
Check Method with Chassis Ground) as shown below.

a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis Ground as shown
in [FIG. 6].
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The measured resistance of line 1 and 2 in this example is below 1 Ω and higher than 1MΩ respectively.
English
Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken point, check the sub line of
line 1 as described in the following step.
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and between
(B1) and chassis ground as shown in [FIG. 7].
Symptom Troubleshooting Guide Table
(Symptom 1) Engine Does Not Start
Possible Cause
• Inversion of fuel connections (feed & return)
• Run out of fuel
• Faulty fuel filter
• Faulty starter
• Clogged low pressure fuel circuit
• Not connected fuel feed line
• Clogged fuel filter
• Leakage in high pressure fuel circuit
• Intermittent faulty fuel line connection
• Fuse out of order
• Drift of the rail pressure sensor
• Clogged return line of high pressure fuel pump
• Cam and crank signals missing simultaneously
• Low compression pressure
• Low battery voltage
• Leakage at the injector
• Faulty immobilizer
• Faulty low pressure fuel pump
jammed • Faulty high pressure fuel pump
• Rail pressure regulator valve contaminated, stuck, • Injector jammed open
jammed
• ECM program error or hardware fault
• Bad fuel quality or water ingress in fuel
• Faulty glow system
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(Symptom 2) Engine Starts With Difficulty Or Starts And Stalls English
Possible Cause
• Not connected fuel return line at injector
• Oil level too high or too low
• Clogged air filter
• Sealed or damaged catalytic converter
• Faulty alternator or voltage regulator
• Compensation of individual injector not adapted
• No engine coolant temperature sensor signal
• No rail pressure sensor signal
• Low battery voltage
• Clogged injector return line
jammed
• Injector needle stuck (injection possible over a certain
pressure)
jammed
• Inversion of fuel connections (feed & return)
(Symptom 3) Poor Starting When Hot
Possible Cause
jammed
jammed • Injector needle stuck (injection possible over a certain
pressure)
(Symptom 4) Unstable Idling
Possible Cause
• Not connected fuel return line at injector • Faulty glow system
• Compensation of individual injector not adapted • Low compression pressure
• No rail pressure sensor signal • Poor tightening of injector clamp
• Wiring harness open or poor connection • Faulty high pressure fuel pump
• Air ingress in the low pressure fuel circuit • Injector not adapted
• Bad fuel quality or water ingress in fuel • Carbon deposit on the injector (sealed holes)
• Clogged fuel filter • Injector needle stuck (injection possible over a certain
pressure)
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• Clogged injector return line • Injector jammed open
English
• Leakage in high pressure fuel circuit • Electric EGR control valve blocked open
(Symptom 5) Idle Speed Too High Or Too Low
Possible Cause
• Incorrect state of the electrical pack devices • Electric EGR control valve blocked open
• Faulty alternator or voltage regulator • Faulty accelerator pedal
(Symptom 6) Blue, White, Or Black Smokes
Possible Cause
• Compensation of individual injector not adapted • Clogged air filter
• No engine coolant temperature sensor signal • Oil suction (engine racing)
• No rail pressure sensor signal • Faulty glow system
• Electric EGR control valve blocked open • Low compression pressure
• Fuel pressure regulator valve contaminated, stuck, • Poor tightening of injector clamp
jammed
• Poor injector Oring, no Oring or two Oring installed
jammed • Injector not adapted
• Oil level too high or too low • Carbon deposit on the injector (sealed holes)
• Bad fuel quality or water ingress in fuel • Injector jammed open
• Sealed or damaged catalytic converter • Gasoline in fuel
(Symptom 7) Engine Rattling, Noisy Engine
Possible Cause
• Poor injector Oring, no Oring or two Oring installed
pressure)
(Symptom 8) Nurst Noise
Possible Cause
• Intermittent faulty fuel line connection jammed
• Clogged exhaust system • Rail pressure regulator valve contaminated, stuck,
jammed
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• No rail pressure sensor signal • ECM program error or hardware fault English
(Symptom 9) Untimely Acceleration/deceleration And Engine Racing
Possible Cause
• Blocked accelerator pedal position sensor • Oil suction (engine racing)
• Electric EGR control valve blocked open • No rail pressure sensor signal
• Intermittent faulty fuel line connection • ECM program error or hardware fault
(Symptom 10) Gap When Accelerating And At Recoupling (Response Time)
Possible Cause
• Leakage in intake system
• Incorrect state of the electrical pack devices • Fuel pressure regulator valve contaminated, stuck,
jammed
• Blocked accelerator pedal position sensor
jammed
• Damaged turbocharger or leakage in vacuum line
• Clogged fuel filter pressure)
• Low compression pressure • ECM program error or hardware fault
(Symptom 11) Engine Stop
Possible Cause
• Run out of fuel
• Not connected fuel feed line • Rail pressure regulator valve contaminated, stuck,
jammed
• Faulty alternator or voltage regulator
• Sealed or damaged catalytic converter
• Faulty high pressure fuel pump
• Crank signals missing
jammed
(Symptom 12) Engine Judder
Possible Cause
• Run out of fuel
• Poor valve clearance
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• Faulty fuel filter • Poor injector Oring, no Oring or two Oring installed
English
• Clogged fuel filter pressure)
• Intermittent faulty fuel line connection • Injector jammed open
• Wiring harness open or poor connection • Gasoline in fuel
• Faulty glow system • ECM program error or hardware fault
(Symptom 13) Lack Of Power
Possible Cause
• Compensation of individual injector not adapted • Clogged fuel filter
• Blocked accelerator pedal position sensor • Leakage at the injector
• Incorrect state of the electrical pack devices • Clogged return line of high pressure fuel pump
• Electric EGR control valve blocked open • Clogged injector return line
• Leakage in intake system • Low compression pressure
• Clogged air filter • Injector not adapted
• Sealed or damaged catalytic converter • Poor valve clearance
• Damaged turbocharger or leakage in vacuum line • Engine coolant temperature too high
• Damaged turbocharger • Fuel temperature too high
(Symptom 14) Too Much Power
Possible Cause
(Symptom 15) Excessive Fuel Consumption
Possible Cause
• Not connected fuel return line at injector • Incorrect state of the electrical pack devices
• Leakage at the Fuel pressure regulator valve • Oil level too high or too low
• Leakage at fuel temperature sensor • Bad fuel quality or water ingress in fuel
• Leakage in high pressure fuel circuit • Sealed or damaged catalytic converter
• Leakage in intake system • Damaged turbocharger
• Clogged air filter • Low compression pressure
• Compensation of individual injector not adapted • Injector not adapted
• Electric EGR control valve blocked open • ECM program error or hardware fault
(Symptom 16) Over Speed Engine When Changing The Gear Box Ratio
Possible Cause
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• Blocked accelerator pedal position sensor • Oil suction (engine racing)
English
• Damaged turbocharger
• Clutch not well set (optional)
(Symptom 17) Exhaust Smells
Possible Cause
• Leakage at electric EGR control valve • Poor injector Oring, no Oring or two Oring installed
• Oil suction (engine racing) • Injector not adapted
• Damaged turbocharger • Carbon deposit on the injector (sealed holes)
• Oil level too high or too low • Injector needle stuck (injection possible over a certain
• Compensation of individual injector not adapted pressure)
• Sealed or damaged catalytic converter • Injector jammed open
• Poor tightening of injector clamp • ECM program error or hardware fault
(Symptom 18) Smokes (Black, White, Blue) When Accelerating
Possible Cause
• Compensation of individual injector not adapted • Intermittent faulty fuel line connection
• Electric EGR control valve blocked open • Poor tightening of injector clamp
• Clogged air filter • Poor injector Oring, no Oring or two Oring installed
• Bad fuel quality or water ingress in fuel • Injector not adapted
• Damaged turbocharger • Injector needle stuck (injection possible over a certain
• Sealed or damaged catalytic converter pressure)
• Oil suction (engine racing) • Injector jammed open
• Faulty air heater • Gasoline in fuel
• Low compression pressure • ECM program error or hardware fault
• Leakage in high pressure fuel circuit • Catalyzed Particulate Filter (CPF) fail
(Symptom 19) Fuel Smells
Possible Cause
• Not connected fuel feed line
• Leakage at fuel temperature sensor
• Leakage at the Fuel pressure regulator valve
(Symptom 20) The Engine Collapses At Take Off
Possible Cause
• Blocked accelerator pedal position sensor • Intermittent faulty fuel line connection
• Incorrect state of the electrical pack devices • No rail pressure sensor signal
• Clogged air filter •
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Fuel pressure regulator valve contaminated, stuck,
• Inversion of fuel connections (feed & return) English
jammed
• Faulty fuel filter
• Bad fuel quality or water ingress in fuel jammed
• Air ingress in the low pressure fuel circuit • Gasoline in fuel
• Clogged fuel filter • ECM program error or hardware fault
• Sealed or damaged catalytic converter • Faulty accelerator pedal position sensor
(Symptom 21) Engine Does Not Stop
Possible Cause
• Stuck or worn lubrication circuit of turbocharger • Leakage at vacuum hose
• Too much engine oil • ECM program error or hardware fault
(Symptom 22) Different Mechanical Noises
Possible Cause
• Buzzer noise (discharge by the injectors) • Leakage in intake system
• Broken clip (vibrations, resonance, noises) • Poor tightening of injector clamp
• Incorrect state of the electrical pack devices • Damaged turbocharger
• Sealed or damaged catalytic converter • Poor valve clearance
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Description and Operation English
DESCRIPTION
If the disel control system components (sensors, ECM, injector, etc.) fail, interruption to the fuel supply or failure to supply the proper
amount of fuel for variousengine operating conditions will result. The following situations may be encountered
1) Engine is hard to start or does not start at all.
2) Nstable idle.
3) Poor driveability.
If any of the above conditions are noted, first perform a routine diagnosis that includes basic engine checks (ignition system
malfunction, incorrectengine adjustment, etc.). Then, inspect the disel contorl system components with a scan tool.

• Before removing or installing any part, read the diagnostic trouble codesand then disconnect the battery negative
() terminal.
• Before disconnecting the cable from battery terminal, turn the ignition switch to OFF. Removal or connection of
the battery cable during engine operationor while the ignition switch is ON could cause damage to the ECM.
• Wchecking the generator for the charging state, do not disconnect the battery '+' terminal to prevent the ECM
from damage due to the voltage.
• Wcharging the battery with the external charger, disconnect the vehicleside battery terminals to prevent damage
to the ECM.
SelfDiagnosis
The ECM monitors the input/output signals (some signals at all times and theothers under specified conditions). When the ECM
detects an irregularity, it records the diagnostic trouble code, and outputs the signal to the Data Link connector. The diagnosis results
can be read with the MIL or scan tool. Diagnostic Trouble Code(DTC) will remain in the ECM and may be deleted by the scan tool.

If a sensor connector is disconnected with the ignition switch turned on, the diagnostic trouble code (DTC) is
recorded. In this case, disconnect the battery negative terminal () for 15 seconds or more, and the diagnosis memory
will be erased.
Checking Procedure (SelfDiagnosis)

• When attery voltage is excessively low, diagnostic trouble codes can not be read. Be sure to check the battery
for voltage and the charging system before starting the test
• Diagnosis memory is erased if the battery or the ECM connector is disconnected. Do not disconnect the battery
before the diagnostic trouble codes are completely read and recorded.
Inspection Procedure (Using Generic Scan Tool)
1. Turn OFF the ignition switch.
2. Connect the scan tool to the data link connector on the lower crash pad.
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3. Turn ON the ignition switch.
4. Use the scan tool to check the diagnostic trouble code.
5. Repair the faulty part from the diagnosis chart.
6. Erase the diagnostic trouble code.
7. Disconnect the scan tool.

When deleting diagnostic trouble code, use scan tool as possible.
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Components and Components Location
English
COMPONENT LOCATION
1. ECM (Engine Control Module) [With ISG option]
2. Mass Air Flow Sensor (MAFS) 32. Battery Sensor
3. Intake Air Temperature Sensor (IATS) #1 built in MAFS 4. 33. Brake Booster Vacuum Pressure Sensor
Boost Pressure Sensor (BPS) 34. AGM Battery
5. Intake Air Temperature Sensor (IATS) #2 built in BPS 35. DC DC Converter
6. Crankshaft Position Sensor (CKPS) 36. ISG OFF Switch
7. Camshaft Position Sensor (CMPS) 37. Alternator
8. Engine Coolant Temperature Sensor (ECTS) 38. Starter
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9. Rail Pressure Sensor (RPS) 39. Neutral Switch
English
10. Lambda Sensor 40. Clutch Switch
11. Fuel Temperature Sensor (FTS) 41. Door Switch
12. Differential Pressure Sensor (DPS) [With CPF] 42. Seat Belt Switch
13. Exhaust Gas Temperature Sensor (EGTS) #1 for 43. Hood Switch
Turbo Charger [With CPF]
14. Exhaust Gas Temperature Sensor (EGTS) #2 for CPF
[With CPF]
15. Water Sensor (included in Fuel Filter)
16. Accelerator Pedal Position Sensor (APS)
17. Vehicle Speed Sensor (VSS)
18. A/C Pressure Transducer (APT)
19. Injector
21. Electric EGR Control Valve
22. WGT/VGT Control Solenoid Valve
23. Throttle Flap Control Solenoid Valve [Without CPF]
24. Air Control Valve [With CPF]
25. Variable Swirl Control Actuator
26. Main Relay
27. Glow Relay
28. PTC Heater Relay (Optional)
29. Air Heater Relay [M/T only]
30. Data Link Connector (DLC)
31. MultiPurpose Check Connector
1. ECM (Engine Control Module) 2. Mass Air Flow Sensor (MAFS)
3. Intake Air Temperature Sensor (IATS) #1 built in MAFS
4. Boost Pressure Sensor (BPS) 6. Crankshaft Position Sensor (CKPS)
5. Intake Air Temperature Sensor (IATS) #2 built in BPS 17. Vehicle Speed Sensor (VSS)
7. Camshaft Position Sensor (CMPS) 8. Engine Coolant Temperature Sensor (ECTS)
21. Electric EGR Control Valve
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9. Rail Pressure Sensor (RPS) 10. Lambda Sensor
19. Injector 13. Exhaust Gas Temperature Sensor (EGTS) #1 for Turbo
charger
11. Fuel Temperature Sensor (FTS) 12. Differential Pressure Sensor (DPS) [With CPF]
14. Exhaust Gas Temperature Sensor (EGTS) #2 for CPF 15. Water Sensor (included in Fuel Filter)
[With CPF]
16. Accelerator Pedal Position Sensor (APS) 18. A/C Pressure Transducer (APT)
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22. WGT/VGT Control Solenoid Valve 24. Air Control Valve [With CPF]
23. Throttle Flap Control Solenoid Vlave [Without CPF]
25. Variable Swirl Control Actuator 26. Main Relay
27. Glow Relay 29. Air Heater Relay [M/T]
28. PTC Heater Relay (Optional)
31. Multipurpose Check Connector 32. Battery Sensor
34. AGM Battery
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33. Brake Booster Vacuum Pressure Sensor (BBVPS) 35. DC DC Converter [LHD]
35. DC DC Converter [RHD] 36. ISG OFF Switch
37. Alternator 38. Starter
39. Neutral Switch 40. Clutch Switch
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41. Door Switch 42. Seat Belt Switch
43. Hood Switch
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Engine Control Module (ECM) >English
Schematic Diagrams
ECM (ENGINE CONTROL MODULE)
1. ECM Harness connector
2. ECM Terminal function
Connector [CUDA]
Injector (Cylinder #3) [High] control output Injector (Cylinder #3) [With Immobilizer]
1
Injector (Cylinder #2) [High] control output Injector (Cylinder #2) [Without Immobilizer]
2
3
4 Motor [+] control output Air Control Valve (ACV) [With CPF]
5
6 Sensor power (+5V) Position Sensor in Throttle Control Actuator
7 Sensor power (+5V) Boost Pressure Sensor (BPS)
8
9
10 Sensor power (+5V) Rail Pressure Sensor (RPS)
11
12 Sensor power (+5V) Position Sensor in Variable Swirl Control Actuator
13 Crankshaft Position Sensor (CKPS) [] signal input Crankshaft Position Sensor (CKPS)
14 Crankshaft Position Sensor (CKPS) [+] signal input Crankshaft Position Sensor (CKPS)
15
16
17
18
Motor [] control output Air Control Valve (ACV) [With CPF]
19
Throttle Flap Control Solenoid Valve control output Throttle Flap Control Solenoid Valve [Without CPF]
20
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21
English
22 A/C Compressor Relay control output A/C Compressor Relay
23
24
25
26
27
28 Sensor ground Boost Pressure Sensor (BPS)
29 Electric EGR Control Valve control output Electric EGR Control Valve
30
Injector (Cylinder #2) [Low] control output Injector (Cylinder #2) [With Immobilizer]
31
Injector (Cylinder #3) [Low] control output Injector (Cylinder #3) [Without Immobilizer]
32 Sensor ground Position Sensor in Air Control Valve (ACV) [With CPF]
33
34 Motor [+] control output Variable Swirl Control Actuator
35 Sensor ground Camshaft Position Sensor (CMPS)
Exhaust Gas Temperature Sensor (EGTS) #2 signal Exhaust Gas Temperature Sensor (EGTS) #2 [With
36
input CPF]
37 Engine Coolant Temperature Sensor (ECTS) signal input Engine Coolant Temperature Sensor (ECTS)
38 Feed back signal input Position Sensor in Throttle Control Actuator
39 Feed back signal input Position Sensor in Variable Swirl Control Actuator
40 Sensor ground Rail Pressure Sensor (RPS)
41 Sensor ground Position Sensor in Variable Swirl Control Actuator
42 Alternator feedback signal input Alternator
43
44 Auto Stop Lamp output ISG OFF Switch [With ISG]
45
46
47
48 Start Relay control output Start Relay [With ISG]
49 Motor [] control output Variable Swirl Control Actuator
50 Sensor ground Engine Coolant Temperature Sensor (ECTS)
51
52 Rail Pressure Sensor (RPS) signal input Rail Pressure Sensor (RPS)
53 Intake Air Temperature Sensor (IATS) #2 signal input Intake Air Temperature Sensor (IATS) #2 [BPS]
54 Boost Pressure Sensor (BPS) signal input Boost Pressure Sensor (BPS)
Sensor ground Exhaust Gas Temperature Sensor (EGTS) #2 [With
55
CPF]
56 Sensor shield Crankshaft Position Sensor (CKPS)
57 Camshaft Position Sensor (CMPS) signal input Camshaft Position Sensor (CMPS)
58 PTC Heater Relay #1 control output PTC Heater Relay #1
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59
English
60 Fuel Pressure Regulator Valve control output Fuel Pressure Regulator Valve
Connector [CUDK]
1 Battery power Main Relay
7 Lambda Sensor Heater control output Lambda Sensor
8
9 Cruise control switch signal input Cruise control switch
10 Head Lamp Switch signal input Body Control Module (BCM) [With ISG]
11 ISG OFF switch signal input ISG OFF Switch [With ISG]
12 Reference frequency Mass Air Flow Sensor (MAFS)
Exhaust Gas Temperature Sensor (EGTS) #1 signal Exhaust Gas Temperature Sensor (EGTS) #1 [With
13
input CPF]
14 Fuel Temperature Sensor (FTS) signal input Fuel Temperature Sensor (FTS)
15 Brake Booster Vacuum Pressure Sensor signal input Brake Booster Vacuum Pressure Sensor [With ISG]
16
17 Sensor ground A/C Pressure Transducer (APT)
18
19 Vehicle Speed Sensor (VSS) signal input Vehicle Speed Sensor (VSS)
20 Mass Air Flow Sensor (MAFS) signal input Mass Air Flow Sensor (MAFS)
21
22 Sensor power (+5V) Accelerator Position Sensor (APS) #2
23 Sensor power (+5V) Position Sensor in Electric EGR control valve
24 Sensor power (+5V) Brake Booster Vacuum Pressure Sensor [With ISG]
25
26 Sensor power (+5V) A/C Pressure Transducer (APT)
27 Sensor power (+5V) Differential Pressure Sensor (DPS) [With CPF]
28 Sensor power (+5V) Accelerator Position Sensor (APS) #1
29
30 Ground Immobilizer Control Module
31 Feedback signal input Position Sensor in Electric EGR control valve
32 A/C Pressure Transducer (APT) signal input A/C Pressure Transducer (APT)
Exhaust Gas Temperature Sensor (EGTS) #1 [With
33 Sensor ground
CPF]
34
35 Intake Air Temperature Sensor (IATS) #1 signal input Intake Air Temperature Sensor (IATS) #1 [MAFS]
36
37
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38 Stop Lamp Switch signal input Stop Lamp Switch English
39 Sensor ground Position Sensor in Electric EGR control valve
40 ESP Auto recognition signal input With ESP : Ground, Without ESP : Open
41 LIN communication (KLine) Battery Sensor
42
43
44 Immobilizer signal Immobilizer Control Module
45
46 Battery power Ignition Switch
47 Main Relay control output Main Relay
48
49
50 Sensor power (+5V) Cruise control switch
51 Chip heating Mass Air Flow Sensor (MAFS)
52 Start Switch signal input
53 Wiper motor signal input Multi function switch
54
55 Clutch Switch signal input Clutch Switch
56 Power ground Chassis ground
57
59 Differential Pressure Sensor (DPS) signal input Differential Pressure Sensor (DPS) [With CPF]
60 Accelerator Position Sensor (APS) #2 signal input Accelerator Position Sensor (APS) #2
61 VS+ (NERNST Cell Voltage) Lambda Sensor
62 Rc/Rp (Pumping Cell Voltage) Lambda Sensor
63 Sensor ground MAFS & IATS #1
64 CAN 1 [Low] Other control module
65
66 CAN [High] Other Control Module
68 Start Relay control output
69 WGT/VGT Control Solenoid Valve control output WGT/VGT Control Solenoid Valve
70 Immobilizer Lamp control output [With Immobilizer] Immobilizer Lamp
71 Air Heater Relay control output Air Heater Relay [Without CPF]
72 Sensor ground Brake Booster Vacuum Pressure Sensor [With ISG]
73 Alternator Regulator Alternator
74
75 Neutral Switch signal input Neutral Switch
76 Power ground Chassis ground
77 Water Sensor signal input Water Sensor [Fuel filter]
78 Brake Switch signal input Brake Switch
79
80 Sensor ground Differential Pressure Sensor (DPS) [With CPF]
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81 Accelerator Position Sensor (APS) #1 signal input Accelerator Position Sensor (APS) #1
English
82
83 VS/IP (Virtual Ground) Lambda Sensor
84 Rc (Compensative Resistance) Lambda Sensor
85 Sensor ground Fuel Temperature Sensor (FTS)
86 CAN 1 [High] Other control module
87 CAN [Low] Other Control Module
88
89 Sensor ground Cruise control switch
90 Glow Relay control output Glow Relay
91
92 Malfunction Indicator Lamp (MIL) control output Malfunction Indicator Lamp (MIL)
93 Cooling Fan Relay [High] control output Cooling Fan Relay [High]
94 Cooling Fan Relay [Low] control output Cooling Fan Relay [Low]
3. ECM Terminal input / Output signal
Connector [CUDA]
Vehicle
Pin Description Type Level Test Result
State
Injector (Cylinder #3) [High]
45V
control output
1 Idle Pulse Battery Voltage ~ 80V
14.1Hz
control output
45V
control output
2 Idle Pulse Battery Voltage ~ 80V
14.1Hz
control output
3
Hi: Battery Voltage
4 Motor [+] control output Active Pulse Low: Max. 1.0V
Frequency: 1,000Hz
5
IG OFF Max. 0.5V 23mV
6 Sensor power (+5V) DC
IG ON 4.9 ~ 5.1V 4.91V
IG ON 4.9 ~ 5.1V 4.95V
8
9
IG ON 4.9 ~ 5.1V 4.91V
11
IG ON 4.9 ~ 5.1V 4.91V
Crankshaft Position Sensor
13 Idle Sine Wave Vp_p: Min. 1.0V 52.8V
(CKPS) [] signal input
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Crankshaft Position Sensor English
14 Idle Sine Wave Vp_p: Min.1.0V 52.8V
(CKPS) [+] signal input
15
46.4V
control output [With Immobilizer]
16 Injector (Cylinder #4) [High] Idle Pulse Battery Voltage ~ 80V
control output [Without 7.418Hz
Immobilizer]
46.4V
control output [With Immobilizer]
17 Injector (Cylinder #1) [High] Idle Pulse Battery Voltage ~ 80V
control output [Without 7.418Hz
Immobilizer]
18
High : Battery Voltage
Motor [] control output Engine
Pulse Low : Max. 1.0V
[With CPF] Running
19 Frequency : 1,000Hz
Throttle Flap Control Solenoid
Valve control output IG ON PWM 300Hz
[Without CPF]
20
21
A/C Compressor Relay control A/C OFF Battery Voltage 13.9V

22 DC
output A/C ON Max. 1.0V 60mV
23
24
25
26
27
28 Sensor ground Always DC Max. 50mV 100mV
Electric EGR Control Valve High : Battery Voltage 14.7V

29 Idle Pulse
control output Low : Max. 1.0V 20mV
30
Injector (Cylinder #2) [Low] High : Battery Voltage 11.2V

control output [With Immobilizer] Low : Max. 1.0V 200mV
31 Idle Pulse
Injector (Cylinder #3) [Low]
control output [Without Peak Current : Max. 80V 51.8V
Immobilizer]
32 Sensor ground Idle DC Max. 50mV 1.7mV

33 Idle Pulse
Immobilizer]
High : Battery Voltage
Engine
34 Motor [+] control output Pulse Low : Max. 1.0V
Running
Frequency : 1,000Hz
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35 Sensor ground Always DC Max. 50mV 30mV
English
Exhaust Gas Temperature
36 Idle Analog 0.5 ~ 4.5V 910mV
Sensor (EGTS) #2 signal input
Engine Coolant Temperature
Sensor (ECTS) signal input
38 Feed back signal input IG ON Analog 0.15 ~ 4.9V 255mV
39 Feed back signal input IG ON Analog 0.15 ~ 4.9V 255mV
41 Sensor ground Idle DC Max. 50mV 12mV
42 Alternator feedback signal input
43
44 Auto Stop Lamp output
45

46 Idle Pulse
Immobilizer]

47 Idle Pulse
Immobilizer]
48
High : Battery Voltage 14.23V
Engine
49 Motor [] control output Pulse Low : Max. 1.0V 20mV
Running
Frequency : 1,000Hz
50 Sensor ground Always DC Max. 50mV 3.301mV
51 Start Relay control output
IG ON Max. 1.0V 512mV
Rail Pressure Sensor (RPS)
52 Idle Analog 1.0 ~ 1.5V 1.089V
signal input
3000 RPM 1.5 ~ 3.0V 1.886V
Intake Air Temperature Sensor
53 Idle Analog 0.5 ~ 4.5V 2.7V
(IATS) #2 signal input
Boost Pressure Sensor (BPS)
54 IG ON Analog 0.5 ~ 4.5V 1.59mV
signal input
55 Sensor ground [With CPF] Idle DC Max. 50mV 12mV
56 Sensor shield Idle DC Max. 50mV 31mV
Camshaft Position Sensor High : Vcc or Battery Voltage 4.76V

57 Idle Pulse
(CMPS) signal input Low : Max. 1.0V 200mV
PTC Heater Relay #1 control IG OFF Max. 1.0V 116mV

58 DC
output IG ON Battery Voltage 11.68V
59
Fuel Pressure Regulator Valve High : Battery Voltage 14.2V

60 Idle Pulse
control output Low : Max. 1.0V 234mV
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Connector [CUDK] English
Pin Description Vehicle State Type Level Test Result
IG OFF Max. 1.0 V 175mV
1 Battery power DC
IG ON Battery Voltage 12.77V
2 Power ground Idle DC Max. 50mV
3 Battery power DC
5 Battery power DC
Lambda Sensor Heater control High: Battery Voltage 14.3V

7 Vehicle Run Pulse
output Low: Max. 1.0V 220mV
8
9 Cruise control switch signal input
10 Head Lamp Switch signal input
11 ISG OFF switch signal input
High : Vcc or Battery Voltage 4.94V
12 Reference frequency Idle Pulse
Low : Max. 1.0V 340mV
Exhaust Gas Temperature
Sensor (EGTS) #1 signal input
Fuel Temperature Sensor (FTS)
14 IG ON Analog 0.5 ~ 4.5V 2.311V
signal input
Brake Booster Vacuum Pressure
15
Sensor signal input
16
18
Vehicle Speed Sensor (VSS) High: Min. 5.0V 13.18V

19 Vehicle Run Pulse
signal input Low: Max. 1.0V 60mV
Mass Air Flow Sensor (MAFS) High : Vcc 4.95V

20 Idle Pulse
signal input Low : Max. 1.0V 350mV
21
IG ON 4.9 ~ 5.1V 4.99V
IG ON 4.9 ~ 5.1V 4.91V
IG ON 4.9 ~ 5.1V 4.91V
25
IG ON 4.9 ~ 5.1V 4.91V
IG ON 4.9 ~ 5.1V 4.99V
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28 Sensor power (+5V) DC English
IG ON 4.9 ~ 5.1V 4.99V
29
30 Ground Always DC Max. 50mV 3.8mV
31 Feedback signal input
A/C Pressure Transducer (APT) A/C OFF Max. 4.8V 1.76V

32 DC
signal input A/C ON Max. 50mV 12mV
34
Intake Air Temperature Sensor
35 Idle Analog 0.2 ~ 4.8V 1.48V
(IATS) #1 signal input
36
37
Release Max. 0.5V 47mV
38 Stop Lamp Switch signal input DC
Push Battery Voltage 13.57V
39 Sensor ground
40
41 LIN Communication (KLine)
42
43
When High: Min. 8.5V 10.8V
44 Immobilizer communication line communicating Pulse
after IG ON Low: Max. 3.5V 1.1V
45
46 Battery power DC
Relay OFF Battery Voltage 12.94V
47 Main Relay control output DC
Relay ON Max. 1.0V 740mV
48
49
IG ON 4.9 ~ 5.1V 4.91V
51 Chip heating
High : Vcc 11.02V
52 Start Switch signal input Cranking Pulse
Low : Max. 0.5V 68mV
53 Wiper motor signal input
54
Push Max. 0.5V 20mV
55 Clutch Switch signal input DC
Release Battery Voltage 13.74V
56 Power Ground Idle DC Max. 50mV 0mV
57
1.039V (Idle)
Differential Pressure Sensor
59 Idle Analog 0.5 ~ 4.5V 1.319V
(DPS) signal input [with CPF]
(acceleration)
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Accelerator Position Sensor C.T 0.3 ~ 0.9V 0.39mV
English
60 Analog
(APS) #2 signal input W.O.T 1.5 ~ 3.0V 2.14V
Normal: 450±50mV
Engine
61 VS+ (NERNST Cell Voltage) Analog Rich: Max. Normal +150mV 2.94V
Running
Lean: Min. Normal 150mV
Normal: 0±500mV
Engine
62 Rc/Rp (Pumping Cell Voltage) Analog Rich: Min. Normal 1.5mV 2.84V
Running
Lean: Max. Normal +1.5mV
64 CAN 1 [Low]
65
RECESSIVE 2.0 ~ 3.0V
66 CAN [High] Pulse
DOMINANT 2.75 ~ 4.5V
68 Start Relay control output DC
VGT Control Solenoid Valve
69 Idle Pulse High: Battery Voltage 14.97V
control output
Immobilizer Lamp control output Lamp OFF Battery Voltage 12.54V

70 DC
[With Immobilizer] Lamp ON Max. 1.0V 65mV
71 Air Heater Relay control output DC
73 Alternator Rgulator
74
Switch OFF
Battery Voltage 12.54V
(1st)
75 Neutral Switch signal input DC
Switch ON
Max. 0.5V 20mV
(Neutral)
76 Power Ground Idle DC Max. 50mV 0mV
Full of water Battery Voltage 11.26V
77 Water Sensor signal input Analog
No water Max. 1V 20mV
Release Battery Voltage 14.14V
78 Brake Switch signal input DC
Push Max. 0.5V 20mV
79
Accelerator Position Sensor C.T 0.3 ~ 0.9V 682.8mV

81 Analog
(APS) #1 signal input W.O.T 4.0 ~ 4.8V 4.029V
With VDC Max. 0.5V
82 VDC auto recognition signal input DC
Without VDC Battery Voltage
Engine
83 VS/IP (Virtual Ground) Analog 2.4 ~ 2.6V 2.462V
Running
Engine |Current Pump Current
84 Rc (Compensative Resistance) Analog 2.83mV
Running Adjust| < 0.2V
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English
86 CAN 1 [High]
RECESSIVE 2.0 ~ 3.0V 2.57V
87 CAN [Low] Pulse
DOMINANT 0.5 ~ 2.25V 1.62V
88
90 Glow Relay control output DC
91
Malfunction Indicator Lamp (MIL) Lamp OFF Battery Voltage 12.3V

92 DC
control output Lamp ON Max. 1.0V 80mV
Cooling Fan Relay [High] control Relay OFF Battery Voltage 12.3V

93 DC
output Relay ON Max. 1.0V 121mV
Cooling Fan Relay [Low] control Relay OFF Battery Voltage 14.1V

94 DC
output Relay ON Max. 1.0V 215mV
CIRCUIT DIAGRAM
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English
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English
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English
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English
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Engine Control Module (ECM) > Repair
English
procedures
REPLACEMENT

When replacing the ECM, the vehicle equipped with immobilizer must be performed the procedure as below.
[In the case of installing used ECM]
1) Perform "Neutral mode" procedure with GDS. (Refer to "Immobilizer" in BE group)
2) Insert the key and turn it to the IGN ON and OFF position.
Then the ECM key register process is completed automatically.
[In the case of installing new ECM]
– Insert the key and turn it to the IGN ON and OFF position.
Then the ECM key register process is completed automatically.
2. Disconnect the ECM connector (A).
4. Unscrew the ECM mounting bolts (B) and remove the ECM.
5. Install a new ECM.
ECM installation bolts:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lbft)
6. Connect the negative() battery cable.
7. Perform "ECM Change" procedure [With CPF].
(1) Turn ignition switch OFF.
(2) Connect a GDS Data Link Connector (DLC).
(3) Turn ignition switch ON.
(4) Select "Vehicle, Model year, Engine, System".
(5) Select "Vehicle S/W Management".
(6) Select "Component Change Routine".
(7) Select "ECU Change".
(8) Input the mileage in odometer.
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English
(9) Confirm the "Complete" message and then turn ignition switch OFF.
(10) Wait for more than 10 seconds, and then turn ignition switch ON.
8. Perform "Injector Specific Data Input" procedure (Refer to "Injector" in this group).
9. Perform "Key Teaching" procedure (Refer to "Immobilizer" in BE group).
1.
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TEST ECM GROUND CIRCUIT: Measure resistance between ECM and chassis ground using the backside of ECM harness
English
connector as ECM side check point. If the problem is found, repair it.
harness side for bent pins or poor contact contact pressure. If the problem is found, repair it.
3. If problem is not found in Step 1 and 2, the ECM could be faulty. If so, replace the ECM with a new one, and then check the
vehicle again. If the vehicle operates normally then the problem was likely with the ECM.
4. RETEST THE ORIGINAL ECM : Install the original ECM (may be broken) into a knowngood vehicle and check the vehicle.
If the problem occurs again, replace the original ECM with a new one. If problem does not occur, this is intermittent problem
(Refer to INTERMITTENT PROBLEM PROCEDURE in BASIC INSPECTION PROCEDURE)
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Injector > Components and English
Components Location
COMPONENTS
1. Injector
2. Fuel Inlet
3. Connector
4. Oring
5. Clamp
6. Clamp Bolt
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Injector > Repair procedures English
REMOVAL

• Common Rail Fuel Injection System operates with extremely high pressure (approximately 1,600bar), so never
perform any work on injection system with engine running or within 30 seconds after the engine stops.
• Keep cleanly the parts and the working area.
• Pay attention to a foreign substance.
• Just before installing injector, tube or hose, remove the protectcap attached on them.
• Do not remove injector except for special case.
• When installing Injector
Wash the contact area of the injector and replace the Oring with a new one.
Spread oil on the injector Oring.
To protect damage caused by shock, vertically insert the injector into the cylinder head.
• When installing High Pressure Fuel Pipe
Do not use again the used high pressure fuel pipe.
Install the flange nut correctly.
2. Disconnect the injector connector (A).
3. After removing the clip (B), disconnect the retun hose (C) from the injectors.
4. Disconnect the high pressure fuel pipe (D) connecting the injectors with the common rail.
5. Unscrew the clamp tightening bolt (E) and pull the injector upward.

If the injector adheres to the cylinder head, use the special Service Tool (SST No. : 093514A300)
INSTALLATION
1. Installation is reverse of removal.

When installing the injector, MUST REPLACE the Oring (A) and apply a grease to that.
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English

When installing the high pressure fuel pipe, apply the specified tightening torques with the special service tool
(Refer to below table).

Flange Nut (Injector Side) 14 mm (0.551 in) 0931427110
Injector clamp installation bolt:
28.4 ~ 30.4 N.m (2.9 ~ 3.1 kgf.m, 21.0 ~ 22.4 lbft)
High pressure fuel pipe installation nut:
24.5 ~ 28.4 N.m (2.5 ~ 2.9 kgf.m, 18.1 ~ 20.1 lbft)
REPLACEMENT


After replacing injector, MUST input the injector specific data (7 digits) of each cylinder into ECM with scan tool.
1. Remove the injector (Refer to "Removal" procedure).
2. Install the injector (Refer to "Installation" procedure).
3. Perform "Injector Specific Data Input" procedure (Refer to "Injector Specific Data Input" procedure).
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INJECTOR SPECIFIC DATA INPUT English

After replacing injector, MUST input the injector specific data (7 digit) of each cylinder into ECM with scan tool.

2. Connect a GDS to Data Link Connector (DLC).
4. Select "Vehicle, Model year, Engine, System".
5. Select "Vehicle S/W Management".
6. Select "injector Specific Data".
7. Perform the procedure in accordance with the message.
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English
8. After selecting "OK" on the "Writing success" message, turn ignition switch OFF.
9. In about 10 seconds, turn ignition switch ON and recheck the injector specific data memorized in the ECM.

