Kia Rio 2005

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RIO(BC) > 2005 > G 1.6 DOHC > General Information
General Information > General Information > General Information

FUNDAMENTAL PROCEDURES
SYMBOLS
There are six primary symbols used to complement illustrations. These symbols indicate the areas to apply such materials
during service.
Symbol Meaning Type
Apply oil New engine oil, gear oil, etc. as appropriate
Apply brake fluid Only brake fluid
Apply automatic transmission fluid

Only ATF
(ATF)
Apply grease Appropriate grease
Apply sealant Appropriate sealant
Apply petroleum jelly Appropriate petroleum jelly
Whenever special oil or grease is required, it will be identified in figure.

Notice, Cautions and Warnings
As you read through the various procedures, you will encounter Notice, Cautions and Warnings.Each one is there for a
specific purpose.Notice give you added information that will assist you in completing particular procedure. Cautions
prevent you from making an error that could damage the vehicle. Warnings remind you to be especially careful in specific
areaswhere carelessness can cause personal injury.
The following items contain general procedures you should always follow when working on a vehicle:
Protection of vehicle
Always cover fenders, seats, and floor are as before starting work. Operate the engine only in a well-ventilated area to
avoid carbon monoxide poisoning.
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A word about safety

The following precautions must be followed when jacking up the vehicle:
1. Block the wheels.
2. Use only the specified jacking positions.
3. Support the vehicle with safety stands.
The engine compartment must be clear of tools and people before starting the engine.
Preparation of tools and measuring equipment
All necessary tools and measuring equipment should be available before starting any work.
Special service tools (SST's)

Use special service tools when they are required. SST's can be found under "preparation" prior to any procedure
requiring them.
Removal of parts
Begin work only after first learning which parts and subassemblies must be removed and disassembled for replacement
or repair.
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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. Additionally, these parts should be identified so that
reassembly can be done easily and efficiently.
Inspection of parts
When removed, each part should be carefully inspected for malfunction, deformations, damage, or other problems.
Arrangement of parts
All disassembled parts should be carefully arranged for reassembly. Separate or otherwise identify the parts to be
replaced from those that will be reused.
Cleaning parts for reuse

All parts that will be reused should be carefully and thoroughly cleaned using appropriate methods.
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Reassembly
Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. If
removed, the following parts should be replaced with new ones:
1. Oil seals
2. O-rings
3. Cotter pins
4. Gaskets
5. Lock washers
6. Nylon nuts
Depending on location:
1. Sealant should be applied or new gaskets installed.
2. Oil should be applied to the moving components of parts.
3. Specified oil or grease should be applied at the appropriate locations (such as oil seals) before reassembly.
Adjustments
Use appropriate gauges and/or testers when making adjustments.
Rubber parts and tubing

Prevent gasoline or oil from contacting rubber parts or tubing.
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Electrical troubleshooting tools (Test Light)

The test light, as shown in figure, uses a 12V bulb. The two lead wires should be connected to probes.
The test light is used for simple voltage checks and in checking for short circuits.
When checking the engine control module (ECM), never use a bulb exceeding 3.4W.
Electrical troubleshooting tools(Jumper wire)

The jumper wire is used for testing by shorting across switch terminals and ground connections.
Do not connect a jumper wire from the power source line to a body ground. Such a connection may cause damage to
harnesses or electronic components.
Electrical troubleshooting tools(Voltmeter)

The DC voltmeter measures circuit voltage. A voltmeter with a range of 15V or more is used by connecting the positive
(+) probe (red lead wire) to the point where voltage is to be measured, and the negative (-) probe (black lead wire) to a
body ground.
Electrical troubleshooting tools(Ohmmeter)

The ohmmeter is used to measure the resistance between two points in a circuit and also to check for continuity and the
diagnosis of short circuits.
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Do not attempt to connect the ohmmeter to any circuit in which voltage is applied. Such a connection may damage the
ohmmeter.
Electrical parts
Battery cable
Before disconnecting connectors or replacing electrical parts, disconnect the negative battery cable.
Connectors(Removal of connector)
1. Never pull on the wiring harness when disconnecting connectors.
2. Connectors can be removed by pressing or pulling lock lever.
Connectors(Locking a connector)
Listen for a click when locking connectors. This sound indicates that they are securely locked.
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Connectors(Inspection)
1. When a tester is used to check for continuity or to measure voltage, insert tester probe from wire harness side.
2. Check terminals of waterproof connectors from connector side because they 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.
Terminals(Inspection)
Pull lightly on individual wires to ensure that they are secured in the terminal.
Terminals(Replacement of terminals)
Use appropriate tools to remove terminal as shown. When installing the terminal, insert it until it locks securely.
Insert a thin piece of metal from the terminal side of the connector, and then, with the terminal locking tab pressed down,
pull the terminal out of the connector.
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Follow the same procedure as female-type terminal.
Terminals(Sensors, switches, and relays)

Always handle sensors, switches, and relays carefully. Do not drop them or accidentally strike them against other parts.
Wiring color codes

Two-color wires are indicated by a two-color code symbol. The first color indicates the base color of the wire; the
second color indicates the color of the stripe.
Code Color Code Color
B Black P Pink
Br Brown R Red
Silver
G Green S (Light
blue)
Gy Gray T Tawny
L Blue V Violet
Light
Lg W White
green
O Orange Y Yellow
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Jack and safety stand positions

Front end Jack position:
At the front subframe
Safety stand positions:

On both sides of the side sills
Jack and safety stand positions

Jack position:
At the center of the rear crossmember
Safety stand positions:

On both sides of the side sills
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VEHICLE LIFT(2-SUPPORT TYPE) POSITIONS

Front end
Side sills(both sides)
Rear end
Side sills(both sides)
Towing
Proper towing equipment is necessary to prevent damage to the vehicle. Always observe laws and regulations applicable
to vehicles in tow. As a general rule, towed vehicles should be pulled with the driving wheels off the ground. If excessive
damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use wheel dollies.
With either automatic or manual transmission:

1. Set the ignition switch in the ACC position.
2. Place the selector lever or shift lever in N (Neutral).
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3. Release the parking brake.
• Do not tow vehicle backward with driving wheels on the ground. This may cause internal damage to
transmission.
• Do not use hook loops under the front and rear of the vehicle for towing purposes. These hook loops are
designed ONLY for transport tie-down. If tie-down hook loops are used for towing, the front/rear bumper
will be damaged.
VIN locations
Vehicle identification number arrangement
ENGINE NUMBER LOCATIONS
English/Metric conversion table

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SCHEDULED MAINTENANCE SERVICES

NORMAL MAINTENANCE
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Scheduled maintenance services

Severe maintenance
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Scheduled maintenance services

Maintenance schedule (for Canada)
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RIO(BC) > 2005 > G 1.6 DOHC > Automatic Transaxle System
Automatic Transaxle System > General Information > Special Service Tools (F4E-K)
Special service tools
Tool
Illustration Use
(Number and Name)
0K201 170 AA0A used to remove transaxle.
Support, engine
0K201 190 016 Used to disassemble/assemble 3-4 clutch.

Leak checker
0K130 322 020 Used to measure bearing preload.

Attachment
0K201 170 AA1 Used to install oil seal.

Installer, oil seal
0K201 190 AA1 Used to measure line pressure.

Compressor set, return
spring
0K130 191 034 Used to adjust bearing preload.

Holder, idler gear shaft
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Holder, idler gear shaft
0K201 190 017 Used to disassemble transaxle.

Installer, oil seal
0K201 190 019 Used to remove/install turbine shaft.

Holder, turbine shaft
0K201 175 AA0 Used to adjust preload.

Selector set, shim
0K130 171 013 Used to remove differential bearing.

Puller, bearing
0K2CA 190 AA2 Used to press servo piston lifter.

Servo piston lifter
0K2CA 190 AA1 Used to remove / install spring retainer

Spring retainer assembly
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Spring retainer assembly assembly.
0K2CA 089 HSP Used for diagnosis trouble codes.

Hi-scan pro
Automatic Transaxle System > General Information > Specifications (F4E-K)

Specifications
Automatic Transaxle System > Automatic Transaxle System > Flow Diagram (F4E-K)
Hydraulic circuit(P range)
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Hydraulic circuit(R range)

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Hydraulic circuit(N range)

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Hydraulic circuit(D range:1ST GEAR)

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Hydraulic circuit(D range:2nd GEAR)

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Hydraulic circuit(D range:3rd GEAR)

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Hydraulic circuit(D range:o/d gear converter off)

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Hydraulic circuit(D range:o/d gear torque converter clutch on)

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Hydraulic circuit(2nd gear)

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Hydraulic circuit(1 range)

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Automatic Transaxle System > Automatic Transaxle System > Description and Operation (F4E-K)
STRUCTURAL VIEW
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Power flow diagram

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Component operation table: O/D OFF system

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Solenoid valve operation table: O/D OFF system

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Fluid passage locations

Transaxle case
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Fluid passage locations

Transaxle case
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Automatic Transaxle System > Automatic Transaxle System > Troubleshooting (F4E-K)
Symptom related diagnostic procedure
Introduction
Most of the automatic transaxle control system is electrically controled. This often makes it difficult to diagnose
intermittent problems in system. Before undertaking actual checks, take a few minutes to talk with customers who
approach you with a driveability complaint. The customer is often a good source of information regarding intermittent
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problems. Through talks with customer, one can find out what the symptoms are and under what conditions they
occur.
Work flow
Troubleshooting item
# Each troubleshooting item is assigned a number. There are 28 troubleshooting items. Choose item that most
closely corresponds to actual symptom.
Troubleshooting chart
1 Will start in other than P and N ranges
Description Engine starts in P, N and other ranges.
(TROUBLESHOOTING HINTS)
1. Selector lever installation or adjustment incorrect.
2. Transaxle range switch worn or not adjusted properly.
Step Inspection Action

1 Is selector lever operation OK? Yes Go to next step.
No Adjust selector lever.
2 Operate selector lever. Are selector lever Yes Go to next step.
and range indicator positions aligned?
No Adjust transaxle range switch.
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Description
Further describes symptom. Confirm that chart addresses actual symptom before beginning troubleshooting.
Troubleshooting hints
This describes possible point of malfunction.
Step
This shows order of troubleshooting. Proceed with troubleshooting as indicated.
Inspection
This describes an inspection to quickly determine malfunction of parts. If a detailed procedure is necessary to
perform inspection.
Action
This recommends appropriate action to take as a result (Yes/No) of inspection. How to perform action is described
on reference page shown.
Diagnostic index
Troubleshooting item
Description
# Trouble
1 Will start in other than P and N range Engine
Engine starts in P, N, and other range
starts in P, N, and other range
2 Engine stalls Idle when shifted
Engine stops unexpectedly when shifted from N or P to other
from N or P to other
ranges at idle
ranges
3 On deceleration Engine stops unexpectedly at beginning of deceleration or
recovery from deceleration exhaust afterburn
4 Engine rough On deceleration Engine shakes at beginning of deceleration, during
deceleration, or recovery from deceleration
5 Poor acceleration At drive-away Engine speed increases normally but vehicle speed slowly
increases during drive-away
6 On deceleration Engine speed increases normally but vehicle speed slowly
increases during acceleration
Momentary minor irregularity in engine output at steady
7 Surges while cruising
vehicle speed
8 Poor fuel economy Fuel economy unsatisfactory
9 Vehicle does not move in D, 2, 1 and/or R No creep at all
range Vehicle does not move when accelerator pedal
10 Vehicle moves in N range Depressed after shifted to D, 2, 1 and/or R range
Vehicle creeps in N range
Vehicle moves when accelerator pedal not depressed
11 Vehicle moves in P range Vehicle rolls in P range
12 Excessive creep Vehicle moves quickly in D, 2, 1 and R range
(accelerator pedal not depressed)
Excessive N to R range and N to D range shift shock felt
13 No shift Single range shift

(1GR→2GR, 2GR→3GR or 3GR→O/D)only
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Sometimes shifts correctly
Gear position held in O/D OFF mode
14 Abnormal shift Shifts incorrectly (incorrect shift pattern)

Example: vehicle shifts 1GR→O/D directly when accelerating
with accelerator pedal depressed slightly
15 Frequent shifting Downshift occurs when accelerator depressed slightly in D, S
or 2 and L or 1 ranges (except hold mode)
16 Shift point high or low Shift points do not match shift diagram
Shift delayed when accelerating
Shifts occur too fast when accelerating and engine speed does
not increase
17 No lock-up No lock-up when vehicle speed reaches lock-up range
18 No kickdown Down to downshift when accelerator pedal depressed
19 Engine speed flares When accelerating Engine speed flares up on acceleration
20 up When upshifting Engine flares up when accelerator pedal depressed for
and/or downshifting upshifting
Engine flares up suddenly when accelerator pedal depressed
for downshifting
Excessive shift shock P, N to R and/or N
21 Strong shift shock felt at idle when shift from N to range
to D
22 When upshifting Excessive shift shock felt when accelerating at upshifting
and/or downshifting During cruising, excessive shift shock felt when accelerator
pedal depressed at downshifting
23 No engine braking Engine speed drops to idle but vehicle does not slow when
accelerator pedal released during cruising at medium to high
speed
Engine speed drops to idle but vehicle does not slow when
accelerator pedal released when in 2 or 1 range at low vehicle
speed
24 No mode change O/D OFF mode not selected or not cancelled
25 Transaxle noise All ranges Transaxle noisy in all ranges when vehicle is idling
26 D, 2, 1 and R ranges Abnormal noise from transaxle in D, 2 or 1
27 Transaxle overheats ATF smells burnt and/or is discolored
SYMPTOM TROUBLESHOOTING
Will start in other than P and N ranges
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1 Will start in other than P and N ranges
Description Engine starts in P, N and other ranges.
1. Selector lever installation or adjustment incorrect.
2. Transaxle range switch worn or misadjusted.

2 Operate selector lever. Are selector lever Yes Go to next step.

and range indicator positions aligned? No Adjust transaxle range switch.
3 Operate selector lever. Does transaxle Yes Go to next step.
operate normally and are selector lever and
transaxle positions aligned? No Repair or replace parts as necessary.
4 Are measurements at TCM OK? Yes Temporarily install known good TCM.
Go to step 5. If problem is corrected,
replace TCM.
No Check transaxle range switch and wiring.
• 47, 8, 36, 37
Terminal: Transaxle range switch.
5 Retrun vehicle to original condition. Clear all DTC's. Verify repairs by driving vehicle with scan
tool connected and monitor for pending codes.
Engine stalls when shifted from N or P to other ranges

2 Engine stalls when shifted from N or P to other ranges
Description Engine stops unexpectedly when shifted from N or P to other ranges at idle
1. Idle air control (IAC) valve malfunction
2. Torque converter clutch solenoid malfunction
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3. Transaxle range signal malfunction
4. Oil pump worn
5. Control valve stuck
6. Idle speed and ignition timing misadjust

1 Check that no diagnostic trouble codes exist Yes Go to next step.
by retrieving DTC's with a scan tool.
No Diagnostic trouble code(s) displayed on scan
tool.
• Check for cause of diagnostic trouble
code(s)
If problem remains, go to next step.

2 Are measurements at TCM terminal OK? Yes Go to next step.
No Check for malfunctioning parts

• Throttle position (TP) sensor.
• Wiring
3 Are measurements at TCM OK? Yes Go to next step.
• 47, 8, 36, 37
terminals: Transaxle range switch
4 Is continuity of transaxle range switch OK? Yes Go to next step.
No Adjust and/or replace transaxle range
switch.
5 Are resistance of torque converter clutch Yes Go to next step.
solenoid valve and output voltage of TCM
terminal OK? No If resistance is not OK, check for
malfunctioning parts and wiring.
• Torque converter clutch solenoid valve.
If resistance is OK but voltage is not, check

wiring and TCM.
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6 Is engine stall speed OK? Yes Check ECM parts & Engine.
Stall speed: 2200~2800 rpm No Repair or replace as necessary.
Engine stalls on deceleration

3 Engine stalls on deceleration
Description Engine stalls when brake pedal depressed while driving at low speed or stopping
1. Idle air control (IAC) valve malfunction
3. Idle speed and ignition timing misadjust

tool.
code(s)

terminal 4 OK? No If resistance is not OK, check for
• Torque converter clutch solenoid

wiring and / or replace TCM.
3 Is engine stall speed OK? Yes Check TCM and / or engine parts.
Stall speed: 2200~2800 rpm No Repair or replace parts as necessary.
Symptom troubleshooting 4
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4 Engine rough on deceleration
Engine shakes at beginning of deceleration, during deceleration, or recovery from deceleration
Description
Exhaust afterburn
1. ATF level low
2. Line pressure low
1 Are ATF level and condition OK? Yes Go to next step.
No If ATF level is not OK, add fluid as
Do transaxle seals, sealant and gaskets
necessary.
prevent leakage?
If ATF condition is not OK, repair as
1. Clear pink : Normal condition follows:
2. Dark or black (with fridtion material): • 2 condition - Overhaul transaxle and
Worn powertrain components repair or replace parts as necessary; then
3. Milky pink : Water contamination go to next step.
4. Light to dark brown (oxidation); • 3 or 4 conditions - Replace ATF: then go
to next step.
5. Overheated or old fluid
If there is leakage, repair or replace parts as
necessary and/or replace transaxle: then go
to next step.

• Wiring
3 Is line pressure OK? Yes Go to next step.
No Check linear solenoid valve.

If line pressure is not within specifications
after linear solenoid inspection, replace
control valve body assembly.
Poor acceleration at drive-away

5 Poor acceleration at drive-away
Description Engine speed increases normally but vehicle speed slowly increases during acceleration
1. ATF level low or high
2. Throttle position sensor malfunction or improperly adjusted
3. Line pressure incorrect
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5. Engine stall speed incorrect

tool.
code(s).

Do transaxle seals, sealant, and gaskets No If ATF level is not OK, add fluid as
prevent leakage?
necessary.
1. Clear pink: Normal condition If ATF condition is not OK, repair as
2. Dark or black (with friction material): follows:
Worn powertrain components • 2 condition - Overhaul transaxle and
3. Milky pink: Water contamination repair or replace parts as necessary; then
go to next step.
4. Light to dark brown (oxidation):
Overheated or old fluid • 3 or 4 conditions - Replace ATF; then go
to next step.

necessary, then go to next step.

• Wiring


• Torque converter clutch solenoid.

wiring and /or TCM.
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6 Is engine stall speed OK? Yes Check EMS parts, engine and TCM.
Poor acceleration on acceleration

6 Poor acceleration on acceleration
3. Engine stall speed incorrect correctly
4. Throttle position (TP) sensor malfunction or not adjusted

by retrieving DTC's with a scan tool. No Diagnostic trouble code(s) displayed on scan
tool.
code(s).

prevent leakage?
necessary.
go to next step.
to next step.


• Wiring
4 Is line pressure OK? Yes Check TCM.

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5 Is engine stall speed OK? Yes Check engine parts.

No Repair or replace parts as necessary.
Stall speed: 2200~2800 rpm
Check torque converter.
6 Drive vehicle if D & 1 range. Yes Check engine parts.
Is vehicle starting from stop in 1st gear?
No Check torque converter.
Surges while cruising

Description Momentary minor irregularity in engine output at steady vehicle speed
Poor acceleration on acceleration

8 Poor acceleration on acceleration
2. Throttle position (TP) sensor malfunction or not adjusted

tool.
code(s).

Do transaxle seals, sealant, and gaskets
prevent leakage?
necessary.
1. Clear pink: Normal condition
go to next step.
to next step.

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• Wiring


wiring and TCM.
Poor fuel economy

8 Poor fuel economy
Description Fuel economy unsatisfactory
1. ATF level low
2. Throttle position (TP) sensor malfunction or not adjusted correctly
3. Torque converter clutch solenoid not working

tool.
code(s).

prevent leakage? necessary.
go to next step.
to next step.
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3 Is input voltage of throttle position (TP) Yes Go to next step.
sensor at TCM terminal OK?
No Check throttle position (TP) sensor and

wiring.
4 Are resistance of torque converter clutch Yes Repair or replace parts as necessary.
solenoid and output voltage of TCM
terminals 4 OK? No If resistance is not OK, check for

wiring and TCM.

Vehicle does not move in D, 2, and/or R range

9 Vehicle does not move in D, 2, and/or R range
Description ·No creep at all
·Vehicle does not move when accelerator pedal depressed after shifting to D, 2, 1, and/or R
range
1. ATF level low
2. Selector lever installation or adjustment incorrect
4. Powertrain slippage (forward clutch, 2-4 brake band, one-way clutch No. 1 or No. 2)
7. Torque converter worn
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prevent leakage?
necessary.
go to next step.
to next step.

3 Operate selector lever; are selector lever Yes Go to next step.

4 Operate selector lever; does transaxle Yes Go to next step.
transaxle position aligned? No Repair or replace as necessary.


wiring and TCM.

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7 Is engine stall speed OK? Yes Check EMS parts, Engine and TCM.
8 Stop vehicle on flat paved surface with Yes Repair or replace parts as necessary.
engine OFF.
Does vehicle move when pushed No Shift mechanism malfunction.
(except P range, parking brake released)? Repair or replace as necessary.
Vehicle moves in N range

10 Vehicle moves in N range
Description ·Vehicle creeps in N range
·Vehicle moves when accelerator pedal not depressed
2. Powertrain damaged (forward clutch, coasting clutch, 3-4 clutch)


transaxle position aligned? No Repair or replace parts as necessary.

go to next step.
to next step.

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Vehicle moves in P range
11 Vehicle moves in P range
Description ·Vehicle rolls in P range
2. Parking mechanism worn
3. Powertrain damaged (forward clutch, coasting, 3-4 clutch)


3 Does transaxle operate normally and are Yes Go to next step.
selector lever and transaxle position aligned? No Repair or replace parts as necessary.
engine OFF.
(except P range, parking brake released)? Repair or replace parts as necessary.
Excessive creep
12 Excessive creep
Description ·Vehicle moves quickly in D, 2, 1 and R ranges (accelerator pedal
depressed)
Excessive N to R range and N to D range shift shock felt
Engine idle speed not adjusted correctly.
No shift
13 No shift
Description ·Single range shift (1GR → 2GR, 2GR → 3GR, or 3GR → O/D) only
·Sometimes shifts correctly
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2. Input/turbine speed sensor malfunction
3. Vehicle speed sensor malfunction
4. Throttle position sensor malfunction or misadjusted
5. Transaxle range switch worn or maladjusted
7. Linear solenoid valve malfunction
8. O/D switch malfunction
9. Shift solenoid valve (A, B, C) malfunction
10. TCM malfunction
12. Powertrain damaged (forward clutch, 3-4 clutch, 2-4 band, one-way clutch 1)

by retrieving DTC's with a scan tool. No Diagnostic trouble code(s) displayed on O/D
indicator or scan tool.
code(s)

No Adjust selector.

transaxle position aligned? No Adjust transaxle range switch.


wiring and TCM.
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after linear solenoid valve inspection, replace
7 Is engine stall speed OK? Yes Check EMS parts & Engine and / or replace
TCM.
engine OFF.
(except P range, parking brake released)? Repair or replace parts as necessary.
9 Are resistance and output voltage of shift Yes Go to next step.

solenoids (A, B, C) at TCM terminals OK?
No If resistance is not OK, check for

• Throttle position sensor
• Input/turbine speed sensor
• Vehicle speed sensor
• O/D OFF switch
• Transaxle range switch

TCM.
Go to step 10.
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• 38 terminal: Throttle position (TP)

sensor
• 44 terminal: Input/turbine speed
sensor ground
• 16 terminal: Input / turbine speed
sensor signal
• 42 terminal: Vehicle speed sensor
• 45 terminal: O/D switch
• 48, 8, 36, 37
terminal: Transaxle range switch
10 Replace with known operational TCM. Yes Replace TCM.

Is problem corrected?

Abnormal shift
14 Abnormal shift
Description ·Shifts incorrectly (incorrect shift pattern)
(e.g.: Vehicle shifts from 1st to O/D directly when accelerating with accelerator pedal depressed
slightly)
2. Shift solenoid valves (A, B, C) worn
4. Differential assembly malfunction
5. TCM malfunction

No Diagnostic trouble code(s) displayed on O/D
code(s)

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• Shift solenoid A
• Shift solenoid B
• Shift solenoid C

TCM.
Go to step 4.
• 30 terminal: Shift solenoid A
• 33 terminal: Shift solenoid B
• 32 terminal: Shift solenoid C
3 Are resistance and output voltage of throttle Yes Go to next step.

position (TP) sensor at TCM terminals OK?

TCM.
Go to next step.

sensor
4 Replace with known operational TCM. Is Yes Replace TCM.

problem corrected? No Replace control valve body assembly.
If problem remains, repair or replace parts
as necessary.
Frequent shifting
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15 Frequent shifting
Description Downshift occurs when accelerator depressed slightly in D, 2 and 1 ranges (except O/D OFF
mode)
2. TCM malfunction

code(s)

2 Are measurements at TCM terminals OK? Yes Go to next step.
No Check for malfunctioning parts and wiring.

1. Throttle position (TP) sensor
1. 38 terminal: Throttle position (TP)

sensor (from ECM)
3 Replace with known operational TCM. Is Yes Replace TCM.

problem corrected?
No Replace control valve body assembly.
If problem remains, repair or replace parts
as necessary.
Shift point high or low

16 Shift point high or low
Description ·Shift points do not match shift diagram
·Shift delayed when accelerating
·Shift occurs too fast when accelerating and engine speed does not increase
3. Transaxle fluid temperature sensor malfunction
5. Shift solenoids valves (A, B, C) worn
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6. PCM malfunction
8. Transaxle range switch malfunction or not adjusted correctly

code(s)

No Check for malfunctioning parts and wiring.

• Throttle position (TP) sensor

sensor ground
sensor ground
sensor signal
No Check transaxle fluid temperature sensor.
• 21 terminal: Transaxle fluid

temperature sensor ground
temperature sensor signal

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transaxle position aligned? No Adjust transaxle range switch.

and range indicator positions aligned? No Repair or replace parts as necessary.

No Adjust and/or replace transaxle range
switch.

If resistance is OK but voltage is not,

replace TCM.
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No lock-up
17 No lock-up
Description No lock-up when vehicle speed reaches lock-up range
2. Input / turbine speed sensor malfunction
7. TCM malfunction

tool.
code(s)

2 Are resistance of torque converter clutch Yes Replace control valve body assembly.
solenoid and output voltage of TCM terminal
OK? No If resistance is not OK, check for
• Torque converter clutch solenoid

wiring and / or replace TCM.

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replace TCM.

sensor
sensor ground
sensor signal


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8 Is input voltage of engine coolant Yes Go to next step.

temperature sensor signal at TCM terminals
OK?

wiring.
No kickdown
18 No kickdown
Description Does not downshift when accelerator pedal depressed more than 7/8 while within kickdown
range
1. Throttle position sensor malfunction or not adjusted correctly
3. TCM malfunction

tool.
code(s)

2 Is input voltage of engine coolant Yes Go to next step.
temperature sensor signal at TCM terminals
OK?

wiring.
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3 Is accelerator cable installed correctly and Yes Go to next step.
does it operate smoothly? No Adjust or replace accelerator cable.

5 Replace with known good TCM. Yes Replace TCM.

Is problem corrected?
No Replace control valve body assembly.
If problem remains, overhaul transaxle and
repair or replace parts as necessary.
Engine speed flares up on acceleration

19 Engine speed flares up on acceleration
Description Engine speed flares up on acceleration
1. ATF level low
4. Powertrain slippage (forward clutch, 2-4 brake band, one-way clutch No. 1 or No. 2, 3-4 clutch)
5. Torque converter worn

prevent leakage?
necessary.
go to next step
to next step

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Engine speed flares up when upshifting and/or downshifting

20 Engine speed flares up when upshifting and/or downshifting
Description ·Engine flares up when accelerator pedal depressed for upshifting.
·Engine flares up suddenly when accelerator pedal depressed for downshifting.
1. ATF level low
2. Line pressure incorrect
3. Throttle (TP) sensor malfunction or misadjusted
5. TCM malfunction
6. Servo piston malfunction
7. Orifice valve malfunction
8. 1-2, 2-3 accumulator malfunction
10. Powertrain damaged (forward clutch, 3-4 clutch, 2-4 brake band, one-way clutch No.1)
11. Oil pump malfunction

tool.
code(s)

prevent leakage?
necessary.
go to next step
to next step
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No Check that linear solenoid valve.

4 Are measurements at TCM terminals OK? Yes Temporarily install known good TCM.
Go to next step.
If problem is corrected, replace TCM.


• 38 terminal: Throttle position sensor replace TCM.
sensor ground
sensor signal
5 Return vehicle to original condition. Clear all DTC's. Verify repairs by driving vehicle with scan
Excessive shift shock

21 Excessive shift shock at P, N to R and/or N to D
Description Strong shift shock felt at idle when shifting from P or N to D or R range.
1. AFT level low
2. Idle speed high
3. Line pressure high
4. Transaxle control module malfunction
5. Throttle position (TP) sensor malfunction or misadjusted
6. Input / Turbine speed sensor malfunction
8. TCM malfunction
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10. Selector installation or adjustment incorrect
11. N-D, N-R accumulator malfunction reverse clutch, low and reverse brake one-way clutch No. 1 or No. 2

No Diagnostic trouble code(s) displayed on O/D
code(s)

prevent leakage?
necessary.
go to next step
to next step


6 Drive vehicle in D and 1 range; does vehicle Yes Go to next step.

start from stop in 1st gear?
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replace TCM.

sensor
sensor ground
sensor signal
• 48, 8, 36, 37
terminal: Transaxle range switch

9 Is line pressure OK? Yes Temporarily install known good TCM.
Go to next step.

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Excessive shift shock when upshifting and/or downshifting
22 Excessive shift shock when upshifting and/or downshifting
Description ·Excessive shift shock felt when accelerating and upshifting
·During cruising, excessive shift shock felt when accelerator pedal is depressed and downshifting
1. ATF level low
2. Line pressure high
3. Throttle position sensor malfunction or misadjusted
5. Transaxle fluid temperature sensor malfunction
6. TCM malfunction
8. Orifice valve malfunction
9. 1-2, 2-3 accumulator malfunction
11. Powertrain damaged (3-4 clutch, 2-4 brake band, one-way clutch No. 1)

code(s)

prevent leakage?
necessary.
go to next step
to next step

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• 38 terminal: Throttle position (TP) replace TCM.
sensor
sensor ground
sensor signal
temperature sensor
• 21 terminal: Ground

No If resistance is not OK, check fo

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replace TCM.
• 18, 8, 36, 37 terminals: Transaxle

range switch
7 Check control valve body assembly.
No engine braking
23 No engine braking
Description ·Engine speed drops to idle but vehicle does not slow when accelerator pedal released while
cruising at medium to high speed.
·Engine speed drops to idle but vehicle does not slow when accelerator pedal released when in 1
range at low vehicle speed.
1. Shift solenoids (B, C) malfunction
2. Transaxle range switch worn or not adjusted correctly
3. TCM malfunction
6. Powertrain slippage (3-4 clutch, coasting clutch, low and reverse brake)

tool.
code(s)
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2 Are resistance and output voltage of Yes Go to next step.
solenoid valves (1-2, 2-3, 3-4 shift) at TCM
terminals OK?


replace TCM.


No Overhaul transaxle and repair or replace
transaxle position aligned? parts as necessary.

7 Are measurements at TCM terminals OK? Yes Replace TCM.

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• 18, 8, 36, 37 terminals: Transaxle

range switch
No mode change
24 No mode change
Description O/D OFF mode not selected or not canceled
Inspect parts and wiring and repair, or replace malfunctioning parts as necessary
1. O/D switch malfunction
Transaxle noise in all ranges

25 Transaxle noise in all ranges
Description Transaxle noisy in all ranges when vehicle is idling
Inspect parts and repair, adjust or replace malfunctioning parts as necessary
1. ATF level low
2. Differential worn or damaged
3. Parking mechanism malfunction
Transaxle noise in D, 2, 1 and R ranges

26 Transaxle noise in D, 2, 1 and R ranges
Description Abnormal noise from transaxle in D, 2, 1 and R ranges
Inspect parts and repair, adjust or replace malfunctioning parts as necessary.
1. ATF level low.
2. Differential worn and / or damage.
Transaxle overheats
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27 Transaxle overheats
Description ATF smells burnt and/or is discolored
1. ATF level low
2. TCM malfunction

Worn powertrain components • 2 condition -Overhaul transaxle and
go to next step.
to next step.

2 Check that no diagnostic trouble codes exist Yes Temporarily install known good TCM.
by retrieving DTC's with a scan tool. Go to next step.
tool.
code(s).

Self diagnostic function

Diagnostic trouble codes
Inspection procedure
1. Connect SST(0K2CA 089 HSP) to data link connector.
2. Turn ignition switch to ON.

3. Check diagnostic trouble code(s), referring to Hi-scan pro operating manual.
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4. If a diagnostic trouble code(s) is displayed, check for cause by using number on diagnostic trouble code table.
Repair as necessary.
5. After repairs, perform After-Repair procedure to verify that there are no remaining diagnostic trouble codes.
After-repair procedure
1. Cancel diagnostic trouble code memory by using SST(0K2CA 089 HSP).
2. Remove SST(0K2CA 089 HSP) from data link connector.
3. Drive vehicle at 31 mph (50 km/h) and depress accelerator pedal fully to activate kickdown. Stop vehicle
gradually.
4. Connect SST(0K2CA 089 HSP) to data link connector.
6. Verify that no diagnostic trouble codes are displayed.
7. Remove SST(0K2CA 089 HSP) from data link connector.
Diagnostic trouble code

Code No. Diagnosed circuit MIL
P0601 TCM ROM malfunction ON
P0604 TCM RAM malfunction ON
P0707 Transaxle range signal (P, R, N, D, 2, 1) malfunction (No signal) ON
P0708 Transaxle range signal (P, R, N, D, 2, 1) malfunction (Many signals) ON
P0712 ATF temperature sensor low ON
P0713 ATF temperature sensor high ON
P0716 Input/turbine speed sensor signal malfunction ON
P0717 Input/turbine speed sensor circuit malfunction ON
P0726 Engine speed input signal malfunction ON
P0727 Engine speed input malfunction ON
P0731 Incorrect first gear ratio ON
P0732 Incorrect second gear ratio ON
P0733 Incorrect third gear ratio ON
P0734 Incorrect fourth gear ratio ON
P0741 Torque converter clutch system malfunction (Stuck OFF) ON
P0742 Torque converter clutch system malfunction (Stuck ON) ON
P0743 Torque converter clutch system circuit malfunction ON
P0748 Linear solenoid electrical ON
P0753 Shift solenoid A electrical ON
P0758 Shift solenoid B electrical ON
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P0763 Shift solenoid C electrical ON
P1121 TPS signal circuit from ECM to TCM ON
P1500 Vehicle speed signal malfunction ON
P1700 O/D lamp circuit malfunction OFF
P1780 Torque reduction signal malfunction OFF
P1800 Engine torque signal malfunction OFF
According to TCM logic, transaxle range P0707 and P0708 trouble code accompanies vehicle speed
sensor (P1500) trouble code.
Therefore, P0707 and P0708 should be repaired first. Check P0707 and P0708 is cleared and then
inspect P1500.
Transaxle control module(TCM)
TCM terminal voltage chart
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Input/Turbine speed sensor

Resistance inspection
1. Disconnect negative battery cable.
2. Pull data link connector upward from MAF sensor.
3. Remove air cleaner assembly.
4. Disconnect input/turbine speed sensor connector.
5. Measure resistance between terminals 1 and 2.
Resistance: 300~400Ω (@68°F/20°C)

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6. If not as specified, replace input/turbine speed sensor.
Tightening torque:
69.6~94.8 ib·in (8~11 N·m, 80~110 kg·cm)
7. Install air cleaner assembly.

8. Install data link connector to MAF sensor.
9. Connect negative battery cable.
Vehicle speed sensor
Voltage inspection
1. Turn ignition to ON and use a voltmeter to back probe pin 1.
2. Have an assistant rotate one drive wheel, checking other drive wheel, if necessary. This will rotate vehicle speed
sensor.
3. Voltmeter reading should alternate between approximately 1 and 10 volts.

4. If this requirement is not met, replace vehicle speed sensor.
Automatic transaxle fluid (ATF)
Place vehicle on a flat surface.

Inspection
1. Apply parking brake and position wheel chocks securely to prevent vehicle from rolling after roller test.
2. Warm-up engine until ATF reaches 140~158°F (60~70°C).
3. Firmly depress the foot brake, and shift the selector lever P→R→N→D→1→2→1→D→N→R→P.
(stay at each range for over 3 second)
Use COOL 68°F (20°C) range only as a rough reference.
4. Ensure that the ATF level is in HOT 149°F (65°C) range. Add ATF to specification, if necessary.
ATF type:
SK ATF SP-III or DIAMOND ATF SP-III
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Fluid condition
Carefully check condition of ATF and determine whether or not automatic transaxle should be disassembled.
If ATF is muddy and varnished, it could indicate burned drive plates or brake band.
1. Check ATF for discoloration.
2. Check ATF for any unusual smell.
Fluid condition(Replacement)
General process
1. Place a drain pan under transaxle drain plug.
2. Remove auto transaxle drain plug and allow automatic transaxle fluid to fully drain.
3. Install drain plug with specified torque.
Tightening torque:
29~40 lb·ft (39~54 N·m, 4.0~5.5 kg·m)
4. Remove ATF level gauge, then pour specified ATF.
ATF type:
SK ATF SP-III or DIAMOND ATF SP-III
Capacity :
6.2 US qt (5.9 liter, 5.2 lmp qt)
Do not over fill above Hot range.