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In case of failure, input the injector specific data (7 digits) into ECM again.
English
INSPECTION
[Compression Test]
6. Select "Engine Test Function".
7. Select "Compression Test".
8. Perform the test in accordance with the message.
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English
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If a cylinder's engine speed is higher than the other cylinders, the cylinder's compression pressure is low.
[Idle Speed Comparison]
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7. Select "Idle Speed Comparision".
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English
[Injection Quantity Comparison]
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English
7. Select "Injection Quantity Comparison".
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English
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Mass Air Flow Sensor (MAFS) > Repair
English
procedures
INSPECTION
1. Check the MAFS visually.
– Mounting direction correct.
– Any contamination, corrosion or damage on connector.
– Air cleaner's clogging or wet.
– MAFS cylinder's deforming or blocking by any foreign material.
2. Check any leakage on intake system and intercooler system.
REPLACEMENT

After replacing the Mass Air Flow Sensor (MAFS), MUST perform the "Component Change Routine" procedure.
Otherwise trouble related with engine performance or emission control may occur until ECM learning about the
component is over.
6. Select "Component Change Routine".
7. Select "Air Flow Sensor Change".
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English
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Boost Pressure Sensor (BPS) > English
Schematic Diagrams
CIRCUIT DIAGRAM
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Intake Air Temperature Sensor (IATS) >
English
DESCRIPTION
Intake Air Temperature Sensor (IATS) uses a Negative Temperature Characteristics (NTC) thermistor and senses intake air
temperature. Two intake air temperature sensors are installed in this engine.
IATS #1 in Mass Air Flow Sensor (MAFS) and IATS #2 in Boost Pressure Sensor (BPS) are located in front of and behind turbo
charger respectively. IATS #1 senses air temperature entering turbocharger and the other (IATS #2) does air temperature coming out
from the turbocharger.
Comparing these air temperature values from both sensors, more accurate sensing of intake air temperature is possible. ECM uses
these air temperature signals to perform EGR control correction and fuel injection quantity correction.
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English
Schematic Diagrams
CIRCUIT DIAGRAM
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English
Repair procedures
INSPECTION
2. Disconnect the MAFS (for IATS #1) or BPS (for IATS #2) connector.
3. Measure resistance between IATS signal terminal and sensor ground terminal.
Specification: Refer to Specification section.
REPLACEMENT

After replacing the Intake Air Temperature Sensor (IATS) #1, MUST perform the "Component Change Routine"
procedure. Otherwise trouble related with engine performance or emission control may occur until ECM learning about
the component is over.
7. Select "Air Flow Sensor Change".
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English
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Engine Coolant Temperature Sensor
English
(ECTS) > Description and Operation
DESCRIPTION
coolant temperature. The ECTS uses a thermistor whose resistance changes with the temperature. The electrical resistance of the
ECTS decreases as the temperature increases, and increases as the temperature decreases. The reference 5V in the ECM is
supplied to the ECTS via a resistor in the ECM.
That is, the resistor in the ECM and the thermistor in the ECTS are connected in series. When the resistance value of the thermistor in
the ECTS changes according to the engine coolant temperature, the output voltage also changes. During cold engine operation the
ECM increases the fuel injection duration and controls the ignition timing using the information of engine coolant temperature to
avoid engine stalling and improve drivability.
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(ECTS) > Schematic Diagrams
CIRCUIT DIAGRAM
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(ECTS) > Repair procedures
INSPECTION
2. Disconnect the engine coolant temperature sensor connector.
4. After immersing the thermistor of the sensor into engine coolant, measure resistance between ECTS signal terminal
and ground terminal.
Specification: Refer to Specification section.
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Camshaft Position Sensor (CMPS) >
English
DESCRIPTION
Camshaft Position Sensor (CMPS) a hall sensor and detects the camshaft position by using a hall element. It is related with
Crankshaft Position Sensor (CKPS) and detects the piston position of the each cylinder which the CKPS can't detect. The CMPS are
installed on engine head cover and uses a target wheel installed on the camshaft. This sensor has a halleffect IC which output
voltage changes when magnetic field is made on the IC with current flow. So the sequential injection of the 4 cylinders is impossible
without CMPS signal.
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Schematic Diagrams
CIRCUIT DIAGRAM
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Repair procedures
INSPECTION
1. Check signal waveform of CMPS and CKPS using a scan tool.
Specification: Refer ro "Signal Waveform"
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Crankshaft Position Sensor (CKPS) >
English
DESCRIPTION
Piston position on combustion chamber is the substantial to define the starting of injection timing. All engine pistons are connected to
crankshaft by connecting rod. Sensor on crankshaft can supply the informations concerning all piston positions, revolution speed is
defined by revolution perminute of crankshaft. Prior input variable is determined at ECM by using signal induced from crankshaft
position sensor.
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Crankshaft Position Sensor (CKPS) >
English
Schematic Diagrams
CIRCUIT DIAGRAM
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Lambda Sensor > Description and
English
Operation
DESCRIPTION
Lambda Sensor is installed on exhaust manifold and is a linear oxygen sensor. It senses oxygen density of exhaust gas in order to
control EGR acculately through fuel correction and also limits smoke which is generated by reach airfuel mixture at high engine load
condition. ECM controls pumping current in order to fit λvalue from linear lambda sensor to 1.0.
Lean airfuel mixture(1.0 < λ < 1.1): ECM supplies pumping current to lambda sensor (+pumping current) and activates it for lambda
sensor to have the characteristic at λ =1.0 (0.0 pumping current). With the value of pumping current supplied to lambda sensor, ECM
detects lambda density of exhaust gas.
Rich airfuel mixture(0.9 < λ < 1.0): ECM takes away pumping current from lambda sensor (pumping current) and deactivates it for
lambda sensor to have the characteristic at λ =1.0 (0.0 pumping current). With the value of pumping current taken away from lambda
sensor, ECM detects lambda density of exhaust gas.
This performance is the most active and fast at normal operating temperature (450°C ~ 600°C) thus, in order to reach normal
operating temp. and last at that temperature, a heater (heating coil) is integrated with lambda sensor. The heater coil is controlled by
ECM as Pulse With Modulator (PWM). The resistance of heater coil is low when coil is cold thus, current through it increases while
resistance is high when coil is hot thus, current decreases. With this principle, temperature of lambda sensor is measured and
lambda sensor heater operation varies based on the data.
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Lambda Sensor > Specifications
English
SPECIFICATION
Sensor
0.65 2.22
0.70 1.82
0.80 1.11
0.90 0.50
1.01 0.00
1.18 0.33
1.43 0.67
1.70 0.94
2.42 1.38
Heater
Temperature [°C(°F)] Heater Resistance(Ω)
20 (68) 9.2
100 (212) 10.7
200 (392) 13.1
300 (572) 14.6
400 (752) 17.7
500 (932) 19.2
600 (1,112) 20.7
700 (1,292) 22.5
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Lambda Sensor > Schematic Diagrams
English
CIRCUIT DIAGRAM
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2012 > D 1.6 TCIU2 > Fuel System > Engine Control System > Lambda Sensor > Repair procedures
English
REPLACEMENT

After replacing the Lambda Sensor, MUST perform the "Component Change Routine" procedure. Otherwise trouble
related with engine performance or emission control may occur until ECM learning about the component is over.
7. Select "Lambda Sensor Change".
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English
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2012 > D 1.6 TCIU2 > Fuel System > Fuel Delivery System > Components and Components Location
English
COMPONENT LOCATION
1. Injector 8. Fuel Sender
2. High Pressure Fuel Pump 9. Fuel Filler Hose
3. Common Rail 10. Leveling Hose
4. High Pressure Fuel Pipe (Injector → Common Rail) 11. Ventilation Hose
5. High Pressure Fuel Pipe (Common Rail → High Pressure Fuel Pump) 12. SealRing
6. Fuel Filter 13. Plate Cover
7. Fuel Tank 14. Fuel Tank Band
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English
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2012 > D 1.6 TCIU2 > Fuel System > Fuel Delivery System > Schematic Diagrams English
COMMON RAIL FUEL INJECTION SYSTEM (CRDI)
● Low Pressure Fuel Circuit
Low Pressure Fuel Pump
The low pressure fuel pump is either an electric fuel pump with prefilter, or a geartype fuel pump. The pump draws the fuel from the
fuel tank and continually delivers the required quantity of fuel in the direction of the high pressure fuel pump (via fuel filter).
Fuel Sender
The fuel sender is located into the fuel tank and measures amount of fuel contained in fuel tank.
Fuel Filter
The fuel filter is located in between the low pressure fuel pump and the high pressure fuel pump and filters the fuel delivered from the
fuel tank.
● High Pressure Fuel Circuit
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High Pressure Fuel Pump English
The high pressure fuel pump compresses fuel up to 1,600 bar and delivers the compressed fuel to the common rail.
Common Rail
The common rail is connected with the high pressure fuel pump and the injectors by the high pressure fuel pipes. This rail stores the
fuel compressed in the high pressure fuel pump. The ECM controls the fuel pressure of the common rail by using the rail pressure
sensor and the rail pressure regulator valve installed on the common rail.
Injector
The injector injects the high pressure fuel stored in the common rail into the cylinder by the ECM control signal.
High Pressure Fuel Pipe
The high pressure fuel pipe is a channel in high pressure fuel circuit consisting of the high pressure fuel pump, common rails, and
injectors. It is a steel tube which can withstand high frequency generated when the fuel pressure reaches the maximum pressure or
fuel injection stops.
The differences in length between the common rail and the individual injectors are compensated for by using slight or pronounced
bends in the individual lengths of tubing. Nevertheless, the injection lines should be kept as short as possible.
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2012 > D 1.6 TCIU2 > Fuel System > Fuel Delivery System > Repair procedures English
BLEEDING AIR IN LOW PRESSURE FUEL CIRCUIT
1. After disconnecting the fuel outlet quickconnector (A), press the priming pump (B) several times until fuel comes out of
the fuel outlet.
2. Connect the fuel outlet quickconnector (A).

After removing or replacing the part below, bleed air in low pressure fuel circuit.
– Fuel Tank
– Fuel Sender
– Fuel Filter
– High Pressure Fuel Pump
– Low Pressure Fuel Lines
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2012 > D 1.6 TCIU2 > Fuel System > Fuel Delivery System > Fuel Tank > Repair procedures English
REMOVAL
2. Remove or fold the rear seat cushion (Refer to "SEAT" in BD group).
3. Remove the service cover (A).
4. Disconnect the fuel pump connector (A).
5. Disconnect the fuel feed tube quickconnector (B) and the fuel return tube quickconnector (C).
7. Support the fuel tank with a jack.
8. Disconnect the fuel filler hose (A), the leveling hose (B), and the ventilation hose (C).
9. Remove the undercover (A), after removing 5 nuts.
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10. Unscrew the fuel tank band installation 4 bolts (A), and then remove the fuel tank (B) from the vehicle.
INSTALLATION
Fuel tank band installation bolts:
39.2 ~ 54.0 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lbft)

After removing or replacing the part below, bleed air in low pressure fuel circuit (Refer to "BLEEDING AIR IN LOW
PRESSURE FUEL CIRCUIT" in this group).
– Fuel Tank
– Fuel Sender
– Fuel Filter
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2012 > D 1.6 TCIU2 > Fuel System > Fuel Delivery System > Fuel Sender > Repair procedures English
REMOVAL
2. Remove or fold the rear seat cushion (Refer to "SEAT" in BD group).
3. Remove the service cover (A).
4. Disconnect the fuel sender connector (A).
5. Disconnect the fuel feed tube quickconnector (B) and the fuel return tube quickconnector (C).
6. Unscrew the fuel sender installation bolts, and then remove the fuel sender from the fuel tank.
INSTALLATION
Fuel sender installation bolts:
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2.0 ~ 2.9 N.m (0.2 ~ 0.3 kgf.m, 1.4 ~ 2.2 lbft)
English

– Fuel Tank
– Fuel Sender
– Fuel Filter
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2012 > D 1.6 TCIU2 > Fuel System > Fuel Delivery System > Fuel Filter > Components and English
Components Location
COMPONENTS
1. Fuel Filter 5. Nipple (From Fuel Tank)
2. Heater 6. Nipple (To High Pressure Fuel Pump)
3. Water Sensor 7. Priming pump
4. Thermostat
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2012 > D 1.6 TCIU2 > Fuel System > Fuel Delivery System > Fuel Filter > Repair procedures English
REPLACEMENT
2. Disconnect the water sensor connector (A), the heater connector (B) and the thermostat connector (C).
3. Disconnect the fuel inlet tube quickconnector (D) and the fuel outlet tube quickconnector (E).
4. Unscrew the fuel filter installation nuts (A), and then remove the fuel filter (B) from the vehicle.
5. Remove the water sensor (A).
6. After removing the fuel filter (B) from the fuel filter assembly, replace it with a new one, and then install the fuel filter
assembly in accordance with reverse of above steps.
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When replacing the fuel filter, must replace the Oring.
7. Bleed air in low pressure fuel circuit (Refer to "Bleeding Air In Low Pressure Fuel Circuit").
8. Start the engine and check that there is any leak on the low pressure fuel circuit including the fuel filter.
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2012 > D 1.6 TCIU2 > Fuel System > Fuel Delivery System > FillerNeck Assembly > Repair procedures
English
REMOVAL
1. Disconnect the fuel filler hose (A) and the leveling hose (B), and then disconnect the vapor hose (C).
2. Open the fuel filler door and remove the rubber cover (A).
3. Remove the fuel filler door assembly (A) after removing the hook (B) and the fastener (C).
4. Remove the fillerneck mounting bolts (A).
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5. Remove the rearLH wheel, tire, and the inner wheel house.
6. Remove the bracket mounting bolt (A) and remove the fillerneck assembly.
INSTALLATION
Fillerneck assembly bracket installation bolt:
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lbft)
Fillerneck assembly installation bolt:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lbft)
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2012 > D 1.6 TCIU2 > Fuel System > Fuel Delivery System > Accelerator Pedal > Repair procedures
English
REMOVAL
2. Disconnect the accelerator pedal position sensor connector (A).
3. Remove the accelerator pedal assembly from the vehicle after removing the mounting bolt (B) and nuts (C).
INSTALLATION
Fuel pump installation bolts:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lbft)
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2012 > D 1.6 TCIU2 > Fuel System > Fuel Delivery System > High Pressure Pump > Description and
English
Operation
DESCRIPTION
The high pressure fuel pump is the interface between the low pressure and the high pressure stages. Under all operating conditions,
it is responsible for providing adequate high pressure fuel through out the vehicle's complete service life. This also includes the
provision of extra as needed for rapid starting and for rapid buildup of pressure in the rail. The high pressure pump continually
generates the system pressure as needed in the highpressure accumulator (common rail). This means therefore, that in contrast to
conventional systems, the fuel does not have to be specially compressed for each individual injection process.
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2012 > D 1.6 TCIU2 > Fuel System > Fuel Delivery System > High Pressure Pump > Repair procedures
English
REMOVAL

2. Disconnect the fuel pressure regulator valve connector (A).
3. Remove the high pressure fuel pipe (B) connecting the high pressure fuel pump with the common rail.
4. Remove the oil gage guide.
5. Install the jack under the RH side of the engine.
6. Remove the engine support bracket.
Tightening torque
Nut (D) : 63.8 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lbft)
Bolt (B), Nut (C) : 49.1 ~ 63.8 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lbft)
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7. Remove the engine mounting insulator (B).
8. Disconnect the fuel feed tube (A) and the fuel return tube (B).
9. Unscrew the three high pressure fuel pump mounting bolts (C).
10. Remove the drive belt (Refer to "TIMING SYSTEM" in "EM" group).
11. Turn the crankshaft pulley and align its groove with timing mark "T" of the timing chain cover.
(NO.1 cylinder compression TDC position.)
12. Remove the idler (A) and the timing chain cover plug (B).
13. Remove the high pressure fuel pump sprocket nut (C) after fixing the crank shaft.
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14. Install the high pressure fuel pump sprocket stopper (A) (SST No.: 093312A010) with rotating it clockwise.
15. Lift the RH side of the engine with a jack.
16. Install the high pressure fuel pump remover (SST No.:093312A010) (A) with three mounting bolts (B).
17. Fix the high pressure fuel pump remover (SST No.:093312A010) (A) and sprocket stopper (C) with two fixing bolts (D).
18. Rotate the bolt (E) of the high pressure fuel pump remover (SST No.:093312A010) (A) clockwise till the high pressure
fuel pump is pushed out.
INSTALLATION


Flange Nut
14 mm (0.551 in) 0931427110
(HP Pump Side)
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Flange Nut 17 mm (0.669 in) 0931427120 English
(Common
Rail Side)
High pressure fuel pump installation bolts:
19.6 ~ 25.5 N.m (2.0 ~ 2.6 kgf.m, 14.5 ~ 18.8 lbft)
High pressure fuel pipe installation nut:
24.5 ~ 28.4 N.m (2.5 ~ 2.9 kgf.m, 18.1 ~ 20.1 lbft)

– Fuel Tank
– Fuel Sender
– Fuel Filter
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2012 > D 1.6 TCIU2 > Fuel System > Fuel Delivery System > Common Rail > Description and Operation
English
DESCRIPTION
The common rail stores the fuel at high pressure. At the same time, the pressure oscillations which are generated due to the high
pressure pump delivery and the injection of fuel are damped by the rail volume. This common rail is common to all cylinders, hence
its name "common rail". Even when large quantities of fuel are extracted, the common rail maintains its inner pressure practically
constant from the moment the injector opens.
In order to comply with the wide variety of engine installation conditions, the common rail with its flow limiters and the provistions for
attaching rail pressure sensor, fuel pressure control valve, and pressure limiter valve is available in a number of different designs.
The available common rail volume is permanently filled with pressurized fuel. The compressibility of the fuel resulting from the high
pressure is utilized to achieve the accumulator effect. When fuel leaves the rail for injection, the pressure variations resulting from the
pulsating fuel supply from the highpressure pump are compensated for.
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2012 > D 1.6 TCIU2 > Fuel System > Fuel Delivery System > Common Rail > Repair proceduresEnglish
REMOVAL

1. Turn ignition switch OFF and disconnect the regative () battery cable.
2. Disconnect the rail pressure sensor connector (A).
3. Disconnect the return hose (E) from the common rail.
4. Remove the high pressure fuel pipe (B) connecting the injectors with the common rail.
5. Remove the high pressure fuel pipe (C) connecting the common rail with the high pressure fuel pump.
6. Remove the intake manifold (Refer to "Intake And Exhaust Manifold" in EM group).
7. Unscrew the two mounting bolts (D) and remove the common rail.
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INSTALLATION


Flange Nut
(Injector Side)
14 mm (0.551 in) 0931427110
Flange Nut
(HP Pump Side)
Flange Nut
(Common 17 mm (0.669 in) 0931427120
Rail Side)
· Common rail installation bolts:
14.7 ~ 21.6 N.m (1.5 ~ 2.2 kgf.m, 10.9 ~ 15.9 lbft)
· High pressure fuel pipe installation nut:
24.5 ~ 28.4 N.m (2.5 ~ 2.9 kgf.m, 18.1 ~ 20.1 lbft)
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2006 > G 1.6 DOHC > Engine Mechanical System > General Information > Specifications English
SPECIFICATIONS
Specifications
Description Limit
1.4 1.6
General
Type Inline, DOHC
Bore 77mm (3.0315in) 77mm (3.0315in)
Stroke 74.49mm (2.952in) 85.44mm (3.3638in)
Total displacement 1,396 cc (85.19 cu.in) 1,591 cc (97.09 cu.in)
Firing order 1342
Valve timing
Opens ATDC 12°/BTDC 38° ATDC 10°/BTDC 40°
Intake valve
Closes ABDC 49°/BBDC 1° ABDC 63°/ABDC 13°
Opens BBDC 40° BBDC 40°
Exhaust valve
Closes ATDC 3° ATDC 3°
Cylinder head
Flatness of gasket surface Less than 0.05mm (0.0020in)
Camshaft
Intake 42.85mm (1.687in) 43.85mm (1.726in)
Cam height
Exhaust 42.85mm (1.687in) 42.85mm (1.687in)
Journal outer diameter (Intake, Exhaust) 22.964 ~ 22.980mm (0.9041 ~ 0.9047in)
Camshaft cap oil clearance 0.020 ~ 0.057mm (0.0008 ~ 0.0022in) 0.1mm (0.0039in)
End play 0.10 ~ 0.20mm (0.0039 ~ 0.0079in)
Valve
Valve length
Intake 5.465 ~ 5.480mm (0.2152 ~ 0.2157in)
Stem outer diameter
Exhaust 5.458 ~ 5.470mm (0.2149 ~ 0.2154in)
Face angle 45.25° ~ 45.75°
Thickness of valve Intake 1.1mm (0.0433in) 0.8mm (0.0315in)

head (margin) Exhaust 1.26mm (0.0496in) 1.0mm (0.0394in)
Valve stem to valve Intake 0.020 ~ 0.047mm (0.0008 ~ 0.0019in) 0.10mm (0.0039in)

guide clearance Exhaust 0.030 ~ 0.054mm (0.0012 ~ 0.0021in) 0.15mm (0.0059in)
Valve guide
Intake 40.3 ~ 40.7mm (1.5866 ~ 1.6024in)
Length
Exhaust 40.3 ~ 40.7mm (1.5866 ~ 1.6024in)
Valve spring
Out of squareness Less than 1.5° English
Cylinder block
Flatness of gasket surface
/ Less than 0.02mm (0.0008in) 100mm×100mm
Piston
Piston outer diameter 76.97 ~ 77.00mm (3.0303 ~ 3.0315in)
Piston to cylinder clearance 0.020 ~ 0.040mm (0.0008 ~ 0.0016in)
No. 1 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in) 1.26mm (0.0496in)
Ring groove width No. 2 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in) 1.26mm (0.0496in)
Oil ring groove 2.01 ~ 2.03mm (0.0791 ~ 0.0799in) 2.05mm (0.0807in)
Piston ring
No.1 ring 0.03 ~ 0.07mm (0.0012 ~ 0.0028in) 0.1 mm (0.0039in)
Side clearance No.2 ring 0.03 ~ 0.07mm (0.0012 ~ 0.0028in) 0.1 mm (0.0039in)
Oil ring 0.06 ~ 0.15mm (0.0024 ~ 0.0059in) 0.2 mm (0.0079in)
No. 1 ring 0.14 ~ 0.28mm (0.0055 ~ 0.0110in) 0.30mm (0.0118in)
End gap No. 2 ring 0.30 ~ 0.45mm (0.0118 ~ 0.0177in) 0.50mm (0.0197in)
Oil ring 0.20 ~ 0.70mm (0.0079 ~ 0.0276in) 0.80mm (0.0315in)
Piston pin
Piston pin outer diameter 18.001 ~ 18.006mm (0.7087 ~ 0.7089in)
Piston pin hole inner diameter 18.016 ~ 18.021mm (0.7093 ~ 0.7095in)
Piston pin hole clearance 0.010 ~ 0.020mm (0.0004 ~ 0.0008in)
Connecting rod small end hole inner diameter 17.974 ~ 17.985mm (0.7076 ~ 0.7081in)
Piston pin pressin load 500~1,500 kg (1,102 ~ 3,306 lb)
Connecting rod
Connecting rod big end inner diameter 45.000 ~ 45.018mm (1.7717 ~ 1.7724in)
Connecting rod bearing oil clearance 0.032 ~ 0.052mm (0.0013 ~ 0.0020in) 0.060mm (0.0024in)
Side clearance 0.10 ~ 0.25mm (0.0039 ~ 0.0098in) 0.35m (0.0138in)
Crankshaft
Main bearing oil
No. 1, 2, 3, 4, 5 0.021 ~ 0.042mm (0.0008 ~ 0.0017in) 0.05mm (0.0020in)
clearance
End play 0.05 ~ 0.25mm (0.0020 ~ 0.0098in) 0.3mm (0.0118in)
Engine oil
When replacing a
Oil quantity (Total) 3.7 L (3.91 US qt, 3.26 lmp qt) short engine or a
block assembly
When replacing an
Oil quantity (Excluding oil filer) 3.0 L (3.17 US qt, 2.64 lmp qt)
oil pan only
Oil quantity (Drain and refill including oil filter) 3.3 L (3.49 US qt, 2.90 lmp qt)
Oil quality 5W20 (Above SL / GF 3)
Cooling system
Cooling method Forced circulation with cooling fan
Coolant quantity 5.5 ~ 5.8L(5.81~6.13US qt., 4.84~5.10lmp qt.)
Thermostat Type Wax pellet type
Opening temperature 82 ± 1.5°C (179.6 ± 2.7°F)
Pull opening English
95°C (203°F)
temperature
Main valve opening 93.16 ~ 122.58kpa
pressure (0.95 ~ 1.25kgf/cm², 13.51 ~ 17.78psi)
Radiator cap
Vacuum valve
MAX. 6.86 kpa(0.07kgf/cm², 1.00 psi)
opening pressure
Water temperature sensor
20°C (68°F) 2.45±0.14 kΩ
Resistance
80°C (176°F) 0.3222 kΩ
TIGHTENING TORQUE
Item Quantity N.m kgf.m lbft
Cylinder block
Engine support bracket bolts (engine side) 4 29.4 ~ 41.2 3.0 ~ 4.2 21.7 ~ 30.4
Ladder frame bolts 13 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
(17.7~21.6) + (1.8~2.2) + (13.0~15.9) +
Connecting rod cap bolt 8
(88~92°) (88~92°) (88~92°)
(17.7~21.6) + (1.8~2.2) + (13.0~15.9) +
Crankshaft main bearing cap bolt 10
(88~92°) (88~92°) (88~92°)
Flywheel bolts(M/T) 6 71.6 ~ 75.5 7.3 ~ 7.7 52.8 ~ 55.7
Drive plate bolts(A/T) 6 71.6 ~ 75.5 7.3 ~ 7.7 52.8 ~ 55.7
Timing chain system
Timing chain and oil pump assembly cover
10 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
bolt(M6×20)
1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
bolt(M6×38)
3 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
bolt(M8×22)
Idler pulley assemlby bolt 1 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Timing chain tensioner arm bolt 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain guide bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Crankshaft bolt 1 127.5 ~ 137.3 13.0 ~ 14.0 94.0 ~ 101.3
Timing chain tensioner bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Cylinder head
Engine cover bolt 4 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Cylinder head cover bolt 16 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Camshaft bearing cap bolt(M6) 16 11.8 ~ 13.7 1.2 ~ 1.4 8.7 ~ 10.1
Camshaft bearing cap bolt(M8) 4 18.6 ~ 22.6 1.9 ~ 2.3 13.7 ~ 16.6
(17.7~21.6) + (1.8~2.2) + (13.0~15.9) +
Cylinder head bolt 10 (90~95°) + (90~95°) + (90~95°) +
(100~105°) (100~105°) (100~105°)
Cooling system
Water pump pulley bolt 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt 5 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water temperature control assembly mounting 3 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
bolts
English
Water inlet fitting nut 2 18.6 ~ 23.5 1.9~ 2.4 13.7 ~ 17.4
Heater pipe mounting bolts/Nuts(M6) B1/N2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Heater pipe mounting bolt(M8) 1 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Engine coolant temperature sensor(ECTS) 1 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9
Gauge unit 1 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9
Lubrication system
Oil filter 1 11.8 ~ 15.7 1.2 ~ 1.6 8.7 ~ 11.6
Oil pan bolt 11 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan drain plug 1 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Oil screen bolt 2 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil pressure switch 1 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Oil level gauge assembly mounting bolt 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Intake and exhaust system
Intake manifold and cylinder head mounting nut 5 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Exhaust manifold and cylinder head mounting nut 9 29.4 ~ 41.2 3.0 ~ 4.2 21.7 ~ 30.4
Oxygen sensor mounting 2 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
Exhaust manifold heat cover 6 16.7 ~ 21.6 1.7 ~ 2.2 12.3 ~ 15.9
Head cover protector and cylinder head mounting
2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
bolts
Exhaust manifold and cylinder block, ladder
4 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
frame mounting bolts
Air cleaner lower cover mounting 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Exhaust manifold and front muffler mounting nut 2 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
Front muffler and catalytic convertor mounging
39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
nut
Center muffler and main muffler mounting nut 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
2006 > G 1.6 DOHC > Engine Mechanical System > General Information > Troubleshooting English
TROUBLESHOOTING

Worn piston rings. Inspect the cylinder for a loss of
engine noises.
(Oil consumption may or may not cause the engine to compression .
misfire.) Repair or replace as required.
Worn crankshaft thrust bearings.
required.
Engine misfire with Stuck valves. Repair or replace as required.
abnormal valve train (Carbon buildup on the valve stem can cause the
noise. valve not to close properly.)
Replace the timing chain and sprocket as
Excessive worn or misaligned timing chain.
required.
Worn camshaft lobes. Replace the camshaft and MLA.
Engine misfire with • Faulty cylinder head gasket and/or cracking or • Inspect the cylinder head and engine
coolant consumption. other damage to the cylinder head and engine block for damage to the coolant
block cooling system. passages and/or a faulty head
gasket.
• Coolant consumption may or may not cause the
engine to overheat. • Repair or replace as required.
Engine misfire with Worn valves, valve guides and/or valve stem oil Repair or replace as required.

consumption.
Worn piston rings. Inspection the cylinder for a loss of
(Oil consumption may or may not cause the engine to compression.
misfire) Repair or replace as required.
Engine noise on start Drain the oil.
Incorrect oil viscosity.
up, but only lasting a Install the correct viscosity oil.
few seconds.
Inspect the thrust bearing and crankshaft.
Worn crankshaft thrust bearing.
speed.
Stretched or broken timing chain and/or damaged Replace the timing chain and sprockets.
sprocket teeth.
Replace the timing chain tensioner as
Worn timing chain tensioner, if applicable.
required.
Inspect the camshaft lobes.
Worn camshaft lobes. Replace the camshaft and valve lifters as
required.
Inspect the valves and valve guides, then
repair as required.
Stuck valves. (Carbon on the valve stem or valve Inspect the valves and valve guides, then
seat may cause the valve to stay open.) repair as required.
Lower engine noise, Repair or replace damaged components
Low oil pressure.
regardless of engine as required.
speed.
English
Inspect the oil pan.
Damaged oil pan, contacting the oil pump screen. Inspect the oil pump screen.
Inspect the oil pump screen.
Oil pump screen loose, damaged or restricted.
Inspect the piston and cylinder bore.
Excessive pistontocylinder bore clearance.
Repair as required.
Inspect the piston, piston pin and the
Excessive piston pintobore clearance. connecting rod.
Inspect the following components and
repair as required.
Excessive connecting rod bearing clearance. • The connecting rods.
• The crankshaft.
repair as required.
Excessive crankshaft bearing clearance. • The crankshaft bearings.
Verify the piston pins and connecting
Incorrect piston, piston pin and connecting rod
rods are installed correctly.
installation.
Repair as required.
Engine noise under Low oil pressure. Repair or replace as required.
load.
repair as required.
Excessive connecting rod bearing clearance.
• The crankshaft.
repair as required.
Excessive crankshaft bearing clearance.
• The cylinder block crankshaft
bearing bore.
Engine will not crank. Hydraulically locked cylinder. Remove spark plugs and check for fluid.

(crankshaft will not Inspect for broken head gasket.
• Coolant/antifreeze in cylinder.
rotate) Inspect for cracked engine block or
• Oil in cylinder. cylinder head.
Inspect for a sticking fuel injector and/or
• Fuel in cylinder.
leaking fuel regulator.
Inspect timing chain and gears.
Broken timing chain and/or timing chain gears.
Repair as required.
Foreign material in cylinder.
• Broken valve. Inspect cylinder for damaged components
and/or foreign materials.
• Piston material.
• Foreign material.
Seized crankshaft or connecting rod bearings. Inspect crankshaft and connecting rod
English
bearing.
Inspect connecting rods.
Bent or broken connecting rod.
Inspect crankshaft.
Broken crankshaft.
2006 > G 1.6 DOHC > Engine Mechanical System > General Information > Repair procedures English
INSPECTION
COMPESSION PRESSURE

If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly
charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF
position.
2. Remove the engine cover(A) and the engine enter cover(B).
3. Remove the ignition coil(A).
4. Remove the spark plugs.
Using a 16mm plug wrench, remove the 4 spark plugs.
5. Check the cylinder compression pressure.
(1) Insert a compression gauge into the spark plug hole.
English
(2) Set the throttle plate in the wideopen position.
(3) While cranking the engine, measure the compression pressure.

Always use a fully charged battery to obtain engine speed of 250rpm or more.
(4) Repeat step 1) through 3) for each cylinder.

This measurement must be done in as short time as possible.
Compression pressure
Standard : 1225.83kPa (12.5kg/cm², 177.79psi) (200~250 rpm)
Minimum : 1078.73kPa (11.0kg/cm², 156.46psi)
98kPa (1.0kg/cm², 14psi) or less
(5) If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder
through the spark plug hole and repeat step 1) through 3) for cylinders with low compression.
• If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the
gasket.
6. Reinstall the spark plugs.
7. Install the ignition coil(A).
8. Install the engine cover(A) and the engine center cover(B).
Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lbft)
English

Install the cover surely before driving.
VALVE CLEARANCE INSPECTION AND ADJUSTMENT

Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C) and cylinder head
is installed on the cylinder block.
1. Remove the engine cover(A) and the engine center cover(B).
(1) Disconnect the ignition coil(A).
(2) Disconnect the P.C.V hose(A).
English
(3) Loosen the cylinder head cover bolts and then remove the cover(A).

Do not reuse the disassembled gasket.
3. Set No.1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover.
(2) Check that the marks of the camshaft timing sprockets are in straight line on the cylinder head surface as shown
in the illustration. If not, turn the crankshaft one revolution (360°).
English
4. Inspect the valve clearance.
(1) Check only the intake valves of the 1st and 2nd cylinders and exhaust valves of the 1st and 3rd cylinders for their
clearance.
• Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft.
• Record the outofspecification valve clearance measurements. They will be used later to determine the
required tappet for adjusting.
Valve clearance specification (Engine coolant temperature : 20°C [68°F])
Limit
Intake : 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.)
Exhaust : 0.15 ~ 0.35mm (0.0059 ~ 0.0138in.)
(2) Turn the crankshaft pulley one revolution (clockwise 360°) and align its groove with timing mark of the timing chain
cover.
(3) Check the intake valves of the 3rd and 4th cylinders and exhaust valves of the 2nd and 4th cylinders for their
clearance.
5. Adjust the intake and exhaust valve clearance.
(1) Set the No.1 cylinder to the TDC/compression position.
(2) Mark on the timing chain and camshaft timing sprockets.
(3) Remove the service hole bolt of the timing chain cover.

The bolt must not be reused once it has been assembled.
(4) Insert a thin rod in the service hole of the timing chain cover and release the ratchet.
(5) Remove the front camshaft bearing cap(A).
English
(6) Remove the exhaust camshaft sprocket.
(7) Remove the exhaust camshaft bearing cap and exhaust camshaft.
(8) Remove the intake camshaft bearing cap and intake camshaft.

When disconnecting the timing chain from the camshaft timing sprocket, hold the timing chain.
(9) Tie a timing chain with a string.

Be careful not to drop anything inside timing chain cover.
(10) Measure the thickness of the removed tappet using a micrometer.
(11) Calculate the thickness of a new tappet so that the valve clearance comes within the specificified value.
Valve clearance (Engine coolant temperature : 20°C)
T : Thickness of removed tappet
A : Measured valve clearance
N : Thickness of new tappet
Intake : N = T + [A 0.20mm(0.0079in.)]
Exhaust : N = T + [A0.25mm (0.0098in.)]
(12) Select a new tappet with a thickness as close as possible to the caculated value.

Shims are available in 41size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to 3.600mm
(0.1417in.)
(13) Place a new tappet on the cylinder head.
(14) Hold the timing chain, and place the intake camshaft and timing sprocket assembly.
(15) Align the matchmarks on the timing chain and camshaft timing sprocket.
English
(16) Install the intake and exhaust camshaft.
(17) Install the front bearing cap.
(18) Install the sevice hole bolt.
Tightening torque :
11.8 ~ 14.7N.m (1.2 ~ 1.5kgf.m, 8.7 ~ 10.8lbft)
(19) Turn the crankshaft two turns in the operating direction(clockwise) and realign crankshaft sprocket and camshaft
sprocket timing marks.
(20) Recheck the valve clearance.
[Specification]
Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0091in.)
Exhaust : 0.22 ~ 0.28mm (0.0087 ~ 0.0110in.)
2006 > G 1.6 DOHC > Engine Mechanical System > Timing System > Timing Chain > Components and
English
Components Location
COMPONENTS
2006 > G 1.6 DOHC > Engine Mechanical System > Timing System > Timing Chain > Repair procedures
English
REMOVAL
2. Loosen the water pump mounting bolt and the drive idler mounting bolt.
3. Loosen the alternator tension adjusting bolt(A) to loosen tension.
4. Remove the alternator drive belt(A).
5. Remove the alternator(A). (Refer to Altemator in EE Group).
English
6. Remove the RH front wheel.
7. Remove the engine mounting bracket(A) and the ground line(B).

Support the engine with a jack not to be tilted.
8. Remove the alternator bracket(B).
10. Remove the water pump pulley(A).
English
11. Remove the water pump(A).
12. Remove the drive belt idler(A).
13. Disconnect the ignition coil connector(A) and the breather hose(B).
14. Disconnect the positive crankcase ventilation(PCV) hose(A) and PCSV hose(B).
English
15. Remove the ignition coils(A).
16. Remove the cylinder head cover bolts(A).
17. Remove the cylinder head cover(A) with its gasket(B).
18. Remove side cover.
19. Turn the crankshaft pulley clockwise, and align its groove with the timing mark of the timing chain cover.
English
20. Remove the crankshaft bolt(B) and crankshaft pulley(A).

There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
• Install the SST (092312B100) to hold the ring gear after removing the starter.
• Install the SST (092313D100) to hold the ring gear after removing the dust cover.
1) Remove the bracket (A).
2) Remove the dust cover (A) on the bottom of the ladder frame and unfasten the transaxle mounting bolt (B).
English
3) Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C)
teeth.
4) Adjust the angle of the links (D) so that the bolt 70mm (2.7559in.) can be fastened to the original mounted
hole.
5) Install the SST (092313D100) using the mounting bolts and spacers. Tighten the bolts and nuts of the
holder and links securely.
21. Remove the timing chain cover(A).
English
22. Align the timing marks of the camshaft sproket with the upper surface of the cylinder head to make No.1 cylinder be
positioned at TDC.
(1) Check the dowel pin of the crankshaft for facing upside of the engine at this monent.

Put paint marks on the timing chain links(3 places) that meet with the timing marks of the camshaft
sprockets(In, Ex : 2) and the crankshaft sprocket.
23. Remove the hydraulic tensioner(A).

Before removing the tensioner, fix the piston of the tensioner with a pin through the hole(B) at TDC.
24. Remove the timing chain tensioner arm(A) and guide(B).
25. Remove the timing chain(A).
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INSTALLATION
1. Align the timing marks of the camshaft sprocket with the upper sureface of the cylinder head to make No.1 cylinder be
positioned at TDC.
(2) Install the timing chain guide(A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)
(3) When installing a timing chain, align the timing marks on the sprockets with paint marks of the chain.
Order : Crankshaft sprocket → Timing chain guide → Intake camshaft sprocket → Exhaust camshaft sprocket.
2. Install the chain tensioner arm(A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)
3. Install the hydraulic tensioner(A) and remove the pin(B).
Tightening torque :
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9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)

Recheck the top dead center(TDC) marks on the crankshaft and camshaft.
4. Install the timing chain cover(A).
(1) Before installing, remove the hardened sealant from the cylinder block and ladder frame surface.
(2) Apply the sealant, THREE BOND 1282B on the timing chain cover and the water pump of the oil pump and the
sealant, THREE BOND 1217H on the rest parts.
Width: 3.5 ~ 4.5mm(0.1378~0.1772in.)
(3) Apply the liquid gasket(1217H) on the surface between the cylinder head and the cylinder block and reassemble
the cover(A) within five minites.
Width: 3 ~ 5mm(0.1181~0.1969in.)
(4) Align the dowel pin of the cylinder block and the holes of the oil pump.
Tightening torque :
12mm bolts 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lbft)
10mm bolts 9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)
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After the installation, do not crank engine or apply pressure on the cover for half an hour.
5. Using the SST(0945521200), reassemble the timing chain oil seal(A).
Tightening torque :
127.5 ~ 137.3 N.m (13.0 ~ 14.0 kgf.m, 94.0 ~ 101.3 lbft)

There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
• Install the SST (092312B100) to hold the ring gear after removing the starter.
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• Install the SST (092313D100) to hold the ring gear after removing the dust cover.
1) Remove the bracket (A).
2) Remove the dust cover (A) on the bottom of the ladder frame and unfasten the transaxle mounting bolt (B).
3) Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
4) Adjust the angle of the links (D) so that the bolt 70mm (2.7559in.) can be fastened to the original mounted
hole.
5) Install the SST (092313D100) using the mounting bolts and spacers. Tighten the bolts and nuts of the
holder and links securely.
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When installing the pulley, the groove on the pulley should be positioned outside.
7. Install side cover.
Tightening torque :
8.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~ 8.0 lbft)
8. Install the front right wheel and tire.
9. Before installing the cylinder head cover, remove oil, dust or hardened sealant from the timing chain cover and the
cylinder head upper surface.
10. After applying the liquid gasket, THREE BOND 1217H on the cylinder head cover, reassemble the cover within five
minutes.
Width: 2.0 ~ 2.5mm(0.0787~0.0984in.)
11. Install the cylinder head cover(A) with a new gasket(B).
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12. Tighten the cylinder head cover bolts(A) with the order and steps.
Tightening torque :
1st step 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lbft)
2nd step 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lbft)
13. Install the ignition coils(A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)
14. Install the positive crankcase ventilation(PCV) hose(A) and the positive and PCSV hose(B). English
15. Connect the ignition coil connector(A) and the breather hose(B).
16. Install the drive belt idler(A).
Tightening torque :
42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lbft)
17. Install the water pump(A) with a gasket.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)
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Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)
19. Install the engine support bracket(A).
Tightening torque :
29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lbft)
20. Install the alternator bracket.
Tightening torque :
19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lbft)
21. Supporting the engine with a jack, install the engine mounting bracket(A) and the ground line(B).
Tightening torque :
Bolt(C) 58.8 ~ 83.4 N.m (6.0 ~ 8.5 kgf.m, 43.4 ~ 61.5 lbft)
Bolt, nuts(D,E) 49.0 ~ 58.8 N.m (5.0 ~ 6.0 kgf.m, 36.2 ~ 43.4 lbft)
Bolt(F) 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)
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22. Install the alternator(A).
Tightening torque :
23. Install the drive belt(A).
24. Adjust tension by tightening the alternator tension adjust bolt(A).(Refer to Charging system in EE Group).
Tension
New belt: 882.6 ~ 980.7N (90 ~ 100kg, 198.4 ~ 220.5lb)
Used belt: 637.4 ~ 735.5N (65 ~ 75kg, 143.3 ~ 165.3lb)
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25. Install the engine center cover(B) and the engine cover(A).
Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lbft)

INSPECTION
SPROCKETS, HYDRAULIC TENSIONER, CHAIN GUIDE, TENSIONER ARM
1. Check the camshaft sprocket, crankshaft sprocket teeth for abnormal wear, cracks or damage. Replace if necessary.
2. Check a contact surface of the chain tensioner arm and guide for abnormal wear, cracks or damage. Replace if
necessary.
3. Check the hydraulic tensioner for its piston stroke and ratchet operation. Replace if necessary.
BELT, IDLER, PULLEY
1. Check the idler for excessive oil leakage, abnormal rotation or vibration. Replace if necssery.
2. Check belt for maintenance and abnormal wear of Vribbed part. Replace if necssery.
3. Check the pulleys for vibration in rotation, oil or dust deposit of Vribbed part. Replace if necssery.

• Do not bend, twist or turn the timing belt inside out.
• Do not allow the timing belt to come into contact with oil, water and steam.
2006 > G 1.6 DOHC > Engine Mechanical System > Cylinder Head Assembly > Components and
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Components Location
COMPONENTS
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2006 > G 1.6 DOHC > Engine Mechanical System > Cylinder Head Assembly > Repair procedures
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REMOVAL

• Use Fender cover to avoid damaging painted surfaces.
before removing it.

1. Disconnect the terminals(A) from battery and remove the battery.
2. Remove the engine cover(A) and engine center cover(B).
4. Remove the under cover(A).
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5. Loosen the radiator drain plug(A) and drain engine coolant.
6. Remove the front bumper upper cover(A) and the air duct(B).
7. Remove the intake air hose(A) and air cleaner assembly.
(1) Disconnect the breather hose(B) from intake air hose(A).
(2) Disconnect the intake air hose(A) and accelerator cable(C).
(3) Disconnect the PCM connector(D).
(4) Remove the air cleaner assembly(E).
8. Remove the battery tray(A) and disconnect the front connector(B).
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9. Remove the upper radiator hose(A) and lower radiator hose(B).
10. Loosen the water pump mounting bolt and the drive idler mounting bolt.
11. Loosen the alternator tension adjusting bolt(A) to loosen tension.
12. Remove the alternator drive belt(A).
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13. Remove the alternator(A). (Refer to Alternator in EE Group).
14. Remove the RH front wheel.
15. Remove the engine mounting bracket(A) and the ground line(B).

Support the engine with a jack not to be tilted.

Do not support the engine transaxle subframe assembly with the hangers.
16. Remove the alternator bracket.
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20. Remove the drive belt idler(A).
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21. Disconnect the ignition coil connector(A) and the breather hose(B).
22. Disconnect the positive crankcase ventilation(PCV) hose(A), and PCSV hose(B).
23. Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold.
(1) Disconnect the front(A) and the rear(B) oxygen sensor connector.
(2) Disconnect the ignition coil condenser connector(C) and the purge control solenoid valve(PCSV) connector(D).
(3) Disconnect the throttle position sensor(TPS) connectoe(E).
(4) Disconnect the engine coolant temperature sensor(ECTS) connector(F) and the water hose(G).
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25. Remove the cylinder head cover bolts(A).
26. Remove the cylinder head cover(A) with its gasket(B).
27. Remove side cover.
28. Turn the crankshaft pulley clockwise, and align its groove with the timing mark of the timing chain cover.
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29. Remove the crankshaft bolt(B) and crankshaft pulley(A).
30. Remove the timing chain cover(A).
31. Align the timing marks of the camshaft sprocket with the upper surface of the cylinder head to make No.1 cylinder be
positioned at TDC.

Put paint marks on the timing chain links(3places) that meet with the timing marks of the camshaft
sprockets(In, Ex : 2) and the crankshaft sprocket.
32. Remove the hydraulic tensioner(A).
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33. Remove the timing chain tensioner arm(A) and guide(B).
34. Remove the timing chain(A).
35. Remove the camshaft bearing caps(A) with the order below.
36. Remove the injector connectors(A) and the harness bracket(B).
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37. Remove the delivery pipe(A).
38. Remove the exhaust manifold assembly.
39. Remove the intake manifold module assembly.
40. Disconnect the camshaft position sensor(CMP) connector(A) and remove the purge control solenoid valve(PCSV)
bracket(B) and the module hanger bracket(C).
41. Remove the water temperature control assembly and the oil control valve(OCV).
(1) Uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown.
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(2) Lift the cylinder head from the cylinder block and put the cylinder head on wooden blocks.

INSTALLATION

• Always use a new cylinder head and manifold gasket.
• Always use a new cylinder head bolt.
• Rotate the crankshaft, set the No.1 piston at TDC.
1. Install the cylinder head assembly.
(1) Before installing, remove the hardened sealant from the cylinder block and cylinder head surface.
(2) Before installing the cylinder head gasket, apply sealant on the upper surface of the cylinder block and reassemble
the gasket within five minutes.

Refer to the illustration for applying sealant.
Width: 2.0 ~ 3.0mm(0.0787~0.1181in.)
Position: 1.0 ~ 1.5mm(0.0394~0.0591in.)
Specification: Three bond 1217H
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(3) After installing the cylinder head gasket on the cylinder block, apply sealant on the upper surface of the cylinder
head gasket and reassemble in five minutes.
2. Place the cylinder head carefully not to damage the gasket.
3. Install the cylinder head bolts with washers.
(1) Tighten the 10 cylinder head bolts, in several passes, in the sequence shown.
Tightening torque :
17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lbft) + 90~95° + 100~105°

Always use new cylinder head bolts.
4. Install the oil control valve(OCV)(A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)
5. Tighten the mounting bolts for the water temperature control assembly(A) after installing the heater pipe(B).
Tightening torque :
M6 bolts : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)
M8 bolts : 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lbft)
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6. Connect the camshaft position sensor(CMP) connector(A) and install the purge control solenoid valve(PCSV)
bracket(B) and the module hanger bracket(C).
7. Install the intake manifold module assembly.
8. Install the exhaust manifold assembly.
9. Install the delivery pipe assembly(A).
10. Install the injector connector(A) and harness bracket(B).
11. Install the camshafts.
(1) Before installing, apply engine oil on journals.
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Do not make oil flow down to the front side of the cylinder head.
(2) After installing, check the valve clearance.
12. Install the camshaft bearing caps with the order below.
Tightening torque :
M6 bolts 11.8 ~ 13.7N.m (1.2 ~ 1.4kgf.m, 8.7 ~ 10.1lbft)
M8 bolts 18.6 ~ 22.6N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lbft)
13. Align the timing marks of the camshaft sprocket with the upper sureface of the cylinder head to make No.1 cylinder be
positioned at TDC.
(2) Install the timing chain guide(A).
14. After installation of the chain guide(A), reassemble the timing chain(B).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)
(1) When installing a timing chain, align the timing marks on the sprockets with paint marks of the chain.
Order : Crankshaft sprocket → Timing chain guide → Intake camshaft sprocket → Exhaust camshaft sprocket.
15. Install the chain tensioner arm(A).
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Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)
16. Fix the hydraulic tensioner(A) with a pin(B) before installing the tensioner(A) and remove the pin(B) after installing the
tensioner(A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)

Recheck the top dead center(TDC) marks on the crankshaft and camshaft.
17. Install the timing chain cover(A).
(1) Before installing, remove the hardened sealant from the cylinder block and ladder frame surface.
(2) Apply the sealant, THREE BOND 1282B on the timing chain cover and the water pump of the oil pump and the
sealant, THREE BOND 1217H on the rest parts.
Width: 3.5 ~ 4.5mm (0.1378~0.1772in.)

Remove oil or dust on the surface surely.
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(3) Apply the liquid gasket(1217H) on the surface between the cylinder head and the cylinder block and reassemble
the cover(A) within five minutes.
Width: 3 ~ 5mm (0.1181~0.1969in.)
(4) Align the dowel pin of the cylinder block and the holes of the oil pump.
Tightening torque :

After the installation, do not crank engine or apply pressure on the cover for half an hour.
18. Using the SST(0945521200), reassemble the timing chain oil seal(A).
Tightening torque :
127.5 ~ 137.3 N.m (13.0 ~ 14.0 kgf.m, 94.0 ~ 101.3 lbft)
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When installing the pulley, remove the starter and fix the SST(092312B100).

When installing the pulley, the groove on the pulley should be positioned outside.
20. Install side cover.
Tightening torque :
8.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~ 8.0 lbft)
21. Install front right wheel and tire.
22. Before installing the cylinder head cover, remove oil, dust or hardened sealant from the timing chain cover and the
cylinder head upper surface.
23. After applying the liquid gasket, THREE BOND 1217H on the cylinder head cover, reassemble the cover within five
minutes.
Width : 2.0 ~ 2.5mm(0.0787~0.0984in.)
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24. Install the cylinder head cover(A) with a new gasket(B).

25. Tighten the cylinder head cover bolts(A) with the order and steps.
Tightening torque :
1st step 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lbft)
2nd step 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lbft)
26. Install the ignition coils(A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)
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27. Install the positive crankcase ventilation(PCV) hose(A) and PCSV hose(B).
28. Connect the ignition coil connector(A) and the breather hose(B).
29. Install the drive belt idler(A).
Tightening torque :
42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lbft)
30. Install the water pump(A) with a gasket. English
Tighten bolts with the order below.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)

Tighten the bolts diagonally.
32. Install the engine support bracket(A).
Tightening torque :
29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lbft)
33. Install the alternator bracket(A).
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Tightening torque :
19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lbft)
34. Supporting the engine with a jack, install the engine mounting bracket(A) and the ground line(B).
Tightening torque :
Bolt(C) 58.8 ~ 83.4 N.m (6.0 ~ 8.5 kgf.m, 43.4 ~ 61.5 lbft)
Bolt, nuts(D,E) 49.0 ~ 58.8 N.m (5.0 ~ 6.0 kgf.m, 36.2 ~ 43.4 lbft)
Bolt(F) 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft)
35. Install the alternator(A).
Tightening torque :
36. Install the drive belt(A).
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37. Adjust tension by tightening the alternator tension adjust bolt(A).(Refer to Charging system in EE Group).
Tension
New belt: 882.6 ~ 980.7N (90 ~ 100kg, 198.4 ~ 220.5lb)
Used belt: 637.4 ~ 735.5N (65 ~ 75kg, 143.3 ~ 165.3lb)
38. Connect the connectors on the cylinder head and install the clamps.
(1) Connect the front(A) and the rear(B) oxygen sensor connector.
(2) Connect the ignition coil condenser connector(C) and the purge control solenoid valve(PCSV) conector(D).
(3) Connect the throttle position sense (TPS) connector(E).
(4) Connect the engine coolant temperature sensor (ECTS) connector(F) and the water hose(G).
39. Install the fuel hose(A) and the accelerator cable(B).
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40. Connect the heater hose(A) and the brake booster hose(B).
41. Connect the radiator upper hose(A) and lower hose(B).
42. Install the battery tray(A) and connect front connector(B).
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43. Install the air cleaner assembly.
Tightening torque :
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lbft)
(1) Connect the air cleaner hose(A) and bleeder hose(B).
(2) Install the accelerator cable(A) to the air cleaner assembly.
(3) Connect the opwer control module (PCM) connectors(D).
44. Install the air duct(A) and front bumper upper cover(B).
Tightening torque :
7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbft)
45. Install the under cover(A).
Tightening torque :
8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 8.0lbft)
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46. Install the engine center cover(B) and the engine cover(A).
Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lbft)

47. Install the battery(B) and connect the terminals(A).
48. Refill engine coolant and engine oil.
49. Start engine and check for leakage.
50. Recheck the level of engine oil and coolant.
DISASSEMBLY

Identify MLA(Mechanical lash adjuster), valves, valve springs as they are removed so that each item can be
reinstalled in its original position.
1. Remove the MLAs(A).
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When removing MLAs, mark all the MLAs for their rearrangement.
2. Remove the valves.
(1) Using the SST (09222 3K000, 09222 3K100), compress the valve spring and remove the retainer lock.
(5) Remove the valve stem seal.
(6) Using a magnetic finger, remove the spring seat.

Do not reuse the valve stem seals.
INSPECTION
CYLINDER HEAD
Flatness of cylinder head gasket surface
Standard : Less than 0.05mm (0.0020in)
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the cylinder head.
VALVE AND VALVE SPRING
1. Inspect the valve stems and valve guides.
(1) Using a caliper gauge, measure the inner diameter of valve guide.
Valve guide inner diameter :
5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
(2) Using a micrometer, measure the outer diameter of valve stem.
Valve stem outer diameter
Intake : 5.465 ~ 5.480mm (0.2152 ~ 0.2157in)
Exhaust : 5.458 ~ 5.470mm (0.2149 ~ 0.2154in)
(3) Subtract the valve stem outer diameter measurement from the valve guide inner diameter measurement.
Valve stem toguide clearance
Intake : 0.020 ~ 0.047mm (0.0008 ~ 0.0019in)
Exhaust : 0.030 ~ 0.054mm (0.0012 ~ 0.0021in)
If the clearance is greater than specification, replace the valve or the cylinder head.
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2. Inspect the valves.
(2) Check that the surface of valve for wear.
(3) Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.
Margin
Standard
(4) Check the length of valve.
Valve length
Standard
Intake : 93.15mm (3.6673 in)
Exhaust : 92.60mm (3.6457 in)
(5) Check the surface of valve stem tip for wear.
3. Inspect the valve seats.
(1) Check the valve seat for evidence of overheating and improper contact with the valve face. If the valve seat is
worn, replace the cylinder head.
(2) Check the valve guide for wear. If the valve guide is worn, replace the cylinder head.
4. Inspect the valve springs.
(1) Using a steel square, measure the outofsquare of valve spring.
(2) Using a vernier calipers, measure the free length of valve spring.
Valve spring
Standard
Free height : 44mm (1.7323in)
Out of square : Less than 1.5°
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CAMSHAFT
1. Inspect the cam height.
Using a micrometer, measure the cam height.
Cam height
Intake : 43.85mm (1.7264in)
Exhaust : 42.85mm (1.6870in)
If the cam lobe height is less than specified, replace the camshaft.
2. Inspect the camshaft journal clearance.
(4) Install the bearing caps and tighten the bolts with specified torque.
Tightening torque :
M6 bolts : 11.8 ~ 13.7Nm (1.2 ~ 1.4kgf.m, 8.7 ~ 10.1lbft)
M8 bolts : 18.6 ~ 22.6Nm (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6lbft)

(5) Remove the bearing caps. English
Bearing oil clearance
Standard : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in)
Limit : 0.1mm ( 0.0039in)
If the oil clearance is greater than specified, replace the camshaft. If necessary, replace the bearing caps and
3. Inspect the camshaft end play.
Camshaft end play
Standard : 0.1 ~ 0.2mm (0.0039 ~ 0.0079in)
If the end play is greater than specified, replace the camshaft. If necessary, replace the bearing caps and cylinder
head as a set.
Continuously variable valve timing (CVVT) Assembly
1. Inspect the CVVT for smooth rotation.
(1) Clamp the camshaft using a vise. Be careful not to damage the cam lobes and journals in the vise.
(2) Check that the CVVT is locked by turning it clockwise or counterclockwise. It must not rotate.
(3) Seal one of the two advance holes in the camshaft journal with tape.
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(4) Apply approx. 150 kPa (1.5 kgf/cm², 21 psi ) of compressed air into the unsealed advance hole to release the lock.

Cover the oil paths with a piece of cloth when applying compressed air to prevent oil from spraying.
(5) With compressed air applied, rotate the CVVT into the advance direction (counterclockwise) within its phasing
range and check that the CVVT turns smoothly.
CVVT phasing range
25°±1° (from the most retarded position to the most advanced position)
(6) Rotate the CVVT into the most retarded position (clockwise) and then check that the CVVT is locked.
REASSEMBLY

• Before installing the parts, apply fresh engine oil to all sliding and rotating surface.
• Replace oil seals with new ones.
1. Install the valves.
(1) Install the spring seats.
(2) Using the SST (09222 29000), push in a new oil seal.

Do not reuse old valve stem oil seals.

Intake valve stem seals are different from exhaust ones in type. Do not reassembly ones in the other's
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places.
(3) Install the valve, valve spring and spring retainer, after applying engine oil at the end of each valve.

When installing valve springs, the enamel coated side should face the valve spring retainer.
2. Using the SST(09222 3K000, 09222 3K100), compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring
compressor.

When installing the SST, use the torque, 1.2kgf.m or less.
3. Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating
of the valve and retainer lock.
4. Install the MLA(Mechanical lash adjuster)s.
Check that the MLA rotates smoothly by hand.

All the MLAs should be installed in its original position.
2006 > G 1.6 DOHC > Engine Mechanical System > Engine And Transaxle Assembly > Repair English
procedures
REMOVAL


1. Disconnect the terminals(A) from battery and remove the battery.
Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lbft)
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Tightening torque :
8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 8.0lbft)
6. Loosen the radiator drain plug and drain the engine coolant.
(1) Disconnect the air cleaner hose(A) and the breather hose(B).
(2) Disconnect the accelerator cable(C) from the air cleaner.
(3) Disconnect the PCM connectors(D).
Tightening torque :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbft)
8. Remove the battery tray(A) and disconnect front connector(B).
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10. Remove the ATF oil cooler hoses(A) and the transaxle ground line(B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
11. Remove the heater hoses(A) and brake booster hose(B).
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12. Remove the fuel hose(A) and the accelerator cable(B).
14. Disconnect the terminals(A) from the fuse box.
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
15. After removing the mounting bolts, remove the relay and fuse assembly(A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
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16. Remove the connector wiring(A) and the engine wiring(B).
17. Remove the engine control side ground(A) and, the transaxle control side one(B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
18. Recover refrigerant and remove the high & low pressure pipe. (Refer to Air conditioner compressor in HA Group).
19. Disconnect the transaxle control cable(A). (Refer to Transaxle control system in MT or AT Group).
20. Remove the steering column mounting bolt(A), (Refer to Steering column in ST Group).
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21. Remove the front wheels and tires.
23. Remove the front muffler(B).
Tightening torque :
39.2 ~ 58.8N.m (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lbft)
24. Support the engine and transaxle assembly with a jack.
25. Remove the engine mounting support bracket(A) and the ground line(B).
Tightening torque :
Bolt(C) : 58.8 ~ 83.4N.m ( 6.0 ~ 8.5kgf.m, 43.4 ~ 61.5lbft)
Bolt(D), Nut(E) : 49.0~63.7N.m(5.0~6.5kgf.m,36.2~47.0lbft)
Bolt(F) : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
26. Remove the transaxle mounting bracket(A).
Tightening torque :
58.8 ~ 83.4N.m ( 6.0 ~ 8.5kgf.m, 43.4 ~ 61.5lbft)
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27. Remove the sub frame bolts and nuts.
Tightening torque :
49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lbf.ft)
INSTALLATION
Installation is in the reverse order of removal.
Perform the following :
• Adjust the shift cable.
• Adjust the throttle cable.
• Refill the engine with engine oil.
• Refill the transaxle with fluid.
• Refill the radiator and reservoir tank with engine coolant.
• Place the heater control knob on "HOT" position.
• Bleed air from the cooling system
– Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
– Turn Off engine. Check the coolant level and add coolant if needed. This will allow trapped air to be removed from
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the cooling system.
– Put the radiator cap on tightly, then run engine again and check for leaks.
• Clean the battery posts and cable terminals with sandpaper, assemble them and then apply grease to prevent
corrosion.
– After assembling fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump could run for
approximately two seconds and fuel line could be pressurized.
– Repeat this operation two or three times and check for fuel leakage at any point in the fuel line.
2006 > G 1.6 DOHC > Engine Mechanical System > Cylinder Block > Components and Components
English
Location
COMPONENTS
English
2006 > G 1.6 DOHC > Engine Mechanical System > Cylinder Block > Repair procedures English
DISASSEMBLY
1. M/T : Remove the fly wheel.
2. A/T : Remove the drive plate.
3. Install the engine to engine stand for disassembly.
4. Remove the timing chain.
5. Remove the cylinder head.
6. Remove the oil level gauge tube.
7. Remove the knock sensor(A) and the oil filter(B).
8. Remove the oil pressure switch(A).
9. Remove the oil pan.

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of ① arrow.
10. Remove the oil screen(A).
11. Remove the rear oil seal(A).
12. Remove the ladder frame(A).
13. Check the connecting rod end play.
14. Remove the connecting rod caps and check oil clearance.
15. Remove the piston and connecting rod assemblies.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. English

16. Remove the crankshaft bearing cap and check oil clearance.
18. Lift the crankshaft(A) out of the engine, being careful not to damage journals.

Arrange the main bearings and thrust bearings in the correct order.
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
20. Remove the piston rings.
(1) Using a piston ring expander, remove the 2 compression rings.
(2) Remove the 2 side rails and oil ring by hand.

21. Remove the connecting rod from the piston.
Using a press, remove the piston pin from piston.
(Pressin load : 500 ~ 1,500kg(1,102 ~ 3,306lb))
INSPECTION
CONNECTING ROD AND CRANKSHAFT
Using feeler gauge, measure the end play while moving the connecting rod back and forth.
End play
Standard : 0.1 ~ 0.25mm (0.0039 ~ 0.0098in)
Maximum : 0.35mm (0.0138in)
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2. Check the connecting rod bearing oil clearance.
(1) Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove the 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and lower bearing.
(4) Clean the crankshaft pin journal and bearing.
(5) Place a plastigage across the crankshaft pin journal.
(6) Reinstall the lower bearing and cap, and tighten the bolts. Do not reuse the bolts.
Tightening torque :
17.7 ~ 21.6N.m (1.8 ~ 2.2kgf.m, 13.0 ~ 15.9lbft) + 88 ~ 92°

(7) Remove the 2bolts, connecting rod cap and lower bearing .
0.032 ~ 0.052mm (0.0013 ~ 0.0020in)
(9) If the measurement from the plastigage is too wide or too narrow, remove the upper and lower bearing and then
install a new bearings with the same color mark.

Do not file, shim, of scrape the bearings or the caps to adjust clearance.
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crankshaft and restart over.

Connecting rod bigend
Mark
inner diameter
45.000 ~ 45.006mm
A
(1.7717 ~ 1.7719in)
45.006 ~ 45.012mm
B
(1.7719 ~ 1.7721in)
45.012 ~ 45.018mm
C
(1.7721 ~ 1.7724in)
Crankshaft pin journal mark location
Discrimination of crankshaft pin journal
Crankshaft pin journal
Mark
outer diameter
1 41.972 ~ 41.966mm
(1.6524 ~ 1.6522in)
English
41.966 ~ 41.960mm
2
(1.6522 ~ 1.6520in)
41.960 ~ 41.954mm
3
(1.6520 ~ 1.6517in)
Connecting rod bearing color location
Mark Color Connecting rod bearing thickness
1.514 ~ 1.517mm
A Blue
(0.0596 ~ 0.0597in)
1.511 ~ 1.514mm
B Black
(0.0595 ~ 0.0596in)
1.508 ~ 1.511mm
C None
(0.0594 ~ 0.0595in)
1.505 ~ 1.508mm
D Green
(0.0593 ~ 0.0594in)
1.502 ~ 1.505mm
E Red
(0.0591 ~ 0.0593in)
Connecting rod bearing selection table
Connecting rod mark

A B C
E D C
1
(Red) (Green) (None)
Crank shaft pin D C B
2
journal mark (Green) (None) (Black)
C B A
3
(None) (Black) (Blue)
3. Check the connecting rods.
(1) When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match.
When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the
same side.
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(2) Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough
(3) Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair
0.05mm / 100mm (0.0020in / 3.94in ) or less
0.1mm / 100mm (0.0039in / 3.94in) or less

When the connecting rods installed without bearings, there should be no difference on side surface.
(1) To check main bearingtojournal oil clearance, remove the main bearing caps and lower bearings.
(2) Clean each main journal and lower bearing with a clean shop towel.
(4) Reinstall the lower bearings and caps, then tighten the bolts.
Tightening torque :
17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lbft) + 88~92°

(5) Remove the cap and lower bearing again, and measure the widest part of the plastigage.
No.1, 2, 3, 4, 5 : 0.021 ~ 0.042mm (0.0008 ~ 0.0017in)
bearings with the same color mark. (Refer to crankshaft main bearing selection table in this Group).

Do not file, shim, or scrape the bearings or the cap to adjust clearance.
(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. (Refer to crankshaft
main bearing selection table in this Group).

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Cylinder block crankshaft journal bore mark location
Letters have been stamped on the side surface of the block as a mark for the size of each of the 5 main journal
bores.
Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct
bearings.
Discrimination of cylinder block crankshaft journal bore
Cylinder block crankshaft journal bore
Mark
inner diameter
52.000 ~ 52.006mm
A
(2.0472 ~ 2.0475in)
52.006 ~ 52.012mm
B
(2.0475 ~ 2.0477in)
52.012 ~ 52.018mm
C
(2.0477 ~ 2.0479in)
Crankshaft main journal mark location
Discrimination of crankshaft main journal
Crankshaft main journal
Mark
outer diameter
47.960 ~ 47.954mm
1
(1.8882 ~ 1.8879in)
2 47.954 ~ 47.948mm
(1.8879 ~ 1.8877in)
47.948 ~ 47.942mm English
3
(1.8877 ~ 1.8875in)
Crankshaft main bearing color location
Crankshaft main bearing thickness
Mark Color
No.1, 2, 3, 4, 5
2.026 ~ 2.029
A Blue
(0.0798 ~ 0.0799)
2.023 ~ 2.026
B Black
(0.0796 ~ 0.0798)
2.020 ~ 2.023
C None
(0.0795 ~ 0.0796)
2.017 ~ 2.020
D Green
(0.0794 ~ 0.0795)
2.014 ~ 2.017
E Red
(0.0793 ~ 0.0794)
Crankshaft main bearing selection table
Cylinder block crankshaft journal bore mark

A B C
E D C
1
(Red) (Green) (None)
Crank shaft main D C B
2
journal mark (Green) (None) (Black)
C B A
3
(None) (Black) (Blue)
End play
Standard: 0.05 ~ 0.25mm (0.0020 ~ 0.0098in)
Limit : 0.30mm (0.0118in)
If the end play is greater than maximum, replace the center bearing.
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CYLINDER BLOCK
1. Remove the gasket material.
2. Clean the cylinder block
3. Inspect the top surface of cylinder block for flatness.
Standard :
Less than 0.02mm (0.0008in) 100mm × 100mm
4. Inspect the cylinder bore.
If deep scratchs are present, replace the cylinder block.
5. Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.
Standard diameter :
77.00 ~ 77.03mm (3.0315 ~ 3.0327in)
6. Check the cylinder bore size code on the cylinder block side surface.
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Discrimination of cylinder bore size
Mark Cylinder bore inner diameter
77.00 ~ 77.01mm
A
(3.0315 ~ 3.0319in)
77.01 ~ 77.02mm
B
(3.0319 ~ 3.0323in)
77.02 ~ 77.03mm
C
(3.0323 ~ 3.0327in)
7. Check the piston size mark(A) on the piston top face.
[1.4]
[1.6]
Discrimination of piston outer diameter
Mark Piston outer diameter
76.97 ~ 76.98mm
A
(3.0303 ~ 3.0307in)
76.98 ~ 76.99mm
B
(3.0307 ~ 3.0311in)
C 76.99 ~ 77.00mm English
(3.0311 ~ 3.0315in)
8. Select the piston related to cylinder bore class.
Piston tocylinder clearance :
0.02 ~ 0.04mm (0.0008 ~ 0.0016in)
PISTON AND PISTON RINGS
1. Clean the piston.

2. The standard measurement of the piston outside diameter is taken 33.9mm(1.5697in) from top land of the piston.
Standard diameter :
76.97 ~ 77.00mm (3.0303 ~ 3.0315in)
3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.
0.02 ~ 0.04mm (0.0008 ~ 0.0016in)
Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove.
No.1 ring : 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
No.2 ring : 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
Oil ring : 0.06 ~ 0.15mm (0.0024 ~ 0.0059in)
Limit
No.1 ring : 0.1mm (0.0039in)
No.2 ring : 0.1mm ( 0.0039in)
Oil ring : 0.2mm ( 0.0079in)
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5. Inspect the piston ring end gap.
service limit, replace the piston rings. If the gap is too large, recheck the cylinder bore inner diameter. If the bore is
over the service limit, the cylinder block must be rebored.
Piston ring end gap
Standard
No.1 ring : 0.14 ~ 0.28mm (0.0079 ~ 0.0138in)
No.2 ring : 0.30 ~ 0.45mm (0.0118 ~ 0.0177in)
Oil ring : 0.20 ~ 0.70mm(0.0079 ~ 0.0276in)
Limit
No.1 ring : 0.3mm(0.0118in)
No.2 ring : 0.5mm(0.0197in)
Oil ring : 0.8mm(0.0315in)
PISTON PINS
1. Measure the outer diameter of piston pin
Piston pin diameter :
18.001 ~ 18.006mm (0.7087 ~ 0.7089in)
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Piston pintopiston clearance :
0.010 ~ 0.020mm (0.0004 ~ 0.0008in)
3. Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter.
Piston pintoconnecting rod interference :
0.032 ~ 0.016mm (0.0013 ~ 0.0006in)
OIL PRESSURE SWITCH
1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity, replace the oil
pressure switch.
3. If there is no continuity when a 49.0kpa (0.5kg/cm², 7.1psi) vacuum is applied through the oil hole, the switch is
operating properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.
REASSEMBLY

• Thoroughly clean all parts to assembled. English
1. Assemble the piston and connecting rod.
(1) Use a hydraulic press for installation
(2) The piston front mark and the connecting rod front mark must face the timing chain side of the engine.
[1.4]
[1.6]
3. Install the connecting rod bearings.
(1) Align the bearing(A) claw with the groove of the connecting rod or connecting rod cap(B).
(2) Install the bearings(A) in the connecting rod and connecting rod cap(B).
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4. Install the crankshaft main bearings.

Upper bearings have an oil groove of oil holes ; Lower bearings do not.
(1) Align the bearing claw with the claw groove of the cylinder block, push in the five upper bearings(A).
5. Install the thrust bearing.
Install the thrust bearing(A) on the No.3 journal position of the cylinder block with the oil grooves facing outward.
6. Place the crankshaft on the cylinder block.
7. Place the main bearing caps on the cylinder block.
8. Install the main bearing cap bolts.

The main bearing cap bolts are tightened in 2 progressive steps.
If any of the bearing cap bolts in broken or deformed, replace it.
(1) Apply a light coat of engine oil on the threads and under the bearing cap bolts.
(2) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown. English
Tightening torque :
17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lbft) + 88~92°

Do not reuse the main bearing cap bolts.

Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.
(1) Install the ring compressor, check that the rings are securely in place, then position the piston in the cylinder, and
tap it in using the wooden handle of a hammer.
(2) Stop after the ring compressor pops free, and check the connecting rodtocrank journal alignment before pushing
(3) Install the rod caps with bearings, and tighten the bolts.
Tightening torque :
17.7~21.8Nm (1.8~2.2kgf.m, 13.0~15.9lbft) + 88~92°

Do not reuse the connecting rod cap bolts.
11. Apply the sealant on the ladder frame.

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• Apply the sealant, THREEBOND 1217H on the ladder frame rail portion and install it with in five minutes.
If when sealant is applied to cylinder block bottom position, sealant position to be same with positon that is
applied to ladder frame rail position.
• Apply sealant along the inner line of the bolt holes.
12. Install the ladder frame(A).
Tightening torque :
18.6 ~ 24.2N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lbft)

• Apply the sealant, THREEBOND 1217H on the ladder frame rail portion and install it with in five minutes.
• Apply sealant along the inner line of the bolt holes.
13. Install the rear oil seal.
(2) Using the SST(09231H1100, 092312B200) and a hammer, tap in the oil seal until its surface is flush with the rear
oil seal retainer edge.
Install a new gasket and oil screen with 2 bolts.
Tightening torque :
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lbft)
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(1) Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces.

Check that the mating surfaces are clean and dry before applying liquid gasket.
(2) Apply liquid gasket with the width of Ø3mm, starting 1mmaway position from the inner rounding of the oil pan rail.
Liquid gasket : TB 1217H or equivalent

• To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
• Do not install the parts if five minutes or more have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the residue.
(3) Install the oil pan(A) with the bolts.
Uniformly tighten the bolts in several passes.
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
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16. Install the oil pressure switch.
(1) Apply adhesive to 2 or 3 threads.
(2) Install the oil pressure switch(A).
Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lbft)
17. Install the knock sensor(A) and the oil filter(B).
Tightening torque :
16.7 ~ 26.5N.m (1.7 ~ 2.7kgf.m, 12.3 ~ 19.5lbft)
18. Install the oil level gauge tube.
(1) Install a new Oring on the oil level gauge tube.
(2) Apply engine oil on the Oring.
(3) Install the oil level gauge tube with the bolt.
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
19. Install the cylinder head.
20. Install the timing chain.
21. Remove the engine stand.
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22. A/T :install the drive plate.
Tightening torque :
71.6 ~ 75.5N.m (7.3 ~ 7.7kgf.m, 52.8 ~ 55.7lbft)
23. M/T :install the fly wheel.
Tightening torque :
71.6 ~ 75.5N.m (7.3 ~ 7.7kgf.m, 52.8 ~ 55.7lbft)
2006 > G 1.6 DOHC > Engine Mechanical System > Cooling System > Components and Components
English
Location
COMPONENTS
2006 > G 1.6 DOHC > Engine Mechanical System > Cooling System > Repair procedures English
REMOVAL
WATER PUMP
1. Drain engine coolant.

System is under high pressure when the engine is hot.
To avoid danger of releasing scalding engine coolant, remove the cap only when the engine is cool.
2. Remove the drive belt(A).
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THRMOSTAT

Disassembly of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.
1. Drain engine coolant so that its level would be under the thermostat height.
2. Remove the water inlet fitting(A), gasket and thermostat(B).
RADIATOR
Remove the radiator cap to speed draining.
2. Remove the radiator upper hose(A) and the breather hose(B).
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4. Disconnect the fan motor connector(A).
5. Remove the blower assembly(A) for cooling module.
6. Disconnect the ATF oil cooler hoses(A).
7. Remove the radiator upper bracket(A), then pull up the cooling module.
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8. After pulling back the condenser fixing bracket(A), remove the radiator assembly.
WATER TEMPERATURE CONTROL ASSEMBLY
1. Drain engine coolant.
2. Remove the air cleaner assemlby.
(1) Disconnect the air cleaner hose(A) and breather hose(B).
(2) Remove the accelerator cable(C).
(3) Disconnect the powertrain control module(PCM) connector(D).
(4) Remove the air cleanerassemlby(E).
3. Remove the engine coolant hose(A).
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4. Remove the water temperature control assemlby(A).
5. To install, reverse the removal orders.

Clean the surface of the water temperature control assembly before installing.
INSTALLATION
WATER PUMP
1. Install the water pump.
(1) Install the water pump(A) and a new gasket with the bolts.
Tighten the bolts with the order blow.
(2) Install the water pump pulley(A) with the four bolts.
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
English

Tighten the bolts diagonally.
2. Install the drive belts.
THERMOSTAT
1. Place the thermostat in the block.
(1) Install the thermostat(B) with the jiggle valve upward.
(2) Install a new gasket to the thermostat(B).
2. Install the water inlet fitting(A).
Tightening torque :
18.6 ~ 23.5N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lbft)
RADIATOR
1. Install the radiator.
2. Install the radiator upper bracket(A).
Tightening torque :
3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lbft)
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3. Install the ATF(Automatic Transaxle Fluid) oil cooler hoses(A).
4. Connect the fan motor connector(A).
5. Install the radiator lower hose(A).
6. Connect the radiator upper hose(A) and the breather hose(B).
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INSPECTION
WATER PUMP
necessary.
3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump assembly.

A small amount of “weeping” from the bleed hole is normal.
THERMOSTAT

Valve opening temperature : 82±1.5°C (179.6±2.7°F)
Full opening temperature : 95°C (203°F)
Valve lift : 8mm(0.3in) or more at 95°C (203°F)
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COOLING FAN
1. Disconnect the cooling fan motor connector.
2. Check that the radiator fan rotates when battery voltage is applied between the terminals.
Cooling fan motor connector
Cooing fan inspection Action
1 2 3
+ O
Battery High speed
O
+ O
Battery Low speed
O
ENGINE COOLANT REFILLING AND BLEEDING

Never remove the radiator cap when the engine is hot.
Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.