5. Check ATF level. (Refer to auto transaxle fluid)
ATF changer using process
1. Fill ATF changer with specified ATF.
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2. Disconnect ATF inlet and outlet hose from radiator.
3. Connect ATF inlet and outlet hose to ATF changer.
4. Start engine.
5. While engine is idling, replace ATF. (Refer to ATF changer instruction manual)
6. Check ATF level. (Refer to ATF)
Fluid leaks
Check for transaxle fluid leaks at points shown below and repair or replace as necessary. Additionally, check all of
following:
1. Gaskets, O-rings, and plugs.
2. Oil hoses, oil pipes, and connections.
3. Oil cooler.
COMPONENT
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Oil seal(Removal and replacement)

1. Remove driveshaft. (Refer to section DS Gr.-driveshaft).
2. Remove oil seal with a screwdriver.
3. Tap new oil seal into transaxle case with SST(0K201 170 AA1).
• Tap in until SST(0K201 170 AA1) contacts case.

• Coat oil seal lip with ATF.
Control valve body(Removal)

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Clean transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal.
1. Support engine with SST(0K201 170 AA0).
2. Raise vehicle and support it with safety stands.

3. Drain ATF into a suitable container.
4. Remove both gravel shield from under engine.
5. Remove nuts from No.2 engine mount-to-mounting member.
6. Remove engine mounting member-to-chassis bolts and nuts then remove engine mounting member.
7. Remove oil pan (19 bolts) and gasket.
8. Disconnect all electrical connectors, remove eight bolts, and remove control valve body.
Control valve body(Replacement)

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1. Install control valve body, (8) bolts, and wiring clips as shown.
Bolt length (measured from below the head)

A : 1.18 in (30 mm)
B : 1.97 in (50 mm)
Tightening torque:
69.6~94.8 lb·in (7.9~10.7 N·m, 80~110 kg·cm)
2. Install oil strainer, and (3) bolts.
Tightening torque:
69.6~94.8 lb·in (7.9~10.7 N·m, 80~110 kg·cm)
3. Connect connectors.
4. Install oil pan (19 bolts) and a new gasket.
Tightening torque:
74.4~94.8 lb·in (8.4~10.7 N·m, 85~110 kg·cm)
5. Loosely install nuts A and bolts B of engine mounting member.

6. Install engine mounting member.
Tightening torque:
A : 28~38 lb·ft (38~51 N·m, 38~53 kg·m)
B : 48~65 lb·ft (64~89 N·m, 6.5~9.1 kg·m)
7. Install both gravel shield to under engine.

8. Remove SST(0K201 170 AA0) from engine.
9. Pour in ATF. Check ATF level with engine idling and check for leaks, refer to Automatic Transmission Fluid.
10. Drive vehicle and check shift points, shift schedule, and shift quality.
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MECHANICAL SYSTEM TESTS (STALL TEST)
This test is performed to determine if there is slippage of friction elements or a malfunction of hydraulic components.
• Never unscrew radiator cap while engine is hot.

• Wrap a thick cloth around cap when loosening.
1. Engage parking brake and put wheel chocks at front and rear of each wheel.
2. Warm engine thoroughly to raise ATF temperature to an operating level of 140~158°F (60~70°C).
3. Check and correct as necessary, engine coolant, engine oil and ATF levels before testing.
4. Connect a tachometer to engine.
Mechanical system tests (Procedure)
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1. Start engine.
2. Check idle speed in P range. (Refer to section EC, emission control system)
Idle speed: 750~850 rpm (with parking brake applied)
3. Shift selector lever to R range.
Perform steps 4 and 5 within 5 seconds to prevent possible transaxle

damage.
4. Firmly depress foot brake with left foot and gradually depress accelerator pedal fully with right foot.
5. When engine speed no longer increases, quickly read engine to speed and release accelerator.
6. Move selector lever to N range and allow engine to idle for at least one minute.
• Idling for at least one minute cools ATF and prevents its deterioration.
• Allow sufficient cooling time between each stall test.
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7. Perform stall tests for remaining ranges in same manner.
A. D range
B. 2 range
C. 1 range
Stall speeds: 2200~2800 rpm
Evaluation of stall test O/D OFF system

Condition Possible cause
Above specification In R position and all ranges Insufficient line Worn oil pump
pressure Oil leakage from oil pump,
control valve and/or transaxle
case
Stuck pressure regulator valve
In D range Forward clutch slipping
One-way clutch 1 slipping
One-way clutch 2 slipping
In 2 range 2-4 brake band slipping
In R range Low and reverse brake slipping
Reverse clutch slipping
Perform road test to determine whether problem is low
and reverse brake or reverse clutch
1) Engine brake felt in 1 range, 1st gear reverse clutch
2) Engine brake not felt in 1 range
Low and reverse brake
Below specification in R position and all ranges Engine out of tune
One-way clutch slipping within torque converter
Time lag test

If selector lever is shifted while engine is idling, there will be a certain time lapse, or time lag, before shock is felt.
This step measures time lag to check condition of N-D, 1-2, and N-R accumulators; forward and one-way clutches;
reverse clutch; low and reverse brake and 2-4 brake band.
Preparation
Follow preparation procedure outlined in Stall Test.
Procedure
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1. Start engine.
2. Check idle speed in P range, refer to emission control system, section EC.
Idle speed : 750~850 rpm (with parking brake applied)
3. Shift from N range to D range.

4. Use a stopwatch to measure time it takes from shifting until shock is felt.
5. Shift selector to N range and run engine at idle speed for at least one minute.
Idling for at least one minute cools ATF and prevents its deterioration.
Make three measurements for each test and take average value.
6. Perform test for following shifts in same manner.
A. N→D range
B. N→D range (O/D OFF MODE)
C. N→R range
Time lag : N → D range 0.5 ~ 0.6 second

Time lag : N → R range 0.6 ~ 0.7 second
Evaluation of time lag test

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Condition Possible cause
N→D More than specification Insufficient line pressure
shift Forward clutch slipping
One-way clutch No.1 slipping
Less than specification N/D accumulator not operating
properly
Excessive line pressure
N→2 More than specification Excessive line pressure
range Insufficient line pressure
Forward clutch slipping
2-4 brake band slipping
Less than specification 1-2 accumulator not operating
properly
N→R More than specification Insufficient line pressure
shift Low and reverse brake slipping
Reverse clutch slipping
Less than specification N/R accumulator not operating
properly
Line pressure test

This test measures line pressure as a means of checking hydraulic components and inspecting for oil leakage.
Preparation
1. Perform preparation procedure outlined in Stall Test.
2. Remove splash shield under front left bumper.
3. Connect SST(0K201 190 AA0) to line pressure inspection port (square-head "L" plug). It may be necessary to
raise car to get at inspection port.
Line pressure test(Procedure)

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1. Start engine.
2. Check idle speed in P range, refer to emission control, section EC.
Idle speed: 750~850 rpm (with parking brake applied)
3. Shift selector lever to D range and read line pressure at idle.
Perform steps 4 and 5 within 5 seconds to prevent possible transaxle

damage.
4. Depress brake pedal firmly with left foot and gradually depress accelerator pedal fully with the right foot.
5. Read line pressure as soon as engine speed becomes constant and release accelerator pedal.
Idling for at least one minute cools ATF and prevents deterioration.
6. Shift selector lever to N range and run engine at idle for at least one minute.
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7. Read line pressure at idle and at engine stall speed for each range in same manner.
Specified line pressure [psi (kPa, kg/cm²)]
Range Idle Stall
56.98~127.98 (392.4~882.9, 113.76~184.86 (784.8~1275.3,
D,2,1
4.0~9.0) 8.0~13.0)
71.1~142.2 (490.5~981.0, 199.08~270.18 (1373.4~1863.9,
R
5.0~10.0) 14.0~19.0)
8. Install a new square-head "L" plug in inspection port, refer to line pressure test.
Tightening torque :
44~86 lb·in (5.0~9.8 N·m, 51~100 kg·cm)
Evaluation of line pressure test

Line pressure Possible location of problem
Low pressure in every position Worn oil pump
Fluid leaking from oil pump, control valve, or
transaxle case
Pressure regulator valve sticking
Linear solenoid valve sticking
Low pressure in D and 2 only Fluid leaking from hydraulic circuit of forward clutch
Low pressure in R only Fluid leaking from hydraulic circuit of low and reverse
brake or reverse clutch
Higher than specification Pressure regulator valve stick or linear solenoid valve
sticking
Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Components and
Components Location (F4E-K)
TRANSAXLE UNIT
COMPONENT
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DISASSEMBLY, INSPECTION AND ASSEMBLY PROCEDURES

COMPONENTS
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COMPONENTS (CONTINUED)
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Bearing and Race Locations

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Bearing and race at location 2, 3, 4, 6, and 7 are one-piece units.

Component(continued)
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COMPONENT
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Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Repair
procedures (F4E-K)
REMOVAL
1. Disconnect negative battery cable then positive battery cable.
2. Raise and properly support vehicle.
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3. Place a drain pan under transaxle drain plug.
4. Remove the fresh airduct.

5. Disconnect input/turbine speed sensor, solenoid and tramsaxle range connector.
6. Remove ground strap bolt from top of auto transaxle then disconnect ground strap.
7. Disconnect vehicle speed sensor connector from right side of auto transaxle.
8. Remove U-clip from selector cable to auto transaxle linkage.

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9. Remove nut and washer from auto transaxle linkage.
10. Disconnect crankshaft position sensor connector.
11. Disconnect oxygen sensor connector.
12. Disconnect two ATF cooler hoses.
13. Remove two upper converter housing bolts. (top two)
14. Support engine by using SST(0K201 170 AA0).
15. Remove both front wheels. (four lug nuts each)

16. Remove splash shield from under engine.
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17. Remove two nuts from U-bolt.
18. Remove catalytic converter.

19. Remove converter housing access cover and remove four drive plate-to-torque converter mounting nuts.
Rotate engine at crank pulley to gain access to all four nuts.
20. Remove one lower starter bolt.

21. Remove four engine oil pan-to-transaxle mounting bolts.
22. Remove left tie rod end from steering knuckle by removing one cotter pin and one nut.
23. Remove the tension rod.
A. Remove nut after removing cotter pin from the lower arm side.
B. Remove the tension rod after loosening bolt from the vehicle.
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24. Remove pinch bolt and nut from left ball joint.
25. Remove No.1,2 mounting nuts from engine mounting member.

26. Remove engine mounting member-to-chassis bolts (two front) and nuts (two rear) then remove engine mounting
member.
27. Remove the stabilizer bar and control link. (Refer to section SS-Suspension system)
28. Gently pry left drive shaft from auto transaxle.

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29. Install SST(0K201 270 014) to prevent side gear from becoming misaligned.
30. Remove No.2 engine mounting from auto transaxle.
31. Support (and secure if possible) auto transaxle with a transaxle jack or suitable floor jack.
32. Remove two remaining converter housing bolts on front and rear sides of transaxle.
33. Slowly lower drive train, allowing transaxle to tilt toward ground.
34. Gently separate transaxle from engine and pull unit out through wheel well.
INSTALLATION
1. Set transaxle on transaxle jack or suitable floor jack and place under vehicle.
2. Raise transaxle and align with engine.
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3. Connect transaxle to engine using four convert housing bolts to pull together: two on top and two on side.
Tightening torque :
47~66 lb·ft (64~89 N·m, 6.5~9.1 kg·m)
4. Remove floor jack from auto transaxle.

5. Remove SST(0K201 270 014).
6. Install No.2 engine mounting to auto transaxle then install three bolts.
Tightening torque :
Nut : 49~69 lb·ft (67~93 N·m, 6.8~9.5 kg·m)
Bolt : 32~40 lb·ft (43~54 N·m, 4.4~5.5 kg·m)
7. Install starter and ground stap. (Refer to starting system, section EE)
8. Install three No.1 engine mounting-to-chassis bolts.
Tightening torque :
32~46 lb·ft (43~52 N·m, 4.4~5.4 kg·m)
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9. Install new clip on left drive shaft.
10. Push drive shaft into transaxle with opening of clip pointing upward.
Tightening torque :
32~46 lb·ft (43~52 N·m, 4.4~5.3 kg·m)
11. Install left lower ball joint into spindle then install pinch bolt.
Tightening torque :
40~50 lb·ft (54~68 N·m, 5.5~6.9 kg·m)
12. Install the stabilizer bar and control link.
Tightening torque :
32~46 lb·ft (43~60.8 N·m, 4.4~6.2 kg·m)
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13. Install the tension rod.
A. Install the front part of tension rod to the body after inserting bushing into the tension rod.
Tightening torque :
87~108 lb·ft (118~147 N·m, 12~15 kg·m)
B. Install the rear of the tension rod to the lower arm after inserting bushing into the tension rod.
C. Insert new cotter pin and then bend it.
14. Install four engine oil pan-to-transaxle mounting bolts then install access cover.
Tightening torque :
27.5~38.0 lb·ft (37~52 N·m, 3.8~5.3 kg·m)
15. Install four drive plate-to-torque converter mounting nuts.

Rotate engine at crank pulley to gain access to all four nuts.
Tightening torque :
25~36 lb·ft (34~49 N·m, 3.5~5.0 kg·m)
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16. Install engine mounting member-to-chassis bolts (two front)and nuts. (two rear)
Tightening torque :
48~65 lb·ft (64~89 N·m, 6.5~9.1 kg·m)
17. Install two nuts to No. 1 & 2 engine mount-to-mounting member.
Tightening torque :
28~38 lb·ft (38~51 N·m, 3.8~5.3 kg·m)
18. Install catalytic converter. (five nuts)
Tightening torque :
27.4~38.3 lb·ft (37.2~51.9 N·m, 3.8~5.3 kg·m)
19. Install U-clip to the catalytic coverter.
Tightening torque :
27.4~38.3 lb·ft (37.2~51.9 N·m, 3.8~5.3 kg·m)
20. Install splash shield to under engine then tighten bolts. (three bolts and three fasteners)
21. Install both right and left wheels then tighten both right and left lug nuts. (four lug nuts each)
Tightening torque :
47~66 lb·ft (64~89 N·m, 6.5~9.1 kg·m)
22. Slide ATF inlet and outlet hose onto ATF Cooler.
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23. Install hose clamp onto hose at center of mark and at angle shown.
24. Lower vehicle.

25. Remove SST(0K 201 170 AA0).
26. Connect oxygen sensor connector.

27. Connect crankshaft position sensor connector.
28. Connect solenoid valve connector.

29. Connect auto transaxle range switch connector.
30. Install washer and nut to auto transaxle linkage and tighten nut then insert U-clip.
Tightening torque :
24~34 lb·ft (32~46 N·m, 3.2~4.7 kg·m)
31. Connect vehicle speed sensor connector.

32. Connect input/turbine speed sensor connector.
33. Install air cleaner assembly.
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34. Connect negative and positive battery cable.
35. Fill transaxle with ATF. (Refer to automatic transaxle fluid)
36. Adjust auto transaxle control cable. (Refer to selector lever)
DIASSEMBLY
General note
1. Disassemble transaxle in a clean area (dustproof work space) to prevent entry of dust into mechanisms.
2. Inspect individual transaxle components.
3. Use only plastic hammers when applying force to separate light alloy case joints.
4. Never uses shop towels during disassembly they may leave particles that can clog fluid passages.
5. Several parts resemble one another; organize them so that they do not get mixed up.
6. Disassemble control valve assembly and thoroughly clean it when a clutch or brake band has burned or when
ATF has degenerated.
Cleaning note
1. Clean transaxle exterior thoroughly with a steam cleaner or cleaning solvents before disassembly.
2. Clean removed parts with cleaning solvent, and dry with compressed air. Clean out all holes and passages with
compressed and check that there are no obstructions.
Wear eye protection when using compressed air to clean components.
Do not allow ATF to spill when removing torque converter.

Disassembly
1. Remove torque converter from converter housing.
2. Pull out oil pump shaft by hand.
3. Remove oil level gauge and oil filler tube.

4. Remove input/turbine speed sensor.
5. Remove transaxle range switch.
6. Remove selector cable bracket.
7. Remove bracket.
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8. Remove crankshaft position sensor.
9. Remove vehicle speed sensor and driven gear.
10. Remove inlet pipe.
11. Remove outlet pipe.
12. Assemble SST(0K130 175 011A/0K130 990 007).
Do not lean transaxle to one side during disassembly. It may rotate suddenly and cause injury.
Remove oil pan before turning transaxle over. This will ensure that any foreign material remains in
pan.
13. Remove oil pan and gasket (19 bolts).
A. Examine any material found in pan or on magnet to determine condition of transaxle.
Material Possible source
Clutch facing material Drive plate or brake band
Steel (magnetic) Bearings, gears, or driven plate wear
Aluminum (Nonmagnetic) Bushings or cast aluminum parts wear
B. If large amounts of material are found, replace torque converter and carefully check transaxle for cause.
14. Remove clip (one bolt).

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15. Disconnect solenoid connectors.
16. Remove strainer (three bolts).

17. Remove A, B and C bolts and brackets shown in figure.
Bolt length (Measured from below head):

A: 1.18 in (30 mm)
B: 1.97 in (50 mm)
C: 0.55 in (14 mm)
18. Remove control valve body.

19. Remove manual shaft and manual plate.
A. Loosen nut and pull out manual shaft.
B. Remove nut, washer and manual plate.
20. Remove bolt and parking pawl lever holder.
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21. Remove parking pawl lever (two bolts).
22. Remove detent lever and return spring.
23. Remove actuator support.

24. Remove oil pump assembly (10 bolts).
25. Remove reverse/forward clutch assembly.

A. Remove turbine shaft snap ring.
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B. Pull reverse/forward drum and remove clutch assembly.
26. Remove small sun gear and one-way clutch No. 1.
Use a piece of wire to secure brake band so that it is not damaged by being
stretched.
27. Remove 2-4 brake band.
28. Pull anchor shaft while holding strut.

29. Remove strut.
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30. Remove servo.
A. Compress servo piston and remove snap ring.
B. Remove servo retainer, servo piston and spring.
31. Remove one-way clutch No. 2 and planetary carrier assembly.

A. Remove snap ring.
B. Remove one-way clutch No. 2 together with planetary carrier assembly.

C. Remove friction plate.
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32. Remove internal gear.
A. Remove snap ring.
B. Remove internal gear from output shell.
33. Remove 3-4 clutch assembly.

A. Remove O-ring from turbine shaft at converter housing side.
B. Pull out turbine shaft to remove 3-4 clutch assembly.
C. Remove 3-4 clutch assembly from turbine shaft.

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34. Remove bolts (converter housing side: eight bolts transaxle case side: seven bolts) and remove transaxle case by
tapping lightly with a plastic hammer.
35. Remove output shell from output gear.
36. Remove differential assembly.
37. Remove bearing housing.