When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts of the
1. Remove the radiator cap.
2. Loosen the drain plug, and drain coolant.
3. Tighten the radiator drain plug securely.
4. Remove the coolant reservoir tank. Drain the coolant and reinstall the coolant reservoir tank. Fill the coolant reservoir
tank to the MAX mark with coolant mixture.(coolant 5 : water 5)
5. Fill coolant mixture into the radiator to the base of filler neck. Gently squeeze the upper/lower hoses of radiator so as to
bleed air easily.

• Mix the recommended antifreeze with an equal amount of water in a clean container.
• Use only genuine antifreeze/coolant.
Coolant concentrations less than 50% may not provide sufficient protection against corrosion of freezing.
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• Coolant concentration greater then 60% will impair cooling efficiency and are not recommended.

6. Start engine and allow coolant mixture to circulate.
When the cooling fan operates and coolant circulates, refill coolant through the radiator filler neck.
7. Repeat 6 until the cooling fan 3~5 times and bleed air sufficiently out of the cooling system.
8. Install the radiator cap and fill the reservoir tank to the "MAX" line with coolant.
9. Run the vehicle under idle until the cooling fan operates 2~3 times.
10. Stop the engine and allow coolant to cool.
11. Repeat steps 6 to 11 until the coolant level stays constant and all air is bleed out of the cooling system.

Recheck the coolant level in the reservoir tank for 2~3 days after replacing coolant.
Coolant capacity :
5.8 ~ 5.9 liters(6.13 ~ 6.23 US qt, 5.10 ~ 5.19 lmp qt)
RADIATOR CAP TESTING
1. Remove the radiator cap, wet its seal with engine coolant, then install it on a pressure tester.
2. Apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi)
RADIATOR LEAKGE TEST
2. Apply a pressure tester to the radiator and apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~
17.78psi).
English

2006 > G 1.6 DOHC > Engine Mechanical System > Cooling System > Troubleshooting English
Inspection Remedy
coolant.
coolant.
vehicle.
clamps.
replacing Oring.
torque.
replace.
replacing gasket.
torque.
A/C.
ground cable.
etc.
Unit inspection Inspect water pump impeller. Replace water pump.
foreign materials.
Inspect for stuck thermostat valve. Check valve lift.
Immerse thermostat in water heated to over 95°C (203°F), then Replace thermostat if valve
heat for at least 3 minutes to check valve lift. lift is below specification or
valve is stuck.

2006 > G 1.6 DOHC > Engine Mechanical System > Lubrication System > Components and English
Components Location
COMPONENTS
2006 > G 1.6 DOHC > Engine Mechanical System > Lubrication System > Repair procedures English
REMOVAL
OIL PAN
2. Drain engine oil.
3. Using the SST(092153C000) and remove the oil pan.

of ① arrow.
• Do not turn over the SST abruptly without tapping. It be result in damage of the SST.
REPLACEMENT
OIL AND FILTER

• Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear English
sites.
(1) Remove the oil filler cap.
(2) Remove the oil drain plug, and drain the oil into a container.
2. Replace the oil filter.
(1) Remove the oil filter.
(2) Check and clean the oil filter installation surface.
(3) Check the part number of the new oil filter is as same as old one.
(4) Apply clean engine oil to the gasket of a new oil filter.
(5) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(6) Tighten it with the torque below.
Tightening torque :
11.8 ~ 15.7N.m (1.2 ~ 1.6kgf.m, 8.7 ~ 11.6lbft)
3. Refill with engine oil.
(1) Clean and install the oil drain plug with a new gasket.
Tightening torque :
34.3 ~ 44.1N.m (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lbft)
(2) Fill with fresh engine oil.
Capacity
When replacing a short engine or a block assembly : 3.7 L(3.91US qt, 3.26lmp qt)
When replacing an oil pan : 3.0L(3.17US qt, 2.64lmp qt)
Drain and refill in cluding oil filter : 3.3 L(3.49US qt, 2.90lmp qt)
(3) Install the oil filler cap.
5. Recheck the engine oil level.
INSTALLATION
OIL PAN

Check that the mating surfaces are clean and dry before applying liquid gasket.
(2) Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Liquid gasket : TB 1217H or equivalent

• To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes. English
• Do not install the parts if five minutes or more have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the residue.
(3) Install the oil pan(A) with the bolts.
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
2. Refill engine oil.
INSPECTION
SELECTION OF ENGINE OIL
Recommended ILSAC classification : GF3 OR ABOVE
Recommended API classification : SJ / SL OR ABOVE
Recommended SAE viscosity grades :
English

1) Satisfy the requirement of the API classification.
2) Have proper SAE grade number for expected ambient temperature range.
3) Lubricants that do not have both an SAE grade number and API service classification on the container should
not be used.
ENGINE OIL
1. Check the engine oil quality.
Check the oil deterioration, entry of water, discoloring of thinning.
2. Check the engine oil level.
After warning up the engine and then 5 minutes after the engine stop, oil level should be between the "L" and "F" marks
in the dipstick.

Do not fill with engine oil above the "F" mark.
2006 > G 1.6 DOHC > Engine Mechanical System > Intake And Exhaust System > Intake Manifold >
English
COMPONENTS
English
Repair procedures
REMOVAL
Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lbft)
2. Disconnect the harness connectors over the cylinder head.
(1) Disconnect the oil control valve(OCV) connector(A) and alternator connector(B).
(2) Disconnect the air conditioning compressor connector(C).
(3) Remove the ignition coil harness mounting bolts(D).
(4) Disconnect the MAP sensor(F) and the bracket(E) for the knock sensor.
3. Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold.
(1) Disconnect the front(A) and the rear(B) oxygen sensor connector.
(2) Disconnect the ignition coil condenser connector(C) and the purge control solenoid valve(PCSV) connector(D).
(3) Disconnect the throttle position sensor(TPS) connectoe(E).
(4) Disconnect the engine coolant temperature sensor(ECTS) connector(F) and the water hose(G).
English
4. Remove the oil level gange bracket.
5. Remove the intake manifold assembly(A).
6. To install, reverse the removal or dec with a new gasket.

Install the engine cover surely before driving.
2006 > G 1.6 DOHC > Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold >
English
COMPONENTS
English
Repair procedures
REMOVAL
1. Disconnect the front oxygen sensor connector(A) and the rear one(B).
Tightening torque :
39.2 ~ 49.0N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lbft)
2. Remove the heat protector(A).
Tightening torque :
16.7 ~ 21.6N.m (1.7 ~ 2.2kgf.m, 12.3 ~ 15.9lbft)
3. Remove the sub heat protector(A).
Tightening torque :
16.7 ~ 21.6N.m (1.7 ~ 2.2kgf.m, 12.3 ~ 15.9lbft)
4. Remove the head cover protector(B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
English
Tightening torque :
39.2 ~ 58.8N.m (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lbft)
6. Remove the exhaust manifold assembly stay(A).
Tightening torque :
7. Remove the exhaust manifold(A) with its gasket.
Tightening torque :
29.4~ 41.2N.m (3.0 ~ 4.2kgf.m, 21.7 ~ 30.4lbft)
English
REMOVAL
1. Disconnect the front oxygen sensor connector(A) and the rear one(B).
Tightening torque :
39.2 ~ 49.0N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lbft)
2. Remove the heat protector(A).
Tightening torque :
16.7 ~ 21.6N.m (1.7 ~ 2.2kgf.m, 12.3 ~ 15.9lbft)
English
3. Remove the sub heat protector(A).
Tightening torque :
16.7 ~ 21.6N.m (1.7 ~ 2.2kgf.m, 12.3 ~ 15.9lbft)
4. Remove the head cover protector(B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
Tightening torque :
39.2 ~ 58.8N.m (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lbft)
6. Remove the exhaust manifold assembly stay(A).
Tightening torque :
English
7. Remove the exhaust manifold(A) with its gasket.
Tightening torque :
29.4~ 41.2N.m (3.0 ~ 4.2kgf.m, 21.7 ~ 30.4lbft)
2006 > G 1.6 DOHC > Engine Mechanical System > Intake And Exhaust System > Front Exhsust Pipe >
English
Repair procedures
REMOVAL
Tightening torque :
39.2 ~ 58.8N.m (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lbft)
2. Remove the main muffler(A).
Tightening torque :
39.2 ~ 58.8N.m (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lbft)
2006 > G 1.6 DOHC > Engine Electrical System > General Information > Specifications English
SPECIFICATIONS
IGNITION SYSTEM
Items Specification
Primary resistance 0.7 ± 15 % (Ω)
Ignition coil
Secondary resistance
Spark plugs Type ZFR5F11

(Unleaded) Gap 1.0 ~ 1.1 mm (0.0394 ~ 0.0433in.)
Spark plugs Type ZFR5F

(Leaded) Gap 0.9 ~ 1.0 mm (0.0354 ~ 0.0394in.)
STARTING SYSTEM
Items Specification
Rated voltage 12.V, 2.0 kW
Voltage 11V
Noload characteristics Ampere 130 MAX
Starter
Speed 3.600 rpm, MIN
Commutator diameter Standard 32.9 ~ 33.1 mm (1.2953 ~ 1.3031in.)
Standard 0.5 ~ 1.0 mm (0.0197 ~ 0.0394in)
Under cut depth
Limit 0.2 mm (0.0079in)
CHARGING SYSTEM
Items Specification
Type Battery voltage sensing
Rate voltage 13.5 V, 90A
Alternator
Voltage regulator IC Regulator builtin type
Regulator setting voltage 14.4 ± 0.3 V (At 20°C full chareged batt)
Temperature compensation 7 ± 3 mV / °C
Type MF 45AH
Cold cranking amperage
410 A
Battery [at 18°C(0.4°F)]
Specific gravity [at 20°C(68°F)] 1.280 ± 0.01

• COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminal
• RESERVE CAPACITY RATING is amount of time a battery can deliver 25A and maintain a minimum terminal
English
2006 > G 1.6 DOHC > Engine Electrical System > General Information > Troubleshooting English
TROUBLESHOOTING
IGNITION SYSTEM
Engine will not start or is hard to Ignition lock switch Inspect ignition lock switch, or replace as
start (Cranks OK) Ignition coil required
Spark plugs Inspect ignition coil, or replace as required
Ignition wiring disconnected or broken Inspect spark plugs, or replace as required
Spark plugs cable Repair wiring, or replace as required
Inspect cable, or replace as required
Rough idle or stalls Ignition wiring Repair wiring, or replace as required
Ignition coil Inspect ignition coil, or replace as required
Spark plugs cable Inspect cable, or replace as required
Engine hesitates / poor acceleration Spark plugs and spark plug cables Inspect spark plugs / cable, or replace as
Ignition wiring required
Repair wiring, or replace as required
Poor mileage Spark plugs and spark plug cables Inspect spark plugs / cable, or replace as
required
CHARGING SYSTEM
Charging warning indicator does not Fuse blown Check fuses
light with ignition switch "ON" and Light burned out Replace light
engine off. Wiring connection loose Tighten loose connection
Charging warning indicator does not Drive belt loose or worn Adjust belt tension or replace belt
go out with engine running. (Battery Battery cable loose, corroded or worn Inspect cable connection, repair or replace
requires frequent recharging) Electronic voltage regulator or alternator cable
Wiring Replace voltage regulator or alternator
Repair or replace wiring
Overcharge Electronic voltage regulator Replace voltage regulator
Voltage sensing wire Repair or replace wiring
Discharge Drive belt loose or worn Adjust belt tension or replace belt
Wiring connection loose or short circuit Inspect wiring connection, repair or replace
Electronic voltage regulator or alternator wiring
Poor grounding Replace voltage regulator or alternator
Worn battery Inspect ground or repair
Replace battery
STARTING SYSTEM
Transaxle range switch (Vehicle with Refer to TR groupautomatic transaxle
automatic transaxle only)
Fuse blown Replace fuse
Ignition switch faulty Replace
Engine cranks slowly Battery charge low Charge or replace battery English
Starter keeps running Starter motor Replace
Ignition switch Replace
Starter spins but engine will not Short in wiring Repair wiring
crank Pinion gear teeth broken or starter motor Replace
Ring gear teeth broken Replace fly wheel or torque converter
2006 > G 1.6 DOHC > Engine Electrical System > Ignition System > Description and OperationEnglish
DESCRITION
Ignition timing is controlled by the electronic control ignition timing system. The standard reference ignition timing data for the engine
operating conditions are preprogrammed in the memory of the ECM (Engine Control Module).
The engine operating conditions (speed, load, warmup condition, etc.) are detected by the various sensors. Based on these sensor
signals and the ignition timing data, signals to interrupt the primary current are sent to the ECM. The ignition coil is activated, and
timing is controlled.
2006 > G 1.6 DOHC > Engine Electrical System > Ignition System > Repair procedures English
SPARK TEST
2. Remove the ignition coils(A).
3. Remove the fuel pump relay(A) from the fuse box for fuel not to be injected while checking.
4. Using a spark plug socket, remove the spark plug.
5. Install the spark plug to the ignition coil.
6. Ground the spark plug to the engine.
English
7. Check if spark occurs while engine is being cranked.

Do not crank engine for more then 5~10 seonds.
8. Inspect all the spark plugs.
9. Using a spark plug socket, install the spark plug.
10. Install the ignition coil.
Tightening torque :
9.8 ~11.8 Nm (1.0~1.2 kgf.m, 7.2~8.7 Ibft)
11. Install a engine center cover and a engine cover.
Tightening torque :
7.8 ~11.8 Nm (0.8~1.2 kgf.m, 5.8~8.7 Ibft)
INSPECT SPARK PLUG

When removing the ignition coil connector, pull the lock pin(A) and push the clip(B).
English
2. Using a spark plug socket, remove the spark plug.

Be careful that no contaminates enter through the spark plug holes.
3. Inspect the electrodes (A) and ceramic insulator (B).
INSPECTION OF ELECTRODES
Condition Dark deposits White deposits
– Fuel mixture too lean
Description – Fuel mixture too rich
– Advanced ignition timing
– Low air intake
– Insufficient plug tightening torque
4. Check the electrode gap (A).
Standard
Unleaded : 1.0 ~ 1.1 mm (0.0394 ~ 0.0433 in.)
Leaded: 0.9 ~ 1.0 mm (0.0354 ~ 0.0394in.)
INSPECT IGNITION COIL English
1. Measure the primary coil resistance between terminals (+) and ().
Standard value: 0.75Ω ± 15%
2006 > G 1.6 DOHC > Engine Electrical System > Charging System > Description and Operation
English
DESCRIPTION
The charging system included a battery, an alternator with a builtin regulator, and the charging indicator light and wire.
The Alternator has eight builtin diodes, each rectifying AC current to DC current.
Therefore, DC current appears at alternator "B" terminal.
In addition, the charging voltage of this alternator is regulated by the battery voltage detection system.
The alternator is regulated by the battery voltage detection system. The main components of the alternator are the rotor, stator,
rectifier, capacitor brushes, bearings and Vribbed belt pulley. The brush holder contains a builtin electronic voltage regulator.
2006 > G 1.6 DOHC > Engine Electrical System > Charging System > Repair procedures English
ONVEHICLE INPECTION

CHECK THE BATTERY TERMINALS AND FUSES
2. Check the fuses for continuity.
INSPECT DRIVE BELT
1. Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should
be replaced.
2. Measure drive belt tension and adjust it if necessary.
Drive belt tension measurement and adjustment
Belt tension measurement
Measure the belt tension using a mechanical tension gauge or a sonic tension meter.
Tension
New belt: 882.6 ~ 980.7N (90 ~ 100kg, 198.4 ~ 220.5lb)
Used belt: 637.4 ~ 735.5N (65 ~ 75kg, 143.3 ~ 165.3lb)

• If the engine has run for 5 minutes or more, the belt tension must be adjusted as a used belt.
• When installing the Vribbed belt, all grooves on the pulley should be covered with belt ribs.
• A loose belt causes slip noise.
• Too tight belt cause bearing of alternator and water pump to damage.
Using a mechanical tension gauge (BT3373F, BTG2 type) English
1. While pressing the handle (A) of the gauge, insert the belt (B) between pulley and pulley (or idler) into the gap between
spindle (C) and hook (D).
2. After releasing the handle (A), read a value on the dial pointed by the indicator (B).
Using a sonic tension meter (U505/507 type)
1. Input the belt specifications into the tension meter.
Input data
Belt type Location of measurement
M (Mass, g/m.rib) W (Width, rib) S (Span, mm)
Crankshaft pulley to A/C
With A/C 013.4 006.0 178.9
compressor pulley
Idler to alternator pulley Actual measurement
Without A/C 013.4 006.0
value

Measurement of S (Span) : Caculate average value after measuring the distance 3~4 times.
D : Idler
d : Alternator pulley
English
2. Locate the micro phone (B) close to the center of belt span (A) and bounce the belt by finger 2~3 times. Read a value
on the display.
[With A/C]
[Without A/C]
If adjustment is necessary:
1. Loosen the mounting bolts (A).
2. Tighten the adjusting bolt(B) clockwise in loose tension ; loosen the bolt counterclockwise in high tension.
English
3. Recheck tension of the belt.
4. After adjusting tension, tighten the through bolts.
Tightening torque
12mm (0.47in) bolt : 19.6 ~ 26.5 Nm (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 Ibft)
14mm (0.55in) bolt : 29.4 ~ 41.2 Nm (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 Ibft)
VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES
CHECK DISCHARGE WARNING LIGHT CIRCUIT
3. Turn the ignition switch "ON". Check that the discharge warning light is lit.
4. Start the engine. Check that the light is lit.
If the light does not go off as specified, troubleshoot the discharge light circuit.
INSPECT CHARGING SYSTEM
VOLTAGE DROP TEST OF ALTERNATOR OUTPUT WIRE
This test determines whether or not the wiring between the alternator "B" terminal and the battery (+) terminal is good by the voltage
drop method.
PREPARATION
2. Disconnect the output wire from the alternator "B" terminal. Connect the (+) lead wire of ammeter to the "B" terminal of
alternator and the () lead wire of ammeter to the output wire. Connect the (+) lead wire of voltmeter to the "B" terminal
of alternator and the () lead wire of voltmeter to the (+) terminal of battery.
English
TEST
2. Turn on the headlamps and blower motor, and set the engine speed until the ammeter indicates 20A.
And then, read the voltmeter at this time.
RESULT
Standard value: 0.2V max
2. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case check
the wiring from the alternator "B" terminal to the battery (+) terminal. Check for loose connections, color change due to
an overheated harness, etc. Correct them before testing again.
3. Upon completion of the test, set the engine speed at idle.
Turn off the headlamps, blower motor and the ignition switch.
OUTPUT CURRENT TEST
This test determines whether or not the alternator gives an output current that is equivalent to the normal output.
PREPARATION
Check the battery installed in the vehicle to ensure that it is good condition. The battery checking method is described
in the section "Battery".
Check the tension of the alternator drive belt. The belt tension check method is described in the section "Inspect drive
belt".

6. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the alternator "B"
terminal and () lead wire to a good ground.
English
TEST
1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the
open circuit in the wire between alternator "B" terminal and battery () terminal or poor grounding is suspected.
2. Start the engine and turn on the headlamps.
3. Set the headlamps to high beam and the heater blower switch to HIGH, quickly increase the engine speed to 2,500 rpm
and read the maximum output current value indicated by the ammeter.

After the engine start up, the charging current quickly drops.
Therefore, the above operation must be done quickly to read the maximum current value correctly.
RESULT
Limit value : 50% of the rate voltage

• The output current value changes with the electrical load and the temperature of the alternator itself.
Therefore, the nominal output current may not be obtained. If such is the case, keep the headlamps on the
cause discharge of the battery, or use the lights of another vehicle to increase the electrical load.
The nominal output current may not be obtained if the temperature of the alternator itself or ambient
temperature is too high.
In such a case, reduce the temperature before testing again.
PREPARATION
English
Check that the battery installed on the vehicle is fully charged. The battery checking method is described in the section
"Battery".
Check the alternator drive belt tension. The belt tension check method is described in the section "Inspect drive belt".
4. Connect a digital voltmeter between the "B" terminal of the alternator and ground. Connect the (+) lead of the voltmeter
to the "B" terminal of the alternator. Connect the () lead to good ground or the battery () terminal.
6. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire.
Connect the () lead wire of the ammeter to the disconnected output wire.
TEST
Voltage: Battery voltage
If it reads 0V, there is an open circuit in the wire between the alternator "B" terminal and the battery and the battery ()
terminal.
less
RESULT
1. If the voltmeter reading is within 13.5 ~ 15.2V, the voltage regulator is functioning correctly. If the reading is other than
the standard value, the voltage regulator or the alternator is faulty.
2006 > G 1.6 DOHC > Engine Electrical System > Charging System > Alternator > Components and
English
Components Location
COMPONENTS
2006 > G 1.6 DOHC > Engine Electrical System > Charging System > Alternator > Repair procedures
English
REPLACEMENT
1. Disconnect the battery negative terminal first, then the positive terminal.
Tightening torque :
7.8~11.8 Nm (0.8~1.2 kgf.m, 5.8~8.7 Ibft)
3. Remove the drive belt(B), after loosening the tension adjusting bolt(A).
4. Disconnect the air compressor connector(A) and the alternator connector (B), and remove the cable (C) from alternator
"B" terminal.
5. Pull out the through bolt (A) and then remove the alternator.
Tightening torque :
19.6~26.5 Nm (2.0~2.7 kgf.m, 14.5~19.5 Ibft)12mm bolt
29.4~41.2 Nm (3.0~4.2 kgf.m, 21.7~30.4 Ibft)14mm bolt
English
7. Adjust the alternator belt tension after installation.
DISASSEMBLY
1. Remove the alternator cover(A).
English
4. Remove the nut, pulley(A) and spacer.
INSPECTION
ROTOR
1. Check that there is continuity between the slip rings (A).
English
2. Check that there is no continuity between the slip rings and the rotor (B) or rotor shaft (C).
STATOR
1. Check that there is continuity between each pair of leads (A).
3. If the coil fails either continuity check, replace the alternator.
2006 > G 1.6 DOHC > Engine Electrical System > Charging System > Battery > Description andEnglish
Operation
DESCRIPTION
1. The maintenancefree battery is, as the name implies, totally maintenance free and has no removable battery cell caps.
2. Water never needs to be added to the maintenancefree battery.
3. The battery is completely sealed, except for small vent holes in the cover.
2006 > G 1.6 DOHC > Engine Electrical System > Charging System > Battery > Repair procedures
English
INSPECTION
BATTERY DIAGNOSTIC FLOW
LOAD TEST
1. Perform the following steps to complete the load test procedure for maintenance free batteries.
2. Connect the load tester clamps to the terminals and proceed with the test as follow:
(1) If the battery has been on charge, remove the surface charge by connect a 300ampere load for 15 seconds.
English
(2) Connect the voltmeter and apply the specified load.
(3) Read the voltage after the load has been applied for 15 seconds.
(4) Disconnect the load.
(5) Compare the voltage reading with the minimum and replace the battery if battery test voltage is below that shown
in the voltage table.
Voltage Temperature
9.6V 20°C (68.0°F) and above
9.5V 16°C (60.8°F)
9.4V 10°C (50.0°F)
9.3V 4°C (39.2°F)
9.1V 1°C (30.2°F)
8.9V 7°C (19.4°F)
8.7V 12°C (10.4°F)
8.5V 18°C (0.4°F)

– If the voltage is greater shown in the table, the battery is good.
– If the voltage is less than shown in the table, replace the battery.
CLEANING

English

2006 > G 1.6 DOHC > Engine Electrical System > Starting System > Description and OperationEnglish
DESCRIPTION
The starting system includes the battery, starter, solenoid switch, ignition switch, inhibitor switch (A/T), ignition lock switch, connection
wires and the battery cable.
The contacts close and the starter motor cranks. In order to prevent damage caused by excessive rotation of the starter armature
when the engine starts, the clutch pinion gear overruns.
2006 > G 1.6 DOHC > Engine Electrical System > Starting System > Repair procedures English
TROUBLESHOOTING
STARTER CIRCUIT

If the starter normally cranks the engine, starting system is OK. If the starter will not crank the engine at all, go to next
step.
If the starter cranks normally the engine, repairing the loose connection repaired the problem. The starting system is
now OK.
4. Disconnect the connector from the Sterminal of solenoid. Connect a jumper wire from the Bterminal of solenoid to the
Sterminal of solenoid.
• Check the wire and connectors between the driver's underdash fuse/relay box and the ignition switch, and
between the driver's underdash fuse/relay box and the starter.
STATER SOLENOID TEST
1. Disconnect the field coil wire from the Mterminal of solenoid switch.
2. Connect the battery (+) line to the Sterminal and () line to the Mterminal and the stater body.

English
3. Connect the field coil wire to the Mterminal.
4. If the pinion moves out, the pullin coil of solenoid is working properly.
If the pinion does not move, replace the magnetic switch.
5. Disconnect the () line from the Mterminal.
6. If the pinion doesn't have moved, the holdin coil of the solenoid is working properly.

7. If the pinion goes back in its original position when you disconnecting the () line from the body, the system must be in
good condition.

FREE RUNNING TEST
1. Place the starter motor in a vise equipped with soft jaws and connect a fullycharged 12volt battery to starter motor as
English
follows.
2. Connect a test ammeter (100ampere scale) and carbon pile rheostats shown is the illustration.
5. Connect the battery cable from battery’s negative post to the starter motor body.
6. Adjust until battery voltage shown on the voltmeter reads 11volts.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely.
Current : 130A MAX
Speed : 3600 rpm. MIN
2006 > G 1.6 DOHC > Engine Electrical System > Starting System > Starter > Components and English
Components Location
COMPONENTS
English
2006 > G 1.6 DOHC > Engine Electrical System > Starting System > Starter > Repair procedures
English
REPLACEMENT
(1) Disconnect the air cleaner hose (A) and the bleeder hose (B).
(2) Remove the accelerator cable (C) from the air cleaner.
(3) Disconnect the PCM connectors (D).
Tightening torque :
7.8~9.8 Nm (0.8~1.0 kgf.m, 5.8~7.2 Ibft)
3. Disconnect the starter cable (B) from the B terminal on the solenoid, then disconnect the connector (A) from the S
terminal.
Tightening torque :
42.2~53.9 Nm (4.3~5.5 kgf.m, 31.1~39.8 Ibft)
DISASSEMBLY
1. Disconnect the Mterminal (A) on the magnet switch assembly (B).
English
2. After loosening the 2 screws (A), detach the magnet switch assembly (B).
3. Loosen the brush holder mounting screw (A) and through bolts (B).
4. Remove the rear bracket (A) and brush holder assembly (B).
5. Remove the yoke (A) and armature (B).
English
6. Remove the, lever plate (A) and packing (B).
7. Disconnect the planetary gear(A).
8. Remove the overrunning clutch (A) and lever (B).
9. Press the stop ring (A) using a socket (B).
English
10. After removing the stop ring (A) using stopper pliers (B).
11. Remove the stop ring (A), stop per (B), overrunning clutch (C).

Using a suitable pulling tool (A), pull the overrunning clutch stop ring (B) over the stopper (C).
INSPECTION
ARMATURE INSPECTION AND TEST English
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace
the armature.
4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the
following specifications, or recondition with #500 or #600 sandpaper (B).
5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.
Commutator diameter
Standard (New) : 29.4 mm (1.1575 in)
6. Measure the commutator (A) runout.
– If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between
the segments.
– If the commutator run out is not within the service limit, replace the armature.
Commutator runout
Standard (New): 0.05mm (0.0020in.) max
Service limit: 0.1mm (0.0039in.)
English
7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut
away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or v
shaped (D).
Commutator mica depth
Standard (New) : 0.5 mm (0.0197 in.)
Service limit : 0.2mm (0.0079 in.)
8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace
the armature.
9. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and between
the commutator and armature shaft (C). If continuity exists, replace the armature.
INSPECT STARTER BRUSH English
Brushes that are worm out, or oilsoaked, should be replaced.
Bruch length
Standard : 12.3 mm (0.4843 in)
Service linit : 5.5 mm (0.2165 in)

To seat new brushes, slip a strip of #500 or #600 sandpaper, with the grit side up, between the commutator and each
brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as
the commutator.
INSPECT OVERRUNNING CLUTCH
2. Rotate the overrunning clutch both ways.
Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction of it locks in both
3. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly. (the gear is not available
separately).
CLEANING
1. Do not immerse parts in cleaning solvent. Immersing the yoke assembly and/or armature will damage the insulation.
Wipe these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent. The overrun clutch is prelubricated at the factory and solvent will
wash lubrication from the clutch.
3. The drive unit may be cleaned with a cloth or air.
Any solvent should not be used.
2006 > G 1.6 DOHC > Engine Electrical System > Starting System > Starter Relay > Repair procedures
English
INSPECTION
2. Remove the starter relay (A).
3. Using an ohmmeter, check that there is continuity between each terminal.
Terminal Continuity
30 87 NO
85 86 YES
4. Apply 12V to terminal 85 and ground to terminal 86.
Check for continuity between terminals 30 and 87.
5. If there is no continuity, replace the starter relay.
6. Install the starter relay.
7. Install the fuse box cover.
2006 > G 1.6 DOHC > Emission Control System > General Information > Specifications English
SPECIFICATIONS
▷ Specification
Item Specification
Coil Resistance (Ω) 16.0Ω [20°C (68°F)]
TIGHTENING TORQUES
Item N·m kgf·m lbf·m

Positive Crankcase Ventilation Valve 8.0 ~ 12.0 0.8 ~ 1.2 6.0 ~ 8.0
Canister band installation nut / bolts 2.9 ~ 5.9 0.3 ~ 0.6 2.2 ~ 4.3
2006 > G 1.6 DOHC > Emission Control System > General Information > Schematic Diagrams English
SCHEMATIC DIAGRAM
2006 > G 1.6 DOHC > Emission Control System > General Information > Description and Operation
English
DESCRIPTION
Components Function Remarks

Crankcase Emission System
– Positive Crankcase Ventilation (PCV) HC reduction Variable flow rate type
valve
Evaporative Emission System
– Evaporative emission canister HC reduction
HC reduction Duty control solenoid valve
– Purge Control Solenoid Valve (PCSV)
Exhaust Emission System
– MFI system (airfuel mixture control CO, HC, NOx reduction Heated oxygen sensor feedback type
device) CO, HC, NOx reduction Monolithic type
– Threeway catalytic converter
2006 > G 1.6 DOHC > Emission Control System > General Information > Components and Components
English
Location
COMPONENT LOCATION
[1.6 DOHC]
1 Purge Control Solenoid Valve (PCSV) 2 Positive Crankcase Ventilation (PCV) Valve
English
3 Canister 4 Catalytic Converter
[2.0 DOHC]
English
3 Canister 4 Catalytic Converter English
2006 > G 1.6 DOHC > Emission Control System > General Information > Troubleshooting English
TROUBLESHOOTING

Vacuum hose disconnected or damaged Repair or replace
Engine will not start or hard to start
Malfunction of the Purge Control Solenoid Valve Repair or replace
Malfunction of the PCV valve Replace
Rough idle or engine stalls
Check the system; if there is a
Malfunction of the evaporative emission
problem, check related components
canister purge system
parts
Check positive crankcase
Excessive oil consumption Positive crankcase ventilation line clogged
ventilation system
2006 > G 1.6 DOHC > Emission Control System > Crankcase Emission Control System > Components
English
COMPONENTS
[1.6 DOHC]
[2.0 DOHC] English
2006 > G 1.6 DOHC > Emission Control System > Crankcase Emission Control System > Repair
English
procedures
INSPECTION
1. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve. Remove the PCV valve from the
rocker cover and reconnect it to the ventilation hose.
2. Run the engine at idle and put a finger on the open end of the PCV valve and make sure that intake manifold vacuum
can be felt.

The plunger inside the PCV valve will move back and forth.
2006 > G 1.6 DOHC > Emission Control System > Crankcase Emission Control System > Positive
English
Crankcase Ventilation (PCV) Valve > Description and Operation
OPERATION
English
Crankcase Ventilation (PCV) Valve > Repair procedures
REMOVAL
1. Disconnect the vacuum hose (A) and remove the PCV valve (B).
INSTALLATION
Install the PCV valve and tighten to the specified torque.
PCV Valve installation : 7.8 ~ 11.8 N·m (0.8 ~ 1.2 kgf·m, 5.8 ~ 8.7lbf·ft)
INSPECTION
1. Remove the PCV valve.
2. Insert a thin stick(A) into the PCV valve(B) from the threaded side to check that the plunger moves.
3. If the plunger does not move, the PCV valve is clogged. Clean it or replace.
English
2006 > G 1.6 DOHC > Emission Control System > Evaporative Emission Control System > Description
English
and Operation
DESCRIPTION
2006 > G 1.6 DOHC > Emission Control System > Evaporative Emission Control System > Repair
English
procedures
INSPECTION
1. Disconnect the vacuum hose from the throttle body, and connect a vacuum pump to the vacuum hose.
2. Check the following points when the engine is cold [engine coolant temperature 60°C(140°F) or below] and when it is
warm [engine coolant temperature 80°C(176°F) or higher].
WHEN ENGINE IS COLD
Engine operating condition Applied vacuum Result
Idling 50 kPa
Vacuum is held
3,000 rpm (7.3 psi)
WHEN ENGINE IS WARM
Engine operating condition Applied vacuum Result
50 kPa
Idling Vacuum is held
(7.3 psi)
Within 3 minutes after engine start at 3,000 rpm Try to apply vacuum Vacuum is released
After 3 minutes have passed after engine start 50 kPa Vacuum will be held momentarily,
at 3,000 rpm (7.3 psi) after which, it will be released
2006 > G 1.6 DOHC > Emission Control System > Evaporative Emission Control System > Canister >
English
Repair procedures
REMOVAL
1. Remove the fuel tank (Refer to "FUEL TANK" in FL group).
2. Disconnect the vacuum hoses (A,B,C).
3. Remove the band (D) and remove the canister assembly from the fuel tank.
INSTALLATION
Install the canister according to the reverse order of "REMOVAL" procedure.
Canister band installation nut/bolts : 2.9 ~ 5.9N·m (0.3 ~ 0.6kgf·m, 2.2 ~ 4.3 lbf·ft)
INSPECTION
1. Look for loose connections, sharp bends or damage to the fuel vapor lines.
2. Look for distortion, cracks or fuel damage.
3. After removing the canister, inspect for cracks, damage or saturated canister.
2006 > G 1.6 DOHC > Emission Control System > Evaporative Emission Control System > Purge
English
Control Solenoid Valve (PCSV) > Repair procedures
INSPECTION

When disconnecting the vacuum hose, make an identification mark on it so that it can be reconnected to its original
position.
1. Disconnect the vacuum hose from the solenoid valve.
2. Detach the harness connector.
3. Connect a vacuum pump to the nipple which is connected to intake manifold.
4. Apply vacuum and check when voltage is applied to the PCSV and when the voltage is discontinued.
Battery voltage Normal condition
When applied Vacuum is released
When discontinued Vacuum is maintained
5. Measure the resistance between the terminals of the solenoid valve.
PCSV coil resistance(Ω) : 16.0Ω at 20°C (68°F)
INSPECTION
Purge Control Solenoid Valve (PCSV) is installed on the surge tank and controls the passage between the canister and the intake
manifold. It is a solenoid valve and is open when the PCM grounds the valve control line. When the passage is open (PCSV ON),
fuel vapors stored in the canister is transferred to the intake manifold.
SPECIFICATION
Item Specification
Coil Resistance (Ω) 16.0Ω at 20°C (68°F)
CIRCUIT DIAGRAM
(A/T)
English
(M/T)
2. Disconnect PCSV connector.
3. Measure resistance between PCSV terminals 1 and 2.
Specification: Refer to SPECIFICATION.
2006 > G 1.6 DOHC > Emission Control System > Evaporative Emission Control System > Fuel Filler
English
Cap > Description and Operation
DESCRIPTION
2006 > G 1.6 DOHC > Emission Control System > Evaporative Emission Control System > Fuel Tank Air
English
Filter > Repair procedures
REPLACE
1. Remove the rear left wheel house inner cover (Refer to "BD" Group in this WORKSHOP MANUAL).
2. Disconnect the hose (A) connected with the canister and remove the fuel tank air filter (B) from the fillerneck
assembly.
2006 > G 1.6 DOHC > Emission Control System > Exhaust Emission Control System > Description and
English
Operation
DESCRIPTION
Modifications to the combustion chamber, intake manifold, camshaft and ignition system form the basic control system.
These items have been integrated into a highly effective system which controls exhaust emissions while maintaining good
driveability and fuel economy.
AIR/FUEL MIXTURE CONTROL SYSTEM [MULTIPORT FUEL INJECTION (MFI) SYSTEM]
This in turn allows the engine to produce exhaust gases of the proper composition to permit the use of a three way catalyst. The three
way catalyst is designed to convert the three pollutants (1) hydrocarbons (HC), (2) carbon monoxide (CO), and (3) oxides of nitrogen
(NOx) into harmless substances. There are two operating modes in the MFI system.
1. Open Loop air/fuel ratio is controlled by information programmed into the ECM.
2. Closed Loop air/fuel ratio is adjusted by the ECM based on information supplied by the oxygen sensor.
2006 > G 1.6 DOHC > Emission Control System > Exhaust Emission Control System > CVVT English
(Continuously Variable Valve Timing) System > Description and Operation
DESCRIPTION
The CVVT (Continuously Variable Valve Timing) which is installed on the exhaust camshaft controls intake valve open and close
timing in order to improve engine performance.
The intake valve timing is optimized by CVVT system depending on engine rpm.
This CVVT system improves fuel efficiency and reduces NOx emissions at all levels of engine speed, vehicle speed, and engine load
by EGR effect because of valve overlap optimization.
The CVVT changes the phase of the intake camshaft via oil pressure.
It changes the intake valve timing continuously.
OPERATION
The CVVT system makes continuous intake valve timing changes based on operating conditions.
Intake valve timing is optimized to allow the engine to produce maximum power.
Cam angle is advanced to obtain the EGR effect and reduce pumping loss. The intake valve is closed quickly to reduce the entry of
the air/fuel mixture into the intake port and improve the changing effect.
Reduces the cam advance at idle, stabilizes combustion, and reduces engine speed.
If a malfunction occurs, the CVVT system control is disabled and the valve timing is fixed at the fully retarded position.
English
1. The above figure shows the relative operation structures of the housing vane to the rotor vane.
2. If the CVVT is held a certain control angle, to hold this state, oil is replenished as much as oil leaks from the oil pump.
The OCV (Oilflow Control Valve) spool location at this time is as follows.
Oil pump → Advance oil chamber (Little by little open the inflow side to the advance oil chamber) → Almost close the drain side
Be sure there might be a difference in the position according to the engine running state (rpm, oil temperature, and oil pressure).
2006 > G 1.6 DOHC > Fuel System > General Information > Specifications English
SPECIFICATIONS
Items Specification
Fuel Tank Capacity 55lit. (14.5 U.S.gal., 12.1 Imp.gal.)
Fuel Filter
Type High pressure type
(built in Fuel Pump Assembly)
Fuel Pressure Regulator Regulated 338 ~ 348kpa (3.45 ~ 3.55kgf/cm², 49.0 ~
(built in Fuel Pump assembly) Fuel Pressure 50.5psi)
Type Electrical, intank type
Fuel Pump
Driven by Electric motor
Fuel Retrun System Type Returnless
SENSORS
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS)
▷ Specification
20.0 0.79
46.7 1.84
101.32 4.0
INTAKE AIR TEMPERATURE SENSOR (IATS)
▷ Specification
Temperature [°C(°F)] Resistance (kΩ)
40(40) 40.93 ~ 48.35
30(22) 23.43 ~ 27.34
20(4) 13.89 ~ 16.03
10(14) 8.50 ~ 9.71
0(32) 5.38 ~ 6.09
10(50) 3.48 ~ 3.90
20(68) 2.31 ~ 2.57
25(77) 1.90 ~ 2.10
30(86) 1.56 ~ 1.74
40(104) 1.08 ~ 1.21
60(140) 0.54 ~ 0.62
80(176) 0.29 ~ 0.34
▷ Specification
[For ECM (2 pin)] English
40(40) 48.14
20(4) 14.13 ~ 16.83
0(32) 5.79
20(68) 2.31 ~ 2.59
40(104) 1.15
60(140) 0.59
80(176) 0.32
[For Gauge (1 pin)]
Temperature [°C(°F)] Resistance (Ω)
60(140) 125
85(185) 42.6 ~ 54.2
110(230) 22.1 ~ 26.2
125(257) 15.2
THROTTLE POSITION SENSOR (TPS)
▷ Type: Variable resistor type
▷ Specification
Throttle Angle Output Voltage (V)
C.T 0.25 ~ 0.9
W.O.T Min. 4.0V
Items Specification
Sensor Resistance (kΩ) 1.6 ~ 2.4
HEATED OXYGEN SENSOR (HO2S)
▷ Type: Zirconia (ZrO2) type
▷ Specification
A/F Ratio Output Voltage (V)
Rich 0.6 ~ 1.0
Lean 0 ~ 0.4
Item Resistance (Ω)
Heater Resistance (Ω) Approx. 9.0 (20°C)
▷ Type: Magnetic field sensitive Type
KNOCK SENSOR (KS)
▷ Specification
Item Specification
Capacitance (pF) 950 ~ 1,350
Resistance(MΩ) 4.87
English
ACTUATORS
INJECTOR
▷ Number: 4
▷ Specification
Item Specification
Coil Resistance (Ω) 13.8 ~ 15.2 [20°C (68°F)]
IDLE SPEED CONTROL ACTUATOR (ISCA)
▷ Type: Double coil type
▷ Specification
Item Specification
Closing Coil Resistance (Ω) 14.6 ~ 16.2 [20°C (68°F)]
Opening Coil Resistance (Ω) 11.1 ~ 12.7 [20°C (68°F)]
Duty (%) Air Flow Rate ( ㎥ /h)