A. Remove roll pin with a pin punch.
B. Remove (11) bolts securing bearing housing.
C. Remove bearing housing by tapping lightly with a plastic hammer.
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38. Remove idler gear assembly and output gear assembly by tapping out from torque converter side.
39. Remove bearing cover.

A. Remove bearing cover bolts.
B. Remove converter housing from SST(0K130 175 011A).
C. Press bearing cover assembly out of converter housing.
Install bearing outer race during reassembly to adjust

preload.
40. Press out bearing outer races by using SST(0K130 170 012).
Precaution
1. If drive plates or brake band are replaced with new ones, soak new part in ATF for at least two hours before
installation.
2. Before assembly, apply ATF to all seal rings, rotating parts, O-rings, and sliding parts.
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3. All O-rings, seals, and gaskets must be replaced with new ones.
4. Use petroleum jelly, not grease, during reassembly.
5. When it is necessary to replace a bushing, replace the subassembly that includes that bushing.
6. Assemble housing within 10 minutes after applying sealant and allow it to cure at least 30 minutes after assembly
before filling transaxle with ATF.
Disassembly
1. Remove accumulator pistons and springs from clutch housing by applying compressed air through oil passage as
shown in figure.
REASSEMBLY
1. Align bush cover with guide bolts as shown and press it in.
Tightening torque:
96 ~120 Ib·in (10.8~13.7 N·m, 110~140 kg·cm)
2. Install idler gear and output gear as an assembly by tapping it with a plastic hammer.
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3. Install bearing housing.
A. Install bearing housing on converter housing.
B. Align groove on idler shaft with mark on bearing housing.

C. Tap a new roll pin in with a pin punch and hammer.
D. Install 11 mounting bolts.
Tightening torque:
14~18 Ib·ft (19~25 N·m, 1.9~2.6 kg·m)
4. Install parking pawl.

A. Install parking pawl and shaft.
B. Install spring and snap ring.
C. Move manual shaft and verify that parking pawl operates.
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5. Install actuator support with new bolts.
Tightening torque:
11~13 Ib·ft (15~17 N·m, 1.5~1.8 kg·m)
6. Install detent lever and return spring.
7. Install parking assist lever.
8. Install lever holder and bolt.
Tightening torque:
69.6~94.8 Ib·in (7.9 ~10.7 N·m, 80~110 kg·cm)
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9. Install manual shaft and manual plate.
A. Install manual plate, washer and nut.
B. Tighten nut to specified torque.
Tightening torque:
31~40 Ib·ft (42~54 N·m, 4.2~5.6 kg·m)
10. Install differential assembly into converter housing. Install SST(0K201 270 014) or equivalent.
11. Install a new oil control ring onto output gear assembly.
12. Install output shell to output gear and install bearing race onto output shell.
Thrust bearing outer diameter:

2.84 in (72.1 mm)
13. Apply a thin coat of silicone sealant (TB-1217B) to contact surfaces of converter housing and transaxle case.
14. Install new O-rings onto converter housing.
Insure that sealer will not be forced into oil passages when transaxle case is
installed.
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15. Mount transaxle case to converter housing.
Tightening torque:
28~38 Ib·ft (38~51 N·m, 3.8~5.3 kg·m)
16. Install SST(0K201 190 019) to hold turbine shaft.
17. Install turbine shaft and 3-4 clutch assembly.

A. Assemble turbine shaft and 3-4 clutch assembly.
B. Verify that thrust bearing is properly installed.

C. Install turbine shaft and 3-4 clutch assembly into transaxle case as an assembly.
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18. Install internal gear.
A. Install internal gear to output shell.
B. Install snap ring.
19. Install planetary carrier assembly.

A. Verify that thrust bearing and bearing race are properly installed.
B. Hold turbine shaft with one hand to prevent it from rotating.

C. Install planetary carrier assembly into 3-4 clutch drum by rotating it.
20. Install low and reverse brake drive and driven plates (four each).
Installation order:
Driven-Drive-Driven-Drive-Driven-Drive-Driven-Drive
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21. Install retaining plate.
22. Install snap ring.

23. Install friction plate.
24. Install one-way clutch No. 2.
A. Hold one-way clutch No. 2 horizontally.
B. Install it by turning planetary carrier counterclockwise.
C. Install snap ring.
25. Install anchor strut and shaft.
Interlock 2-4 brake band and anchor strut as

shown.
26. Install 2-4 brake band in transaxle case so that it is fully expanded.
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27. Install small sun gear and one-way clutch No. 1.
A. Verify that thrust bearing and bearing race are installed in correct position.
B. Install small sun gear and one-way clutch No. 1 while rotating it.
28. Install reverse/forward clutch assembly.

A. Verify that thrust bearing is installed in correct position.
B. Install reverse/forward clutch assembly while rotating it.
Measure height difference between reverse/forward drum and transaxle case.
Maximum: 0.035 in (0.9 mm)

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29. Install snap ring into bottom ring groove of turbine shaft.
30. Measure total end play select a suitable bearing race as follows:
A. Set thrust bearing onto reverse/forward clutch assembly.
B. Remove previously used race and gasket.

C. Set thickest bearing race 0.087 in (2.2 mm) onto oil pump.
D. Set oil pump onto clutch assembly.
Do not install oil pump gasket at this time.
E. Measure clearance (A) between transaxle case and oil pump.

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F. Select a suitable bearing race from chart below.
G. Remove oil pump.

H. Place selected bearing race and a new gasket onto oil pump.
I. Install oil pump onto transaxle assembly.
Tightening torque:
14~18 Ib·ft (19~25 N·m, 190~260 kg·cm)
31. Verify 2-4 brake band adjustment as follows:

A. Install servo piston to SST(0K201 190 021).
B. Install servo retainer O-ring onto SST(0K201 190 021).
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C. Coat O-ring with ATF, install band servo assembly and SST into transaxle case and secure it with snap
ring..
Insure that 2-4 brake band is correctly positioned against band servo piston stem.
D. Set a dial indicator against piston stem.
E. Apply compressed air through fluid passage with a rubber-tipped air nozzle as shown and measure piston
stem stroke.
Air pressure:
57 psi (392 kPa, 4.0 kg/cm²) maximum
Stroke: 0.039~0.067 in (1.0~1.7 mm)
F. If not within specification, select proper piston stem from below.

Page 115 of 243
G. Remove band servo assembly and remove SST.
Do not deform snap ring when removing it.
32. Install servo into transaxle case.

A. Install servo spring and servo assembly.
B. Install snap ring.
C. Position 2-4 brake band onto band servo piston stem.
33. Align manual valve with pin on manual plate and install control valve body.
Tightening torque:
69.6~94.8 Ib·in (7.9~10.7 N·m, 80~110 kg·cm)
Bolt length:
(measured from below the head)
A: 1.18 in (30 mm)
B: 1.97 in (50 mm)
C: 0.55 in (14 mm)
34. Connect solenoid valve and ATF temperature sensor connectors.

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35. Connect solenoid connector.
Attach magnets inside oil pan in positions shown on illustration (in oil
pan).
36. Install a new gasket and oil pan tighten 19 bolts.
Tightening torque:
74.4~94.8 Ib·in (8.4~10.7 N·m, 80~110 kg·cm)
37. Install inlet pipe and outlet pipe.

38. Install driven gear and vehicle speed sensor.
39. Install crankshaft position sensor.
40. Install bracket and select bracket.
41. Install transaxle range switch.
A. Turn manual shaft to N position.
B. Install transaxle range switch.
C. Tighten transaxle range switch mounting bolts.
Tightening torque:
70~95 Ib·in (7.9~10.7 N·m, 80~110 kg·cm)
D. Verify that the selector lever range position and transaxle range switch correspond.
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42. Remove transaxle from SST(0K 130 990 007/0K130 175 011A).
43. Install a new O-ring and install oil level gauge and oil filler tube to transaxle case.
Tightening torque:
69.6~94.8 Ib·in (7.9~10.7 N·m, 80~110 kg·cm)
44. Install input/turbine speed sensor.
Tightening torque:
69.6~94.8 Ib·in (7.9~10.7 N·m, 80~110 kg·cm)
45. Install oil pump shaft.

46. Install a new O-ring onto turbine shaft.
47. Fill torque converter with ATF.
ATF type: SK ATF SP-III or DIAMOND ATF SP-III
• Hold torque converter in an upright position when filling it with ATF. Do not allow fluid to
overflow.
• If converter does not fit in easily, do not try to force it: install carefully.
• Do not damage O-ring onto turbine shaft.
48. Install torque converter in converter housing while rotating it to align splines.
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49. To ensure that the torque converter is installed accurately, measure distance "A" between face of torque
converter and mounting surface of converter housing.
Distance (A): 0.535 in (13.6 mm)
Bearing preload
1. Remove bearing outer race from bearing cover.
2. Install bearing cover with SST(0K201 190 017).
3. Align bearing cover with guide bolts as shown, and press it in. Torque bearing cover bolts.
Tightening torque:
96~120 Ib·in (10.8~13.7 N·m, 110~140 kg·cm)
4. Remove bearing outer race and adjustment shims from bearing housing using a pin punch and hammer.
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5. Install bearing outer race to bearing housing.
Do not install adjustment shims.

Eliminate gap (arrow) by turning A or B of selector.
6. Set SST(0K201 175 A01) onto converter housing.

7. Install outer race removed in step 1 to SST(0K201 175 A01).
8. Set output gear assembly onto SST(0K130 191 A03).

9. Set four SST(0K130 191 A03) on converter housing in positions shown.
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10. Set bearing housing on output gear assembly and install four SST(0K130 175 A04) then tighten them to
specified torque.
Tightening torque:
14~18 Ib·ft (19~25 N·m, 1.9~2.6 kg·m)
11. To seat bearing, turn SST(0K201 175 A01) to increase clearance indicated by arrow with SST(0K130 175
A03) until SST(0K130 175 A03) no longer turns.
12. Turn selector in opposite direction until gap is reduced.
13. Mount SST(0K130 322 020) and torque meter on output gear.
14. Adjust clearance of SST(0K130 175 A03) to obtain specified preload.
Preload:
0.27~7.8 Ib·in (0.03~0.8 N·m, 0.3~9.0 kg·cm)
Read preload when output gear is rotating.

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• Measure clearance around entire circumference and select shims equivalent to maximum
clearance.
• The maximum allowable number of shims is 7.
15. Measure clearance. Select adjustment shim(s) equivalent to measured clearance.
16. Remove bearing housing and SST(0K201 175 AA0).

17. Remove bearing outer race from bearing housing, refer to Bearing and Race Locations.
18. Install required shim(s).

19. Press bearing race into bearing housing with SST (or equivalent)
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20. Press bearing outer race into bearing cover.
21. Install output gear assembly and bearing housing.
Tightening torque:
14~18 Ib·ft (19~25 N·m, 1.9~2.6 kg·m)
Do not install idler gear at this time.
22. Using SST(0K130 191 A04) and a torque meter, verify that preload reading is within specification.
Preload:
0.27~7.8 Ib·in (0.03~0.8 N·m, 0.3~9.0 kg·cm)
23. Remove bearing housing and output gear assembly.

REASSEMBLY
Installation order
2-3 accumulator: piston-spring-stopper
1-2 accumulator: piston-spring-stopper
N-D accumulator: piston-spring-stopper
N-R accumulator: spring-piston-stopper
Page 123 of 243
Apply even pressure to perimeter of accumulator pistons and stops to avoid damaging O-ring and seal rings while
installing.
1. Apply ATF to new seal rings and install them onto accumulator pistons.
2. Install accumulator pistons and springs.

3. Install stopper and snap ring.
Inspection
The torque converter is welded together and cannot be disassembled.
1. Check outer surface of converter for damage or cracks and replace it if necessary.
2. Check whether there is any rust on pilot hub of converter or on boss. If there is any, remove it completely.
3. Measure bushing of converter boss. Replace converter assembly if bushing is worn.
Bushing inner diameter

Standard: 2.088 in (53.030 mm)
Maximum: 2.090 in (53. 075 mm)
Washing inside converter

1. Drain any ATF remaining in converter.
2. Pour in ATF 0.5 US qt (0.5 liter, 0.44 lmp qt).
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3. Shake converter to clean inside. Pour out ATF.
4. Pour in ATF.
5. Shake converter to clean inside. Pour out ATF.
Replace torque converter if it contains any metallic

particles.
INSPECTION
Accumulator spring
1. Measure spring free length.
2. If not within specification, replace spring.
Automatic Transaxle System > Automatic Transaxle System > Kick Down Band > Components and
DISASSEMBLY
1. Disassembly in order shown in figure.
Page 125 of 243
COMPONENT
Use a piece of wire to secure 2-4 brake band so that it is not damaged by being allowed to fully expand.
Automatic Transaxle System > Automatic Transaxle System > Kick Down Band > Repair procedures
(F4E-K)
Inspection
2-4 Brake band
Page 126 of 243
1. Check 2-4 brake band for wear and burnt friction material.
Servo return spring

1. Measure servo return spring free length and check for deformation.
Free length: 1.703 in (43.25 mm)
2. If not within specification, replace servo return spring.

Orifice check spring
Do not compress spring when measuring it with vernier calipers.

2. If not as specified, replace spring.
Re-Assembly
Install spring exactly in direction shown.

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1. Install orifice valve, orifice check spring and orifice holder as shown.
2. Install orifice assembly and washer to transaxle case.

3. Tighten orifice assembly using a hexagonal wrench.
Tightening torque:
29~39 Ib·ft (40~53 N·m, 4.0~5.0 kg/cm²)
4. Install band strut.

5. Install 2-4 brake band.
6. Apply ATF to new O-rings and install them to servo piston.
D-ring inner diameter

Piston stem side: 2.303 in (58.5 mm)
Servo retainer side: 1.157 in (29.4 mm)
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7. Insert piston stem into servo piston and secure it with a new spring clip.
8. Apply ATF to new O-ring and install it to servo retainer.
O-ring inner diameter: 2.587 in (65.7 mm)
9. Assemble servo piston and servo retainer.
Do not install servo piston and retainer into transaxle case at this
time.
Automatic Transaxle System > Automatic Transaxle System > Differential > Components and
PRE-INSPECTION
Backlash of side gear and pinion gear
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1. Before disassembly, measure backlash of side gears and pinion gears. If not within specification, replace
differential assembly.
Backlash
Standard: 0.001~0.004 in (0.025~0.1 mm)
Do not remove side bearings unless necessary.
COMPONENT
Page 130 of 243
Automatic Transaxle System > Automatic Transaxle System > Differential > Repair procedures (F4E-
K)
DISASSEMBLY
1. Remove two side gears and two thrust washers.
1) Use protective plates in vise to prevent damage to

differential.
2) Insert punch into spring pin hole from ring gear side.
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2. Place gear case on a vise and knock pin out with suitable pin punch and hammer. Then remove two thrust
washers, two pinion gears and pinion shaft.
3. Remove side bearing inner race (side opposite ring gear) from gear case with SST(0K130 171 013).
4. Remove speedometer drive gear.
5. Remove side bearing (ring gear side) from gearcase with SST(0K670 990 AA0)
REASSEMBLY
1. Set speedometer drive gear onto ring gear and case assembly.
Do not reuse side bearings if they were removed.
2. Press side bearing (side opposite ring gear) into ring gear and case assembly with SST(0K990 175 AA1).
3. Press on other side bearing (ring gear side) in same manner.

4. Install pinion gears and thrust washers into case.
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5. Install pinion shaft.
6. Install spring pin, and stake hole to prevent spring pin from coming out of gear case.
7. Install thrust washers and side gears into gear case at same time, then rotate them around pinion gears and align
them with driveshaft holes.
Be certain that both side gears are centered in their respective driveshaft holes. If not, remove both side
gears and re?nstall them again.
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8. Measure backlash of side gears and pinion gears as follows:
A. Install left and right driveshafts in differential assembly.
B. Support driveshafts on V-blocks.
C. Measure backlash of both pinion gears.
Backlash
Standard: 0.001~0.004 in (0.025~0.1 mm)
9. If backlash is not within specification, replace differential assembly.
DIFFERENTIAL BEARING (SIDE BEARING) PRELOAD
The next eighteen steps measure differential side bearing preload and select proper adjustment shim(s).
1. Remove side bearing outer race and adjustment shims from transaxle case.
2. Set transaxle case on a stand and install SST (0K130 191 A07).
3. Tighten SST(0K130 191 A06) to specified torque.
Tightening torque: 27~38 Ib·ft (36~51 N·m, 3.7~5.3 kg·m)

Page 134 of 243
4. Set differential assembly into converter housing.
Eliminate gap (arrow) by turning either A or B of selector. Do not

overtighten.
5. Install side bearing outer race removed from transaxle case into SST(0K201 175 A01). Set SSTand outer race
onto differential assembly.
6. Set SST(0K130 175 A02) on converter housing in positions shown.
7. To seat bearing, turn SST(0K201 175 A01) to increase clearance indicated by arrow with SST(0K130 175
A03) until it no longer turns.
8. Turn selector in opposite direction until gap is reduced.
9. Insert SST through transaxle case and attach it to pinion shaft.

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10. Install torque meter.
Read preload when differential is

rotating.
11. Adjust clearance between A and B to obtain specified preload reading.
Preload: 4.3 Ib·in (0.5 N·m, 0.05 kg·cm)
12. Measure clearance between A and B.

13. Add 0.0118 in (0.3 mm) to measured clearance and select shim(s) closest in value to measurement.
• Measure clearance around entire circumference and select shims based on maximum
clearance.
Thickness of shim in (mm)

0.020 (0.50) 0.022 (0.55) 0.024 (0.60) 0.026 (0.65)
0.028 (0.70) 0.030 (0.75) 0.031 (0.80) 0.034 (0.85)
0.035 (0.90) 0.037 (0.95) 0.039 (1.00) 0.041 (1.05)
0.43 (1.10) 0.045 (1.15) 0.047 (1.20) 0.049 (1.25)
0.051 (1.30) 0.053 (1.35) 0.055 (1.40) 0.057 (1.45)
14. Remove transaxle case.