15 0.5 ~ 1.5
35 5.5 ~ 9.3
70 28.5 ~ 36.5
96 39.0 ~ 48.0
PURGE CONTROL SOLENOID VALVE (PCSV)
▷ Specification
Item Specification
Coil Resistance (Ω) 16.0 [20°C (68°F)]
CVVT OIL CONTROL VALVE (OCV)
▷ Specification
Item Specification
Coil Resistance (Ω) 6.9 ~ 7.9 [20°C (68°F)]
IGNITION COIL
▷ Type: Stick type
▷ Specification
Item Specification
Primary Coil Resistance (Ω) 0.75Ω±15％ [20°C (68°F)]
Secondary Coil Resistance (kΩ) Measurement is impossible because a diode is inserted
SERVICE STANDARD
Ignition Timing BTDC 5° ± 10°
Neutral,N,Prange
A/CON OFF
Drange
Idle Speed 660 ± 100 rpm
Neutral,N,Prange
A/CON ON
Drange
English
TIGHTENING TORQUES
Item Kgf·m N·m lbf·ft
PCM/ECM installation bolts 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
Manifold absolute pressure sensor installation bolt 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
Throttle position sensor installation screws 0.15 ~ 0.25 1.5 ~ 2.5 1.1 ~ 1.8
Knock sensor installation bolt 1.9 ~ 2.5 18.6 ~ 24.5 13.7 ~ 18.1
Heated oxygen sensor (Bank 1 / Sensor 1) installation 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
Idle speed control actuator installation screws 0.6 ~ 0.8 5.9 ~ 7.8 4.3 ~ 5.8
CVVT Oil control valve installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Ignition coil installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Fuel pump installation bolt 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
Delivery pipe installation bolts 2.0 ~ 2.5 19.6 ~ 24.5 14.5 ~ 18.1
2006 > G 1.6 DOHC > Fuel System > General Information > Troubleshooting English
English

English

● SIMULATING HEAT


CONNECTOR INSPECTION PROCEDURE English
side.
harness side.
English


English
• Voltage Check

step.
English
(C) and (B).

in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ω and higher than 1MΩ respectively. English
SYMPTOM TROUBLESHOOTING GUIDE CHART
MAIN SYMPTOM DIAGNOSTIC PROCEDURE ALSO CHECK FOR
Unable to start 1) Test the battery
(Engine does not turn
2) Test the starter
over)
3) Inhibitor switch (A/T) or clutch start switch (M/T)
1) Test the battery • DTC
Unable to start 2) Check the fuel pressure • Low compression
(Incomplete
3) Check the ignition circuit • Intake air leaks
combustion)
4) Troubleshooting the immobilizer system (In case of • Slipped or broken timing belt
immobilizer lamp flashing) • Contaminated fuel
• DTC
1) Test the battery
• Low compression
Difficult to start 2) Check the fuel pressure
• Intake air leaks
3) Check the ECT sensor and circuit (Check DTC)
• Contaminated fuel
4) Check the ignition circuit
• Weak ignition spark
Poor idling
(Rough, unstable or 1) Check the fuel pressure • DTC English
incorrect Idle)
2) Check the Injector • Low compression
3) Check the long term fuel trim and short term fuel trim • Intake air leaks
(Refer to CUSTOMER DATASTREAM)
4) Check the idle speed control circuit (Check DTC)
5) Inspect and test the Throttle Body
1) Test the Battery
• DTC
2) Check the fuel pressure
Engine stall • Intake air leaks
3) Check the idle speed control circuit (Check DTC)
5) Check the CKPS Circuit (Check DTC)
2) Inspect and test Throttle Body • DTC
3) Check the ignition circuit • Low compression
Poor driving
(Surge) 4) Check the ECT Sensor and Circuit (Check DTC) • Intake air leaks
5) Test the exhaust system for a possible restriction • Contaminated fuel
6) Check the long term fuel trim and short term fuel trim • Weak ignition spark
Knocking 2) Inspect the engine coolant • DTC

3) Inspect the radiator and the electric cooling fan • Contaminated fuel
4) Check the spark plugs
1) Check customer's driving habits
• Is A/C on full time or the defroster mode on?
• Are tires at correct pressure? • DTC
• Is excessively heavy load being carried? • Low compression
Poor fuel economy
• Is acceleration too much, too often? • Intake air leaks
2) Check the fuel pressure • Contaminated fuel
3) Check the injector • Weak ignition spark
4) Test the exhaust system for a possible restriction
5) Check the ECT sensor and circuit
Hard to refuel
(Overflow during 1) Test the canister close valve • Malfunctioning gas station
refueling) filling nozzle (If this problem
2) Inspect the fuel filler hose/pipe
occurs at a specific gas
• Pinched, kinked or blocked? station during refueling)
• Filler hose is torn
3) Inspect the fuel tank vapor vent hose between the
EVAP. canister and air filter English
4) Check the EVAP. canister
2006 > G 1.6 DOHC > Fuel System > Engine Control System > Description and Operation English
DESCRIPTION
1. Engine is hard to start or does not start at all.
2. Unstable idle.
3. Poor driveability
malfunction, incorrect engine adjustment, etc.). Then, inspect the Gasoline Engine Control system components with the HISCAN
(Pro).

• Before removing or installing any part, read the diagnostic trouble codes and then disconnect the battery
negative () terminal.
the battery cable during engine operation or while the ignition switch is ON could cause damage to the ECM.
• The control harnesses between the ECM and heated oxygen sensor are shielded with the shielded ground wires
to the body in order to prevent the influence of ignition noises and radio interference. When the shielded wire is
faulty, the control harness must be replaced.
• When checking the generator for the charging state, do not disconnect the battery '+' terminal to prevent the
ECM from damage due to the voltage.
• When charging the battery with the external charger, disconnect the vehicle side battery terminals to prevent
damage to the ECM.
Malfunction Indicator Lamp (MIL)
Faults with the following items will illuminate the MIL.
• Catalyst
• Fuel system
• Mass Air Flow Sensor (MAFS)
• Intake Air Temperature Sensor (IATS)
• Engine Coolant Temperature Sensor (ECTS)
• Throttle Position Sensor (TPS)
• Upstream Oxygen Sensor
• Upstream Oxygen Sensor Heater
• Downstream Oxygen Sensor
• Downstream Oxygen Sensor Heater
• Injector
• Misfire
• Crankshaft Position Sensor (CKPS)
• Camshaft Position Sensor (CMPS)
• Evaporative Emission Control System
• Vehicle Speed Sensor (VSS)
• Idle Speed Control Actuator (ISCA)
• Power Supply English
• ECM/ PCM
• MT/AT Encoding
• Acceleration Sensor
• MILon Request Signal
• Power Stage

Refer to "INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES (DTC)" for more information.
Faults with the following items will illuminate the MIL
• Heated oxygen sensor (HO2S)
• Mass Air Flow sensor (MAFS)
• Throttle position sensor (TPS)
• Engine coolant temperature sensor (ECTS)
• Idle speed control actuator (ISCA)
• Injectors
• ECM

1. After turning ON the ignition key, ensure that the light illuminates for about 5 seconds and then goes out.
2. If the light does not illuminate, check for an open circuit in the harness, a blown fuse or a blown bulb.
SelfDiagnosis

will be erased.
THE RELATION BETWEEN DTC AND DRIVING PATTERN IN EOBD SYSTEM
English
1. When the same malfunction is detected and maintained during two sequential driving cycles, the MIL will automatically
illuminate.
2. The MIL will go off automatically if no fault is detected after 3 sequential driving cycles.
3. A Diagnostic Trouble Code(DTC) is recorded in ECM memory when a malfunction is detected after two sequential
driving cycles. The MIL will illuminate when the malfunction is detected on the second driving cycle.
If a misfire is detected, a DTC will be recorded, and the MIL will illuminate, immediately after a fault is first detected.
4. A Diagnostic Trouble Code(DTC) will automatically erase from ECM memory if the same malfunction is not detected for
40 driving cycles.

• A "warmup cycle" means sufficient vehicle operation such that the coolant temperature has risen by at least 40
degrees Fahrenheit from engine starting and reaches a minimum temperature of 160 degress Fahrenheit.
• A "driving cycle" consists of engine startup, vehicle operation beyond the beginning of closed loop operation.
2006 > G 1.6 DOHC > Fuel System > Engine Control System > Components and Components Location
English
COMPONENTS LOCATION
1. ECM (Engine Control Module) [M/T] 2. Manifold Absolute Pressure Sensor (MAPS)
PCM (Powertrain Control Module) [A/T] 3. Intake Air Temperature Sensor (IATS)
English
4. Engine Coolant Temperature Sensor (ECTS) 5. Throttle Position Sensor (TPS)
6. Crankshaft Position Sensor (CKPS) 7. Camshaft Position Sensor (CMPS)
8. Knock Sensor (KS) 9. Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 1]
10. Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 2] 11. A/C Pressure Transducer (APT)
English
12. Injector
13. Idle Speed Control Actuator (ISCA)
16. Ignition Coil
14. Purge Control Solenoid Valve (PCSV) 15. CVVT Oil Control Valve (OCV)
17. Main Relay
18. Fuel Pump Relay
2006 > G 1.6 DOHC > Fuel System > Engine Control System > Power train Control Module (PCM) >
English
Schematic Diagrams
CIRCUIT DIAGRAM
[A/T]
English
English
English
[M/T]
English
English
English
English
2006 > G 1.6 DOHC > Fuel System > Engine Control System > Power train Control Module (PCM) >
English
Repair procedures
PCM PROBLEM INSPECTION PROCEDURE
1. TEST PCM GROUND CIRCUIT: Measure resistance between PCM and chassis ground using the backside of PCM
harness connector as PCM side check point. If the problem is found, repair it.
Specification (Resistance): 1Ω or less
2. TEST PCM CONNECTOR: Disconnect the PCM connector and visually check the ground terminals on PCM side and
harness side for bent pins or poor contact pressure. If the problem is found, repair it.
3. If problem is not found in Step 1 and 2, the PCM could be faulty. If so, replace the PCM with a new one, and then
check the vehicle again. If the vehicle operates normally then the problem was likely with the PCM.
4. RETEST THE ORIGINAL PCM : Install the original PCM (may be broken) into a knowngood vehicle and check the
vehicle. If the problem occurs again, replace the original PCM with a new one. If problem does not occur, this is
intermittent problem (Refer to INTERMITTENT PROBLEM PROCEDURE in BASIC INSPECTION PROCEDURE).
REPLACEMENT
2. Disconnect the battery () cable from the battery.
3. Disconnect the PCM connectors (A).
4. Unscrew the PCM mounting bolts (B) and remove the PCM from the air cleaner assembly.
5. Install a new PCM.
PCM mounting bolts: 3.9~ 5.9 N·m (0.4 ~ 0.6 kgf·m, 2.9 ~ 4.3 lbf·ft)
2006 > G 1.6 DOHC > Fuel System > Engine Control System > Manifold Absolute Pressure Sensor
English
(MAPS) > Repair procedures
INSPECTION
Manifold Absolute Pressure Sensor (MAPS) is speeddensity type sensor and is installed on the surge tank. This MAPS senses
absolute pressure in surge tank and transfers this analog signal proportional to the pressure to the PCM. The PCM calculates the
intake air quantity and engine speed based on this signal. This MAPS consists of piezoelectric element and hybrid IC that amplifies
the element output signal. The element is silicon diaphragm type and adapts pressure sensitive variable resistor effect of semi
conductor. 100% vacuum and the manifold pressure applies to both sides of it respectively. That is, this sensor outputs the silicon
variation proportional to pressure change by voltage.
SPECIFICATION
Pressure(kPa) Output Voltage (V)
20.0 0.79
46.66 1.84
101.32 4.0
CIRCUIT DIAGRAM
(A/T)
English
(M/T)
1. Connect a scantool on Diagnisis Link Connector (DLC).
2. Check MAPS output voltage at idle and IG ON.
Condition Output Voltage (V)
Idle 0.8V ~ 1.6V English
IG ON 3.9V ~ 4.1V
2006 > G 1.6 DOHC > Fuel System > Engine Control System > Intake Air Temperature Sensor (IATS) >
English
Repair procedures
INSPECTION
Intake Air Temperature Sensor (IATS) is installed inside the Manifold Absolute Pressure Sensor (MAPS) and detects the intake air
temperature. To calculate precise air quantity, correction of the air temperature is needed because air density varies according to the
temperature. So the PCM uses not only MAPS signal but also IATS signal. This sensor has a Negative Temperature Coefficient
(NTC) and its resistance is in inverse proportion to the temperature.
SPECIFICATION
Temperature [°C (°F)] Resistance (kΩ)
40 (40) 40.93 ~ 48.35
30 (22) 23.43 ~ 27.34
20 (4) 13.89 ~ 16.03
10 (14) 8.50 ~ 9.71
0 (32) 5.38 ~ 6.09
10 (50) 3.48 ~ 3.90
20 (68) 2.31 ~ 2.57
25 (77) 1.90 ~ 2.10
30 (86) 1.56 ~ 1.74
40 (104) 1.08 ~ 1.21
60 (140) 0.54 ~ 0.62
80 (176) 0.29 ~ 0.34
CIRCUIT DIAGRAM
(A/T)
English
(M/T)
2. Disconnect IATS connector.
3. Measure resistance between IATS terminals 3 and 4. English
2006 > G 1.6 DOHC > Fuel System > Engine Control System > Engine Coolant Temperature Sensor
English
INSPECTION
ECTS decreases as the temperature increases, and increases as the temperature decreases. The reference 5 V in the PCM is
supplied to the ECTS via a resistor in the PCM.That is, the resistor in the PCM and the thermistor in the ECTS are connected in
series. When the resistance value of the thermistor in the ECTS changes according to the engine coolant temperature, the output
voltage also changes. During cold engine operation the PCM increases the fuel injection duration and controls the ignition timing
using the information of engine coolant temperature to avoid engine stalling and improve drivability.
SPECIFICATION
[For ECM (2 pin)]
40(40) 48.14
20(4) 14.13 ~ 16.83
0(32) 5.79
20(68) 2.31 ~ 2.59
40(104) 1.15
60(140) 0.59
80(176) 0.32
[For Gauge (1 pin)]
Temperature [°C(°F)] Resistance (Ω)
60(140) 125
85(185) 42.6 ~ 54.2 English
110(230) 22.1 ~ 26.2
125(257) 15.2
CIRCUIT DIAGRAM
(A/T)
(M/T)
English
2. Disconnect ECTS connector.
3. Remove the ECTS.
4. After immersing the thermistor of the sensor into engine coolant, measure resistance between ECTS terminals 1 and 2.
2006 > G 1.6 DOHC > Fuel System > Engine Control System > Injector > Repair procedures English
INSPECTION
Based on information from various sensors, the PCM measures the fuel injection amount. The fuel injector is a solenoidoperated
valve and the fuel injection amount is controlled by length of time that the fuel injector is held open. The PCM controls each injector
by grounding the control circuit. When the PCM energizes the injector by grounding the control circuit, the circuit voltage should be
low (theoretically 0V) and the fuel is injected. When the PCM deenergizes the injector by opening control circuit, the fuel injector is
closed and circuit voltage should momentarily peak.
SPECIFICATION
Item Specification
Coil Resistance (Ω) 13.8 ~ 15.2Ω at 20°C (68°F)
CIRCUIT DIAGRAM
(A/T)
English
(M/T)
English
2. Disconnect injector connector.
3. Measure resistance between injector terminals 1 and 2.
2006 > G 1.6 DOHC > Fuel System > Engine Control System > Throttle Position Sensor (TPS) > Repair
English
procedures
INSPECTION
The Throttle Position Sensor (TPS) is mounted on the throttle body and detects the opening angle of the throttle plate. The TPS has a
variable resistor (potentiometer) whose characteristic is the resistance changing according to the throttle angle. During acceleration,
the TPS resistance between the reference 5V and the signal terminal decreases and output voltage increases; during deceleration,
the TPS resistance increases and TPS output voltage decreases. The PCM supplies a reference 5V to the TPS and the output
voltage increases directly with the opening of the throttle valve. The TPS output voltage will vary from 0.25~0.9V at closed throttle to
minimum 4.0V at wideopen throttle. The PCM determines operating conditions such as idle (closed throttle), part load,
acceleration/deceleration, and wideopen throttle from the TPS. Also The PCM uses the Manifold Absolute Pressure Sensor (MAPS)
signal along with the TPS signal to adjust fuel injection duration and ignition timing.
SPECIFICATION
C.T 0.25 ~ 0.9
W.O.T Min. 4.0V
Items Specification
CIRCUIT DIAGRAM
(A/T)
English
(M/T)
1. Connect a scantool on the Data Link Connector (DLC).
2. Start engine and check output voltages of TPS at C.T and W.O.T. English
3. Turn ignition switch OFF and disconnect the scantool from the DLC.
4. Disconnect TPS connector and measure resistance between TPS terminals 2 and 3
2006 > G 1.6 DOHC > Fuel System > Engine Control System > Heated Oxygen Sensor (HO2S) > Repair
English
procedures
INSPECTION
Heated Oxygen Sensor (HO2S) consists of zirconium and alumina and is installed on upstream and downstream of the Manifold
Catalyst Converter (MCC). After it compares oxygen consistency of the atmosphere with the exhaust gas, it transfers the oxygen
consistency of the exhaust gas to the PCM. When A/F ratio is rich or lean, it generates approximately 1V or 0V respectively. In order
that this sensor normally operates, the temperature of the sensor tip is higher than 370°C (698°F). So it has a heater which is
controlled by the PCM duty signal. When the exhaust gas temperature is lower than the specified value, the heater warms the sensor
tip.
SPECIFICATION
RICH 0.6 ~ 1.0
LEAN 0 ~ 0.4
Item Specification
English
Heater Resistance (Ω) Approx. 9.0Ω at 20°C (68°F)
WAVEFORM
CIRCUIT DIAGRAM
(A/T)
(M/T)
English
1. Check signal waveform of HO2S using a scantool.
Specification: Refer to "waveform".
2. Disconnet the HO2S connector.
3. Measure resistance between HO2S heater terminals 3 and 4.
2006 > G 1.6 DOHC > Fuel System > Engine Control System > Knock Sensor (KS) > Repair procedures
English
INSPECTION
Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine damage. Knock Sensor (KS)
senses engine knocking and is installed on the cylinder block. When knocking occurs, the vibration from the cylinder block is applied
as pressure to the piezoelectric element. At this time, this sensor transfers the voltage signal higher than the specified value to the
PCM and the PCM retards the ignition timing. If the knocking disappears after retarding the ignition timing, the PCM will advance the
ignition timing. This sequential control can improve engine power, torque and fuel economy.
SPECIFICATION
Item Specification
Resistance (MΩ) 4.87
WAVEFORM
English
CIRCUIT DIAGRAM
(A/T)
(M/T)
English
2006 > G 1.6 DOHC > Fuel System > Engine Control System > Crankshaft Position Sensor (CKPS) >
English
Repair procedures
INSPECTION
Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one of the most important sensors of the engine control
system. If there is no CKPS signal input, the engine may stop because of CKPS signal missing. This sensor is installed on transaxle
housing and generates alternating current by magnetic flux field which is made by the sensor and the target wheel when engine
runs. The target wheel consists of 58 slots and 2 missing slots on 360 CA (Crank Angle).
WAVEFORM
CIRCUIT DIAGRAM
(A/T)
English
(M/T)
1. Check signal waveform of CKPS and CMPS using a scantool.
Specification : Refer to "WAVE FORM"
2006 > G 1.6 DOHC > Fuel System > Engine Control System > Camshaft Position Sensor (CMPS) >
English
Repair procedures
INSPECTION
Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft position by using a hall element. It is related with
Crankshaft Position Sensor (CKPS) and detects the piston position of each cylinder which the CKPS can't detect. The CMPS are
installed on engine head cover and uses a target wheel installed on the camshaft. This sensor has a halleffect IC which output
voltage changes when magnetic field is made on the IC with current flow.
WAVEFORM
CIRCUIT DIAGRAM
(A/T)
English
(M/T)
1. Check signal waveform of CMPS and CKPS using a scantool.
Specification : Refer to "WAVE FORM"
2006 > G 1.6 DOHC > Fuel System > Engine Control System > Idle Speed Control Actuator (InodeA) >
English
Repair procedures
INSPECTION
The Idle Speed Control Actuator (ISCA) is installed on the throttle body and controls the intake airflow that is bypassed around the
throttle plate to keep constant engine speed when the throttle valve is closed. The function of the ISCA is to maintain idle speed
according to various engine loads and conditions, and also to provide additional air during starting. The ISCA consists of an opening
coil, a closing coil, and a permanent magnet. Based on information from various sensors, the PCM controls both coils by grounding
their control circuits. According to the control signals from the PCM, the valve rotor rotates to control the by pass airflow into the
engine.
SPECIFICATION
Items Specification
Closing Coil Resistance (Ω) 14.6 ~ 16.2 [20°C (68°F)]
Opening Coil Resistance (Ω) 11.1 ~ 12.7 [20°C (68°F)]

15 0.5 ~ 1.5
35 5.5 ~ 9.3
70 28.5 ~ 36.5
96 39.0 ~ 48.0
CIRCUIT DIAGRAM
(A/T)
English
(M/T)
2. Disconnect ISCA connector.
3. Measure resistance between ISCA terminals 2 and 1 [Opening Coil].
4. Measure resistance between ISCA terminals 2 and 3 [Closing Coil].
English
Check that the resistance is within the specification.
2006 > G 1.6 DOHC > Fuel System > Engine Control System > CVVT Oil Control Valve (OCV) > Repair
English
procedures
INSPECTION
The Continuously Variable Valve Timing (CVVT) system controls the amount of valve overlap by varying the amount of oil flow into an
assembly mounted on the intake camshaft through PCM control of an oil control valve. As oil is directed into the chambers of the
CVVT assembly, the cam phase is changed to suit various performance and emissions requirements..
1. When camshaft rotates engine rotationwise: IntakeAdvance / ExhaustRetard
2. When camshaft rotates counter engine rotationwise: Intake Retard / Exhaust Advance
SPECIFICATION
Item Specification
CIRCUIT DIAGRAM
(A/T)
English
(M/T)
2. Disconnect OCV connector.
3. Measure resistance between OCV terminals 1 and 2.
English
2006 > G 1.6 DOHC > Fuel System > Fuel Delivery System > Components and Components Location
English
COMPONENT LOCATION
2006 > G 1.6 DOHC > Fuel System > Fuel Delivery System > Repair procedures English
FUEL PRESSURE TEST
English
English
2006 > G 1.6 DOHC > Fuel System > Fuel Delivery System > Fuel Tank > Repair procedures English
REMOVAL (INCLUDING FUEL FILTER AND FUEL PRESSURE REGULATOR)
1. Preparation
(1) Remove the rear seat cushion (Refer to "SEAT" in BD group).
(2) Open the service cover (A).
(3) Disconnect the fuel pump connector (A).
(4) Start the engine and wait until fuel in fuel line is exhausted.
(5) After engine stalls, turn the ignition switch to OFF position.
2. Disconnect the fuel feed quickconnector (A) and vapor tube quickconnector (B).
3. Lift the vehicle and support the fuel tank with a jack.
4. Disconnect the fuel filler hose (A), the leveling hose (B) and the vapor hose (C).
English
5. Unscrew the fuel tank band mounting nuts(A) and remove the fuel tank.
INSTALLATION
Installation is reverse of removal.
2006 > G 1.6 DOHC > Fuel System > Fuel Delivery System > Fuel Pump > Repair procedures English
1. Preparation
2. Disconnect the fuel feed tube quickconnector (A) and the vapor tube quickconnector (B).
3. Unscrew the fuel pump installation bolts (C) and remove the fuel pump assembly.
English
INSTALLATION
Fuel Pump installation bolts : 3.9 ~ 5.9 N·m (0.4 ~ 0.6 kgf·m, 2.9 ~ 4.3 lbf·ft)
2006 > G 1.6 DOHC > Fuel System > Fuel Delivery System > FillerNeck Assembly > Repair procedures
English
REMOVAL
3. Unfasten the fillerneck assembly mounting screws (A).
5. Remove the bracket mounting bolts (A) and remove the fillerneck assembly.
English
INSTALLATION
2006 > G 1.6 DOHC > Fuel System > Fuel Delivery System > Accelerator Cable > Repair procedures
English
ADJUSTMENT
1. Turn on the ignition key, but don't start the engine.
2. Remove the fixing clip (A) after holding for 15 seconds under IG ON condition.
3. Adjust the position of the accelerator cable grommet (B) to secure free stroke.
(1) Pull the grommet (B) by taking the cable cap (C) in the direction of an arrow ① until the cable wire tighten.
(2) Push the grommet (B) by taking the cable cap (C) in the direction of an arrow ② as below free stroke specification.
Free stroke specification: 1 ~ 3 mm (0.0393 ~ 0.1181 in.)
4. Install the fixing clip (A).
[Abnormal wire tension: No free stroke]
[Normal wire tension: Free stroke]
5. Check the normal operation of the accelerator pedal.
REMOVAL English
1. Disconnect the battery negative () cable.
2. Remove the air intake hose.
(Refer to Engine Mechnical System "Engine & Transaxle system")
3. Remove the accelerator cable freeplay adjustment clip (A).
4. Remove the accelerator cable retaining grommet (B) from the accelerator cable bracket.
5. Manually open the throttle body to the Wide Open throttle (W.O.T) position and disconnect the throttle cable from the
bell crank .

Damage to the accelerator cable or the cruise control cable may result if the throttle body cam is rotated by lifting
up on the cable.
When disconnecting the accelerator cable from the throttle body, rotate the throttle body cam (A) only by lifting up
on the cam itself.
6. Disconnect the retaining clip (A) from the top of the accelerator pedal assembly.
7. Remove the accelerator cable from the vehicle; the accelerator end will have to be guided out through the bulkhead
access hole.

Install the accelerator cable end, route the cable through the accelerator pedal and snap the clip (A) into the
place.
When installing the accelerator cable to the throttle body, be careful not to twist or bend the cable.
After installling the accelerator pedal, adjust the throttle cable freeplay (Refer to Accelerator cable adjustment)
Check the cable and hose routings to ensure that they do not interfere with the throttle or cruise control cables.
Depress the accelerator pedal to Wide Open Throttle (W.O.T) several times to ensure proper operation.
2006 > G 2.0 DOHC > Engine Mechanical System > General Information > Specifications English
SPECIFICATIONS
Description Specifications Limit

General
Type Inline, Double Overhead Camshaft
Number of cylinder 4
Bore 82mm (3.228in)
Stroke 93.5mm (3.681in)
Total displacement 1975cc (120.52cu.in)
Firing order 1 3 4 2
Valve timing
Opens ATDC 11° ~ BTDC 29°
Intake valve
Closes ABDC 59° ~ 19°
Opens BBDC 42°
Exhaust
Closes ATDC 6°
Valve
Intake 114.34mm (4.5016in)
Valve length
Intake 5.965 ~ 5.98mm (0.2348 ~ 0.2354in)
Stem outer diameter
Exhaust 5.950 ~ 5.965mm (0.2343 ~ 0.2348in)
Face angle thickness of valve head (Margin)
Intake 1.6±0.15mm (0.0630±0.0059in) 0.8mm (0.031in)
Exhaust 1.8±0.15mm (0.0709±0.0059in) 1.0mm (0.039in)
Valve stem to valve guide clearance
Intake 0.02 ~ 0.05mm (0.0008 ~ 0.0019in) 0.10mm (0.0039in)
Exhaust 0.035 ~ 0.065mm (0.0014 ~ 0.0026in) 0.13mm(0.0051in)
Valve guide
Installed dimension outer Intake 45.8~46.2mm (1.8031~1.8189in)

diameter Exhaust 52.8~53.2mm (2.0787~2.0945in)
Service oversize 0.05, 0.25, 0.50mm (0.002, 0.010, 0.020in) oversize
Valve seat
Intake 1.1 ~ 1.5mm (0.043 ~ 0.059in)
Width of seat contact
Exhaust 1.3 ~ 1.7mm (0.051 ~ 0.066in)
Oversize 0.3, 0.6mm (0.012, 0.024in) oversize
Valve spring
18.8k±0.9kg/39.0mm(41.4±2.0lb/1.5354in)
Load
41.0±1.5kg/30.5mm(90.4±3.3lb/1.2008in)
Squarences 1.5° or less
Valve clearance
English
0.17~0.23mm
(0.0067~0.0091in)
Cold (20°C[68°F])
0.25~0.31mm
(0.0098~0.0122in)
Hot (80°C[176°F]) : only for Intake 0.29mm (0.0114in)

reference Exhaust 0.34mm (0.0134in)
Cylinder head
Flatness of gasket surface Max. 0.03mm (0.0012in) 0.06mm(0.0024in)
Flatness of manifold mounting surface Max. 0.15mm (0.0059in) 0.03mm(0.0012in)
Oversize rework dimensions of valve seat hole
0.3mm (0.012in)
33.300 ~ 33.325mm (1.3110 ~ 1.3120in)
O.S.
Intake
0.6mm (0.024in)
33.600 ~ 33.625mm (1.3228 ~ 1.3238in)
O.S.
0.3mm (0.012in)
28.800 ~ 28.821mm (1.1338 ~ 1.1346in)
O.S.
Exhaust
0.6mm (0.024in)
29.100 ~ 29.121mm (1.1456 ~ 1.1465in)
O.S.
Oversize rework dimensions of valve guide hole (both intake and exhaust)
0.05mm (0.002in) O.S 11.05 ~ 11.068mm (0.435 ~ 0.4357in)
0.25mm (0.010in) O.S 11.25 ~ 11.268mm (0.443 ~ 0.4436in)
0.50mm (0.020in) O.S 11.50 ~ 11.518mm (0.453 ~ 0.4535in)
Cylinder block
Outofround and taper of cylinder bore Less than 0.01mm (0.0004in)
Clearance with piston (To set limits to new
0.02 ~ 0.04mm (0.0008 ~ 0.0016in)
parts)
Piston
Outer diameter (To set limits to new parts) 81.97 ~ 82.00mm (3.2271 ~ 3.2283in)
Service oversize 0.25, 0.50mm (0.010, 0.020in) oversize
Piston ring
No.1 0.04 ~ 0.08mm (0.0015 ~ 0.0031in) 0.1mm (0.004in)
Side clearance
No.2 0.03 ~ 0.07mm (0.0012 ~ 0.0027in)
No.1 0.20 ~ 0.35mm (0.0079 ~ 0.0138in) 1mm (0.039in)
End gap
No.2 0.37 ~ 0.52mm (0.0146 ~ 0.0205in) 1mm (0.039in)
Oil ring side rail 0.20 ~ 0.60mm (0.0078 ~ 0.0236in) 1mm (0.039in)
Service oversize 0.25, 0.50mm (0.010, 0.020in.) oversize
Piston pin
Outer diameter 20.001 ~ 20.006mm (0.7874 ~ 0.7876in)
Hole inner diameter 20.016 ~ 20.021mm (0.7880 ~ 0.7882in)
Hole clearance 0.010 ~ 0.020mm (0.0004 ~ 0.0008in)
Connecting rod small end inner diameter 19.974 ~ 19.985mm (0.7864 ~ 0.7868in)
Connecting rod
Bend 0.05mm (0.0020in) or less
Twist 0.1mm (0.004in) or less
English
Connecting rod big end to crankshaft side 0.100 ~ 0.250mm (0.0039 ~ 0.010in)
0.4mm(0.0157in)
clearance
Connecting rod bearing
Oil clearance (To seat limits to new parts) 0.024 ~ 0.042mm (0.0009 ~ 0.0017in)
Undersize 0.25mm (0.01in)
Camshaft
Intake 44.618mm (1.7566in) 44.518mm(1.7527in)
Cam height 44.418mm
(1.7487in)
Jourmal outer diameter 28mm (1.1023in)
Bearing oil clearance 0.02 ~ 0.061mm (0.0008 ~ 0.0024in) 0.1mm(0.0039in)
End play 0.1 ~ 0.2mm (0.0040 ~ 0.0079in)
Crankshaft
Pin outer diameter 44.946 ~ 44.966mm (1.7695 ~ 1.7703in)
Journal outer diameter 56.942 ~ 56.962mm (2.2418 ~ 2.2426in)
Bend 0.03mm (0.0012in) or less
Outofround, taper of journal and pin 0.01mm (0.0004in) or less 0.030mm (0.0012in)
End play 0.06 ~ 0.260mm (0.0023 ~ 0.010in)
Undersize rework dimension 0.25mm
44.725 ~ 44.740mm (1.7608 ~ 1.7614in)
of pin (0.010in)
Undersize rework dimension 0.25mm
56.727 ~ 56.742mm (2.2333 ~ 2.2339in)
of journal (0.010in)
Crankshaft bearing
Oil clearance 0.028 ~ 0.046mm (0.0011 ~ 0.0018in)
Flywheel
Runout 0.1mm (0.0039in) 0.13mm(0.0051in)
Watercooled, pressurized. Forced circulation with
Cooling method
electrical fan
Coolant
Quantity 6.2~6.3liter (6.55~6.66U.S qts, 5.46~5.54lmp.qts)
Radiator
Type Pressurized corrugated fin type
Radiator cap
93.16 ~ 122.58kpa(0.95 ~ 1.25kg/cm², 13.51 ~
Main valve opening pressure
17.78psi)
Vacuum valve opening pressure MAX. 6.86 kpa(0.07kg/cm², 1.00 psi)
Thermostat
Type Wax pellet type with jiggle valve
Valve opening temperature 82°C (177°F)
Valve closing temperature 77°C (170.6°F)
Fullopening temperature 95°C (201°F)
Coolant pump Centrifugal type impeller
Drive belt
Type Vribbed belt
Engine coolant temperature sensor
English
Type Heatsensitive thermistor type
2.31 ~ 2.59kΩ at 20°C (68°F)
Resistance
0.3222kΩ at 80°C (176°F)
Oil pump
Clearance between outer circumference and
0.120 ~ 0.185mm (0.0049 ~ 0.0073in)
front case.
Front case tip clearance 0.025 ~ 0.069mm (0.0009 ~ 0.0027in)
Side clearance
Inner gear 0.04 ~ 0.085mm (0.0016 ~ 0.0033in)
Outer gear 0.04 ~ 0.09mm (0.0016 ~ 0.0035in)
Engine oil pressure at 1500 RPM 245KPa (2.5kg/cm², 35.5psi)
[Oil temperature is 90 to 110°C 194 to 230°F)]
Engine oil
When replacing a
Oil quantity(Total) 4.1L (4.33US qt, 3.60lmp.qt) short engine or
block assembly
When replacing an
Oil quantity(Excluding oil filer) 3.7L (3.91US qt, 3.26lmp.qt)
oil pan only
Oil quantity(Drain and refill including oil filer) 4.0L (4.23US qt, 3.52lmp.qt)
Relief spring
Free height 43.8mm (1.725in.)
Load 3.7kg at 40.1mm (3.15lb/1.578in)
Air cleaner
Type Dry type
Element Unwoven cloth type
Exhaust pipe
Muffler Expansion resonance type
Suspension system Rubber hangers
SERVICE STANDRDS
Standard value
Antifreeze Maxture ratio of antifreeze in coolant
Ethylene glycol base for aluminum 50%
TIGHTENING TORQUE
Item Nm kgf.m lbft
Cylinder Block
Front engine support bracket bolt and nut 34.3 ~ 49.0 3.5 ~ 5.0 25.3 ~ 36.2
Front roll stopper bracket bolt 68.6 ~ 88.3 7.0 ~ 9.0 50.6 ~ 65.1
Rear roll stopper bracket bolt 68.6 ~ 88.3 7.0 ~ 9.0 50.6 ~ 65.1
Rear engine stopper bracket bolt 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
Engine Mounting
Right mounting insulator (large) nut 88.3 ~ 107.9 9.0 ~ 11.0 65.1 ~ 79.6
Right mounting insulator (small) nut 44.1 ~ 58.8 4.5 ~ 6.0 32.5 ~ 43.4
Right mounting bracket to engine nuts and bolts 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
English
Transmission mount insulator nut 88.3 ~ 107.9 9.0 ~ 11.0 65.1 ~ 79.6
Transmission insulator bracket to side member
39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
bolt
Rear roll stopper insulator nut 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Rear roll stopper bracket to center member bolts 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
Front roll stopper insulator nut 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Front roll stopper bracket to center member
39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
bolts.
Main Moving
Connecting rod cap nut 49.0 ~ 52.0 5.0 ~ 5.3 36.2 ~ 38.3
Crankshaft bearing cap bolt (27.5~31.4) + (60°~64°) (2.8~3.2) + (60°~64°) (20.3~23.1) + (60°~64°)
Fly wheel M/T bolt 117.7 ~ 127.5 12.0 ~ 13.0 86.8 ~ 94.0
Drive plate A/T bolt 117.7 ~ 127.5 12.0 ~ 13.0 86.8 ~ 94.0
Engine cover 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
Heat protector 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~14.5
Water pipe bracket bolts 11.8 ~ 14.7 1.2 ~ 1.5 8.7 ~ 10.8
Cooling system
Alternator support bolt and nut 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Alternator lock bolt 11.8 ~ 14.7 1.2 ~ 1.5 8.7 ~ 10.8
Alternator brance mounting bolt 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Coolant pump pulley bolts 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Coolant pump bolts 19.6 ~ 23.5 2.0 ~ 2.4 14.5 ~ 17.4
Coolant temperature sensor 19.6 ~ 39.2 2.0 ~ 4.0 14.5 ~ 28.9
Coolant inlet fitting nuts 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Thermostat housing bolts and nuts 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Lubrication system
Oil filter 11.8 ~ 15.7 1.2 ~ 1.6 8.7 ~ 11.6
Oil pan bolts 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan drain plug (Aluminum) 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
Oil pan drain plug (Steel) 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Oil screen bolts 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~15.9
Oil pressure switch 12.7 ~ 14.7 1.3 ~ 1.5 9.4 ~10.8
Intake and Exhaust system
Air cleaner body mounting bolts 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Intake manifold to cylinder head nuts and bolts 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6
Intake manifold stay to cylinder block bolts 17.7 ~ 24.5 1.8 ~ 2.5 13.0 ~ 18.1
Throttle body to surge tank nuts 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Exhaust manifold to cylinder head nuts 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Exhaust manifold cover to exhaust manifold
14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
bolts
Oxygen sensor to front muffler 49.0 ~ 58.8 5.0 ~ 6.0 36.2 ~ 43.4
Oxygen sensor to exhaust manifold 49.0 ~ 58.8 5.0 ~ 6.0 36.2 ~ 43.4
Front exhaust pipe to exhaust manifold nuts 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9
Front exhaust pipe bracket bolts 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9
English
Front exhaust pipe to catalytic converter bolts 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Main muffler hanger support bracket bolts 9.8 ~ 14.7 1.0 ~ 1.5 7.2 ~ 10.8
Cylinder head
(22.6~26.5) + (60°~65°) (2.3~2.7) + (60°~65°)+ (16.6~19.5) + (60°~65°)
Cylinder head bolts M10
+ (60°~65°) (60°~65°) + (60°~65°)
(27.5~31.4) + (60°~65°) (2.8~3.2) + (60°~65°) + (20.3~33.1) + (60°~65°)
Cylinder head bolts M12
+ (60°~65°) (60°~65°) + (60°~65°)
Intake manifold nuts 17.7 ~ 24.5 1.8 ~ 2.5 13.0 ~ 18.1
Exhaust manifold nuts 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Cylinder head cover bolts 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Camshaft bearing cap bolts 13.7 ~ 14.7 1.4 ~ 1.5 10.1 ~ 10.8
Oil control valve bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
OCV Filter 40.2 ~ 50.0 4.1 ~ 5.1 29.7 ~ 36.9
CVVT unit to exhaust camshaft bolt 64.7 ~ 76.5 6.6 ~ 7.8 47.7~ 56.4
Rear plate bolts 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Timing Belt
Crankshaft pulley bolt 156.9 ~ 166.7 16.0 ~ 17.0 115.7 ~ 123.0
Camshaft sprocket bolt 98.1 ~ 117.7 10.0 ~ 12.0 72.3 ~ 86.8
Timing belt auto tensioner bolts 22.6 ~ 28.4 2.3 ~ 2.9 16.6 ~ 21.0
Timing belt cover bolts 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Front case bolts 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Timing belt idler bolt 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
2006 > G 2.0 DOHC > Engine Mechanical System > General Information > Troubleshooting English
TROUBLESHOOTING
Symption Suspect area Remedy (See page)