15. Install required shim(s) and tap bearing race into transaxle case.
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16. Install transaxle case.
Tightening torque: 28~38 lb·ft (38~51 N·m, 3.8~5.1 kg·m)
17. Using SST(0K130 191 A05) and a torque meter, verify that preload is within specification. If not within
specification, return to Step 1.
Preload: 27.6~33.6 Ib·in (3.0~3.9 N·m, 30~40 kg·cm)
18. Remove transaxle case.
Automatic Transaxle System > Hydraulic System > Oil Cooler > Components and Components
Location (F4E-K)
Component
Page 137 of 243
Automatic Transaxle System > Hydraulic System > Oil Cooler > Repair procedures (F4E-K)
Removal
2. Remove RH side gravel shield (seven bolts) from under engine.
3. Place a drain pan under radiator.
4. Disconnect ATF inlet hose and outlet hose.
5. Remove ATF inlet pipe and outlet pipe.
6. Remove radiator.
(Refer to section EM, cooling system)
Installation
Page 138 of 243
1. Install radiator.
(Refer to section EM, cooling system)
2. Install ATF inlet pipe and outlet pipe.
Tightening torque:
24~84 Ib·ft (32~47 N·m, 3.3~4.8 kg·m)
3. Slide ATF inlet and outlet hose onto ATF cooler pipe until it is fully seated against the ridge.
4. Install hose clamp onto hose at center of mark and at angle shown.
5. Verify that the hose clamp does not interfere with any other parts.
6. Install RH side gravel shield under engine.
7. Lower vehicle.
8. Check ATF level.
(Refer to Automatic transaxle fluid)
Automatic Transaxle System > Hydraulic System > Oil Pump > Components and Components Location
(F4E-K)
COMPONENT
Page 139 of 243
Automatic Transaxle System > Hydraulic System > Oil Pump > Repair procedures (F4E-K)
DISASSEMBLY
1. Remove bearing race.
2. Remove four seal rings.
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3. Loosen six mounting bolts evenly in pattern shown and remove oil pump cover from oil pump housing.
Do not use a punch to mark outer and inner rotors.

4. Mark outer and inner rotors as shown, and separate them from oil pump housing.
5. Remove plug then remove washer, spring and fluid pressure bypass valve.
INSPECTION
Oil pump housing, outer rotor, inner rotor
1. Install outer rotor and inner rotor.
2. Measure clearance between end of oil pump housing and outer rotor and inner rotor at no less than four places
along their circumferences.
Clearance
Standard: 0.00079~0.0157 in (0.02~0.04 mm)
Maximum: 0.0020 in (0.05 mm)
3. If not as specified, replace oil pump assembly.

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4. Measure clearance between oil pump boss and inner rotor in at least four places and calculate average value.
Inner diameter
Standard:
0.00157~0.00453 in (0.04~0.115 mm)
Maximum:
0.0049 in (0.125 mm)
5. If not within specification, replace oil pump as an assembly.

INSPECTION (Spring)
2. If not as specified, replace oil pump as an assembly.

Fluid pressure by pass valve
1. Measure fluid pressure by pass valve and check for wear.
Outer diameter
Minimum: 0.550 in (13.98 mm)
2. If not as specified, replace oil pump as an assembly.
RE-ASSEMBLY
1. Install fluid pressure by pass valve spring into oil pump housing, and verify that fluid pressure by pass valve moves
smoothly.
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2. Install a new washer and plug.
Tightening torque:
24~33.6 lb·in (32~47 N·m, 3.2~4.8 kg·m)
3. Align marks and install outer and inner rotors.
4. Install oil pump flange.

5. Mount oil pump cover onto oil pump housing.
6. Tighten six bolts evenly and gradually in order shown.
Tightening torque:
72~97.2 lb·in (8.1~10.9 N·m, 82~112 kg·m)
7. Install oil pump shaft and rotate pump rotors to verify smooth oil pump operation.
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8. Install four seal rings.
9. Apply petroleum jelly to bearing race and secure it on oil pump cover.
Bearing race outer diameter: 3.46 in (88.0mm)
Automatic Transaxle System > Valve Body System > Valve Body > Components and Components
Location (F4E-K)
Component
• Be especially careful when handling control valve because it consists of most precise and delicate parts of
transaxle.
• Neatly arrange removed parts to avoid confusing similar parts.
• Clean removed parts with cleaning solvent, and dry them with compressed air. Clean out all holes and passages
with compressed air.
Page 144 of 243
Component (Continued)
Page 145 of 243
Page 146 of 243
• Before assembly, make sure all parts are perfectly clean.

• Apply ATF to all parts.
• Do not reuse gaskets or O-rings.
Page 147 of 243
Oil strainer installation positions

Low control valve body
Page 148 of 243
Premain control valve body

Lower control valve body side
Main control valve body side
Main control valve body

Premain control valve body side
Page 149 of 243
Upper control valve body side
Upper control valve body
Bolt installation positions and external parts locations

Page 150 of 243
Tightening torque
Identification Length
Ib·in (N·m,
mark in (mm)
kg·cm)
0.551
(14)
1.181
A
(30)
1.575
B
(40)
70~95
1.969
C (7.9~10.7,
(50)
80~110)
3.228
D
(82)
3.543
E
(90)
3.740
01
(95)
Page 151 of 243
Automatic Transaxle System > Valve Body System > Valve Body > Repair procedures (F4E-K)
DISASSEMBLY
1. Remove oil pipe assembly.
2. Remove O-rings from oil pipe assembly.

3. Remove shift solenoid A.
4. Remove torque converter clutch solenoid valve and oil strainer.
5. Remove shift solenoids B and C.
6. Remove linear solenoid valve.

Page 152 of 243
7. Remove nine upper control valve body bolts.
8. Remove two screws from upper control valve body.

9. Remove gasket B, upper separator plate, oil filter, oil strainer and gasket A.
10. Remove seven main control valve body bolts then remove main control valve.
11. Remove gasket D, main separator plate and gasket C.

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12. Remove four rubber balls from main control valve body.
13. Remove oil strainer, steel ball and two rubber balls from premain control valve body.
14. Remove six bolts then remove premain control valve body.
15. Remove gasket E, lower separator plate, oil filter, and gasket F.
16. Remove oil strainer from lower control valve body.
DISASSEMBLY (MAIN CONTROL VALVE BODY)

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• Each valve should slide in/out under its own weight.

• When a valve will not slide in/out under its own weight, depending on valve, push it out with a wire or replace
valve body open-side down and lightly tap it with a soft hammer.
• If a valve surface or bore is scratched or damaged, replace control valve body.
• Do not drop or lose valves or internal parts.
• Before assembly, make sure all parts are thoroughly clean.
• Apply ATF to all parts and bores.
• Note proper direction of valves and internal parts.
• Do not reuse any part that has been dropped.
• Wrap a screwdriver or rod with tape before using it to insert a valve.
1. Disassemble in order shown in figure.
COMPONENT
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Reassembly note
1. Install oil strainer into lower control valve body, refer to oil strainer installation positions.
2. Set oil filter into lower separator plate.
Gasket F and gasket E are not interchangeable. They are identified by their shape in area designated in
illustration.
3. Set new gasket F, lower separator plate and new gasket E onto lower valve body.
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4. Set premain control valve body onto lower valve body and install seven bolts.
Tightening torque:
69.6~94.8 Ib·in (7.9~10.7 N·m, 80~110 kg·cm)
5. Install two rubber balls and oil strainers into their proper positions in premain control valve body. (Refer to
Rubber Ball and oil strainer installation positions)
6. Install rubber balls into their proper positions in main control valve body. (Refer to main control valve body.)
Gasket C and gasket D are not interchangeable.

They are identified by their shape in area designated in illustration.
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7. Set the new gasket C, main separator plate, and gasket D onto main control valve body.
8. Secure gasket C, main separator plate and gasket D to main control valve body with two screws in locations
shown.
Tightening torque:
11.3~16.5 Ib·in (1.27~1.86 N·m, 13~19 kg·cm)
9. Set main control valve body onto premain control valve body.
Match bolt head letters as shown.

10. Loosely tighten bolts, refer to bolt installation positions and external parts locations.
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11. Set the oil filter in upper separator plate.
Gasket A and gasket B are not interchangeable.

They are identified by their shape in area designated in
illustration.
12. Set new gasket A, upper separator plate, and new gasket B onto upper control valve body.
13. Secure gasket A, upper separator plate and gasket B to upper control valve body with two screws in locations
shown.
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14. Set upper control valve body onto main control valve body and install nine bolts.
Tightening torque:
69.6~94.8 Ib·in (7.9~10.7 N·m, 80~110 kg·cm)
Match bolt head letters as shown.
15. Loosely tighten lower control valve body bolts. (Refer to bolt installation positions and external parts locations)
16. Install linear solenoid valve.
Tightening torque:
69.6~94.8 Ib·in (7.9~10.7 N·m, 80~110 kg·cm)
17. Install shift solenoids B and C, oil strainers and bracket.

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18. Tighten mounting bolts.
Tightening torque:
69.6~94.8 Ib·in (7.9~10.7 N·m, 80~110 kg·cm)
19. Install torque converter clutch solenoid and oil strainer.
Tightening torque:
69.6~94.8 Ib·in (7.9~10.7 N·m, 80~110 kg·cm)
20. Install shift solenoid A and oil strainer onto upper valve body.
Tightening torque:
69.6~94.8 Ib·in (7.9~10.7 N·m, 80~110 kg·cm)
21. Apply ATF to new O-rings and install them onto oil pipe assembly.
22. Install oil pipe assembly.
Tightening torque:
69.6~94.8 Ib·in (7.9~10.7 N·m, 80~110 kg·cm)
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23. Apply ATF to new O-ring and install it onto oil strainer assembly.
24. Install oil strainer onto control valve body and then tighten three bolts.
Tightening torque:
69.6~94.8 Ib·in (7.9~10.7 N·m, 80~110 kg·cm)
RE-ASSEMBLY
1. Insert 3-4 shift spring, 3-4 shift valve and stop plug. Secure them with stop pin.
2. Insert low reducing spring, low reducing valve and stop plug. Secure them with stop pin.
3. Insert 1-2 shift spring, 1-2 shift valve and stop plug. Secure them with stop pin.
4. Insert pressure regulator valve, pressure regulator spring, pressure regulator spring seat, regulator plug sleeve,
pressure regulator plug and stop plug. Secure them with roll pin.
5. Insert 2-3 timing valve and 2-3 timing spring. Secure them with spring retainer.
6. Proceed to insert manual valve.
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INSPECTION
1. Measure spring free lengths.
2. If not within specification, replace spring(s).
Automatic Transaxle System > Valve Body System > Upper Control Valve Body > Repair procedures
(F4E-K)
DISASSEMBLY

1. Disassemble in order shown in the figure.
COMPONENT
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INSPECTION
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RE-ASSEMBLY
1. Insert solenoid reducing valve and solenoid reducing spring then secure them with spring retainer.
2. Insert P.E accumulator valve and P.E accumulator spring then secure them with spring retainer.
Automatic Transaxle System > Valve Body System > Pre Main Control Valve Body > Repair
procedures (F4E-K)
DISASSEMBLY

COMPONENT
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INSPECTION
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RE-ASSEMBLY
1. Insert bypass spring, bypass valve and stop plug. Secure them with stop pin.
2. Insert 2-3 shift spring, 2-3 shift valve and plug. Secure them with stop pin.
3. Insert converter relief valve and converter relief spring. Secure them with spring retainer.
4. Insert lock up control spring, lock up control valve, and stop plug. Secure them with stop pin.
Page 167 of 243
Automatic Transaxle System > Clutch & Brake > Reverse and Overdrive Clutch > Components and
COMPONENT
Automatic Transaxle System > Clutch & Brake > Reverse and Overdrive Clutch > Repair procedures
(F4E-K)
Page 168 of 243
INSPECTION
Clutch operation
1. Set reverse/forward clutch assembly onto oil pump.
2. Check clutch operation by applying compressed air through fluid passages shown.
Applied air pressure:

Clutch clearance
Reverse clutch
1. Measure clearance between retaining plate and snap ring.
Clearance: 0.035~0.047 in (1.2~1.9 mm)
2. If not as specified, replace parts as necessary.

Forward clutch
Clearance: 0.039~0.047 in (1.0~1.2 mm)

Coasting clutch
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1. Remove snap ring, retaining plate, drive plates, driven plates and dished plate of forward clutch, refer to
disassembly.
Clearance: 0.039~0.047 in (1.0~1.2 mm)

INSPECTION
Drive plates
1. Measure facing thickness in three places and determine average of three readings.

Minimum: 0.055 in (1.4 mm)
2. If not within specification, replace spring and retainer assembly.

Spring and retainer assembly
1. Measure spring free length and check for deformation.
Free length: 0.805 in (20.45 mm)

Reverse clutch piston
1. Verify that there is no air leakage when applying compressed air through oil hole opposite return spring.
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2. Verify that there is air flow when applying compressed air through oil hole on return spring side.
Air pressure:
Coasting clutch piston

1. Verify that there is no air leakage when applying compressed air through oil hole opposite return spring.
Air pressure:
Reverse/forward drum
1. Verify that there is air flow when applying compressed air through backside of drum.
2. Verify that there is no air leakage when applying compressed air through inside of drum.
Air pressure:
DISASSEMBLY
1. Remove thrust bearing.
2. Remove snap ring.
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3. Remove retaining plate.
4. Remove forward clutch drive plates and driven plates. (each three)
5. Remove dished plate.
6. Install SST(0K201 190 AA1) in coasting clutch drum as shown.
7. Compress spring and retainer assembly.

9. Remove SST(0K201 190 AA1) then remove spring and retainer assembly.
12. Remove coasting clutch drive plates and driven plates. (each two)
13. Remove coasting clutch drum from reverse/forward drum by applying compressed air through fluid passage.
14. Remove coasting clutch piston from coasting clutch drum by applying compressed air through fluid passage.
15. Remove outer seal and inner seal from coasting piston.
16. Remove two seal rings and outer seal from coasting clutch drum.
17. Install SST(0K201 190 AA1) in reverse/forward drum as shown.
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18. Compress piston return spring.
19. Remove snap ring from groove with snap ring pliers.
20. Remove SST(0K201 190 AA1) from reverse/forward drum.

21. Remove snap ring with a screwdriver.

23. Remove reverse clutch driven plates and driven plates. (each two)
25. Remove return spring stopper and piston.
26. Place reverse/forward drum on oil pump.
27. Remove reverse piston by applying compressed air through reverse clutch fluid passage.
28. Remove two seal rings from reverse piston.
RE-ASSEMBLY
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1. Install reverse clutch piston.
A. Apply ATF to inner and outer faces of seals, and install them to reverse clutch piston.
B. Insert reverse clutch piston by pushing evenly around circumference, bearing careful not to damage seal rings.
2. Install piston return spring with tabs facing away from reverse clutch piston.
3. Install return spring stop with step facing upward.

4. Install snap ring half-way down reverse/forward drum as shown.
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5. Install SST(0K201 190 AA1) on reverse/forward drum.

7. Install snap ring with a screwdriver.
8. Remove SST(0K201 190 AA1).
9. Install dished plate with dished side facing downward into drum as shown.
10. Install drive and driven plates. (two each)
Installation order:
Driven-Drive-Driven-Drive
13. Measure reverse clutch clearance.
A. Measure clearance between snap ring and retaining plate of reverse clutch.
B. If clearance is not within specification, adjust it by selecting correct thickness snap ring.
Reverse clutch clearance:

0.035~0.047 in (0.9~1.2 mm)
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14. Install coasting clutch drum.
A. Apply ATF to inner and outer faces of seal, and install it onto coasting clutch drum.
B. Face outer seal lip toward inside by gently rolling it down around circumference for easier installation into
drum.
C. Install coasting clutch drum in correct position in reverse/forward drum as shown.

D. Push evenly around circumference, being careful not to damage outer seal.
15. Install coasting clutch piston.

A. Apply ATF to inner and outer faces of seals and install them onto coasting clutch piston.
drum.
16. Install spring and retainer assembly.

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17. Install SST(0K201 190 AA1) in coasting clutch as shown.

21. Install dished plate with dished side facing out of drum as shown.
22. Install drive and driven plate.
Installation order:
Driven-Drive-Driven-
Drive
25. Measure coasting clutch clearance.

A. Measure clearance between snap ring and retaining plate of coasting clutch.
Coasting clutch clearance:

0.039~0.048 in (1.0~1.2 mm)
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26. Install dished plate with dished side facing downward into drum, as shown.
27. Install drive and driven plates.
Installation order:
Driven-Drive-Driven-Drive-Driven-
Drive

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30. Measure forward clutch clearance.
A. Measure clearance between snap ring and retaining plate of forward clutch.
Forward clutch clearance:

0.039~0.048 in (1.0~1.2 mm)
31. Check clutch operation as follows:

A. Set clutch assembly onto oil pump.
B. Check clutch operation by applying compressed air though fluid passages shown.
Air pressure:
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32. Apply petroleum jelly to thrust bearings, and secure them on each side of reverse/forward drum.
Thrust bearing outer diameter

Oil pump side: 3.39 in (86.0 mm)
Small sun gear and one-way clutch side:
2.21 in (56.1 mm)
Automatic Transaxle System > Clutch & Brake > One Way Clutch > Components and Components
Location (F4E-K)
Small sun gear one-way clutch No.1
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Automatic Transaxle System > Clutch & Brake > One Way Clutch > Repair procedures (F4E-K)
INSPECTION
One-way clutch No.1 operation
1. While holding one-way clutch outer race, verify that one-way clutch inner race rotates smoothly when turned
counterclockwise and locks when turned clockwise. If not as specified, replace one-way clutch No.1.
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INSPECTION
Small sun gear, sun gear drum
1. Measure small sun gear and sun gear drum inner diameters.
Inner diameter
Small sun gear:
0.828 in (21.021 mm) maximum
Sun gear drum:
1.198 in (30.425 mm) maximum
INSPECTION
One-way clutch No.2
1. Check for following and repair or replace as necessary.
Assembly one-way clutch and inner race, then verify that one-way clutch rotates only clockwise and
smoothly.
A. Damaged or worn one-way clutch and operation.

B. Detached roller.
Planetary carrier
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1. Check for following and repair or replace as necessary.
A. Damage or worn gear and operation.
B. Clearance between pinion washers and planetary carrier.
Clearance: 0.008~0.028 in (0.2~0.7 mm)
DISASSEMBLY
1. Remove thrust bearing from small sun gear.
2. Remove snap ring with a snap ring pliers.
3. Remove one-way clutch inner race from sun gear drum.
4. Remove thrust bearing.
5. Remove snap ring with a snap ring pliers.
6. Remove small sun gear.
7. Remove one-way clutch No.1, one-way clutch outer race and thrust bearing from sun gear drum.
DISASSEMBLY
1. Disassembly in order shown in figure.
COMPONENT (ONE-WAY CLUTCH NO.2 AND PLANETARY CARRIER)
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RE-ASSEMBLY
1. Install small sun gear into sun gear drum.
2. Install new snap ring.
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3. Apply petroleum jelly to thrust bearing, and secure it to one-way clutch inner race.

3.39 in (86.0 mm)
Install one-way clutch into outer race with spring cage facing as shown.
4. Install one-way clutch No.1 into one-way clutch outer race.
Align splines of one-way clutch inner race and small sun gear clutch
hub.
5. Install one-way clutch inner race into one-way clutch outer race by turning inner race counterclockwise.
6. Hold one-way clutch outer race. Verify that the inner race turns only counterclockwise.
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7. Install new snap ring.
8. Verify that when small sun gear is held, one-way clutch outer race turns smoothly and only clockwise.
9. Apply petroleum jelly to thrust bearing, and secure it to sun gear drum.