Engine misfire with abnormal Loose or improperly installed engine
Repair or replace the flywheel as required.
internal lower engine noises. flywheel.
Worn piston rings Inspect the cylinder for a loss of
(Oil cousnmption may or may not cause compression.
the engine to misfire.) Repair or replace as required.
Worn crankshaft thrust bearings
required
Engine misfire with abnormal valve Stuck valves.
Repair or replace as required
train noise. (Carbon buidup on the valve stem)
Excessive worn or misaligned timing Replace the timing chain and sprocket as
chain required.
• Faulty cylinder head gasket and/or
• Inspect the cylinder head and engine
cranking or other damage to the
block for damage to the coolant
Engine misfire with coolant cylinder head and engine block
passages and/or a faulty head
cousmption cooling system.
gasket.
• Coolant consumption may or may
not cause the engine to overheat.
Engine misfire with excessive oil Worn valves, guides and/or valve stem oil
consumption seals.
Worn piston rings. • Inspect the cylinder for a loss of
(Oil consumption may or may not cause compression.
the engine to misfire) • Repair or replace as required.
Engine noise on startup, but only • Drain the oil.
lasting a few seconds. Incorrect oil viscosity
• Install the correct viscosity oil.
• Inspect the thrust bearing and
Worn crankshaft thrust bearing. crankshaft.
Upper engine noise, regardless of Low oil pressure Repair or repalce as required.

engine speed.
Stetched or broken timing chain and/or
Replace the timing chain and sprockets.
damaged sprocket teeth.
Replace the timing chain tensioner as
Worn timing chain tensioner, if applicable.
required.
• Inspect the camshaft lobes.
Worn camshaft lobes. • Replace the timing camshaft and
valve lifters as required.
Inspect the valves and valve guides, then
repair as required.
Stuck valves. (Carbon on the valve stem Inspect the valves and valve guides, then
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or valve seat may cause the valve to stay repair as required.
open.
Lower engine noise, regardless of Low oli pressure. Repair or required.
engine speed
• Inspect the oil pan.
Damaged oil pan, contacting the oil pump
• Inspect the oil pump screen.
screen.
Oil pump screen loose, damaged or • Inspect the oil pump screen.
restircted. • Repair or replace as required.
• Inspect the piston, piston pin and
Excessive pistontocylinder bore cylinder bore.
clearance.
• Inspect the piston, piston pin and
Excessive piston pintoclearance the connecting rod.
repair as required.
Excessive connecting rod bearing rod
clearance • The connecting rods.
• The crankshaft.
Inspect the following components, and
repair as required.
Excessive crankshaft bearing clearance • The crankshaft bearing.
• Verify the piston pins and
Incorrect piston, piston pin and connecting rods are installed
connecting rod installation correctly.
Engine noise under load Low oil pressure Repair or replace as required.

repair as required :
Excessive connecting rod bearing • The connecting rod bearings.
clearance
• The crankshaft
Inspect the following components, and
repair as required.
Excessive crankshaft bearing clearance
• The cylinder block crankshaft
Engine will not crankcrankkshaft Hydraulically cylinder 1) Remove spark plugs and check for

will not rotate • Coolant/antifreeze in cylinder. fluid.
• Oil in cylinder. 2) Inspect for broken head gasket.
• Fuel in cylinder 3) Inspect for cracked engine black or
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cylinder head.
4) Inspect for a sticking fuel injector
and/or leaking fuel regulator.
Broken timing chain and/or timing chain 1) Inspect timing chain and gears.
and/or timing chain gears. 2) Repair as required.
Material cylinder
1) Inspect cylinder for damaged
• Broken valve components and/or foreign
• Piston material materials.
• Foreign material 2) Repair or replace as required.
1) Inspect crankshaft and connecting
Seized crankshaft or connecting rod rod bearing.
bearings.
1) Inspect connecing rods.
Bent or broken connecting rod.
1) Inspect crankshaft.
Broken crankshaft
2006 > G 2.0 DOHC > Engine Mechanical System > General Information > Repair procedures English
INSPECTION
COMPRESSION PRESSURE

If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.
1. Warm up and stop engine.
Allow the engine to warm up to normal operating temperature.
2. Remove ignition coils.
3. Remove spark plugs.
Using a 16mm plug wrench, remove the 4 spark plugs.
4. Check cylinder compression pressure
a. Insert a compression gauge into the spark plug hole.
b. Fully open the throttle.
c. while cranking the engine, measure the compression pressure.

Always use a fully charged battery to obtain engine speed of 250 rpm or more.
d. Repeat steps (a) through (c) for each cylinder.

This measurement must be done in as short a time as possible.
Compression pressure :
1421.96kPa (14.5kgf/cm², 206.24psi)
Minimum pressure :
1274.86kPa (13.0kgf/cm², 184.90psi)
98.07kPa (1.0kgf/cm², 14.22psi) or less
e. If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the
spark plug hole and repeat steps (a) through (c) for cylinders with low compression.
• If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.
5. Reinstall spark plugs.
6. Install ignition coils.
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Timing belt tension adjustment
1. Remove a engine cover.
2. Remove RH front wheel.
3. Remove the 4bolts and timing belt upper cover (A).
4. Slacker the tensioner bolt.

When check the timing belt tension or install the timing belt tensioner, must it the engine oil temperature is between
15°C(59°F) and 25°C(77°F)
5. Using a hex wrench, turn the adjuster counterclockwise to make the indicator of the arm(A) located at the center of the base
notch.

Do not rotate the adjuster clockwise.
It will result in auto tensioner's functional problem.
6. Tightening tensioner bolt with fixing the indicator not to move.
Tightening torque
Tensioner bolt :
22.6 ~ 28.4Nm (2.3 ~ 2.9kgf.m, 16.6 ~ 21.0lbft)
7. Turn the crankshaft two revolutions in the operating direction (clockwise) and check that the indicator is in the center of base.
8. If the indicator is not located at the center of base, slacken the bolt and repeat the above procedure.
9. Install the timing belt upper cover (A). English
Tightening torque :
7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbft)
10. Install RH front wheel.
11. Install a engine cover.
VALVE CLEARANCE INSPECTION AND ADJUSTMENT
MLA (MECHANICAL LASH ADJUSTER)

Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C) and cylinder head is
installed on the cylinder block.
2. Remove the upper timing belt cover (A).
a. Loosen the upper timing cover bolts and then remove the cover.
(1) Disconnect the spark plug cables and do not pull on the spark plug by force.

Pulling on or bending the cables may damage the connductor inside.
(2) Disconnect the P.C.V hose (A) and the breather hose (B) from the cylinder head cover.
(3) Disconnect the accelerater cable (C) and the autocruise cable(D) from the cylinder head cover.
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(4) Loosen the cylinder head cover bolts (B) and then remove the cover (A) and gasket.
4. Set No. 1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing belt cover.
(2) Check that the hole of the camshaft timing pulley (A) is aligned with the timing mark of the bearing cap.
If not, turn the crankshaft one revolution (360°)
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5. Inspect the valve clearance
(1) Check only the valve indicated as shown. [No. 1 cylinder : TDC/Compression] measure the valve clearance.
• Using a thickness gauge, measure the clearance between the tappe shim and the base circle of camshaft.
• Record the outofspecification valve clearance measurements. They will be used later to determine the required
replaement adjusing shim.
Valve clearance
Specitication
Engine coolant temperature : 20°C [68°F]
Intake : 0.20mm (0.0079in.)
Exhaust : 0.28mm (0.0110in.)
Engine coolant temperature : 80°C [176°F]
Intake : 0.29mm (0.0114in.)
Exhaust : 0.34mm (0.0134in.)
Limit
Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.091in.)
Exhaust : 0.25 ~ 0.31mm (0.0098 ~ 0.0122in.)
(2) Turn the crankshaft pulley one revolution (360°) and align the groove with timing mark "T" of the lower timing belt cover.
(3) Check only valves indicated as shown. [NO. 4 cylinder : TDC/compression]. Measure the valve clearance. (See
procedure in step (6))
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6. Adjust the intake and exhaust valve clearance.
(1) Turn the crankshaft so that the cam lobe of the camshaft on the adjusting valve is upward.
(2) Using the SST(09220 2D000), press down the valve lifter and place the stopper between the camshaft and valve lifter
and remove the special tool.
(3) Remove the adjusting shim with a small screw driver (A) and magnet(B).
(4) Measure the thickness of the removed shim using a micrometer.
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(5) Calculate the thickness of a new shim so that the valve clearance comes within the specificified value.
T : Thickness of removed shim
A : Measured valve clearance
N : Thickness of new shim
Intake : N = T + [A 0.20mm(0.0079in.)]
Exhaust : N = T + [A0.28mm (0.0110in.)]
(6) Select a new shim with a thickness as close as possible to the caculated value. [Refer to the Adjusting shim selection
chart]

Shims are available in 20size increments of 0.04mm (0.0016in.) from 2.00mm (0.079in.) to 2.76mm (0.1087in.)
(7) Place a new adjusting shim on the valve lifter.
(8) Using the SST(09220 2D000), press down the valve lifter and remove the stopper.
(9) Recheck the valve clearance.
[Specification]
Intake : 0.20mm (0.0079in.)
Exhaust : 0.28mm (0.0110in.)
[Limit] (After adjusting valve clearance)
Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0091in.)
Exhaust : 0.25 ~ 0.31mm (0.0098 ~ 0.0122in.)
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2006 > G 2.0 DOHC > Engine Mechanical System > Timing System > Timing Belt > Components and
English
Components Location
COMPONENTS
2006 > G 2.0 DOHC > Engine Mechanical System > Timing System > Timing Belt > Repair procedures
English
REMOVAL
2. Remove RH front wheel.
3. Remove 2bolts (B) and RH side cover (A).
4. Remove the engine mount bracket.
(1) Set the jack to the engine oil pan.

Place wooden block between the jack and engine oil pan.
(2) Remove the bolt(B), three nuts(C, D) and engine mount bracket (A), and the groud line(F).
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(3) Remove the bolt (B) and stay plate (A).
5. Temporarily loosen the water pump pulley bolts.
6. Remove alternator belt.
7. Remove air compressor belt.
8. Remove power steering belt.
9. Remove four bolts and water pump pulley.
10. Remove the timing belt upper cover (A).
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11. Turn the crankshaft pulley, and align its groove with timing mark “T”of the timing belt cover.
12. Remove the crankshaft pulley bolt (B) and crankshaft pulley (A).
13. Remove the crankshaft flange (A).
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14. Remove the 5bolts (B) and timing belt lower cover (A).
15. Remove the timing belt tensioner (A) and timing belt (B).
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If the timing belt is reused, make an arrow indicating the turning direction to make sure that the belt is reinstalled
in the same direction as before.
16. Remove the bolt (B) and timing belt idler (A).
17. Remove the crankshaft sprocket (A).
(1) Remove the spark plug cable.
(2) Remove the accelerator cable (C) and the autocruise cable (D) from the cylinder head cover.
(3) Remove the PCV(Positive Crankcase ventilation) hose (A) and breather hose (B).
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(4) Remove the bolts and cylinder head cover.
19. Remove camshaft sprocket.
(1) Hold the hexagonal head wrench (A) portion of the camshaft with a wrench (B), and remove the bolt and camshaft
sprocket (C).

Be careful not to damage the cylinder head and valve lifter with the wrench.
INSTALLATION
1. Install the camshaft sprocket and tighten the bolt to the specified torque.
(1) Temporarily install the camshaft sprocket bolt.
(2) Hold the hexagonal head wrench (A) portion of the camshaft with a wrench (B), and tighten the camshaft sprocket
(C) bolt.
Tightening torque
Camshaft sprocket bolt :
98.1 ~ 117.7Nm (10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lbft)
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2. Install cylinder head cover.
(1) Install cylinder head cover (A) and the twelve bolts (B).
Tightening torque :
7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbft)
(2) Install the PCV hose (A) and breather hose (B).
(3) Install the accelerator cable (C) and the autocruise cable (D) from the cylinder head cover.
(4) Install the spark plug cable.
3. Install the crankshaft sprocket (A).
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4. Align the timing marks of the camshaft sprocket (A) and crankshaft sprocket (B) with the No. 1 piston placed at top
dead center and its compression stroke.
5. Install the idler pulley (A) and tighten the bolt (B) to the specified torque.
Tightening torque
Idler pulley bolt :
42.2 ~ 53.9Nm (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lbft)
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6. Install the timing belt tensioner loosely enough for the adjuster to rotate. Make sure that the stopper of base is leaning
against the lowering sealing cap on the cylinder head.
7. Belt so as not give slack at each center of shaft. Do as following procedures when installing timing belt.
Crankshaft sprocket (A) → Idler pulley (B) → Camshaft sprocket (C) → timing belt tensioner (D).
(The tensioner can be installed after the timing belt.)
8. Check the alignment of the timing marks on each sprocket.
9. Remove the pin fixing the tensioner arm.
10. Using a hex wrench, turn the adjuster counterclockwise to make the indicator of the arm(A) located at the center of the
base notch.
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Do not rotate the adjuster clockwise.
It will result in auto tensioner's functional problem.
11. Tightening tensioner bolt with fixing the indicator not to move.
Tightening torque
Tensioner bolt :
22.6 ~ 28.4Nm (2.3 ~ 2.9kgf.m, 16.6 ~ 21.0lbft)
12. Turn the crankshaft two revolutions in the operating direction (clockwise) and check that the indicator is in the center
of base.
13. If the indicator is not located at the center of base, slacken the bolt and repeat the abore procedure.
14. Install the timing belt lower cover (A) with 5 bolts (B).
Tightening torque
Timing belt cover bolt :
7.8 ~ 9.8Nm (0.8 ~1.0kgf.m, 5.8 ~ 7.2lbft)
15. Install the flange and crankshaft pulley (A).
Make sure that crankshaft sprocket pin fits the small hole in the pulley.
Tightening torque
Crankshaft pulley bolt :
156.9 ~ 166.7N.m (16.0 ~ 17.0kgf.m, 115.7 ~ 123.0lbft)
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16. Install the timing belt upper cover (A).
Tightening torque :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbft)
17. Install the coolant pump pulley with 4bolts.
18. Install power steering belt.
19. Install air compressor bolt.
20. Install alternator belt.
21. Install the engine mount bracket
(1) Install the stay plate (A) with bolt (B).
Tightening torque
Stay plate bolt :
42.2 ~ 53.9Nm (4.3 ~ 5.5kgf.m 31.1 ~ 39.8lbft)
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(2) Install engine mount bracket(A) with the three nuts (C, D) and bolt (B).
Tightening torque
17mm nut : 68.6 ~93.2Nm (7.0 ~ 9.5kgf.m 50.6 ~ 68.7lbft)
14mm nut : 49.0 ~63.7Nm (5.0 ~ 6.5kgf.m 36.2 ~ 47.0lbft)
22. Install RH side cover (A) with 2bolts (B).
23. Install RH front wheel.
INSPECTION
SPROCKET, TENSIONER, IDLER
1. Check the camshaft sproket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks, or
damage. Replace as necessary.
2. Inspect the tensioner pulley and the idler pulley for easy and smooth rotation and check for play or noise.
Replace as necessary.
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3. Replace the pulley if there is a grease leak from its bearing.
TIMING BELT
1. Check the belt for oil or dust deposits.
Replace, if necessary.
Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, check the belt carefully. If any of the following flaws are
evident, replace the belt.

• Do not bend, twist or turn the timing belt inside out.
• Do not allow the timing belt to come into contact with oil, water and stem.
2006 > G 2.0 DOHC > Engine Mechanical System > Cylinder Head Assembly > Components and
English
Components Location
COMPONENTS
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2006 > G 2.0 DOHC > Engine Mechanical System > Cylinder Head Assembly > Repair procedures
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REMOVAL

before removing it.

• Inspect the timing belt before removing the cylinder head.
1. Disconnect the negative terminal (A) from the battery and remove the battery (B).
4. Remove the radiator cap to speed draing.
5. Loosen the radiator drain plug(A) and drain engine coolant.
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6. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the PCM connectors (A).
(2) Remove the intake air hose (B) and the air cleaner assembly (C).
8. Remove the heater hoses (A).
9. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold.
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(1) OCV(Oil control Valve) connector (A).
(2) Oil temperature sensor (OTS) connector (B).
(3) Engine coolant temperature (ECT) sensor connector (C).
(4) Ignition coil connector (D).
(5) TPS(Throttle Position Sensor) connector (A).
(6) ISA(Idle Speed Actuator) connector (B).
(7) CMP(Camshaft Position Sensor) connector (C).
(8) Four fuel injector connectors.
(9) Knock sensor connector (D).
(10) PCSV(Purge Control Solenoid Valve) connector (E).
(11) Front heated oxygen sensor connector.
10. Remove the fuel inlet hose (A) from delivery pipe and brake booster vacuum hose(B).
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Pulling on or bending the cables may damage the conductor inside.
(2) Disconnect the positive crankcase ventilation (P.C.V) hose (A) and the breather hose (B) from the cylinder head
cover.
(3) Disconnect the accelerator cable (C) and the autocruise cable (D) from the cylinder head cover.
13. Remove the exhaust manifold.
15. Remove the camshaft sprocket.
16. Remove the timing chain auto tensioner (A).
17. Remove the camshaft bearing caps (A) and camshafts (B).
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18. Remove the OCV(oil control valve) (A).
19. Remove the OCV(oil control valve) filter (A).
(1) Using 8mm and 10mm hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several
passes, in the sequence shown. Remove the 10 cylinder head bolts and plate washers.
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(2) Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on wooden blocks on a
bench.

REPLACEMENT
VALVE GUIDE
1. Using the SST(092213F100A), withdraw the old valve guide toward the bottom of cylinder head.
2. Recondition the valve guide hole so that it can match the newly pressfitted oversize valve guide.
3. Using the SST(092213F100A/B), pressfit the valve guide. The valve guide must be pressfitted from the upper side of
the cylinder head. Keep in mind that the intake and exhaust valve guides are different in length.
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Over size mm(in.) Size mark Oversize valve guide hole size mm(in.)
11.05 ~ 11.068
0.05 (0.002) 5
(0.4350 ~ 0.4357)
11.25 ~ 11.268
0.25 (0.010) 25
(0.4429 ~ 0.4436)
11.50 ~ 11.518
0.50 (0.020) 50
(0.4528 ~ 0.4535)
Valve guide length
Intake : 46mm (1.8in.)
Exhaust : 54.5mm (2.15in.)

Before the valve guide is pressfitted using the SST (092213F100A/B), remove the valve spring seat to install the
valve guide correctly.
4. After the valve guide is pressfitted, insert a new valve and check for proper stem toguide clearance.
5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as necessary.
INSTALLATION

• Always use a new head and manifold gasket.
• Rotate the crankshaft, set the No. 1 piston at TDC.
1. Install the cylinder head gasket (A) on the cylinder block.
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Be careful of the installation direction.
2. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
3. Install cylinder head bolts.
(1) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
(2) Using 8mm and 10mm hexagon wrench, install and tighten the 10 cylinder head bolts and plate washers, in several
passes, in the sequence shown.
Tightening torque
M10 :
22.6~26.5 (2.3~2.7, 16.6~19.5) + (60° ~ 65°) + (60° ~ 65°)
M12 :
27.5~31.4 (2.8~3.2, 20.3~23.1) + (60° ~ 65°) + (60° ~ 65°)

Always use a new cylinder head bolts.
4. Install OCV filter (A).
Tightening torque
40.2 ~ 50.0Nm (4.1 ~ 5.1kgf.m, 29.7 ~ 36.9lbft)
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Always use a new OCV filter gasket.
Keep clean the OCV filter.
5. Install OCV (A).
Tightening torque
9.8 ~ 11.8Nm(1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)

• Do not reuse the OCV when dropped.
• Keep clean the OCV.
• Do not hold the OCV sleeve during servicing.
• When the OCV is installed on the engine, do not move the engine with holding the OCV yoke.
6. Install the camshafts.
(1) Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown.
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(2) Install the camshafts (A) and bearing caps (B).
Tightening torque
13.7 ~ 14.7Nm (1.4 ~ 1.5kgf.m, 10.1 ~ 10.8lbft)
(3) Install the timing chain auto tensioner (A).
Tightening torque
7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbft)
(4) Remove the auto tensioner stopper pin (B).
7. Check and adjust valve clearance.
8. Using the SST (0922121000), install the camshaft bearing oil seal.
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9. Install the camshaft sprocket.
11. Install the cylinder head cover.
(1) Install the cylinder head cover gasket (A) in the groove of the cylinder head cover(B).

• Before installing the head cover gasket, thoroughly clean the head cover gasket and the groove.
• When installing, make sure the head cover gasket is seated securely in the corners of the recesses
with no gap.
(2) Apply liquid gasket to the head cover gasket at the corners of the recess.
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• Use liquid gasket, loctite No. 5999.
• Check that the mating surfaces are clean and dry before applying liquid gasket
(3) Install the cylinder head cover (A) with the 12bolts(B). Uniformly tighten the bolts in several passes.
Tightening torque
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lbft)
(4) Connect the accelerator cable (C) and the autocruise cable (D) from the cylinder head cover.
(5) Connect the positive crankcase ventilation (P.C.V) hose (A) and the breather hose (B) from the cylinder head
cover.

Pulling on or bending the calbes may damage the conductor inside.
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12. Install the intake manifold.
13. Install the exhaust manifold.
14. Install the fuel inlet hose (A).
15. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.
(1) Front heated oxygen sensor connector.
(2) Knock sensor connector (D).
(3) Four fuel injector connectors.
(4) CMP connector (C).
(5) PCSV connector (E).
(6) ISA connector (B).
(7) TPS connector (A).
(8) Ignition coil connector (D).
(9) ECT sensor connector (C).
(10) Oil temperature sensor connector (B).
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(11) OCV connector (A).
16. Install the heater hoses (A).
17. Install the upper radiator hose (A) and lower radiator hose (B).
18. Install the intake air hose and air cleaner assembly.
20. Connect the negative terminal to the battery.
21. Filll with engine coolant.
22. Start the engine and check for leaks.
23. Recheck engine coolant level and oil level.
DISASSEMBLY
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Identify MLA(Mechanical Lash Adjuster), valves, valve springs as they are removed so that each item can be
reinstalled in its original position.
1. Remove MLAs (A).
2. Remove valves.
(1) Using SST(0922228000, 0922228100), compress the valve spring and remove retainer lock.
(5) Remove the using needlenose pliers, remove the oil seal.
(6) Using a magnetic finger, remove the spring seat.
INSPECTION
CYLINDER HEAD
Flatness of cylinder head gasket surface
Standard : Less than 0.03mm(0.0012 in)
Limit : 0.06 mm ( 0.0024 in)
English
the cylinder head.
VALVE AND VALVE SPRING
1. Inspect valve stems and valve guides.
(1) Using a caliper gauge, measure the inside diameter or the valve guide.
Valve guide inside.
(2) Using a micrometer, measure the diameter of the valve stem.
(3) Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stemtoguide clearance
[Standard]
Intake : 0.02 ~ 0.05mm (0.0008 ~ 0.0020in)
Exhaust : 0.035 ~ 0.065mm (0.0014 ~ 0.0026in)
[Limit]
If the clearance is greater than maximum, replace the valve and valve guide.
English
2. Inspect valves.
(2) Check that the surface of the valve for wear.
(3) Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.
Margin
[Standard]
Intake : 1.6 mm(0.0630 in)
Exhaust : 1.8 mm(0.0709 in)
[Limit]
Intake : 1.45 mm(0.0571 in)
Exhaust : 1.65 mm(0.0650 in)
(4) Check the surface of the valve stem tip for wear.
3. Inspect valve seats
Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then recondition
the seat. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within
specifications and centered on the valve face.
4. Inspect valve springs.
(1) Using a steel square, measure the outofsquare of the valve spring.
(2) Using a vernier calipers, measure the free length of the valve spring.
Valve spring
[Standard]
Free height : 48.86mm (1.9236 in)
Load :
18.8±0.9kg/39.0mm (41.4±2.0lb/1.5354in)
41.0±1.5kg/30.5mm (90.4±3.3lb/1.2008in)
Outofsquare : 1.5°
[Limit]
Outofsquare : 3°
English
If the free length is not as specified, replace the valve spring.
CAMSHAFT
1. Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake : 44.518~44.718mm (1.7527~1.7605in)
Exhaust : 44.418~44.618mm (1.7487~1.7566in)
If the cam lobe height is less than minimum, replace the camshaft.
2. Inspect camshaft journal clearance.
(4) Install the bearing caps.

(5) Remove the bearing caps.
English
Bearing oil clearance :
[Standard value] : 0.02 ~ 0.061mm(0.0008 ~ 0.0024in)
[Limit] : 0.1mm(0.0039in)
If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and
(7) Completely remove the plastigage.
3. Inspect camshaft end play.
Camshaft end play
[Standard value] : 0.1 ~ 0.15mm(0.0039 ~ 0.0059in)
If the end play is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder
head as a set.
CVVT ASSEMBLY
1. Inspect CVVT assembly.
(1) Check that the CVVT assembly will not turn.
(2) Apply vinyl tape to all the parts except the one indicated by the arrow in the illustration.
English
(3) Wind tape around the tip of the air gun and apply air of approx. 100kpa(1kgf/cm², 14psi) to the port of the
camshaft.
(Perform this order to release the lock pin for the maximum delay angle locking.)

When the oil splashes, wipe it off with a shop rag and the likes.
(4) Under the condition of (3), turn the CVVT assembly to the advance angle side (the arrow marked direction in the
illustration) with your hand.
Depending on the air pressure, the CVVT assembly will turn to the advance side without applying force by hand.
Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there
may be the case that the lock pin could be hardly released.
(5) Except the position where the lock pin meets at the maximum delay angle, let the CVVT assembly turn back and
forth and check the movable range and that there is no disturbance.
Standard: Movable smoothly in the range about 20°
(6) Turn the CVVT assembly with your hand and lock it at the maximum delay angle position.
REASSEMBLY

Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.
1. Install valves.
(1) Install the spring seats.
(2) Using SST(0922222001), push in a new oil seal.

Do not reuse old valve stem seals.
English
(3) Install the valve, valve spring and spring retainer.

Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then
installs the retainer.
(4) Using the SST(0922228000,0922228100), compress the spring and install the retainer locks. After installing the
valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor.
(5) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper
seating of the valve and retainer lock.
2. Install MLAs. English
Check that the MLA rotates smoothly by hand.
2006 > G 2.0 DOHC > Engine Mechanical System > Engine And Transaxle Assembly > Repair English
procedures
REMOVAL


• Inspection the timing belt before removing the cylinder head.
1. Disconnect the terminal(A) from the battery(B).
2. Remove A engine cover.
4. Remove the radiator cap to speed daring.
English
(1) Disconnect the power train module (PCM) connector (A).
(2) Disconnect the intake hose (B).
(3) Remove the air cleaner assembly (C).
7. Remove the battery tray (A) and the front connector (B).
8. Remove the upper radiator hose (A) and lower radiator hose (B).
9. Disconnect the auto transaxle fluid (ATF) hose (A).
English
10. Remove the heater hose (A).
11. Remove the junction box cover.
12. Remove the engine wire harness connectors(A) and wire harness clamps from the engine room fuse and relay junction
box.
13. Remove the el inlet from delivery pipe (A) and brake booster vacuum hose (B).
14. Disconnect the accelerator cable (C) and the autocruise cable(D) from the cylinder head cover.
English
15. Remove the transaxle wire and control cable. (Refer to Transaxle control system in MTA or ATA Group).
16. Remove the high & low pressure pipe. (Refer to Air conditioner compressor in HA Group).
17. Remove the steering ujoint mounting bolt(A).
18. Install the SST (0920038001, 092001C000), the engine support fixture and the adapter, on the engine and transaxle
assembly.
19. Remove the engine mounting bracket (A) by removing the bolt(B) and nuts(C, D) and ground line (F).
English
20. Remove the transaxle mounting bracket (A) and the ground line (B).
21. Remove the front tires.
23. Remove the front muffler (A) and disconnect the rear oxygen sensor connector(B).
24. Remove the sub frame bolts (A).
English
25. Remove the engine support fixture and the adapter.
26. Jack up the vehicle.
INSTALLATION
Perform the following :
• Adjust shift cable.
• Adjust throttle cable.
• Refill engine with engine oil.
• Refill transaxle with fluid.
• Refill radiator with engine coolant.
• Bleed air from the cooling system with the heater valve open.
• Clean battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent corrosion.
After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for
approximately two seconds and fuel line pressureizes.
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
2006 > G 2.0 DOHC > Engine Mechanical System > Cylinder Block > Components and Components
English
Location
COMPONENTS
English
2006 > G 2.0 DOHC > Engine Mechanical System > Cylinder Block > Repair procedures English
DISASSEMBLY
1. M/T : remove flywheel.
2. A/T : remove drive plate.
3. Install engine to engine stand for disassembly.
4. Remove timing belt.
5. Remove cylinder head.
6. Remove oil level gauge assembly (A).
7. Remove knock sensor.
8. Remove oil pressure sensor (A).
9. Remove water pump.
10. Remove oil pan.
11. Remove oil screen.
Remove the 2bolts(C), oil screen (A) and gasket (B).
English
13. Remove the connecting rod caps and check oil clearance.
14. Remove piston and connecting rod assemblies.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

15. Remove front case.
16. Remove rear oil seal case.
Remove the 5 bolts(B) and rear oil seal case (A).
17. Remove crankshaft bearing cap and check oil clearance.
19. Lift the crankshaft (A) out of the engine, being careful not to damage journals.

Arrange the main bearings and trust washers in the correct order.
English
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
21. Remove piston rings.
(1) Using a piston ring expender, remove the 2 compression rings.
(2) Remove the 2side rails and oil ring by hand.

22. Disconnect connecting rod from piston.
INSPECTION
CONNECTING ROD AND CRANKSHAFT
Using a feeler gauge, measure the end play while moving the connecting rod back and forth.
Standard end play : 0.1~ 0.25mm(0.004 ~ 0.010in)
Maximum end play : 0.4mm(0.016in)
2. Check the connecting road bearing oil clearance.
(1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove the 2 connecting rod cap nuts.
(3) Remove the connecting rod cap and bearing half.
(4) Clean the crank pin and bearing. English
(5) Place plastigage across the crank pin.
(6) Reinstall the bearing half and cap, and torque the nuts.
Tightening torque
49.0 ~ 52.0 Nm (5.0 ~ 5.3kgf.m, 36.2 ~ 38.3lbft)

(7) Remove the 2 nuts, connecting rod cap and bearing half.
0.024 ~ 0.042mm(0.0009 ~ 0.0017in)
(9) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete
bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above
or below that one), and check clearance again.


English
CLASS MARK INSIDE DIAMETER

48.00 ~ 48.006mm
A WHITE
(1.8896 ~ 1.8899in.)
48.006 ~ 48.012mm
B NONE
(1.8899 ~ 1.8902in.)
48.012 ~ 48.018mm
C YELLOW
(1.8902 ~ 1.8904in.)
Crankshaft pin mark location
Discrimination of crankshaft
CLSASS MARK OUTSIDE DIAMETER OF PAN
English
44.960 ~ 44.966mm
I YELLOW
(1.7700 ~ 1.7703in.)
44.954 ~ 44.960mm
II NONE
(1.7698 ~ 1.7700in.)
44.948 ~ 44.954mm
III WHITE
(1.7696 ~ 1.7698in.)
Place of identification mark (Connecting rod bearing)
CLASS MARK THICKNESS OF BEARING
1.514 ~ 1.517mm
AA BLUE
(0.0596 ~ 0.0597in.)
1.511 ~ 1.514mm
A BLACK
(0.0595 ~ 0.0596in.)
1.508 ~ 1.511mm
B NONE
(0.0594 ~ 0.0595in.)
1.505 ~ 1.508mm
C GREEN
(0.0593 ~ 0.0594in.)
1.502 ~ 1.505mm
D YELLOW
(0.0591 ~ 0.0593in)
(11) Selection
ASSEMBING
CONNECTING ROD
CRANKSHAFT INDENTIFICATION MARK CLASSIFICATION OF
IDENTIFICATION MARK
BEARING
A (WHITE) D (YELLOW)
I (YELLOW) B (NONE) C (GREEN)
C (YELLOW) B (NONE)
A (WHITE) C (GREEN)
II (NONE) B (NONE) B (NONE)
C (YELLOW) A (BLACK)
A (WHITE) B (NONE)
III (WHITE) B (NONE) A (BLACK)
C (YELLOW) AA (BLUE)
English
(1) To check main bearingtojournal oil clearance, remove the main caps and bearing halves.
(2) Clean each main journal and bearing half with a clean shop tower.
(4) Reinstall the bearings and caps, then torque the bolts.
Tightening torque :
27.5~31.4Nm (2.8~3.2kgf.m, 20.3~23.11lbft) + 60° ~ 64°

(5) Remove the cap and bearing again, and measure the widest part of the plastigage.
0.028 ~ 0.046mm (0.0011 ~ 0.0018in)
(6) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete
bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above
or below that one), and check clearance again.


Connecting rods
1) When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When a
new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
2) Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough
3) Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair
English
0.05mm / 100mm (0.0020 in./3.94 in) or less
0.1mm / 100mm (0.0039 in./3.94 in) or less
Letters have been stamped on the end of the block as a mark for the size of each of the 5 main journal bores.
Discrimination of cylinder block
CALSS MARK INSIDE DIAMETER
59.000 ~ 59.006mm
a A
(2.3228 ~ 2.3230in.)
59.006 ~ 59.012mm
b B
(2.3230 ~ 2.3233in.)
59.012 ~ 59.018mm
c C
(2.3233 ~ 2.3235in.)
Crankshaft journal mark location
English
Discrimination of crankshaft
CLASS MARK OUTSIDE DIAMETER OF JOURNAL

54.956 ~ 54.962mm
I YELLOW
(2.1636 ~ 2.1638in.)
54.950 ~ 54.956mm
II NONE
(2.1633 ~ 2.1636in.)
54.944 ~ 54.950mm
III WHITE
(2.1631 ~ 2.1633in.)
Place of identification mark (Crankshaft bearing)
Discrimination of crankshaft bearing
CLASS MARK THICKNESS OF BEARING
2.014 ~ 2.017mm
AA BLUE
(0.0793 ~ 0.0794in.)
2.011 ~ 2.014mm
A BLACK
(0.0791 ~ 0.0793in.)
2.008 ~ 2.011mm
B NONE
(0.0790 ~ 0.0791in.)
2.005 ~ 2.008mm
C GREEN
(0.0789 ~ 0.790in.)
2.002 ~ 2.005mm
D YELLOW
(0.0788 ~ 0.0789in.)
Selection English
CRANKSHAFT BORE ASSEMBLING
CRANKSHAFT IDENTIFICATION MARK
IDENTIFICATION MARK CLASSIFICATION OF BEARING
a (A) D (YELLOW)
I (YELLOW) b (B) C (GREEN)
c (C) B (NONE)
a (A) C (GREEN)
II (NONE) b (B) B (NONE)
c (C) A (BLACK)
a (A) B (NONE)
III (WHITE) b (B) A (BLACK)
c (C) AA (BLUE)
4) Check crankshaft end play.
: 0.06 ~ 0.26mm (0.0023 ~ 0.010in)
Limit : 0.30mm (0.0118in)
If the end play is greater than maximum, replace the thrust bearings as a set.
Thrust bearing thickness :
2.44 ~ 2.47mm(0.096 ~ 0.097in)
5) Inspect main journals and crank pins
Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter :
56.942 ~ 56.962mm (2.2418~2.2426in)
Crank pin diameter :
44.946 ~ 44.966mm (1.7695 ~ 1.7703in)
CYLINDER BLOCK English
1. Remove gasket material.
2. Clean cylinder block
3. Inspect top surface of cylinder block for flatness.
Standard : Less than 0.03mm(0.0012 in)
Limit : 0.05 mm (0.0020 in)
4. Inspect cylinder bore diameter
If deep scratches are present, replace the cylinder block.
5. Inspect cylinder bore diameter
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions.
Standard diameter :
82.00 ~ 82.03mm (3.2283 ~ 3.2295in)
6. Check the cylinder bore size code on the cylinder block bottom face.
English
Size
Class Cylinder bore inner diameter
code
82.00 ~ 82.01mm
A A
(3.228~ 3.2287in)
82.01 ~ 82.02mm
B B
(3.2287~ 3.2291in)
82.02 ~ 82.03mm
C C
(3.2291~ 3.2295in.)
7. Check the piston size code on the piston top face.

Stamp the grade mark of basic diameter with rubber stamp.
Size
Class Piston outer diameter
code
81.97 ~ 81.98mm
A A
(3.2271 ~ 3.2275in)
81.98 ~ 81.99mm

(3.2275 ~ 3.2279in)
81.99 ~ 82.00mm
C C
(3.2279 ~ 3.2283in)
8. Select the piston related to cylinder borre class.
Clearance
0.02 ~ 0.04mm (0.00078 ~ 0.00157in.)
English
1) Oversize pistons should be selected according to the largest bore cylinder.
Identification Mark Size
0.25 0.25mm (0.010in)
0.50 0.50mm (0.020in)

The size of piston is stamped on top of the piston.
2) Measure the outside diameter of the piston to be used.
3) According to the measured O.D., calculate the new bore size.
New bore size = Piston O.D + 0.02 to 0.04 mm
(0.0008 to 0.0016 in.) (clearance between piston and
cylinder) 0.01 mm (0.0004 in.) (honing margin.)
4) Bore each of the cylinders to the calculated size.

To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing
order.
5) Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6) Check the clearance between the piston and cylinder.
Standard : 0.020.04 mm (0.00080.0016 in.)

When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to the
oversize.
PISTON AND RINGS
1. Clean piston

2. The standard measurement of the piston outside diameter is taken 47 mm (1.85 in.) from the top land of the piston.
Standard diameter
81.97 ~ 82.00mm (3.2272 ~ 3.2283in)
English
3. Calculate the difference between the cylinder bore diameter and the piston diameter.
Pistontocylinder clearance
0.02 ~ 0.04mm(0.0008 ~ 0.0016in)
Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.
No. 1 : 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in)
No. 2 : 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in)
Oil ring : 0.06 ~ 0.15 mm (0.0024 ~ 0.0059 in)
Limit
No. 1 : 0.1mm (0.004in)
No. 2 : 0.1mm (0.004in)
Oil ring : 0.2 mm (0.0079 in)
5. Inspect piston ring end gap.
service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter against the wear limits.
If the bore is over the service limit, the cylinder block must be rebored.
Piston ring end gap
Standard
No. 1 : 0.20 ~ 0.35mm (0.0079 ~ 0.0138 in)
No. 2 : 0.37 ~ 0.52mm (0.0146 ~ 0.0205 in)
Oil ring : 0.20 ~ 0.60 mm (0.0079 ~ 0.0236 in)
Limit
No. 1, 2, oil ring : 1.0mm (0.039in)
English
PISTON PINS
1. Measure the diameter of the piston pin.
Piston pin diameter
20.001 ~ 20.006mm (0.7874 ~ 0.7876in)
Piston pintopiston clearance
0.01 ~ 0.02mm (0.0004 ~ 0.0008in)
3. Check the difference between the piston pin diameter and the connecting rod small end diameter.
Piston pintoconnecting rod interference
0.032 ~ 0.016mm (0.0013 ~ 0.00006in)
OIP PRESSURE SWITCH
1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.
3. If there is no continuity when a 50kpa (7psi) vacuum is applied throgh the oil hole, the switch is operaing properly.
English
Check for air leakage. If air leaks, the diahragm is broken. Replace it.
REASSEMBLY

• Thoroughly clean all parts to assembled.
1. Assemble piston and connecting rod.
(1) Use a hydraulic press for installation.
(2) The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
2. Install piston rings.
English
3. Install connecting rod bearings.
(1) Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2) Install the bearings (A) in the connecting rod and connecting rod cap(B).
4. Install main bearings.

Upper 1,2,4,5 bearings have an oil groove of oil holes; Lower bearings do not.
(1) Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings(A).
5. Install thrust bearings.
Install the 2 thrust bearings under the No.3 journal position of the cylinder block with the oil grooves facing outward.
6. Place crankshaft on the cylinder block.
7. Place main bearing caps on cylinder block.
8. Install main bearing cap bolts. English

• The main bearing cap bolts are tightened in 2 progressive steps.
• If any of the bearing cap bolts in broken or deformed, replace it.
(1) Apply a light coat of engine oil on the threads and under the bearing cap bolts.
(2) Install and uniformly tighten the 10 bearing cap bolts(A), in several passes, in the sequence shown.
Tightening torque
27.5 ~ 31.4Nm (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lbft) + 60 ~ 64°

Always use new main bearing cap bolts.
9. Check crankshaft end play.
10. Install piston and connecting rod assemblies.

Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
(1) Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting
rod bolts.
(2) Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder,
and tap it in using the wooden handle of a hammer.
(3) Stop after the ring compressor pops free, and check the connecting rodtocheck journal alignment before pushing
(4) Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the nuts : 50 ~ 53Nm (5.0 ~
5.3kgf.m, 36.9 ~ 39lbft)

Maintain downward force on the ring compressor to prevent the rings from expanding before entering the
cylinder bore.
Always use new connecting rod bearing cap nuts.
English
11. Install a new gasket and rear oil seal case (A) with 5 bolts (B).
Tightening torque
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)

Check that the mating surfaces are clean and dry.
12. Install rear oil seal.
(2) Using SST(0923123200, 09231H1100) and a hammer, tap in the oil seal until its surface is flush with the rear oil
seal retainer edge.
13. Install front case.
14. Install oil screen.
Install a new gasket (A) and oil screen (B) with 2 bolts(C).
Tightening torque
14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lbft)
English
15. Install oil pan.

Check that the mating surfaces are clean and dry before applying liqued gasket.
(2) Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Use liquid gasket 'TB 1217H' or equivalent.

• To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
• Do not install the parts if five minutes or more have elapsed since applying the liquid gasket. Instead,
reapply liquid gasket after removing the residue.
(3) Install the oil pan with the 19 bolts.
Tightening torque
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbft)
16. Install water pump.
17. Install oil pressure sensor.
(1) Apply adhesive to 2 or 3 threads.
Adhesive : Three bond 2310/2350 or equivalent.
(2) Install the oil pressure sensor (A).
Tightening torque
14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lbft)
English
18. Install knock sensor.
Tightening torque
16.7 ~ 26.5Nm (1.7 ~ 2.7kgf.m, 12.3 ~ 19.5lbft)
19. Install oil level gauge assembly.
(1) Install a new Oring on the oil level gauge.
(2) Apply engine oil on the Oring.
(3) Install the oil level gauge assembly (A) with the bolt.
Tightening torque
18.6 ~ 23.5Nm (1.9~ 2.4kgf.m, 13.7 ~ 17.4lbft)
20. Install cylinder head.
21. Install timing belt.
22. Remove engine stand.
23. A/T : Install drive plate.
Tightening torque
117.7 ~ 127.5Nm (12.0 ~ 13.0kgf.m, 86.8 ~ 94.0lbft)
24. M/T : Install flywheel.
Tightening torque
117.7 ~ 127.5Nm (12.0 ~ 13.0kgf.m, 86.8 ~ 94.0lbft)
2006 > G 2.0 DOHC > Engine Mechanical System > Cooling System > Components and Components
English
Location
COMPONENTS
2006 > G 2.0 DOHC > Engine Mechanical System > Cooling System > Repair procedures English
REMOVAL
WATER PUMP

System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant,
remove the cap only when the engine is cool.
2. Remove drive belts.
4. Remove the timing belt idler.
5. Remove the water pump.
(1) Remove the 4 bolts and pump pulley.
(2) Remove the 2 bolts(C), then remove the alternator brace (A).
(3) Remove the water pump (B) and gasket.
THERMOSTAT

Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the
thermostat, even if the engine tends to overheat.
1. Drain engine coolant so its level is below thermostat.
2. Remove water inlet (A), gasket and thermostat.
English
RADIATOR
1. Remove the radiator cap to speed daring.
3. Disconnect the terminal(A) and remove the battery(B).
English
(1) Disconnect the power train module (PCM) connector (A).
(2) Disconnect the intake hose (B).
(3) Remove the air cleaner assembly (C).
6. Disconnect the auto transaxle fluid (ATF) hose (A).
7. Disconnect the fan motor connector (A) and remove the radiator mounting bracket (B).
8. Remove the blower assembly(A).
9. After pulling back the condenser fixing bracket(A), remove the radiator assembly. English
INSTALLATION
WATER PUMP
1. Install the water pump.
(1) Install the water pump (B) and a new gasket with the 3 bolts(C).
Tightening torque
11.8 ~ 14.7Nm (1.2 ~ 1.5kgf.m, 8.7 ~ 10.8lbft)
(2) Install the alternator bracket (A) with the 2 bolts (D).
Tightening torque
19.6 ~ 23.5Nm (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4lbft)
(3) Install the 4 bolts and pump pulley.
2. Install the timing belt idler.
4. Install drive belts.
THERMOSTAT
1. Place thermostat in thermostat housing.
(1) Install the thermostat with the jiggle valve upward.
(2) Install a new gasket (A) to the thermostat (B). English
2. Install water inlet (A).
Tightening torque
14.7 ~ 19.6Nm (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lbft)
RADIATOR
1. Install the radiator.
2. Connect the fan motor connector (A) and install the radiator mounting bracket (B).
3. Connect the auto transaxle fluid (ATF) hose (A).
English
4. Install the upper radiator hose (A) and lower radiator hose (B).
5. Install air cleaner assembly.
6. Install the front bumper upper cover (A) and the air duct (B).
7. Install battery (B) and connect teminal (A).
INSPECTION
WATER PUMP
necessary.
English
3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump assembly

A small amount of “weeping” from the bleed hole is normal.
THERMOSTAT

Valve opening temperature : 82 °C(177 °F)
Full opening temperature : 95 °C(205 °F)
English
Valve lift : 8mm(0.3in.) or more at 95 °C(205 °F)
ENGINE COOLANT REFILLING AND BLEEDING

When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or the
1. Slide the heater temperature control lever to maximum heat. Make sure the engine and radiator are cool to the touch.
2. Remove radiator cap (A).
3. Loosen the drain plug, and drain the coolant.
4. Tighten the radiator drain plug securely.
5. Remove, drain and reinstall the reservoir. Fill the tank halfway to the MAX mark with water, then up to the MAX mark
with antifreeze.
6. Mix the recommended antifreeze with water at the ratio of five to five(coolant 5 : water 5) in a clean container.

• Use only genuine antifreese/coolant.
Coolant concentrations less than 50% may not provide sufficient protection against corrosion or freezing.
• Coolant concentrations greater then 60% will impair cooling efficiency and are not recommended.
English

7. Pour coolant into the radiator up to base of the filler neck, and install the radiator cap loosely.
8. Start the engine and let it run until it warms up (the radiator fan comes on at least twice).
9. Turn off the engine. Check the level in the radiator, add coolant if needed.
10. Put the radiatir cap on tightly, then run the engine again and check for leaks.
Cap Testing
1. Remove the radiator cap, wet its seal with engine coolant, then install it no pressure tester.
2. Apply a pressure of 93.16 ~ 122.58kpa(0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi).
Testing
2. Apply a pressure tester to the radiator and apply a pressure of 93.16 ~ 122.58kpa(0.95 ~ 1.25kg/cm², 13.51 ~
17.78psi).

English
2006 > G 2.0 DOHC > Engine Mechanical System > Cooling System > Troubleshooting English
Inspection Remedy
coolant.
coolant.
vehicle.
clamps.
replacing Oring.
torque.
replace.
replacing gasket.
torque.
A/C.
ground cable.
etc.
Unit inspection Inspect water pump impeller. Replace water pump.
foreign materials.
Inspect for stuck thermostat valve. Check valve lift.
Immerse thermostat in water heated to over 95°C (203°F), then Replace thermostat if valve
heat for at least 3 minutes to check valve lift. lift is below specification or
valve is stuck.

2006 > G 2.0 DOHC > Engine Mechanical System > Lubrication System > Components and English
Components Location
COMPONENTS
2006 > G 2.0 DOHC > Engine Mechanical System > Lubrication System > Repair procedures English
REMOVAL
2. Remove the drive belts.
3. Turn the crankshaft and align the white groove on the crankshaft pulley with the pointer on the lower cover.
5. Remove the oil pan and oil screen.
6. Remove the front case.
(1) Remove the screws (B) from the pump housing, then separate the housing and cover (A).
(2) Remove the inner (A) and outer (B) rotors.
English
OIL AND FILTER

• Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear
sites.
a. Remove the oil filter cap.
b. Remove the oil drain plug, and drain the oil into a container.
2. Replace oil filter.
a. Remove the oil filter.
b. Check and clean the oil filter installation surface.
c. Check the part number of the new oil filter is as same as old one.
d. Apply clean engine oil to the gasket of a new oil filter.
e. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
f. Tighten it an additional 3/4 turn.
3. Refill with engine oil filter.
a. Clean and install the oil drain plug with a new gasket.
Tightening torque :
Aluminum : 39.2 ~ 49.0N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lbft)
Steel : 34.3 ~ 44.1N.m (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lbft)
b. Fill with fresh engine oil
Capacity
When replacing a short engine or a block assembly : 4.1L (4.33US qts, 3.60lmp qts)
When replacing an oil pan : 3.7L (3.91US qts, 3.26lmp qts)
Drain and refill including oil filter : 4.0L (4.23US qts, 3.25lmp qts)
c. Install the oil filter cap.
English
5. Recheck engine oil level.
INSTALLATION
1. Install oil pump.
(1) Place the inner and outer rotors into front case with the marks facing the oil pump cover side.
(2) Install the oil pump cover (A) to front case with the 7 screws(B).
Tightenig torque
5.9 ~ 8.8N.m (0.6 ~ 0.9kgf.m, 4.3 ~ 6.5lbft)
2. Check that the oil pump turns freely.
3. Install the oil pump on the cylinder block.
Place a new front case gasket on the cylinder block. Apply engine oil to the lip of the oil pump seal. Then, install the oil
pump onto the crankshaft. When the pump is in place, clean any excess grease off the crankshaft and check that the
oil seal lip is not distorted.
Body length
(A) : 25mm (0.98 in)
(B) : 20mm (0.787 in)
(C) : 38mm (1.496 in)
(D) : 45mm (1.771 in)
Tightening torque :
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5 lbft)
4. Apply a light coat of oil to the seal lip.
5. Using the SST(0923123100), install the oil seal.
English

Clean the oil pan gasket mating surfaces.
DISASSEMBLY
1. Remove the relief plunger.
Remove the plug(A), spring(B) and relief plunger(C).
INSPECTION
1. Inspect relief plunger.
Coat the valve with engine oil and check that it falls smoothly into the plunger hole by its own weight.If it does not,
replace the relief plunger. If necessary, replace the front case.
2. Inspect relief valve spring.
Inspect for distorted or broken relief valve spring.
Standard value
Free height : 43.8mm (1.724 in.)
Load : 3.7kg/40.1mm (8.14 lb/1.579 in.)
3. Inspect rotor side clearance.
Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight
edge.
Side clearance Outer gear 0.04 ~ 0.09mm
(0.0016 ~ 0.0035in.)
English
0.04 ~ 0.085mm
Inner gear
(0.0016 ~ 0.0033in.)
If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front case.
4. Inspect rotor tip clearance.
Using a feeler gauge, measure the tip clearance between the inner and outer rotor tips.
Tip clearance
0.025 ~ 0.069 mm(0.0010 ~ 0.0027 in.)
If the tip clearance is greater than maximum, replace the rotor as a set.
5. Inspect rotor body clearance
Using a feeler gauge, measure the clearance between the outer rotor and body.
Body clearance
0.12 ~ 0.185 mm(0.0047 ~ 0.0073 in.)
If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front case.
English
SELECTION OF ENGINE OIL (EXCEPT FOR EUROPE)
Recommended ILSAC classification : Above GF3
Recommended API classification : Above SJ or SL

For best performance and maximum protection of all types of operation, select only those lubricants whitch :
• Satisfy the requirement of the API classification.
• Have proper SAE grade number for expected ambient temperature range. English
Lubricants that do not have both an SAE grade number and API service classification on the container should not be
used.
SELECTION OF ENGINE OIL (FOR EUROPE)
Recommended ACEA classification : Above A3
Recommended API classification : Above SL

For best performance and maximum protection of all types of operation, select only those lubricants whitch :
• Satisfy the requirement of the API classification.
• Have proper SAE grade number for expected ambient temperature range.
Lubricants that do not have both an SAE grade number and API service classification on the container should not be
used.
ENEINE OIL
1. Check engine oil quality.
Check the oil for deterioration, entry of water, discoloring or thinning.
2. Check engine oil level.
After warming up the engine and then 5 minutes after the engine stop, oil level should be between the “L” and “F” marks
on the dipstick.
If low, check for leakage and add oil up to the “F” mark.
English

Do not fill with engine oil above the “F” mark.
REASSEMBLY
1. Install relief plunger.
Install relief plunger(C) and spring(B) into the front case hole, and install the plug(A).
Tightening torque
39.2 ~ 49.0N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lbft)
English
COMPONENTS
English
Repair procedures
REMOVAL
1. Removal a engine cover.
2. Disconnect the throttle position sensor(TPS) and the idle speed actuator(ISA) connectors.
3. Disconnect the positive crankcase ventilation(PCV) hose and the breather hose.
4. Disconnect the accelerator cable.
5. Remove the delivery pipe(A).
6. Disconnect the pulge control solenoid valve(PCSV) hose and the brake booster hose from the intake manifold and
throttle body assembly.
7. Remove the intake manifold stay(A).
Tightening torque
17.7 ~ 24.5Nm (1.8 ~ 2.5kgf.m, 13.0 ~ 18.1lbft)
8. Remove the intake manifold assembly(A).
Tightening torque
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lbft)
English
9. To install, reverse the removal procedure with new gaskets.
English
COMPONENTS
English
Repair procedures
REMOVAL
3. Disconnect the front oxygen sensor connector(B).
Tightening torque
39.8 ~ 58.8Nm (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lbft)
4. Remove the heat protector.
5. Remove the exhaust manifold and catalytic converter assembly(A).
6. To install, reverse the removal procedure with new gasket.
2006 > G 2.0 DOHC > Engine Mechanical System > Intake And Exhaust System > Front Exhsust Pipe >
English
Repair procedures
REMOVAL
1. Disconnect the front oxygen sensor connector(B).
Tightening torque
39.8 ~ 58.8Nm (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lbft)
3. Remove the center muffler(A) and the main muffler(B).
Tightening torque
39.8 ~ 58.8Nm (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lbft)
2006 > G 2.0 DOHC > Engine Electrical System > General Information > Specifications English
SPECIFICATION
IGNITION SYSTEM
Items Specification
Primary resistance 0.58 ± 10 % (Ω)
Ignition coil
Secondary resistance 8.8 ± 15 % (kΩ)
NGK BKR5ES
Leaded CHAMPION
Gap 0.8 ~ 0.9 mm (0.0315 ~ 0.0354 in.)
Spark plugs
NGK BKR5ES11
Unleaded CHAMPION RC10YC4
Gap 1.0 ~ 1.1 mm (0.0394 ~ 0.0433 in.)
STARTING SYSTEM
Items Specification
Starter Voltage 11 V
CHARGING SYSTEM
Items Specification
Rate voltage 13.5 V, 90A
Arternator
Regulator setting voltage 14.55 ± 0.2 V
Temperature compensation 7 ± 3 mV / °C
Type CMF 45AH CMF 60AH
Cold cranking amperage [at
410A 550 A
Battery 18°C(0.4°F)]
Reserve capacity 80 min 92 min
Specific gravity [at 20°C(68°F)] → 1.280 ± 0.01

– COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminal
– RESERVE CAPACITY RATING is amount of time a battery can deliver 25A and maintain a minimum terminal
AUTO CRUISE CONTROL SYSTEM English
Items Specification
Actuator
Rated voltage range DC 12V
Operating voltage range DC 11 ~ 16V
Operation temperature rnage 30 ~ 100°C (22 ~ 212°F)
Cruise main switch
Reted voltage DC 5V
Operating temperature range 30 ~80 °C (22 ~ 176°F)
TIGHTENING TORQUE
Items Nm kgf.m lbft
Ignition coil monnting 18.6 ~ 26.5 1.9 ~ 2.7 13.7 ~ 19.5
Stater terminal mounting 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Stater mounting 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Generator mounting A 11.8 ~ 14.7 1.2 ~ 1.5 8.7 ~ 10.8
Generator mounting B 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
2006 > G 2.0 DOHC > Engine Electrical System > General Information > Troubleshooting English
TROUBLESHOOTING
IGNITION SYSTEM
Trouble condition Probable cause Remedy
Engine cranks, but will not start or Ignition coil faulty Replace ignition coil
is hard to start. High tension cable faulty Replace high tension cable
Spark plugs faulty Replace plugs
Incorrect immobilizer system Adjust
Ignition wiring disconnected or broken Inspect and replace
Rough idle or stalling Spark plugs faulty Replace plugs
Ignition wiring faulty Replace wiring
Ingition coil faulty Replace ignition coil
High gension cord faulty Relpace high tension cord
Engine hesitates/poor acceleration Spark plugs faulty Replace plugs
Ignition wiring faulty Replace wiring
Poor fuel Spark plugs faulty Replace plugs
CHARGING SYSTEM
Trouble condition Probable cause Remedy
Fues blown Check fuses
Charging warning indicator does not
Light burnde out Replace light
light with ignition switch "ON" and
Wiring connection loose Tighten loose connections
engine off
Electronic voltage regulator faulty Replace voltage regulator
Drive belt loose or worn
Adjust tension or replace cables
Battery cables loose, corroded or worn
Repair or replace cables
Charging warning indicator does not Fuse blown
Check fuses
go out with engine runing. (Battery Fusible link blown
Replace fusible link
requires fequent recharging) Electronic voltage regulator or generator
Test generator
faulty
Repair wiring
Wiring faulty
Drive belt loose or worn
Wiring connection loose or open circuit Adjust tension or replace drive belt
Fusible link blown Tighten loose connection or repair wiring
Warning indicator and preexcitation Replace fusible link
Discharged battery resistor faulty Replace components
Poor grounding Repair
Electronic voltage regulator or generator Test generator
faulty Replace battery
Battery life
Electronic voltage regulator faulty Replace voltage regulator
Overcharging
Voltage sensing wire faulty Repair wire
STARTING SYSTEM
Trouble condition Probable cause Remedya
Transaxle range switch faulty (Vehicle Adjust or replace switch
with automatic transaxle only)
Fusible link blown Replace fusible link
English
Ignition switch faulty Replace ignition switch
Battery charge low Charge or replace battery
Engine cranks slowly Battery cables loose, corroded or worn Inspect wiring and fix
Starter keeps running
Ignition wiring faulty Repair or replace
Repair wiring
Short in wiring
Repair starter motor
Starter spins but engine will not Pinion gear teeth broken or starter motor
crank faulty
Replace flywheel ring gear or torque
Ring gear teeth broken
converter
2006 > G 2.0 DOHC > Engine Electrical System > Ignition System > Description and OperationEnglish
DESCRIPTION
Ignition timing is controlled by the electronic control ignition timing system. The standard reference ignition timing data for the engine
operating conditions are preprogrammed in the memory of the ECM (engine control module).
The engine operating conditions (speed, load, warmup condition, etc.) are detected by the various sensors. Based on these sensor
signals and the ignition timing data, signals to interrupt the primary current are sent to the ECM. The ignition coil is activated, and
timing is controlled.
2006 > G 2.0 DOHC > Engine Electrical System > Ignition System > Ignition Coil > Repair procedures
English
INSPECTION
1. Measure the primary ciol resistance between terminals 1 and 2.
Standard value : 0.58 ± 10% (Ω)
2. Measure the secondary ciol resistance between the highvoltage terminal for the No.1 and No.4 cylinders, and between
the highvoltage terminals for the No.2 and No.3 cylinders.
Standard value : 8.8 ± 15% (KΩ)

When measuring the resistance of the secondary coil, be sure to disconnect the ignition coil connector.
2006 > G 2.0 DOHC > Engine Electrical System > Ignition System > Spark Plug > Repair procedures
English
INSPECTION
1. Disconnect the spark plug cables from the spark plugs.

When removing the spark plug cable, pull on the spark plug cable boot (not the cable), as it may be damaged.
2. Using a spark plug socket, remove all spark plugs from the cylinder head.

Be careful that no contaminants enter through the spark plug holes.
3. Check the spark plugs for the following :
1) Broken insulator
2) Worn electrode
3) Carbon deposits
4) Damaged or broken gasket
5) Condition of the porcelain insulator at the tip of the spark plug
4. Check the spark plug gap using a wire gap(A) gauge, and adjust if necessary.
Standard value : 1.01.1 mm (0.0390.043 in)
5. Reinsert the spark plug and tighten to the specified torque.
If it is over torqued, damage to the threads of the cylinder head may result.
Tightening torque : 2030 Nm (2.03.0 kgf.m, 1521 Ibft)
ANALYZING SPARK PLUGS English
Engine conditions can be analyzed by examining the tip deposits near the electrode.
Condition Dark deposits White deposits
• Fuel misture too lean
• Fuel mixture too rich
Description • Advanced ignition timing
• Low air intake
• Insufficient plug tightening
RESISTANCE INSPECTION
2006 > G 2.0 DOHC > Engine Electrical System > Charging System > Description and Operation
English
DESCRIPTION
The charging system includes a battery, an generator with a builtin regulator, and the charging indicator light and wire.
The generator has six builtin diodes (three positive and three negtive), each rectifying AC current to DC current.
Therefore, DC curent appears at generator "B" terminal.
In addition, the charging voltage of the generator is regulated by the battery voltage detection system. The main components of the
generator are the rotor(A), stator(B), rectifier(C), brushes(D), bearings(E) Vribbed belt pulley(F). The brush holder contains a builtin
electronic voltage regulator(G).
2006 > G 2.0 DOHC > Engine Electrical System > Charging System > Repair procedures English
INSPECTION
VOLTAGE DROP TEST
PREPARATION
1. Turn the ignition switch to "OFF."

To identify connection problems, be sure not to disturb either of the two terminals or their connections during this
test.
2. Connect a digital voltmeter between the generator "B" terminal and battery (+) terminal. Connect the (+) lead wire of the
voltmeter to the"B" terminal and the () lead wire to the battery (+) terminal.
CONDITIONS FOR TESTING
RESULT
1. The voltmeter should read a standard 0.2V.
2. If the reading is above 0.2V, poor wiring should be suspected.
Check wiring from generator 'B' terminal through the fusible link to the battery (+) terminal.
Check for loose wiring or color change from an overheated harness. Correct and check again.
3. On completion of the test, set the engine at idle.
Then turn off the headlamps, blower motor etc., and ignition.
OUTPUT CURRENT TEST
PREPARATION
(1) Check if that the battery installed in the vehicle is in good condition. For details, see "BATTERY".

English
The battery that is used to test the output current should be one that has been partially discharged. With a
fully charged battery, the test may not be conducted correctly due to an insufficient load.
(2) Check the tension of the generator drive belt. See "COOLING".
4. Disconnect the generator output wire from the generator "B" terminal.
connect the () lead wire ofthe ammeter to the disconnected output wire.

6. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the generator "B"
terminal and () lead wireto a good ground.
TEST
1. Check to see that the voltmeter reads the same value as the battery voltage. If the voltmeter reads 0V, an open circuit
in the wire between the generator "B" terminal and battery () terminal, a blown fusible link or poorground is suspected.
2. Start the engine and turn the headlights on.
3. Set the headlights to high beam and the heater blower switch to HIGH, quickly increase the engine speed to 2,500 rpm
and read the maximumoutput current value indicated by the ammeter.

After the engine starts, the charging current quickly drops. Therefore, the above operation must be done quickly
to readthe maximum current value correctly.
RESULT
1. The ammeter reading must be higher than the limit value. If it is lower but the generator output wire is in good condition,
remove the generatorfrom the vehicle and test it.
Limit value : 45A

1) The nominal output current value is shown on the nameplate affixed to the generator body. English
2) The output current value changes with the electrical load and the temperature of the generator itself.
Therefore, the nominal output current may not be obtained. In such case, keep the headlights on to
discharge the battery, or use the lights of another vehicle to increase the electrical load.
The nominal output current may not be obtained if the temperature of the generator itself or ambient
temperature is too high.
In such a case, reduce the temperature before testing again.
5. Connect the generator output wire to the generator "B" terminal.
PREPARATION
(1) Check that the battery installed in the vehicle is fully charged. For battery checking method, see the "BATTERY"
section.
(2) Check the generator drive belt tension. For belt tension check, see section, "COOLING."
2. Turn ignition switch to "OFF."
4. Connect a digital voltmeter between the "S(L)" terminal of the generator and ground.
Connect the (+) lead of the voltmeter to the "S(L)" terminal of the generator. Connect the () lead to a good ground or the
battery () terminal.
5. Disconnect the generator output wire from the generator "B" terminal.
6. Connect a DC ammeter (0 to 100A) in series between the "B" terminal and the disconnected output wire. Connect the ()
lead wire of the ammeterto the disconnected output wire.
TEST
Voltage : Battery voltage
If it reads 0V, there is an open circuit in the wire between the generator "S(L)" terminal and the battery and the battery
(+), or the fusible link isblown.
English
3. Run the engine at a speed of about 2,500 rpm and read the voltmeter when the generator output current drops to 10A or
less.
RESULT
1. If the voltmeter reading agrees with the value, the voltage regulator is functioning correctly. If the reading is other than
the standard value, the voltage regulator or the generatoris faulty.
4. Remove the voltmeter, ammeter, and the engine tachometer.
5. Connect the generator output wire to the generator "B" terminal.
6. Reconnect the battery ground cable.
2006 > G 2.0 DOHC > Engine Electrical System > Charging System > Alternator > Components and
English
Components Location
COMPONENTS
2006 > G 2.0 DOHC > Engine Electrical System > Charging System > Alternator > Repair procedures
English
REMOVAL
1. Disconnect the battery negative terminal(A) first, then the positive terminal(A).
2. Deisconnect the generator connector(A) and "B" terminal cable from the generator. Losen the cpip(B).
3. Remove the adjusting bolt(A), mounting bolt(B), the generator belt(C) and the generator mounting bracket(D).
4. Pull out the through bolt, then remove the generatorE).
6. Adjust the generator belt tension after installation.
DISASSEMBLY
1. Remove the generator cover(A) after removing three nuts(B).
English
4. Remvoe the nut, pully(A) and spacer.
English
INSPECTION
ROTOR
1. Check that there is continuity between the slip rings(A).
2. Check that there is no continuity between the slip rings and the rotor(B) or rotor shaft(C).
3. If the rotor fails either continuity check, replace the generator.
STATOR
1. Check that there is continuity between each pair of leads(A).
English
3. If the coil fails either continuity check, replace the generator.
ALTERNATOR BELT INSPECTION AND ADJUSTMENT

When using a new belt, first adjust the deflection or tension to the values for the new belt, then readjust the deflection
or tension to the values for the used belt after running engine for five minutes.
Deflection method :
Apply a force of 98N (10 kgf, 22 lbf), and measure the deflection between the alternator and crankshaft pulley.
Deflection
Used Belt : 8.5 ~ 11.5 mm (0.33 ~ 0345 in)
New Belt : 5.5 ~ 8.0 mm (0.22 ~ 0361 in)

If the belt is worn or damaged, replace it.
Belt tension gauge method :
Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions.
Tension
Used Belt : 340~490 N (35~50 kgf, 77~110 lbf)
New Belt : 690~880 N (70~90 kgf, 150~200 lbf)

If the belt is worn or damaged, replace it.
English
If adjustment is necessary :
1. Loosen the adjusting bolt(A) and the lock bolt(B).
2. Move the alternator to obtain the proper belt tension, then retighten the nuts.
3. Recheck the deflection or tension of the belt.
2006 > G 2.0 DOHC > Engine Electrical System > Charging System > Battery > Repair procedures
English
CLEANING


English
INSPECTION
BATTERY DIAGNOSTIC FLOW
English
LOAD TEST
1. Perform the following steps to complete the load test procedure for maintenance free batteries.
2. Connect the load tester clamps to the terminals and proceed with the test as follow:
(1) If the battery has been on charge, remove the surface charge by connect a 300ampere load for 15 seconds.
(2) Connect the voltmeter and apply the specified load.
(3) Read the voltage after the load has been applied for 15 seconds.
(4) Disconnect the load.
(5) Compare the voltage reading with the minimum and replace the battery if battery test voltage is below that shown
in the voltage table.
Voltage Temperature
English
9.6V 20°C (68.0°F) and above
9.5V 16°C (60.8°F)
9.4V 10°C (50.0°F)
9.3V 4°C (39.2°F)
9.1V 1°C (30.2°F)
8.9V 7°C (19.4°F)
8.7V 12°C (10.4°F)
8.5V 18°C (0.4°F)

– If the voltage is greater shown in the table, the battery is good.
– If the voltage is less than shown in the table, replace the battery.
2006 > G 2.0 DOHC > Engine Electrical System > Starting System > Description and OperationEnglish
DESCRIPTION
The starting system includes the battery, starter motor, solenoid switch, ignition switch, inhibitor switch(A/T), ignition lock switch,
connection wires and the battery cable.
The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear and the starter motor cranks. In
order to prevent damage caused by excessive rotation of the starter armature when the engine starts, the clutch pinion gear
overruns.
2006 > G 2.0 DOHC > Engine Electrical System > Starting System > Repair procedures English
INSPECTION
START TEST

The air temperature must be between 59 and 100°F (15 and 38°C) before testing.
Recommended procedure :
• Use a starter system tester.
• Connect and operate the equipment in accordance with the manufacturer's instructions.
• Test and troubleshoot as described.
Alternate Procedure :
• Use the following equipment :
Ammeter, 0~400A
Voltmeter, 0~20V (accurate within 0.1 volt)
Tachometer, 0~1,200 rpm
• Hook up a voltmeter and ammeter as shown.

After this test, or any subsequent repair, reset the ECM/PCM to clear any codes.
Check the Starter Engagement :
1. Remove the No.8(10A) fuse from the fuse/relay box.
2. Turn the ignition switch to START (III) with the shift lever in or position (A/T) or with the clutch pedal depressed (M/T).
The starter should crank the engine.
• If the starter does not crank the engine, go to step 3.
• If it cranks the engine erratically or too slowly, go to "Check for Wear and Damage" on the next page.
3. Check the battery, battery positive cable, ground, starter cut relay, and the wire connections for looseness and
corrosion. Test again.
If the starter still does not crank the engine, go to step 4.
4. Unplug the connector from the starter.
5. Connect a jumper wire from the battery positive (+) terminal to the solenoid terminal.
The starter should crank the engine.
• If the starter still does not crank the engine, remove it, and diagnose its internal problem.
• If the starter cranks the engine, go to step 6.
6. Check the ignition switch.
7. Check the starter relay.
8. Check the A/T gear position switch (A/T) or the clutch interlock switch (M/T).
9. Check for an open in the wire between the ignition switch and starter.
If cranking voltage is too low, or current draw too high, check for :
• dead or low battery.
• open circuit in starter armature commutator segments.
• starter armature dragging. English
• shorted armature winding.
• excessive drag in engine.
Check Cranking rpm
Engine speed during cranking should be above 100 rpm.
If speed is too low, check for :
• loose battery or starter terminals.
• excessively worn starter brushes.
• open circuit in commutator segments.
• dirty or damaged helical splines or drive gear.
• defective drive gear overrunning clutch.
Check starter disengagement
With the shift lever in N or P position (A/T) or with the clutch pedal depressed (M/T), turn the ignition switch to START(III), and release
to ON(II).
The starter drive gear should disengage from the torque converter ring gear or flywheel ring gear when you release the key.
If the drive gear hangs up on the torque converter ring gear or flywheel ring gear, check for :
• solenoid plunger and switch malfunction.
• dirty drive gear assembly or damaged overrunning clutch.
STARTER SOLENOID TEST
1. Check the holdin coil for continuity between the S terminal(A) and the armature housing(B) (ground). The coil is OK if
there is continuity.
2. Check the pullin coil for continuity between the S and M terminals. The coil is OK if there is continuity.
FREE RUNNING TEST
1. Place the starter motor in a vise equipped with soft jaws and connecta fullycharged 12volt battery to starter motor as
follows :
2. Connect a test ammeter (100ampere scale) and carbon pile rheostatas shown is the illustration.
5. Connect the battery cable from battery's negative post to the startermotor body.
6. Adjust until battery voltage shown on the voltmeter reads 11 volts.
7. Confirm that the maximum amperage is within the specifications andthat the starter motor turns smoothly and freely :
English
: Max. 90 Amps
: Min. 2,800 rpm
2006 > G 2.0 DOHC > Engine Electrical System > Starting System > Starter > Components and English
Components Location
COMPONENTS
English
2006 > G 2.0 DOHC > Engine Electrical System > Starting System > Starter > Repair procedures
English
REMOVAL
2. Remove the speedometer cavble and the shift cable.
3. Disconnect the starter motor connector and terminal.
4. Remove the starter motor assembly.
INSPECTION
BRUSH
A brush worn down to the wear limit line should be replaced.
BRUSH HOLDER
Make sure there is no continuity between the (+) brush holder (A) and () plate (B). If there is continuity, replace the brush holder
assembly.
OVERRUNNING CLUTCH
Inspect the pinion and spline teeth for wear or damage. Replace if damaged. Also inspect the flywheel ring gear for damage.
Rotate the pinion. It should turn freely in a clockwise direction, and lock when turned counterclockwise.
English
PINION GAP ADJUSTMENT
1. Disconnect the wire from the Mterminal.
2. Connect a 12V battery between the Sterminal and the Mterminal.
3. Set the switch to "ON", and the pinion will move out.

4. Check the pinion to stopper clearance (pinion gap) with a feeler gauge. If the pinion gap is out of specification, adjust by
adding or removingwashers between the solenoid and the front bracket.
SOLENOID PULLIN TEST
1. Disconnect the connector from the Mterminal.
2. Connect a 12V battery between the Sterminal and Mterminal.