3.39 in (86.0 mm)
RE-ASSEMBLY
1. Assembly planetary carrier to inner race.
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Install tangs of bearing race into alignment holes.
3. Apply petroleum jelly to bearing race and secure them to each side of one-way clutch No.2 and planetary carrier
assembly.
Bearing race outer diameter

Sun gear drum side:
3.307 in (84.0 mm)
Automatic Transaxle System > Clutch & Brake > Low and Reverse Brake > Components and
COMPONENT
Page 187 of 243
Automatic Transaxle System > Clutch & Brake > Low and Reverse Brake > Repair procedures (F4E-
K)
INSPECTION
Low and reverse brake operation
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1. Check low and reverse brake operation by applying compressed air as shown.
Air pressure:
57 psi (392 kPa, 4.0 kg/cm²)maximum
Brake clearance
Low and reverse brake clearance:

0.083~0.094 in (2.1~2.4 mm)
INSPECTION
Drive plates
1. Measure facing thickness in three places, and determine average of three readings.

2. If not within specification, replace drive plate(s).

Spring and retainer assembly
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1. Measure spring free length and check for deformation.
Free length of spring: 0.563 in (14.3 mm)
DISASSEMBLY
3. Remove drive plates and driven plates. (each four)
4. Install SST(0K2CA 190 AA1) in transaxle case as shown.

7. Remove SST(0K201 190 AA1), then remove spring and spring retainer assembly.
8. Remove low and reverse brake piston by applying compressed air through fluid passage.
Air pressure: 57 psi (392 kPa, 4.0 kg/cm²)
9. Remove outer seal and inner seal from low and reverse brake piston.
REASSEMBLY
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1. Install low and reverse brake piston.
A. Apply ATF to inner and outer seals, and install them onto low and reverse brake piston.
Seal Ring Inner Diameter:

Inner Seal: 5.539 in (140.7 mm)
Outer Seal: 6.713 in (170.5 mm)
case.
C. Install low and reverse brake piston by pushing evenly around circumference, being careful not to damage
outer seal.
2. Install spring and retainer assembly.
3. Install SST(0K201 190 AA1) in transaxle case.

5. Install snap ring with snap-ring pliers.
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7. Check low and reverse brake piston operation.
A. Pour in ATF until low and reverse brake piston is fully submerged.
B. Check that no bubbles come from between piston and seals when applying compressed air through fluid
passage.
Air pressure: 57 psi (392 kPa, 4.0 kg/cm²)
8. Install drive and driven plates.(each four)
Installation order:
Driven-Drive-Driven-Drive-Driven-Drive-Driven-
Drive

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11. Measure low and reverse brake clearance.
A. Measure clearance between snap ring and low and reverse brake retaining plate.
B. If clearance is not within specification, adjust it by selecting a proper snap ring.
Low and reverse brake clearance:

0.094 ~ 0.083 in (2.1 ~ 2.4 mm)
12. Check low and reverse brake operation by applying compressed air through fluid passage as shown in figure.
Air pressure:
13. Remove snap ring, retaining plate, drive and driven plates and set aside for later assembly.
Automatic Transaxle System > Clutch & Brake > The Other Clutch & Brake Component >
Components and Components Location (F4E-K)
Component
Page 193 of 243
Automatic Transaxle System > Clutch & Brake > The Other Clutch & Brake Component > Repair
procedures (F4E-K)
INSPECTION
Clutch operation
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1. Install SST(0K201 190 AA1) as shown, and check clutch operation by applying compressed air.
Air pressure:
Clutch clearance
1. Measure clearance between snap ring and retaining plate of 3-4 clutch.
2. If clearance is not within specification, replace parts as necessary.
3-4 clutch clearance:

0.051~0.063 in (1.3~1.6 mm)
Inspection
Drive plate
1. Measure facing thickness in three places, and determine average of three readings.

2. If not within specification, replace drive plate(s).

Return spring
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2. If not within specification, replace spring.
3-4 clutch piston

1. Verify that there is not air leakage when applying compressed air through oil hole opposite return spring.
Air pressure:
Disassembly
1. Remove two trust bearings.
2. Install SST(0K201 190 AA1) to 3-4 clutch as shown.
5. Remove SST(0K201 190 AA1), then remove spring and retainer.
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8. Remove drive and driven plates. (each three)
9. Install SST(0K201 190 016) onto 3-4 clutch drum and remove 3-4 clutch piston using compressed air.
Air pressure:
10. Remove SST(0K201 190 016).

11. Remove outer seal and inner seal 3-4 clutch piston.
Re-Assembly
1. Install 3-4 clutch piston.
A. Apply ATF to inner and outer seals, and install them onto 3-4 clutch piston.
B. Install piston by pushing evenly around circumference, being careful not to damage seal rings.
2. Install return spring and spring retainer.

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3. Install SST(0K 201 190 AA1) to 3-4 clutch as shown.
4. Compress return spring and spring retainer.

7. Install drive and driven plates. (each three)
Installation order:
Driven-Drive-Driven-Drive-Driven-
Drive
10. Measure 3-4 clutch clearance.

A. Measure clearance between snap ring and retaining plate of 3-4 clutch.
3-4 clutch clearance:

0.051~0.063 in (1.3~1.6 mm)
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11. Check clutch operation as follows:
A. Install SST(0K201 190 AA1) as shown, and check clutch operation by applying compressed air.
Air pressure:
12. Apply petroleum jelly to thrust bearings and secure them to each side of 3-4 clutch drum.
Thrust bearing outer diameter

Planetary carrier side: 2.21 in (56.1 mm)
Output shell side: 2.84 in (72.1 mm)
Automatic Transaxle System > Gear System > Idle Gear > Components and Components Location
(F4E-K)
COMPONENT
Page 199 of 243
Use protective plates in vise to prevent damage to SST(0K130 191 034).
Automatic Transaxle System > Gear System > Idle Gear > Repair procedures (F4E-K)
DISASSEMBLY
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1. Secure idler shaft in a vise with SST(0K130 191 034), and remove lock nut.
2. Remove bearing outer race from idler gear with SST(0K130 170 012).
RE-ASSEMBLY
1. Press bearing outer races.
2. Install idler gear bearing onto idler shaft, then install idler gear, adjustment shims, spacer and bearing.
Use protective plates in vise to prevent damage to SST.

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3. Secure idler shaft in a vise with SST(0K130 191 034) and tighten lock nut to lower limit of tightening torque.
Tightening torque:
95~130 Ib·ft (128~176 N·m, 13~18 kg·m)
Use protective plates in vise to prevent damage to idler gear.
4. Check and adjust idler gear bearing preload.

A. Turn idler gear assembly and SST(0K130 191 034) over and secure gear in vise.
B. Attach SST(0K130 191 034) and spring scale or torque wrench and measure preload while tightening lock
nut.
Read preload when idler shaft is rotating.
Tightening torque:
95~130 Ib·ft (128~176 N·m, 13~18 kg·m)
Preload:
0.27~7.8 Ib·in (0.03~0.8 N·m, 0.3~0.9 kg·cm)
Page 202 of 243

• Preload is reduced by increasing thickness of shims, or increased by reducing thickness.
5. If specified preload cannot be obtained within specified tightening torque, adjust by selecting proper adjustment
shims.
Automatic Transaxle System > Gear System > Output Gear > Components and Components Location
(F4E-K)
COMPONENT
Automatic Transaxle System > Gear System > Output Gear > Repair procedures (F4E-K)
DISASSEMBLY
1. Remove two seal rings.
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2. Remove bearings from output gear with suitable tools.
RE-ASSEMBLY
1. Press new bearings onto output gear with suitable tools.
2. Apply ATF to new seal rings and install them to each side of output gear.
Automatic Transaxle System > Gear System > Bearing Cover Assembly > Components and
COMPONENT
Page 204 of 243
Automatic Transaxle System > Gear System > Bearing Cover Assembly > Repair procedures (F4E-K)
DISASSEMBLY
1. Remove oil seal.
2. Remove bearing outer race with a pin punch and hammer as shown.
3. Remove O-ring.
RE-ASSEMBLY
1. Apply ATF to new O-ring and install O-ring.
2. Press bearing outer race into the cover.
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3. Press new oil seal into bearing cover with SST(0K201 190 017).
Automatic Transaxle System > Automatic Transaxle Control System > Troubleshooting (F4E-K)
Transaxle range switch (Inhibitor switch)
Operation inspection
1. Verify that the starter operates only with ignition switch in START position and selector lever in P or N position.
2. Verify that the back-up lights illuminate when shifted to R position with ignition switch in ON position.
3. Verify that the position of selector lever and shift pattern indicator of instrument cluster correspond.
4. If not as specified, check the transaxle range switch.
Continuity inspection
2. Disconnect transaxle range switch connector.
3. Check for continuity at transaxle range switch.
4. If not as specified, replace or adjust transaxle range switch.

5. Connect transaxle range switch connector.
ATF temperature sensor

1. Remove air cleaner and fresh air duct.
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2. Connect ohmmeter between terminals 5 and 8.
3. Measure resistance while warming up ATF (driving vehicle).

4. Verify that the resistance drops as shown in following table and graph.
Solenoid valves
2. Disconnect solenoid valve connector.
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3. Measure resistance between each terminal and a ground.
Resistance: 14~18 Ω
• D: Torque converter clutch solenoid

• A: Shift solenoid valve A
• B: Shift solenoid valve B
• C: Shift solenoid valve C
4. If not correct, check wiring for an open or short-circuit. Replace solenoid valve.
1. Disconnect 55-pin connector from transaxle control module.
2. Check continuity between terminals A, D, G and B and C ground.
3. If not correct, check wiring for an open or short circuit.

Linear solenoid valve
3. Measure resistance between ground terminals and solenoid valve connector terminal 7.
Resistance: 4.1~5.1Ω
4. If not connect, check wiring for an open or short-circuit, replace pressure control valve.
5. Connect solenoid valve connector.
SHIFT MECHANISM
SELECTOR LEVER
Operation inspection
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Shift selector lever from P range to other ranges with ignition switch ON and brake pedal depressed.
1. Verify that selector lever can only be shifted as shown in figure.
2. Verify that there is a click at each range when shifted from P to 1 range.
3. Verify that positions of selector lever and indicator are aligned.

4. Verify that button returns smoothly when pushed.
Adjustment
1. Shift selector lever to P range.
2. Loosen the selector cable adjust nut at the transaxle side then verify that the position of selector lever is P range.
(If not, turn the adjust nut to P range.)
3. Tighten the selector cable adjust nut at the transaxle side.
Tightening torque :
5.8~8.0 lb·ft (7.8~10.8 N·m, 0.8~1.1 kg·m)
Automatic Transaxle System > Automatic Transaxle Control System > Repair procedures (F4E-K)
Auto transaxle (electrical system)
O/D off switch
1. Turn ignition switch ON.
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2. Verify that the O/D OFF indicator light is not illuminated. Depress O/D OFF switch and verify that the O/D OFF
indicator light illuminates.
3. If O/D OFF indicator light does not operate, continue with inspection of voltage test.
INSPECTION
Voltage
1. Remove Console. (Refer to section Body).
3. Measure voltage at O/D switch connector.
4. If not as specified, check for continuity at O/D switch.
2. Disconnect O/D switch connector.
3. Check for continuity at O/D switch H-05.
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4. Replace selector lever Knob if not as specified. (refer to removal and replacement).
5. Check wiring harness for continuity if switch is operating correctly (O/D switch to transaxle control module, O/D
switch to body ground).
6. Connect O/D switch connector.
7. Install console. (Refer to section BD, Body)
9. If not as specified, replace transaxle fluid temperature sensor and connector wiring as an assembly.
10. Install air cleaner and fresh air duct.
Automatic Transaxle System > Automatic Transaxle Control System > Shift Lever > Schematic
Diagrams (F4E-K)
WIRING HARNESS DIAGRAM
Page 211 of 243
Automatic Transaxle System > Automatic Transaxle Control System > Shift Lever > Description and
Operation (F4E-K)
Shift Lock System
DISCRIPTION AND OPERATION
To operate actuator and move the sellector lever, operation conditions of shift lock system installed on the automatic
transaxle are just ignition switch 'ON' brake switch 'ON' and shift sellector lever 'P' range. Also, Ignition switch can
be pulled out when only shifting 'P' range.
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Detail operation condition
Automatic Transaxle System > Automatic Transaxle Control System > Shift Lever > Components and
COMPONENT
Page 213 of 243
COMPONENT (SELECT LEVER)

Page 214 of 243
Automatic Transaxle System > Automatic Transaxle Control System > Shift Lever > Repair
procedures (F4E-K)
REMOVAL
2. Remove ash tray then remove two screws.
3. Disconnect cigarette lighter connector then remove center panel.
4. Remove rear console and front console.
Page 215 of 243
6. Remove selector cable mounting bolts.
7. Remove selector cable nut.
8. Loosen the shift lock cable nut and then disconnect the shift lock cable.
9. Remove the console bracket.
10. Disconnect the O/D OFF Connector.
11. Loosen the set plate nut after raising the vehicle then disconnect the selector lever.
REPLACEMENT
1. Install selector lever then tighten selector lever base plate nuts.
Tightening torque:
11.5~16.6 Ib·ft (15.7~22.6 N·m, 1.6~2.3 kg·m)
Install the set plate with the arrow headed to the front as shown in the figure.
2. Install the console bracket.

3. Connect the O/D OFF Connector.
Page 216 of 243
5. Tighten selector lever base plate nut.
Tightening torque:
60~86 Ib·in (6.8~9.8 N·m, 70~100 kg·cm)
6. Tighten selector cable mounting bolt and nut.
Tightening torque:
60~86 Ib·in (6.8~9.8 N·m, 70~100 kg·cm)
7. Tighten the shift lock cable nut.
Tightening torque:
7~10.8 Ib·ft (9.8~14.7 N·m, 1.0~1.5 kg·m)
8. Install the front and rear console.

9. Install cover penel then connect cigar lighter connector.
10. Install Ash tray.
12. Verify correct operation of selector lever.
DISASSEMBLY
1. Insert a thin piece of metal from terminal side of connector then with terminal locking tab pressed down, pull
terminal out of connector.
2. Place gear case on a vise and knock pin out with suitable pin punch and hammer to remove two strut washers,
pinion gear and pinion shaft.
3. Remove the indicator panel.
4. Remove cover.
5. Turn position indicator lamp counterclockwise to remove position indicator lamp from indicator panel.
6. Remove two detent roller assembly screw then remove assist plate, upper spring plate and spring plate.
7. Remove bolt from base plate.
8. remove two guide plate bolts then remove guide plate.
Page 217 of 243
9. Remove selector lever.
RE-ASSEMBLY
1. Install the selector lever to the base plate.
2. Install the guide plate to the base plate.
Tightening torque:
61~86.81Ib·in (6.9~9.8N·m,70~100kg·cm)
3. Apply grease(spec: O-GL02) to inside of roller.

5. Loosenly install spring plate and assist plate.
Tightening torque:
18~26 Ib·in (2.0~2.9N·m,20~30kg·cm)
6. Apply grease(0-GL02) to inside and outside of the guide plate.
OPERATION INSPECTION
1. Turn ignition switch to "ON" positon.
2. Verify that the sellector lever is shifted to P range.
3. Verify that the sellector lever isn't shifted from P range to any other position with not applying the brake pedal.
4. Verfy that selector lever isn't shifted without applying the brake pedal.
Page 218 of 243
5. Shift the sellector lever to R range.
6. Verify that ignition switch isn't shifted to LOCK position.
7. Shift the selector lever to P range.
8. Verify that ignition switch isn't shifted to LOCK position.
9. Repair it if necessary.
Manual release method of shift lock
1. Verify that the selector lever locks on the P range.
2. Press screwdriver after opening cap and putting it into the hole.
3. Shift sellector lever.
Actuator Voltage & Continuity inspection

1. Remove console (refer to BD, Body).
Remove F-07 connector when checking the continuity between connector terminal and ground
terminal.
2. Shift the selector lever to P range and inspect terminal voltage and continuity.
3. Replace the actuator or repair wiring harness if necessary.
Automatic Transaxle System > Troubleshooting > P0604

TCM ROM/RAM
Diagnostic trouble code • TCM ROM malfunction
P0601, P0604 • TCM RAM malfunction
Details Transaxle control module does not read diagnostic trouble codes from output
1. TCM malfunction
Possible cause
2. Short circuit in wiring output device
Page 219 of 243

Temporarily install known good TCM.
Verify harness connectors. Are connectors Yes Go to next step.
1 If problem is corrected, replace TCM.
OK?
No Repair or replace connectors as necessary.
Return vehicle to original condition. Clear all DTC's. Verify repairs by driving vehicle with scan too
2
connected and monitor for pending codes.

TRANSAXLE RANGE SIGNAL MALFUNCTION

• Transaxle range signal (P, R, N, D, 2, 1) malfunction (No signal)
P0707
• Transaxle range signal (P, R, N, D, 2, 1) malfunction (No
P0708
signals)
Details • Corroded or faulty Range Switch.
• Open between Meter Fuse and Range Switch.
• Open between Range Switch and TCM on one or more circuits.
• Short to Battery between Range Switch and TCM on one or
more circuits.
• Short between two or more wires between Range Switch and
TCM.
If a P1500 is stored along with a P0750, there is a problem

with the Meter Fuse circuit. Any shorts or opens in the Meter
Fuse circuit should be repaired before continuing with this
troubleshooting tree.
Possible 1. Transaxle range switch malfunction.

cause 2. Damaged wiring or connectors between transaxle range switch
and transaxlecontrol module.
3. Transaxle control module malfunction.
Page 220 of 243
1 With ignition off, disconnect A-03 from Range Yes Spray inside of A-03 and Range Switch with
Switch. Check for any signs of corrosion or silicone lubricant and blow out connector and
water.Is any water or corrosion present? Range Switch with compressed air. Check A-03
and Range Switch carefully for cracks or missing
water seals and replace as necessary. If corrosion
has penetrated terminals or wiring, replace Front
Harness and Range Switch.
No Go to step 2.
2 Verify Meter Fuse is okay. Turn ignition on and, Yes Go to step 3.
measure voltage at A-03/I (B+).
No Locate source of open between Meter Fuse and
Is battery voltage available?
A-03/I.
3 Turn ignition off and reconnect A-03 to Range Yes Go to step 4.
Switch. Remove connector cover from H-01 No If voltage is below specs in R, D, 2 or 1 (or more
(TCM) (leave H-01 connected to TCM to do than 0v in P or N), referring to chart "A", measure
tests). Turn ignition on and measure voltages per
resistance across Range Switch with ignition off
chart "A".
and A-03 disconnected. Replace Range Switch if
Are voltages correct per chart "A"?
resistance between terminals is greater than 1
ohm. If Range Switch tests okay, check affected
circuit per diagram "A" and repair as necessary. If
voltage is available in R, D, 2 or 1 when Gear
Selector is in "All other positions", disconnect A-
03 from Range Switch and measure incorrect
voltage(s) at TCM again. Replace Range Switch if
voltage drops to 0v. If voltage does not drop to
0v, refer to chart "A" and locate source of short to
voltage.
If voltage is 0v in Park or Neutral when gear

selector is "All other gear positions", disconnect
A-03 from Range Switch and measure voltage at
H-01/18 again. Replace Range Switch if voltage
returns to specification. If voltage remains at 0v,
locate short to ground between A-03/9 and H-
01/18 (refer to chart "A").
4 Clear codes and verify any repairs by starting vehicle with Hi-scan Pro connected to OBD-II connector and
monitoring for pending codes (refer to section 3 of the Hi-scan Pro Generic OBD-II Program Card
reference manual). Allow to idle in each gear position for a minimum of 2 1/2 minutes.
CHART A
Page 221 of 243

ATF SENSOR
Diagnostic trouble
code • ATF sensor low
P0712 • ATF sensor high
P0713
Details • ATF sensor malfunction
Possible 1. Short circuit in wiring
cause 2. ATF sensor malfunction

1 Are all connections at connector and connector Yes Go to next step.
pins OK?
No Repair or replace connector(s).
2 Measure terminal voltage of transaxle control Yes Go to step 5.
module at terminal 22.
Standard voltage:
ATF 68°F (20°C): Approx. 4.0 No Go to next step.
ATF 266°F (130°C): Approx. 1.5
Is terminal voltage as specified?