3. If the pinion moves out, the pullin coil is good. If it doesn't, replace the solenoid.
SOLENOID HOLDIN TEST English
2. Connect a 12V battery between the Sterminal and the body.

3. If the pinion remains out, everything is in order. If the pinion moves in, the holdin circuit is open. Replace the magnetic
switch.
SOLENOID RETURN TEST
2. Connect a 12V battery between the Mterminal and the body.

3. Pull out the pinion and then release it. If the pinion returns quickly to its original position, everything is in order. If it
doesn't, replace thesolenoid
PERFORMANCE TEST (NOLOAD)
1. Make the noload circuit test as shown.
2. After adjusting the rheostat until the battery voltage shown on the voltmeter reads 11.5 volts, confirm that the maximum
amperage draw is within the specifications and that the starter motor turns smoothly and freely.
English
2006 > G 2.0 DOHC > Engine Electrical System > Starting System > Starter Relay > Repair procedures
English
INSPECTION
Remove the starter relay(A) and check continuity between the terminals. If the continuity is not as specified, replace the relay.
2006 > G 2.0 DOHC > Engine Electrical System > Cruise Control System > Troubleshooting English
TROUBLESHOOTING
Before starting troubleshooting, inspect each of the following sections, and if there is an abnormality, carry out a repair.
1. Check that the actuator and pulley assembly are all normal.
2. Check if the pulley assembly and the movement of cables are working smoothly.
3. Check if there is no excessive play or tension in each cable.
TROUBLESHOOTING PROCEDURES
First, select the applicable malfunction symptom from the "TROUBLE SYMPTOM CHARTS" shown on nest pages.
Determine the condition of all function circuits.
1. Make the following preliminary inspections.
• Check that the installation of the actuator, accelerator cable are correct, and that the cables and links are securely
connected.
• Check that the accelerator pedal moves smootyly.
• Adjust the cable so there is not excessive tension or excessive play on the accelerator cable.
• Check that the actuator and unit assembly, cruise main, control switch and the connector of each cancel switch
are connected securely.
2. Check in the sequence indicated in the "TROUBLE SYMPTOM CHARTS".
3. If a normal condition is indicated, replace the cruise control module.
TROUBLE SYMPTOM 1
English
TROUBLE SYMPTOM 2
The set vehicle speed varies greatly Malfunction of the vehicle speed sensor
upward or downwqrd circuit Repair the vehicle speed sensor
"Surging" (repeated alternating system, or replace the part
speedometer drive gear
after setting
TROUBLE SYMPTOM 3
The CC system is not canceled when Damaged or disconnected wiring of the Repair the harness or replace the stop

the brake pedal is deprssed stop lamp switch lamp switch
TROUBLE SYMPTOM 4
English
The CC system is not canceled when Damaged or disconnected wiring of Repair the harness or repair or replace
the shift lever is moved to the "N" inhibitor switch input circuit the ingibitor switch
position (It is canceled, however, when
the brake pedal is depressed Improper adjustment of inhibitor switch
TROUBLE SYMPTOM 5
Temporary damaged or disconnected Repair the harness or replace the SET
Cannot decelerate (coast) by using the wiring of SET switch input circuit switch
SET switch
actuator
TROUBLE SYMPTOM 6
Damaged or disconnected wiring, or
short circuit, or RESUME switch input Repair the harness or RESUME switch
Cannot accelerate or resume speed by
circuit
using the RESUME switch
actuator
TROUBLE SYMPTOM 7
CC system can be set while driving at Malfunction of the vehiclespeed sensor
a vehicle speed of less than 40km/h circuit Repair the vehicle speed sensor
(25mph), or there is no automatic system, or replace the part
cancellation at that speed
the speedometer drive gear
TROUBLE SYMPTOM 8
The cruise main switch indicator lamp Damaged or disconnected bulb of cruise
does not illuminate (But CC system is main switch indicator lamp Repair the harness or replace the part.
normal)
Harness damaged or disconnected
TROUBLE SYMPTOM 9
Malfunction of control function by Malfunction of circuit related to idle
switch function Repair the narness or replace the part
ON/OFF switching of idle switch
Malfunction of the actuator and unit
English
TROUBLE SYMPTOM 10
Overdrive is not canceled during fixed Malfunction of circuit related to overdrive
speed driving cancellation, or malfunction of actuator Repair the harness or replace the part
No shift to overdrive during manual and unit
driving
2006 > G 2.0 DOHC > Engine Electrical System > Cruise Control System > Cruise Control Actuator >
English
Schematic Diagrams
CIRCUIT DIAGRAM
2006 > G 2.0 DOHC > Engine Electrical System > Cruise Control System > Cruise Control Actuator >
English
Repair procedures
REMOVAL
1. Remove the battery negative and the cruise control cable from the throttle assembly by turning the throttle lever to the
fullopen position.
2. Remove the autocruise control cable. (Refer to Cruise Control System Cruise Control Cable)
3. Remove the actuator and unit assembly(A) mounting bolt.
2006 > G 2.0 DOHC > Engine Electrical System > Cruise Control System > Cruise Control Switch >
English
Repair procedures
REMOVAL
1. Remove the air bag module assembly. (Refer to 'RT','ST' group)
INSPECTION
2006 > G 2.0 DOHC > Engine Electrical System > Cruise Control System > Cruise Control Cable >
English
Repair procedures
REMOVAL
2. Remove the auto cruise cable adjustment clip (A).
3. Remove the auto cruise cable retaining grommet (B) from the bracket.
4. Manually open the throttle body to the Wide Open throttle (W.O.T) position and disconnect the throttle cable from the
throttle lever.

Damage to the auto cruise cable or the accelerator cable may result if the throttle lever is rotated by lifting up on
the cable.
When connecting the auto cruise cable from the throttle lever, rotate the throttle lever only by lifting up on the
lever itself.
INSTALLATION
1. Install the cruise control actuator. (Refer to Cruise Control System Cruise Control Actuator)
2. Manually open the throttle body to the Wide Open throttle (W.O.T) position and connect the throttle cable from the
throttle lever.
English

Damage to the auto cruise cable or the accelerator cable may result if the throttle lever is rotated by lifting up on
the cable.
When connecting the auto cruise cable from the throttle lever, rotate the throttle lever only by lifting up on the
lever itself.
3. Install the auto cruise cable retaining grommet (B) from the bracket.
4. Install the auto cruise cable adjustment clip (A) after adjusting the cable to the position just before rotating the throttle
lever.

When installing the auto cruise cable to the throttle lever, be careful not to bend or twist the cable.
Check the cable and hose routings to ensure that they do not interfere with the throttle body, accelerator cable
and etc..
2006 > G 2.0 DOHC > Emission Control System > General Information > Specifications English
SPECIFICATIONS
▷ Specification
Item Specification
Coil Resistance (Ω) 16.0Ω [20°C (68°F)]
TIGHTENING TORQUES
Item N·m kgf·m lbf·m

Positive Crankcase Ventilation Valve 8.0 ~ 12.0 0.8 ~ 1.2 6.0 ~ 8.0
Canister band installation nut / bolts 2.9 ~ 5.9 0.3 ~ 0.6 2.2 ~ 4.3
2006 > G 2.0 DOHC > Emission Control System > General Information > Schematic Diagrams English
SCHEMATIC DIAGRAM
2006 > G 2.0 DOHC > Emission Control System > General Information > Description and Operation
English
DESCRIPTION
Components Function Remarks

Crankcase Emission System
– Positive Crankcase Ventilation (PCV) HC reduction Variable flow rate type
valve
Evaporative Emission System
– Evaporative emission canister HC reduction
HC reduction Duty control solenoid valve
– Purge Control Solenoid Valve (PCSV)
Exhaust Emission System
– MFI system (airfuel mixture control CO, HC, NOx reduction Heated oxygen sensor feedback type
device) CO, HC, NOx reduction Monolithic type
– Threeway catalytic converter
2006 > G 2.0 DOHC > Emission Control System > General Information > Components and Components
English
Location
COMPONENT LOCATION
[1.6 DOHC]
English
3 Canister 4 Catalytic Converter
[2.0 DOHC]
English
3 Canister 4 Catalytic Converter English
2006 > G 2.0 DOHC > Emission Control System > General Information > Troubleshooting English
TROUBLESHOOTING

Engine will not start or hard to start
Malfunction of the Purge Control Solenoid Valve Repair or replace
Malfunction of the PCV valve Replace
Rough idle or engine stalls
Check the system; if there is a
Malfunction of the evaporative emission
problem, check related components
canister purge system
parts
Check positive crankcase
Excessive oil consumption Positive crankcase ventilation line clogged
ventilation system
2006 > G 2.0 DOHC > Emission Control System > Crankcase Emission Control System > Components
English
COMPONENTS
[1.6 DOHC]
[2.0 DOHC] English
2006 > G 2.0 DOHC > Emission Control System > Crankcase Emission Control System > Repair
English
procedures
INSPECTION
1. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve. Remove the PCV valve from the
rocker cover and reconnect it to the ventilation hose.
2. Run the engine at idle and put a finger on the open end of the PCV valve and make sure that intake manifold vacuum
can be felt.

The plunger inside the PCV valve will move back and forth.
English
Crankcase Ventilation (PCV) Valve > Description and Operation
OPERATION
English
Crankcase Ventilation (PCV) Valve > Repair procedures
REMOVAL
1. Disconnect the vacuum hose (A) and remove the PCV valve (B).
INSTALLATION
Install the PCV valve and tighten to the specified torque.
PCV Valve installation : 7.8 ~ 11.8 N·m (0.8 ~ 1.2 kgf·m, 5.8 ~ 8.7lbf·ft)
INSPECTION
1. Remove the PCV valve.
2. Insert a thin stick(A) into the PCV valve(B) from the threaded side to check that the plunger moves.
3. If the plunger does not move, the PCV valve is clogged. Clean it or replace.
English
2006 > G 2.0 DOHC > Fuel System > General Information > Specifications English
SPECIFICATIONS
Items Specification
Fuel Tank Capacity 55lit. (14.5 U.S.gal., 12.1 Imp.gal.)
Fuel Filter (built in Fuel Pump Assembly) Type High pressure type
Fuel Pressure Regulator Regulated Fuel 338 ~ 348kpa (3.45 ~ 3.55kgf/cm²,
(built in Fuel Pump Assembly) Pressure 49.0 ~ 50.5psi)
Type Electrical, intank type
Fuel Pump
Driven by Electric motor
Fuel Retrun System Pressure Returnless
SENSORS
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS)
▷ Specification
20.0 0.79
46.7 1.84
101.32 4.0
INTAKE AIR TEMPERATURE SENSOR (IATS)
▷ Specification
40(40) 40.93 ~ 48.35
30(22) 23.43 ~ 27.34
20(4) 13.89 ~ 16.03
10(14) 8.50 ~ 9.71
0(32) 5.38 ~ 6.09
10(50) 3.48 ~ 3.90
20(68) 2.31 ~ 2.57
25(77) 1.90 ~ 2.10
30(86) 1.56 ~ 1.74
40(104) 1.08 ~ 1.21
60(140) 0.54 ~ 0.62
80(176) 0.29 ~ 0.34
▷ Specification
40(40) 48.14
English
20(4) 14.13 ~ 16.83
0(32) 5.79
20(68) 2.31 ~ 2.59
40(104) 1.15
60(140) 0.59
80(176) 0.32
THROTTLE POSITION SENSOR (TPS)
▷ Type: Variable resistor type
▷ Specification
C.T 0.25 ~ 0.9V
W.O.T Min. 4.0V
Items Specification
HEATED OXYGEN SENSOR (HO2S)
▷ Specification
Rich 0.6 ~ 1.0
Lean 0 ~ 0.4
Items Specification
Heater Resistance (Ω) Approx. 9.0 [20°C(68°F)]
KNOCK SENSOR (KS)
▷ Specification
Items Specification
Resistance(MΩ) 4.87
CVVT OIL TEMPERATURE SNESOR (OTS)
▷ Specification
40(40) 52.15
20(4) 16.52
0(32) 6.0
20(68) 2.45
40(104) 1.11
English
60(140) 0.54
80(176) 0.29
ACTUATORS
INJECTOR
▷ Number: 4
▷ Specification
Items Specification
IDLE SPEED CONTROL ACTUATOR (ISCA)
▷ Type: Double coil type
▷ Specification
Closing Coil Resistance (Ω) 14.6 ~ 16.2 [20°C(68°F)]
Opening Coil Resistance (Ω) 11.1 ~ 12.7 [20°C(68°F)]

15 1.0 ~ 2.3
35 7.5 ~ 12.7
70 43.0 ~ 55.0
96 63.0 ~ 71.0
PURGE CONTROL SOLENOID VALVE (PCSV)
▷ Specification
Items Specification
Coil Resistance (Ω) 16.0 [20°C(68°F)]
CVVT OIL CONTROL VALVE (OCV)
▷ Specification
Items Specification
IGNITION COIL
▷ Type: Stick type
▷ Specification
Items Specification
Primary Coil Resistance (Ω) 0.58Ω±10％ [20°C(68°F)]
Secondary Coil Resistance (kΩ) 8.8kΩ±15％ [20°C(68°F)]
SERVICE STANDARD
Ignition Timing BTDC 5° ± 10°
Idle Speed Neutral,N,Prange 660 ± 100 rpm
A/CON OFF
Drange
A/CON ON Neutral,N,Prange
English
Drange
TIGHTENING TORQUES
Manifold absolute pressure sensor installation bolt 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
Throttle position sensor installation screws 0.15 ~ 0.25 1.5 ~ 2.5 1.1 ~ 1.8
Knock sensor installation bolt 1.7 ~ 2.7 16.7 ~ 26.5 12.3 ~ 19.5
CVVT Oil temperature sensor installation 0.2 ~ 0.4 2.0 ~ 3.9 1.4 ~ 2.9
Idle speed control actuator installation screws 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
CVVT Oil control valve installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Ignition coil assembly installation bolts/nuts 1.9 ~ 2.7 18.6 ~ 26.5 13.7 ~ 19.5
Throttle body installation nuts 1.9 ~ 2.4 18.6 ~ 26.5 13.7 ~ 17.4
Fuel pump installation bolt 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
Delivery pipe installation bolts 1.9 ~ 2.4 18.6 ~ 23.5 13.7 ~ 17.4
2006 > G 2.0 DOHC > Fuel System > General Information > Troubleshooting English
English

English

● SIMULATING HEAT


CONNECTOR INSPECTION PROCEDURE English
side.
harness side.
English


English
• Voltage Check

step.
English
(C) and (B).

in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ω and higher than 1MΩ respectively. English
SYMPTOM TROUBLESHOOTING GUIDE CHART
MAIN SYMPTOM DIAGNOSTIC PROCEDURE ALSO CHECK FOR
1) Test the battery
Unable to start
(Engine does not turn 2) Test the starter
over)
3) Inhibitor switch (A/T) or clutch start switch (M/T)
1) Test the battery • DTC
2) Check the fuel pressure • Low compression
Unable to start
(Incomplete 3) Check the ignition circuit • Intake air leaks
combustion)
4) Troubleshooting the immobilizer system (In case of • Slipped or broken timing belt
immobilizer lamp flashing) • Contaminated fuel
• DTC
1) Test the battery
• Low compression
Difficult to start • Intake air leaks
Poor idling 1) Check the fuel pressure • DTC

(Rough, unstable or
incorrect Idle) 2) Check the Injector • Low compression
3) Check the long term fuel trim and short term fuel trim • Intake air leaks
(Refer to CUSTOMER DATASTREAM) • Contaminated fuel English
4) Check the idle speed control circuit (Check DTC) • Weak ignition spark
5) Inspect and test the Throttle Body
1) Test the Battery
• DTC
• Intake air leaks
Engine stall 3) Check the idle speed control circuit (Check DTC)
5) Check the CKPS Circuit (Check DTC)
2) Inspect and test Throttle Body • DTC
3) Check the ignition circuit • Low compression
Poor driving
4) Check the ECT Sensor and Circuit (Check DTC) • Intake air leaks
(Surge)
5) Test the exhaust system for a possible restriction • Contaminated fuel
6) Check the long term fuel trim and short term fuel trim • Weak ignition spark
2) Inspect the engine coolant • DTC
Knocking
3) Inspect the radiator and the electric cooling fan • Contaminated fuel
4) Check the spark plugs
1) Check customer's driving habits
• Is A/C on full time or the defroster mode on?
• Are tires at correct pressure? • DTC
• Is excessively heavy load being carried? • Low compression
Poor fuel economy • Is acceleration too much, too often? • Intake air leaks
2) Check the fuel pressure • Contaminated fuel
3) Check the injector • Weak ignition spark
4) Test the exhaust system for a possible restriction
5) Check the ECT sensor and circuit
1) Test the canister close valve
2) Inspect the fuel filler hose/pipe
• Pinched, kinked or blocked? • Malfunctioning gas station
Hard to refuel
filling nozzle (If this problem
(Overflow during • Filler hose is torn occurs at a specific gas
refueling)
station during refueling)
3) Inspect the fuel tank vapor vent hose between the
EVAP. canister and air filter
4) Check the EVAP. canister
2006 > G 2.0 DOHC > Fuel System > Engine Control System > Description and Operation English
DESCRIPTION
1. Engine is hard to start or does not start at all.
2. Unstable idle.
3. Poor driveability
malfunction, incorrect engine adjustment, etc.). Then, inspect the Gasoline Engine Control system components with the HISCAN
(Pro).

• Before removing or installing any part, read the diagnostic trouble codes and then disconnect the battery
negative () terminal.
the battery cable during engine operation or while the ignition switch is ON could cause damage to the ECM.
• The control harnesses between the ECM and heated oxygen sensor are shielded with the shielded ground wires
to the body in order to prevent the influence of ignition noises and radio interference. When the shielded wire is
faulty, the control harness must be replaced.
• When checking the generator for the charging state, do not disconnect the battery '+' terminal to prevent the
ECM from damage due to the voltage.
• When charging the battery with the external charger, disconnect the vehicle side battery terminals to prevent
damage to the ECM.
Malfunction Indicator Lamp (MIL)
Faults with the following items will illuminate the MIL.
• Catalyst
• Fuel system
• Mass Air Flow Sensor (MAFS)
• Intake Air Temperature Sensor (IATS)
• Engine Coolant Temperature Sensor (ECTS)
• Throttle Position Sensor (TPS)
• Upstream Oxygen Sensor
• Upstream Oxygen Sensor Heater
• Downstream Oxygen Sensor
• Downstream Oxygen Sensor Heater
• Injector
• Misfire
• Crankshaft Position Sensor (CKPS)
• Camshaft Position Sensor (CMPS)
• Evaporative Emission Control System
• Vehicle Speed Sensor (VSS)
• Idle Speed Control Actuator (ISCA)
• Power Supply English
• ECM/ PCM
• MT/AT Encoding
• Acceleration Sensor
• MILon Request Signal
• Power Stage

Faults with the following items will illuminate the MIL
• Heated oxygen sensor (HO2S)
• Mass Air Flow sensor (MAFS)
• Throttle position sensor (TPS)
• Engine coolant temperature sensor (ECTS)
• Idle speed control actuator (ISCA)
• Injectors
• ECM

1. After turning ON the ignition key, ensure that the light illuminates for about 5 seconds and then goes out.
2. If the light does not illuminate, check for an open circuit in the harness, a blown fuse or a blown bulb.
SelfDiagnosis

will be erased.
THE RELATION BETWEEN DTC AND DRIVING PATTERN IN EOBD SYSTEM
English
1. When the same malfunction is detected and maintained during two sequential driving cycles, the MIL will automatically
illuminate.
2. The MIL will go off automatically if no fault is detected after 3 sequential driving cycles.
3. A Diagnostic Trouble Code(DTC) is recorded in ECM memory when a malfunction is detected after two sequential
driving cycles. The MIL will illuminate when the malfunction is detected on the second driving cycle.
If a misfire is detected, a DTC will be recorded, and the MIL will illuminate, immediately after a fault is first detected.
4. A Diagnostic Trouble Code(DTC) will automatically erase from ECM memory if the same malfunction is not detected for
40 driving cycles.

• A "warmup cycle" means sufficient vehicle operation such that the coolant temperature has risen by at least 40
degrees Fahrenheit from engine starting and reaches a minimum temperature of 160 degress Fahrenheit.
• A "driving cycle" consists of engine startup, vehicle operation beyond the beginning of closed loop operation.
2006 > G 2.0 DOHC > Fuel System > Engine Control System > Components and Components Location
English
COMPONENTS LOCATION
2. Manifold Absolute Pressure Sensor (MAPS)
3. Intake Air Temperature Sensor (IATS)
1. ECM (Engine Control Module)
13. Injector
14. Idle Speed Control Actuator (ISCA)
English
4. Engine Coolant Temperature Sensor (ECTS)
11. CVVT Oil Temperature Sensor (OTS) 5. Throttle Position Sensor (TPS)
16. CVVT Oil Control Valve (OCV)
6. Crankshaft Position Sensor (CKPS) 7. Camshaft Position Sensor (CMPS)
8. Knock Sensor (KS) 9. Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 1]
10. Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 2] 12. A/C Pressure Transducer (APT)
English
15. Purge Control Solenoid Valve (PCSV) 17. Ignition Coil
18. Main Relay
19. Fuel Pump Relay
2006 > G 2.0 DOHC > Fuel System > Engine Control System > Engine Control Module (ECM) > Repair
English
procedures
1. TEST ECM GROUND CIRCUIT: Measure resistance between ECM and chassis ground using the backside of ECM
harness connector as ECM side check point. If the problem is found, repair it.
Specification (Resistance): 1Ω or less
harness side for bent pins or poor contact pressure. If the problem is found, repair it.
3. If problem is not found in Step 1 and 2, the ECM could be faulty. If so, replace the ECM with a new one, and then
check the vehicle again. If the vehicle operates normally then the problem was likely with the ECM.
4. RETEST THE ORIGINAL ECM : Install the original ECM (may be broken) into a knowngood vehicle and check the
vehicle. If the problem occurs again, replace the original ECM with a new one. If problem does not occur, this is
intermittent problem (Refer to INTERMITTENT PROBLEM PROCEDURE in BASIC INSPECTION PROCEDURE).
REPLACEMENT
2. Disconnect the battery () cable from the battery.
3. Disconnect the ECM connector(s) (A).
4. Unscrew the ECM mounting bolts (B) and remove the ECM from the air cleaner assembly.
5. Install a new ECM.
ECM mounting bolts: 9.8 ~ 11.8 N·m (1.0 ~ 1.2 kgf·m, 7.2 ~ 8.7 lbf·ft)
2006 > G 2.0 DOHC > Fuel System > Engine Control System > Manifold Absolute Pressure Sensor
English
(MAPS) > Repair procedures
INSPECTION
Manifold Absolute Pressure Sensor (MAPS) is speeddensity type sensor and is installed on the surge tank. This MAPS senses
absolute pressure in surge tank and transfers this analog signal proportional to the pressure to the ECM. The ECM calculates the
intake air quantity and engine speed based on this signal. This MAPS consists of piezoelectric element and hybrid IC that amplifies
the element output signal. The element is silicon diaphragm type and adapts pressure sensitive variable resistor effect of semi
conductor. 100% vacuum and the manifold pressure applies to both sides of it respectively. That is, this sensor outputs the silicon
variation proportional to pressure change by voltage.
SPECIFICATION
Pressure(kPa) Output Voltage (V)
20.0 0.79
46.66 1.84
101.32 4.0
CIRCUIT DIAGRAM
English
1. Connect a scantool on Diagnisis Link Connector (DLC).
2. Check MAPS output voltage at idle and IG ON.
Condition Output Voltage (V)
IG ON 3.9 ~ 4.1
Idle 0.8 ~ 1.6
2006 > G 2.0 DOHC > Fuel System > Engine Control System > Intake Air Temperature Sensor (IATS) >
English
Repair procedures
INSPECTION
Intake Air Temperature Sensor (IATS) is installed inside the Manifold Absolute Pressure Sensor (MAPS) and detects the intake air
temperature. To calculate precise air quantity, correction of the air temperature is needed because air density varies according to the
temperature. So the ECM uses not only MAPS signal but also IATS signal. This sensor has a Negative Temperature Coefficient
(NTC) and its resistance is in inverse proportion to the temperature.
SPECIFICATION
40(40) 40.93 ~ 48.35
30(22) 23.43 ~ 27.34
20(4) 13.89 ~ 16.03
10(14) 8.50 ~ 9.71
0(32) 5.38 ~ 6.09
10(50) 3.48 ~ 3.90
20(68) 2.31 ~ 2.57
25(77) 1.90 ~ 2.10
30(86) 1.56 ~ 1.74
40(104) 1.08 ~ 1.21
60(140) 0.54 ~ 0.62
80(176) 0.29 ~ 0.34
CIRCUIT DIAGRAM
English
2. Disconnect IATS connector.
3. Measure resistance between IATS terminals 3 and 4.
2006 > G 2.0 DOHC > Fuel System > Engine Control System > Engine Coolant Temperature Sensor
English
INSPECTION
ECTS decreases as the temperature increases, and increases as the temperature decreases. The reference 5 V in the PCM is
supplied to the ECTS via a resistor in the PCM.That is, the resistor in the PCM and the thermistor in the ECTS are connected in
series. When the resistance value of the thermistor in the ECTS changes according to the engine coolant temperature, the output
voltage also changes. During cold engine operation the PCM increases the fuel injection duration and controls the ignition timing
using the information of engine coolant temperature to avoid engine stalling and improve drivability.
SPECIFICATION
40(40) 48.14
20(4) 14.13 ~ 16.83
0(32) 5.79
20(68) 2.31 ~ 2.59
40(104) 1.15
60(140) 0.59
80(176) 0.32
CIRCUIT DIAGRAM
English
2. Disconnect ECTS connector.
3. Remove the ECTS.
4. After immersing the thermistor of the sensor into engine coolant, measure resistance between ECTS terminals 1 and 3.
2006 > G 2.0 DOHC > Fuel System > Engine Control System > Injector > Repair procedures English
INSPECTION
Based on information from various sensors, the ECM measures the fuel injection amount. The fuel injector is a solenoidoperated
valve and the fuel injection amount is controlled by length of time that the fuel injector is held open. The ECM controls each injector
by grounding the control circuit. When the ECM energizes the injector by grounding the control circuit, the circuit voltage should be
low (theoretically 0V) and the fuel is injected. When the ECM deenergizes the injector by opening control circuit, the fuel injector is
closed and circuit voltage should momentarily peak.
SPECIFICATION
Item Specification
CIRCUIT DIAGRAM
English
2. Disconnect injector connector.
3. Measure resistance between injector terminals 1 and 2.
2006 > G 2.0 DOHC > Fuel System > Engine Control System > FillerNeck Assembly > Repair English
procedures
REMOVAL
3. Unfasten the fillerneck assembly mounting screws (A).
5. Remove the bracket mounting bolts (A) and remove the fillerneck assembly.
English
INSTALLATION
2006 > G 2.0 DOHC > Fuel System > Engine Control System > Throttle Position Sensor (TPS) > Repair
English
procedures
INSPECTION
The Throttle Position Sensor (TPS) is mounted on the throttle body and detects the opening angle of the throttle plate. The TPS has a
variable resistor (potentiometer) whose characteristic is the resistance changing according to the throttle angle. During acceleration,
the TPS resistance between the reference 5V and the signal terminal decreases and output voltage increases; during deceleration,
the TPS resistance increases and TPS output voltage decreases. The ECM supplies a reference 5V to the TPS and the output
voltage increases directly with the opening of the throttle valve. The TPS output voltage will vary from 0.2~0.8V at closed throttle to
4.3~4.8V at wideopen throttle. The ECM determines operating conditions such as idle (closed throttle), part load,
acceleration/deceleration, and wideopen throttle from the TPS. Also The ECM uses the Manifold Absolute Pressure Sensor (MAPS)
signal along with the TPS signal to adjust fuel injection duration and ignition timing.
SPECIFICATION
C.T 0.25 ~ 0.9
W.O.T Min. 4.0V
Items Specification
Sensor Resistance (kΩ) 1.6 ~ 2.4kΩ at 20°C(68°F)
CIRCUIT DIAGRAM
English
1. Connect a scantool on the Data Link Connector (DLC).
2. Start engine and check output voltages of TPS at C.T and W.O.T.
3. Turn ignition switch OFF and disconnect the scantool from the DLC.
4. Disconnect TPS connector and measure resistance between TPS terminals 2 and 3
2006 > G 2.0 DOHC > Fuel System > Engine Control System > Heated Oxygen Sensor (HO2S) > Repair
English
procedures
INSPECTION
Heated Oxygen Sensor (HO2S) consists of zirconium and alumina and is installed on upstream and downstream of the Manifold
Catalyst Converter (MCC). After it compares oxygen consistency of the atmosphere with the exhaust gas, it transfers the oxygen
consistency of the exhaust gas to the ECM. When A/F ratio is rich or lean, it generates approximately 1V or 0V respectively. In order
that this sensor normally operates, the temperature of the sensor tip is higher than 370°C (698°F). So it has a heater which is
controlled by the ECM duty signal. When the exhaust gas temperature is lower than the specified value, the heater warms the sensor
tip.
SPECIFICATION
RICH 0.6 ~ 1.0
LEAN 0.1 ~ 0.4
Item Specification
English
Heater Resistance (Ω) Approx. 9.0Ω at 20°C (68°F)
CIRCUIT DIAGRAM
1. Disconnet the HO2S connector.
2. Measure resistance between HO2S heater terminals 3 and 4.
2006 > G 2.0 DOHC > Fuel System > Engine Control System > CVVT Oil Temperature Sensor (OTS) >
English
Repair procedures
INSPECTION
The CVVT Oil Temperature Sensor (OTS) is a negative coefficient thermistor used by the PCM tl measure engine oil temperature for
the purpose of adjusting CVVT calculations.
SPECIFICATION
40(40) 52.15
20(4) 16.52
0(32) 6.0
20(68) 2.45
40(104) 1.11
60(140) 0.54
80(176) 0.29
CIRCUIT DIAGRAM
English
2. Disconnect OTS connector.
3. Remove the OTS.
4. After immersing the thermistor of the sensor into water (or engine coolant), measure resistance between OTS terminals
1 and 2.
2006 > G 2.0 DOHC > Fuel System > Engine Control System > Knock Sensor (KS) > Repair procedures
English
INSPECTION
Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine damage. Knock Sensor (KS)
senses engine knocking and the cylinder block. When knocking occurs, the vibration from the cylinder block is applied as pressure to
the piezoelectric element. At this time, this sensor transfers the voltage signal higher than the specified value to the ECM and the
ECM retards the ignition timing. If the knocking disappears after retarding the ignition timing, the ECM will advance the ignition
timing. This sequential control can improve engine power, torque and fuel economy.
SPECIFICATION
Item Specification
Resistance (MΩ) 4.87
WAVEFORM
English
CIRCUIT DIAGRAM
2006 > G 2.0 DOHC > Fuel System > Engine Control System > CVVT Oil Control Valve (OCV) > Repair
English
procedures
INSPECTION
The Continuously Variable Valve Timing (CVVT) system controls the amount of valve overlap by varying the amount of oil flow into an
assembly mounted on the intake camshaft through ECM control of an oil control valve. An Oil Temperature Sensor (OTS) is used to
allow ECM monitoring of engine oil temperature. As oil is directed into the chambers of the CVVT assembly, the cam phase is
changed to suit various performance and emissions requirements..
1. When camshaft rotates engine rotationwise: IntakeAdvance / ExhaustRetard
2. When camshaft rotates counter engine rotationwise: Intake Retard / Exhaust Advance
SPECIFICATION
Item Specification
CIRCUIT DIAGRAM
2. Disconnect OCV connector.
English
3. Measure resistance between OCV terminals 1 and 2.
2006 > G 2.0 DOHC > Fuel System > Fuel Delivery System > Components and Components Location
English
COMPONENT LOCATION
2006 > G 2.0 DOHC > Fuel System > Fuel Delivery System > Repair procedures English
FUEL PRESSURE TEST
English
English
2006 > G 2.0 DOHC > Fuel System > Fuel Delivery System > Fuel Tank > Repair procedures English
1. Preparation
2. Disconnect the fuel feed quickconnector (A) and vapor tube quickconnector (B).
3. Lift the vehicle and support the fuel tank with a jack.
English
5. Unscrew the fuel tank band mounting nuts(A) and remove the fuel tank.
INSTALLATION
2006 > G 2.0 DOHC > Fuel System > Fuel Delivery System > Fuel Pump > Repair procedures English
1. Preparation
2. Disconnect the fuel feed tube quickconnector (A) and the vapor tube quickconnector (B).
3. Unscrew the fuel pump installation bolts (C) and remove the fuel pump assembly.
English
INSTALLATION
Fuel Pump installation bolts : 3.9 ~ 5.9 N·m (0.4 ~ 0.6 kgf·m, 2.9 ~ 4.3 lbf·ft)
2006 > G 2.0 DOHC > Fuel System > Fuel Delivery System > Accelerator Cable > Repair procedures
English
ADJUSTMENT
1. Turn on the ignition key, but don't start the engine.
2. Remove the fixing clip (A) after holding for 15 seconds under IG ON condition.
3. Adjust the position of the accelerator cable grommet (B) to secure free stroke.
(1) Pull the grommet (B) by taking the cable cap (C) in the direction of an arrow ① until the cable wire tighten.
(2) Push the grommet (B) by taking the cable cap (C) in the direction of an arrow ② as below free stroke specification.
Free stroke specification: 1 ~ 3 mm (0.0393 ~ 0.1181 in.)
4. Install the fixing clip (A).
[Abnormal wire tension: No free stroke]
[Normal wire tension: Free stroke]
5. Check the normal operation of the accelerator pedal.

Kia Ceed 2006 - 2012 Gasoline Diesel Factory Workshop Service Repair Manual

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Kia Ceed 2006 - 2012 Gasoline Diesel Factory Workshop Service Repair Manual

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Contents

HOOD Type Rear hinged, gas lifter type

Items N·m kgf·m Lbf·ft

Symptom Suspect Area Remedy (Refer to page)

Door glass fails to operate up and Incorrect window glass installation Adjust position

Water leak through windshield end Defective seal Fill with sealant

Tool (Number and name) Illustration Use

1. Crash pad main panel 7. Crash pad centr tray 13. Air vent

1. Side C/shelf trim 6. Front luggage box 11. Cargo screen

• Audio/ MP3 rejected by 1) CD may be dirty 1) Clean CD with damp cloth.

• The operating panel 1) No error 1) Normal. The unit feels warm.

• The volume decreases 1) An integrated safety circuit 1) Allow the unit to cool down (set low volume)

• Navigation radio not No power supply Check the fuse (unit and vehicle) and the connections

• The required station 1) The desired station is too 1) Set desired station manually (manu. tuning)

• CD player does not work 1) In cold weather conditions, 1) With the set on, wait for 5 minutes until the

• Problems with new 1) See notes on Audio and MP3 1) Some copy protection procedures are incompatible

• Display shows "Please The map CD is required for some Insert the C­IQ map CD into the radio CDdrive with the

• The direction advices Navi volume to low Set the navigation volume in the setup menu under

• Guidance is not accurate An inaccuracy of appr. 30 m is 1) If greater inaccuracies ocur repeatedly, please

• Display position does not It is possible that the car's position The routing may have been changed and does not

Item Requirement Remark

M­F SW 0~1 Kohm 13 Kohm ± 10% 24 Kohm ± 10% 38 Kohm ± 10% 50 Kohm ± 10%

Pin NO. Connector A Connector B Connector C

Symptom Possible cause Remedy

Symptom Possible cause Remedy

One lamp does not light Bulb burned out Replace bulb

Instrument lamps do not light Rheostat faulty Check rheostat

Position No. Rotation Voltage (V) (±5%)

Immobilizer Related Faults Fault types Diagnostic codes

PCM(ECM) fault 1) Non­Immobilizer­EMS connected to an Immobilizer P1610

PCM(ECM) internal permanent 1) PCM(ECM) internal permanent memory (EEPROM) fault P1695

Hi­Scan fault 1) Hi­Scan message error P1697

HECU (Hydraulic and Type Motor, valve relay intergrated type ·ABS system: ABS &

Item Recommended lubricant Quantity

Tool (Number and Name) Illustration Use

Symptom Suspect Area Remedy

Brake fades 1) Master cylinder Replace

Inlet valve(IV) Outlet valve(OV) Return pump

Inlet valve(IV) Outlet valve(OV) Return pump

Item N.m kgf.m lb­ft

Items Specified lubricants Quantity

Tool (Number and name) Illustration Use

Trouble symptom Suspect area Remedy (See page)

Tool(Number and Name) Illustration Use

Trouble Symptom Probable cause Remedy

Description Specification 2.0(D4EA) Limit

Tool (Number and name) Illustration Use

Symptom Suspect Remedy

Engine misfire with Worn valves, valve guides and/or valve stem oil Repair or replace as required.

Engine noise on start­ Incorrect oil viscosity. • Drain the oil

Upper engine noise, Low oil pressure. Repair or replace as required.

Engine noise under load Low oil pressure Repair or replace as required.

Engine will not crank­ Hydraulically cylinder 1) Remove injectors and check for fluid.

Test Condition Rail pressure (bar) Output Voltage(V)

Tool (Number and name) Illustration Application

26 Reference voltage (+5V) Position Sensor in Variable Swirl Control Actuator

Batter voltage supply after main relay IG OFF Max. 1.0 V

Accelerator Position Sensor (APS) #1 signal C.T 0.3 ~ 0.9V

Accelerator Position Sensor (APS) #2 signal C.T 0.3 ~ 0.9V

35 Sensor ground Idle DC Max. 50 mV

Item Dimension SST No.

Item Dimension SST No.

Part tightened N.m Kgf.m lbf.ft

• Display shows "Please The map CD is required for some Insert the CIQ map CD into the radio CDdrive with the

MF SW 0~1 Kohm 13 Kohm ± 10% 24 Kohm ± 10% 38 Kohm ± 10% 50 Kohm ± 10%

PCM(ECM) fault 1) NonImmobilizerEMS connected to an Immobilizer P1610

HiScan fault 1) HiScan message error P1697

Item N.m kgf.m lbft

Engine noise on start Incorrect oil viscosity. • Drain the oil

Engine will not crank Hydraulically cylinder 1) Remove injectors and check for fluid.

Door position Voltage (56) Error detecting

Door position Voltage (56) Error detecting

Item kgf·m Nm lbft

AM/FM GPS 2 I/PB 1 I/PA See Vehicle See Backup

5 6 M54C2 3 8 M54C3 2 7 8 M54A

1 R22 2 I/PB 1 I/PA See Vehicle See Backup

3 8 M54C3 2 7 8 M54A 6 5 M54C2

AMP 09362895 AMP 09362892 AMP_025_24F_W AMP_MQS_04M_B

2 I/PB 1 I/PA See Vehicle See Backup

5 6 M54C2 3 8 M54C3 2 7 8 M54A

3 8 M54C3 2 7 8 M54A 6 5 M54C2

(+) () (+) ()

M02R M54A M54B M54C1

M54C2 M54C3 M54D M57

CBG77 M01A M01C M02R

M01A M02L M04A

M04B M08B M21 M54C1

F50 M01A M54A M54C1

5 4 E41 7 I/PA 5 I/PB 21 I/PB 13 I/PC