3 Measure ATF sensor resistance of transaxle Yes Go to step 5.
control module at terminal 21 and 22.
Standard voltage:
ATF 68°F (20°C): 24.461~29.205kΩ No Replace ATF sensor.
ATF 140°F (68°C): 4.29~5.61kΩ
ATF 176°F (80°C): 3.05~3.6kΩ
4 Yes Go to next step.
Are connectors and wiring between transaxle
control module and ATF sensor OK? No Replace or repair connector and wiring.
5 Yes Temporarily install known good TCM.

After diagnostic trouble code has been cleared, Go to next step.
does reinspection diagnostic trouble code appear? If problem is corrected, replace TCM.
Page 222 of 243
No The problem is a temporarily poor connection of
wiring or connectors and should be investigated
further.
6 Return vehicle to original condition. Clear all DTC's. Verify repairs by driving vehicle with scan tool

INPUT/TURBINE SPEED SENSOR
P0716 • Input/turbine speed sensor signal malfunction
P0717 • Input/turbine speed sensor circuit malfunction
Details Input/turbine speed sensor signal is not input to transaxle control
module when vehicle is above 25 mph (40 km/h); turbine is below
96 rpm and vehicle is in D, 2 or 1.
Possible 1. Input/turbine speed sensor malfunction.
cause 2. Damaged wiring or connectors between input/turbine speed
sensor transaxle control module.

1 Are all connections at connectors and connector Yes Go to next step.
pins OK?
module at terminal 44 and 16.
Standard voltage:
Engine running (P, N position): Approx. 2.5 No Go to next step.
Ignition switch ON: Approx. 2.3

3 Measure input/turbine speed sensor resistance at Yes Go to step 6.
terminals 44 and 16 of harness connector as
follows:
2. DisconnDisconnect transaxle control module
connector.
No Go to next step.
3. Measure resistance.
Standard resistance: 300~400Ω(@68°F/20°C)
Is resistance within standard?

4 Measure input/turbine speed sensor resistance at Yes Go to next step.
input/turbine speed sensor itself as follows:
Page 223 of 243
2. . Remove air cleaner assembly.
3. Disconnect input/turbine speed sensor
connector.
No Replace input/turbine speed sensor.
Standard resistance: 300~400Ω(@68°F/20°C)

5 Are connectors and wiring between transaxle Yes Go to next step.
control module and input/turbine speed sensor
OK? No Repair or replace connectors and wiring.
6 After diagnostic trouble code has been cleared, Yes Temporarily install known good TCM.
does reinspection diagnostic trouble code appear? Go to next step.
further.

ENGINE SPEED INPUT
P0726 • Engine speed input signal malfunction
P0727 • Engine speed input malfunction
Details • (P0726): Loss of engine speed sensor signal to the transaxle
control module. DTC is triggered if engine rpm is above 750 rpm
• (P0727): Loss of engine speed sensor signal to the transaxle
control module. DTC is triggered if turbine output is above600
rpm and engine output is below 96 rpm and vehicle is not in P or
N ranges.
Possible 1. Damaged wiring or connectors between engine control module
cause and transaxle control module.
Page 224 of 243
1 Is diagnostic trouble code P0335 displayed? Yes Repair.
No Go to next step.
pin OK? No Repair or replace connector(s).
3 Measure terminal voltage of engine control Yes Go to step 5.
module.
No Go to next step.

4 Are connectors and wiring between engine control Yes Go to next step.
module (31) and transaxle control module (40)
further.

INCORRECT FIRST GEAR RATIO
Incorrect first gear ratio
P0731
Details Shift solenoids A, B, C, vehicle speed sensor, input/turbine speed
sensor, and transaxle fluid temperature sensor function normally, and
vehicle speed is between 12 mph (20 km/h) and 32 mph (51 km/h)
in 3GR. Input/turbine speed sensor and vehicle speed sensor signals
indicate that gear ratio is above set value.
Possible 1. ATF level low
cause 2. Line pressure low
4. Solenoid valve malfunction
6. Forward clutch, 3-4 brake band, one-way clutch No. 1 slippage
7. Linear solenoid valve
Page 225 of 243
10. Damaged wiring or connector between PCM and ECM

1 Are diagnostic trouble codes P0716 and P0717 Yes Repair.
displayed? No Go to next step.
No Go to next step.
No Go to next step.
Do transaxle seals, sealant and gaskets prevent
leakage? No If ATF level is not OK, adjust it.
ATF condition If ATF condition is not OK, repair as follows:
1. Clear pink: Normal condition. • Condition 2 - Replace transaxle.
• Condition 3 and/or 4 - Replace ATF, then go
2. Dark or black (with friction material):
to next step.
Worn powertrain components
3. Milky pink: Water contamination If there is leakage, repair or replace parts as
4. Light to dark brown (oxidation): necessary and/or replace transaxle, then go to next
Overheated or old fluid step.
No Overhaul transaxle and repair or replace parts as

necessary.
6 Is stall test OK? Yes Go to next step.

necessary.
7 Is time lag test OK? Yes Go to next step.
Time lag:
N position → D range : Approx. 0.5~0.6 seconds
NN position → 2 range : Approx. 0.5~0.7
seconds No Replace transaxle.
NN position → R position : Approx.0.6~0.7
seconds
8 Are shift point and shift shock OK? Yes Go to next step
No Replace transaxle.
Page 226 of 243
No The problem is a temporary slip of clutch and
should be investigated further.

INCORRECT SECOND GEAR RATIO
Incorrect second gear ratio
P0732
sensor, and transaxle fluid temperature sensor function normally,
throttle opening angle is over 3/8, and vehicle speed is between 17
mph (28 km/h) and 60 mph (96 km/h) in 2GR. Input/turbine speed
sensor and vehicle speed sensor signals indicate that gear ratio is
above set value.
10. Damaged wiring or connection between PCM and ECM

No Go to next step.
No Go to next step.
to next step.
Page 227 of 243

necessary.

Stall speed: 2200~2800 rpm necessary.
Time lag:
N position → 2 range : Approx. 0.5~0.7 seconds No Replace transaxle.
N position → R position : Approx. 0.6~0.7
seconds
8 Are shift point and shift shock OK? Yes Go to next step.

INCORRECT THIRD GEAR RATIO
Page 228 of 243
Incorrect third gear ratio
P0733
sensor, and transaxle fluid temperature sensor function normally and
vehicle speed is between 19 mph (30 km/h) and 32 mph (51 km/h)
in 3GR. Input/turbine speed sensor and vehicle speed sensor signals
indicate that gear ratio is above set value.

displayed?
No Go to next step.
No Go to next step.
No Go to next step.
No If ATF level is not OK, adjust it.
leakage? If ATF condition is not OK, repair as follows:
ATF condition
• Condition 2 - Replace transaxle and repair or
1. Clear pink: Normal condition.
replace parts as necessary; then go to next
2. Dark or black (with friction material): step.
Worn powertrain components • Condition 3 and/or 4 - Replace ATF, then go
3. Milky pink: Water contamination to next step.
Overheated or old fluid If there is leakage, repair or replace parts as
necessary and/or replace transaxle, then go to next
step.
Page 229 of 243

necessary.

necessary.
Time lag:
seconds

INCORRECT FOURTH GEAR RATIO
Incorrect fourth gear ratio
P0734
sensor, and transaxle fluid temperature sensor function normally and
vehicle speed is between 44 mph (77 km/h) and 65 mph (105
km/h) in 4GR. Input/turbine speed sensor and vehicle speed sensor
signals indicate that gear ratio is above set value.
6. 2-4 brake band, 3-4 clutch slippage
Page 230 of 243

No Go to next step.
No Go to next step.
to next step.

necessary.

necessary.
Time lag:
seconds
Page 231 of 243

Torque converter clutch system malfunction
P0741 • Torque converter clutch system malfunction (Stuck OFF)
P0742 • Torque converter clutch system malfunction (Stuck ON)
sensor and transaxle fluid temperature sensor function normally.
Vehicle speed is between 44 mph (71 km/h) and 65 mph (105
km/h) and difference in the number of engine revolutions and reverse
and forward drum revolutions when in 4GR TCC operation is
above 100 rpm.
Possible 1. Air leak between Throttle Position Sensor (TPS) and Mass Air
cause Flow Sensor (MAFS).
2. ATF level low.
3. Line pressure low.
4. Torque converter clutch slipping.
5. Torque converter control valve or torque converter relief valve
stuck.
6. Torque converter clutch (TCC) solenoid valve malfunction.
If any codes relating to TPS or MAFS are present, do ALL

repairs associated with those codes before proceeding with
troubleshooting for a P0741 and P0742 code. A faulty TPS or
MAFS can set a P0741 and P0742.

1 Check for cracked intake tube, improperly Yes Repair as necessary.
installed intake tube or other source of air leak
between TPS and MAFS.
Were any air leaks found between TPS and No Go to step 2.
MAFS?
2 Check ATF level (transaxle at normal operating Yes Check for any signs of leakage from transaxle.
temperature). Repair as necessary and fill transaxle to full level.
Is ATF level low?
No Go to step 3.
3 Check ATF condition and com Yes For ATF condition #2, replace transaxle.
pare to following chart. For ATF condition #3, replace fluid, repair source
Page 232 of 243
1. Clear reddish pink: Normal condition. of contamination and perform pressure tests. If
2. Dark or black (with friction material): Internal water contamination is severe, replace transaxle.
transaxle malfunction or excessive wear. For ATF condition #4, replace fluid and perform
pressure tests.
3. Milky pink: Water contamination.
4. Light to dark brown (oxidized): Overheated or
worn out fluid.
No Go to step 4.
Is fluid condition other than normal.

4 Check line pressure and compare to the following Yes Go to step 5.
chart.
Is line pressure within specification?

5 Check torque converter front chamber pressure as Yes Replace valve body.
follows:
1. Remove front chamber access plug. NOTE:
Front chamber pressure access plug is
accessible through the front of the cut-out in the
engine support cross member. It is the second
5 mm allen headed plug (counting from the
bottom of the transaxleforward).
No Remove transaxle drain pan and TCC solenoid
2. Screw pressure port adapter into front
from valve body. Attach a short piece of hose to
chamber port and attach adapter to 100 psi
TCC solenoid nipple. Blow through hose and
gauge.
verify air does not escape from hole in body of
3. Disconnect coupler ass? from transaxle and solenoid. Jumper a wire from solenoid body to
attach a 10 amp fused jumper wire to the #2 battery negative and another wire from solenoid
pin at the transaxle (make the jumper wire long terminal to battery positive. Blow through hose
enough to reach the battery positive post). and verify air escapes from hole in body of the
4. Raise vehicle on the lift so the tires are at least solenoid. If TCC solenoid checks okay, replace
5 inches off of the floor and apply hand brake. valve body.
5. Start engine and warm it up to operating Clear codes and verify any repairs by driving
temperature. vehicle with Hi scan pro connected to OBD-II
connector
6. Shift transaxle into D and raise vehicle speed to
approximately 40 to 50 mph.
6. Shift transaxle into D and raise vehicle speed to Page 233 of 243
approximately 40 to 50 mph.
7. While maintaining vehicle speed, touch loose The torque converter can only be checked by
end of jumper wire to battery positive post and the use of special equipment. If replacing
observe front chamber pressure. Front valve body does not repair vehicle, replace
chamber pressure will drop in 2 stages within 2 transaxle.
seconds with TCC energized.
Front chamber pressure
TCC solenoid off - approximately 88 to 92 psi.
TCC solenoid on - approximately 30 to 38 psi.
Is the front chamber pressure within
specification and does it drop as described
within 2 seconds?

Torque converter clutch system circuit malfunction
Torque converter clutch system circuit malfunction
P0743
Details
Possible 1. Short or open circuit in wiring
cause 2. Short or open circuit in transaxle control module
internal transistors.
3. Short or open circuit in torque converter clutch
solenoid valve

pins OK?
1. Connect negative battery cable after turning on
IG switch.
2. Connect transaxle control module connecter.
No Go to next step.
Standard voltage:
Solenoid valve ON: B+
Solenoid valve OFF: 0 V

3 Measure solenoid valve resistance between Yes Go to step 6.
terminal 4 of connector and a ground as follows:
1. Disconnect negative battery cable after turning
off IG. switch.
2. Disconnect transaxle control module connector.
Page 234 of 243
3. Measure resistance. No Go to next step.
Standard resistance: 14~18 Ω

4 Measure solenoid valve resistance at torque Yes Go to next step.
converter clutch solenoid valve terminal of
solenoid valve connector as follows:
1. Disconnect negative battery cable after turning
off IG. switch.
2. Disconnect solenoid valve connector
No Replace torque converter clutch solenoid valve.

5 Is the wiring between transaxle control module Yes Go to next step.
and solenoid valve OK?
No Repair or replace connectors and wiring.
does reinspection diagnostic trouble code appear. Go to next step.
harness or connectors, and should be investigated
further.

Linear solenoid electrical
Diagnostic trouble code Linear solenoid electrical
P0748
Details
Possible 1. Short or open circuit in wiring.
3. Short or open circuit in linear solenoid valve.
Page 235 of 243
pins OK?
No Go to next step.

No Go to next step.
Standard resistance: 4.1~5.1 Ω

4 Measure solenoid valve resistance at torque Yes Go to next step.
converter clutch solenoid valve terminal of
3. Measure resistance. No Replace linear solenoid valve.
Standard resistance: 4.1~5.1 Ω

further.

Shift solenoid A electrical
Page 236 of 243
Shift solenoid A electrical
P0753
Details
3. Short or open circuit in shift solenoid A.

pins OK? No Repair or replace connector(s).
Standard voltage:
Solenoid valve ON: B+ No Go to next step.

No Go to next step.

4 Measure solenoid valve resistance at terminal A of Yes Go to next step.
No Replace shift solenoid A.

Page 237 of 243
further.

Shift solenoid B electrical
Diagnostic trouble code Shift solenoid B electrical
P0758
Details
3. Short or open circuit in shift solenoid B.

pins OK? No Repair or replace connector(s).
Standard voltage:

No Go to next step.

4 Measure solenoid valve resistance at terminal B of Yes Go to next step.
No Replace shift solenoid B.
Page 238 of 243

No Repair or replace TCM concerning connectors
and wiring.
further.

Shift solenoid C electrical
Shift solenoid C electrical
P0763
Details
3. Short or open circuit in shift solenoid C.

pins OK? No
Standard voltage:

No Go to next step.
Page 239 of 243

4 Measure solenoid valve resistance at terminal C of Yes Go to next step.
No Replace shift solenoid C.

and solenoid valve OK? No Repair or replace connectors and wiring.
further.

TPS SIGNAL CIRCUIT FROM PCM TO TCM
Diagnostic trouble
TPS signal circuit from PCM to TCM
code P1121
1. Short circuit to ground.
Details 2. Short circuit to battery voltage or open circuit.
3. Wrong frequency or duty cycle.
1. Short circuit in wiring.
Possible cause
2. TPS sensor malfunction.
Page 240 of 243
Repair
Is diagnostic trouble code P0122 or P0123 Yes
1 Section EC
displayed?
No Go to next step.
Are all connections at connector and Yes Go to next step.
2
connector pins OK? No Repair or replace connector(s).
Measure terminal voltage of engine control
Yes Go to step 5.
module.
3
No Go to next step.
Are connector and wiring between engine Yes Go to next step.

4 control module and transaxle control module
Yes Go to next step.
After diagnostic trouble code has been If problem is corrected, replace TCM.
5 cleared, does reinspection diagnostic trouble
code appear? The problem is a temporarily poor
No connection of wiring or connectors and
6

VEHICLE SPEED SLGNAL MALFUNCTION
Vehicle speed signal malfunction
P1500
The fault is detected when following conditions are fulfilled.
1. D, 2 or 1 range
Details
· Vehicle speed 0 km/h.
2. Turbine rpm is above 600rpm
1. Speedometer assembly malfunction.
Possible cause 2. Open or short in wiring from vehicle speed sensor to meter set.
3. Open or short in wiring from meter set to transaxle control module.
Page 241 of 243
1
connector pins OK? No Repair or replace connector(s).
Measure terminal voltage of transaxle control
Yes Go to step 4.
2
No Go to next step.
Are connectors and wiring between meter set Yes Go to next step.
3
and transaxle control module (TCM) OK? No Repair or replace connectors and wiring.
After diagnostic trouble code has been If problem is corrected, replace TCM.
4 cleared, does reinspection diagnostic trouble
code appear? The problem is a temporarily poor
No connection of harness or connectors, and
5

TORQUE REDUCTION SIGNAL MALFUNCTION
Diagnostic trouble
Torque reduction signal malfunction
code P1780
Details
2. Transaxle control module (TCM) malfunction.
Possible cause
2. Transaxle control module (TCM) malfunction
Page 242 of 243
1
connector pins OK? No Repair or replace.
Measure terminal voltage of transaxle control
module at terminal 51. Yes Go to step 4.
Standard voltage:
2
Ignition switch ON: Approx. 5
Engine idle: Approx. 5 No Go to next step.
Are connectors and wiring between Yes Go to next step.
3 transaxle control module (TCM) and engine
control module (ECM). No Repair or replace connectors and wiring.
Replace transaxle control module (TCM)
Yes
After diagnostic trouble code has been and / or ECM.
4 cleared, does reinspection diagnostic trouble The problem is a temporarily poor
code appear? No connection of wiring or connectors and

O/D OFF lamp circuit malfunction
O/D OFF lamp circuit malfunction
P1700
1. Short circuit to ground
Details
2. O/D off lamp switch malfunction
1. Short circuit to ground.
Possible
2. O/D OFF lamp switch
cause
malfunction

pins OK?
No Repair or replace.
No Go to next step.

3 Measure terminal voltage of O/D off switch. Yes Go to next step.
Page 243 of 243
No Replace or repair O/D off switch.

4 Are connectors and wiring between O/D off Yes Go to next step.
switch and transaxle control module (TCM) OK? No Repair or replace connectors and wiring.
further.
Page 1 of 99
RIO(BC) > 2005 > G 1.6 DOHC > Body (Interior and Exterior)
Body (Interior and Exterior) > General Information > Troubleshooting

TROUBLESHOOTING
Problem Possible cause Action
Hood does not open or close Striker and latch not properly aligned Adjust
completely Incorrectly installed hood Adjust
Incorrect hood bumper height Adjust
Door glass fails to operate up Incorrect window glass installation Adjust position
and down
Damaged or faulty regulator arm or regulator Correct or replace
Door does not open or close Incorrect door installation Adjust position
completely Defective door checker assembly Correct or replace
Door hinge requires grease Apply grease
Water leak through windshield Defective seal Fill with sealant
and rear window
Defective flange Correct
Wind noise around door Weatherstrip not holding firmly Adjust fit of door
Improperly installed weatherstrip Repair or replace
Improperly closed door Adjust
Improperly fit door Adhyst
Improper clearance between door glass and Adjust
division channel
Deformed door Repair or replace
Bumper face damaged Accident Replace
Energy absorbing foam damaged Accident or exposure Replace
or deteriorated
Reinforcement damaged Accident Replace
Brackets or stays damaged Accident Repair or replace
Missing attaching hardware Accident or vibration Replace
Buckle release does not release
Faulty spring or dirt in mechanism Replace buckle assembly
reliably
Buckle release does not depress Jammed mechanism Replace buckle assembly
Buckle release button does not Jammed mechanism Replace buckle assembly
return to normal position
Webbing is frayed Caught in door Replace retractor assembly
Stitching is loose Wear or accident Replace retractor assembly
Belt retracts part-way Faulty spring Replace retractor assembly
Belt does not extend completely Faulty mechanism Replace retractor assembly
Belt does not retract Wear or accident Replace retractor assembly
Page 2 of 99
Belt does not extend Faulty mechanism replace retractor assembly
Buckle assembly is loose Vibration or accident Tighten to specified torque
Retractor assembly is loose Vibration or accident Tighten to specified torque
Anchor assembly is loose Vibration or accident Tighten to specified torque
Driver's Safety belt is fastened Cable harness, computer module, or Isolate fault with continuity tester.
but reminder lamp and chime indicator light If test fails, repair or replace
either do not actuate or fail to cable. If test fails, repair or
deactivate replace faulty component.
Body (Interior and Exterior) > General Information > Specifications

Tightening torque specifications
Body (Interior and Exterior) > Body Dimension > General Information
Body dimension indication
Projected dimensions
The projected dimension indicates a dimension from a reference point on the body. (Height may be different in some
cases)
Page 3 of 99
Straight-line dimensions (Actual measured dimensions)
The straight-line dimension indicates an actual measured dimension between the measurement reference points.
FRONT BODY STRAIGH-LINE DIMENSIONS

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Side frame panel straight-line dimension (5 Door)

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Side frame panel straight-line dimension (4 Door)

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Interior A straight-line dimension (5 Door)

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Interior A straight-line dimension (4 Door)

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Interior B straight-line dimension (5 Door)

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Interior B straight-line dimension (4 Door)

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Interior C straight-line dimension (5 Door)

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Interior C straight-line dimension (4 Door)

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Rear body straight-line dimension (5 Door)

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Rear body straight-line dimension (4 Door)

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Under body projected dimensions

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Measurement
Description Size of hole
Points
Tension rod mounting hole of No. 1
A Ø 12 mm
Crossmember
B Tension rod mounting hole of front sub frame Ø 12 mm
C Front lower frame hole Ø 20 mm
D Front lower frame hole Ø 16 mm
E Front frame B hole Ø 15 mm
F Spring seat mounting hole of rear side frame Ø 14 mm
G Rear side frame B hole Ø 18 x 20 mm
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Under body straight-line dimensions

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Measurement
Description Size of hole
Points
Tension rod mounting hole of No. 1
A Ø 12 mm
Crossmember
B Tension rod mounting hole of front sub frame Ø 12 mm
C Front lower frame hole Ø 20 mm
D Front lower frame hole Ø 16 mm
E Front frame B hole Ø 15 mm
F Spring seat mounting hole of rear side frame Ø 14 mm
G Rear side frame B hole Ø 18 x 20 mm
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Body (Interior and Exterior) > Exterior > Hood > Description and Operation
Description and operation
The vehicle hood is a front-opening type secured by a standard double-release latch. The hood release T-handle is
located below and to left of steering column. When the hood is opened, it pivots on two hinges and is held open by
a hood prop. The two hinges are secured to body with two bolts and to hood with two bolts on each hinge. The
hood alignment can be adjusted fore-and-aft and side-to-side by loosening hood bolts and moving the hood as
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necessary. The hood latch can be adjusted in both axes to match position of the permanently attached striker.
Body (Interior and Exterior) > Exterior > Hood > Components and Components Location
Components
Body (Interior and Exterior) > Exterior > Hood > Repair procedures
Removal
1. Raise hood and support with prop.
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2. Support hood so it will not fall when hinges are removed.
Have an assistant help remove hood.

3. Remove hinges from hood by removing four bolts.
4. Remove prop from hood.

5. Remove hood.
Installation
Have an assistant help install hood.

1. Install in reverse help install hood.
2. Tighten four hinge bolts to just over finger-tight.
3. Lower and lock the hood.
4. Check fit and adjust as required in accordance with illustrated specifications.
Tighten bolts to
14~19 lb·ft (19~26 N·m, 1.9~2.6 kg·m)
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5. Check alignment of locking mechanism and hood striker and align as required.
Tighten lock assembly bolts to

70~96 lb·in (8~11 N·m, 80~110 kg·cm)
Tighten lock assembly nuts to
70~96 lb·in (8~11 N·m, 80~110 kg·cm)
Body (Interior and Exterior) > Exterior > Trunk Lid > Description and Operation
Trunk lid is attached to body by two hinges connected to each other by two balance springs to provide an assist in
raising trunk lid and fully supports it when it is open.
The trunk lid is fully adjustable.
A striker at center-top of the body and a latch attached to the center-bottom of the trunk lid secures trunk lid in the
closed position.
Weatherstripping on trunk lid jamb flange prevents leakage between trunk and body.
Body (Interior and Exterior) > Exterior > Trunk Lid > Components and Components Location
Components
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Body (Interior and Exterior) > Exterior > Trunk Lid > Repair procedures
Removal
1. Raise the trunk lid
Have an assistant help remove trunk

lid.
2. Support trunk lid so trunk lid will not fall when trunk lid installation bolts are removed.
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3. Remove four trunk lid installation bolts and then remove trunk lid.
4. Remove trunk lid rubber cushion.
Installation
Have an assistant help install trunk lid.

1. Install in reverse order of removal.
2. Tighten four trunk lid installations bolts to just over finger-tight.
3. Lower and lock the trunk lid.
4. Check fit and adjust the clearance on all sides before tightening bolts.
Tighten trunk lid hinge bolts to

7~9 lb·ft (9~13 N·m, 0.9~1.3 kg·m)
5. Check alignment of the locking mechanism and trunk lid striker and align as required.
Tighten striker bolts to

5~7 lb·ft (7~10 N·m, 0.7~1.0 kg·m)
Disassembly (Trunk lid hinge)

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1. Remove trunk lid, Refer to "Trunk lid" in this section.
2. Remove the trunk lid balance spring.

3. Remove rear seat cushion and rear seatback.
Refer to "Seat" in this section.
4. Remove high-mounted brake light assembly.
Refer to " Exterior lights" in this section.
5. Remove package trim and C-pillar trim.
Refer to "Trim" in this section.
6. Remove six trunk lid hinge installation nuts, and then remove trunk lid hinge assembly.
Reassembly (Trunk lid hinge)
Have an assistant help install trunk lid hinge.

1. Install in reverse order or removal.
2. Tighten trunk lid hinge installation nut.
Tighten trunk lid hinge nuts to

7~9 lb·ft (9~13 N·m, 0.9~1.3 kg·m)
3. Install trunk lid.
Body (Interior and Exterior) > Exterior > Tailgate > Description and Operation
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The rear hatch is attched to the body by two pin-type hinges riveted to the body and bolted to the hatch.
A damper stay on either side of the hatch provides an assist in raising the hatch and fully supports it when it is open.
A latch at the center-bottom of the opening secures the hatch in the closed position.
Weatherstripping on the hatch jamb flange prevents leaks between the door and the body. The hatch is fully
adjustable.
Body (Interior and Exterior) > Exterior > Tailgate > Components and Components Location
Components
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Body (Interior and Exterior) > Exterior > Tailgate > Repair procedures
Removal
1. Disconnect battery.
2. Raise the rear hatch.
3. Remove the center grommet from the hatch to expose the rear window washer tubing.
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4. Remove the rear window washer nozzle and remove the tybing from the nozzle.
5. Compress the boot to expose the hose coupling. Secure the coupling outside the boot to make installation of the
nozzle hose easier.
6. Remove the nozzle hose from the coupling.
7. Remove the nozzle hose.
8. Remove trunk end trim. Refer to "Trim" in this section.
9. Remove trunk side trim.
10. Remove seat belt anchor mounting bolt and one screw from C-pillar trim.
11. While pulling C-pillar trim, disconnect electrical connector.
12. Pull the cable harness carefully through the acces hole and through the cable harness boot and grommet.
Removal of the damper stay assemblies requires that the rear hatch be well supported to permit it to
remain in the open position so there is access to the hatch hinges. Have an assistant help in rear hatch
removal.
13. Support the rear hatch in the open position.

14. Remove two mounting bolts from damper stay assembly.
15. Remove one bolt from the left and right-head hinges.
The last step in the removal of the rear hatch is a two-man job. Have an assistant help remove the
hatch.
16. Remove the last two bolts from the hatch

17. Remove the rear hatch.
Installation
Install in reverse order of removal.
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Tighten the hinge bolts to

12~17 lb·ft (16~24 N·m, 1.6~2.4 kg·m)
Adjustment
1. Measure the distances for views A,B and B to determine whether or not the fit is within specifications. If they are
acceptable, tighten the ball studs and the hinge bolts as specified below. If not, make the appropriate adjustments
at the hinges. The options are :
A. Move the hatch forward or backward
B. Move the hatch left or right
C. Rotate the hatch colckwise or counterclockwise.
D. Or any combination of the three.
Tighten the hinge bolts to 14 lb·ft (20N·m) after adjustments are complete. Check each dimension once more to
make certain the hatch did not move in the process.
2. Measure the dimension in view B. The position of the wedges on either side of the hatch opening controls the
degree of hatch closure in view B. If the dimension is too large, move the wedges away from each other. If the
dimension is too small, move the wedges toward each other.
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Disassembly (Rear hatch damper stay)

1. Open the rear hatch.
2. Remove two upper mounting nuts from the left and right damper stay.
3. Remove trunk end trim and trunk corner trim. Refer to "Trim" in this section.
4. Remove safety belts anchor mounting bolt and then remove safety belt anchor.
5. Remove one screw on C-pillar trim.
6. While pulling C-pillar trim, remove two lower retaining bolts from the damper stay.
7. Remove damper stay.
Disassembly (Rear hatch lock)

2. Swing spare tire carrier aside.
3. Open rear hatch.
4. Remove high-mounted brake light assembly. Refer to "Exterior lights" in this section.
5. Remove the rear hatch trim. Refer to "Trim" in this section.
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6. Unfasten cylinder rod clip, outer handle rod clip and actuator rod clip.
7. Disconnect electrical connector on the lock assembly.

8. Remove two bolts on the lock assembly.
9. Remove lock assembly.
Disassembly (Outside handle)
1. Remove rear hatch trim. Refer to "Trim" in this section.
2. Licence plate light assembly. Refer to "Exterior lights" in this section.
3. Disconnect remote control rod from outside handle assembly.
4. Remove two mounting bolts from outside handle assembly.
5. Remove outside handle.
Reassembly (Rear hatch damper stay)

1. Install in revere order of removal.
2. Position the damper stay.

3. Install two lower retaining bolts on the damper stay.
4. Install two upper mounting nuts of the damper stay.
5. Close rear hatch.
Reassembly (Rear hatch lock)
1. Position lock assembly.
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2. Connect one connector on the lock assembly.
3. Install two bolts on the lock assembly.
4. Fasten cylinder rod, outer handle rod and actuator rod clip.
5. Install rear hatch trim. Refer to "Trim" in this section.
6. Install high-maunted brake light assembly. Refer to "Trim" in this section.
7. Close rear hatch.
Installation (Outside handle)
1. Install out side handle.
2. Install two mounting bolts to outside handle assembly.
3. Connect remote control rod to outside handle assembly.
4. Install license plate light assembly. Refer to "Exterior light" in this section.
5. Install rear hatch trim. Refer to "Trim" in this section.
Body (Interior and Exterior) > Exterior > Front Door > Description and Operation
Vehicle door is attached to vehicle body by two hinges and a door checker. Door checker limits amount of swing of
the vehicle door. A hollow rubber weatherstrip is installed on the door opening flange to prevents leaks between
vehicle door and inside of vehicle body. The door lock assembly is linked with outside and inside door handle.
The window system is comprised of a window regulator assembly (on which glass is fastened) and a front glass
guide (which guides movement of the window).
A plastic door screen covers door frame, protecting all components. The door striker may be adjusted for proper
operation and easy door closure.
Body (Interior and Exterior) > Exterior > Front Door > Components and Components Location
Components
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Body (Interior and Exterior) > Exterior > Front Door > Repair procedures
Removal
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2. Remove door trim. Refer to "Trim" in this section.
3. Remove door speaker.

A. emove three screw on door speaker.
B. Unfasten harness connector from door frame.

C. Pull out speaker and disconnect connectors.
4. Remove inside door handle.
A. Disconnect control rod.

B. Remove inside door handle.
5. Peel off plastic door screen carefully by pulling it away gradually from door frame.
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6. Remove window glass.
A. Remove two glass mounting bolts from window regulator.
B. Remove glass carefully; hold glass from both its inner and outer surfaces. While tilting it toward hinge side of
door, pull it out from outside door frame.
7. Remove regulator assembly.

A. Remove seven nuts on door frame.
B. Remove regulator assembly from out of access hole.
8. Remove run channel.

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9. Remove door lock assembly.
A. Disconnect two remote control rods from door lock assembly.
B. Remove three screws from door lock assembly and remove assembly from access hole.
C. Remove two mounting nuts from outside door handle.

D. Remove outside door handle.
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10. Remove rearview mirror from door.
A. Disconnect electrical connector.
B. Remove three mounting bolts and rearview mirror.
11. Remove wiring harness.

A. Disconnect harness connectors from inner door frame.
B. Pull out wiring harness from access hole.
12. Remove door checker installation bolt from body.
13. Remove door by removing bolts on both hinges.
Installation
1. Install door.
A. Position door on vehicle properly.
B. Install bolts on both hinges.
Tighten door hinge bolts to

13~22 lb·ft (18~30 N·m, 1.8~3.0 kg·m)
2. Install dust weatherstrip.

3. Install one bolt on door checker pin assembly.
4. Install wiring harness.
A. Position wiring harness in access hole.
B. Fasten harness connectors onto door frame.
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5. Install rearview mirror on door.
A. Position rearview mirror on door as originally positioned.
B. Install three mounting bolts.
C. Connect electrical connector.
6. Install door lock assembly.

A. Position it as originally positioned through access hole.
B. Install three mounting screws.

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7. Install outside door handle.
A. Connect two control rods of door lock assembly.
B. Install two mounting nuts.
8. Install run channel. Use soap and water for lubrication.

9. Install regulator assembly.
A. Position regulator assembly through access hole.
B. Install seven mounting nuts.
Tighten mounting nuts to

78~113 lb·in (9~13 N·m, 90~130 kg·cm)
10. Install window glass.

A. Position glass carefully:
Hold glass from both its inner and outer surfaces. While tilting it towards hinge side of door, place it on small
bracket on window regulator assembly.
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B. Loosely install two glass mounting bolts on window regulator assembly.
C. Tighten two glass mounting bolts on window regulator assembly.
Tighten two bolts to

17~26 lb·in (2~3 N·m, 20~30 kg·cm)
D. position window all way down.

11. Install plastic door screen.
A. Fasten plastic door screen.
B. pull out electrical harness connector from plastic door screen.
C. Pull out remote control rod for inside door handle from plastic door screen.
12. Install inside door handle.
A. Connect one control rod of door lock assembly.
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13. Install door speaker with three mounting screws.
14. Install door trim.

15. Install inner door handle assembly.
16. Fasten door trim. Refer to "Trim" in this section.
17. Install inner weatherstrip.

Disassembly (Door opening weatherstrip)

1. Remove front door scuff plate, and A pillar trim. Refer to "Trim" in this section.
2. Remove door opening weatherstrip from door opening flange.
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Reassembly (Door opening weatherstrip)
1. Position weatherstrip on door opening flange and press it in.
2. Start at one corner and work around entire edge of door opening.
3. Install front door scuff plate, and A-pillar trim. Refer to "Trim" in this section.
Adjustment
1. Check that door can be closed easily and properly. If door is loose, tighten door hinge installation bolts.
2. To that door can be closed easily and properly. If door is loose, tighten door hinge installation bolts.
3. Check that door can be closed easily and properly. If there is a problem, loosen striker installation bolts and
adjust door by moving striker vertically and horizontally.
4. Adjust rear offset of door to body by moving door lock striker horizontally.
Body (Interior and Exterior) > Exterior > Rear Door > Description and Operation
Vehicle door is attached to vehicle body by two hinges and a door checker. Door checker limits amount of swing of
the vehicle door. A hollow rubber weatherstrip is installed on the door opening flange to prevents leaks between
vehicle door and inside of vehicle body. The door lock assembly is linked with outside and inside door handle.
The window system is comprised of a window regulator assembly (on which glass is fastened) and a front glass
guide (which guides movement of the window.
A plastic door screen covers door frame, protecting all components. The door striker may be adjusted for proper
operation and easy door closure.
Body (Interior and Exterior) > Exterior > Rear Door > Components and Components Location
Components
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Body (Interior and Exterior) > Exterior > Rear Door > Repair procedures
Removal
1. Remove one screw on outside belt weatherstrip.
2. Remove outside belt weatherstrip.
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3. Remove door trim. Refer to "Trim" in this section.
4. Remove inside door handle assembly.

A. Disconnect two control rods.
B. Remove inside door handle assembly.
5. Peel off plastic door screen carefully by pulling it away gradually from door frame.
6. Remove glass run channel.
7. Remove one screw and one bolt from center channel.
8. Remove center channel.
9. Remove quarter glass.
10. Remove window glass:
A. Remove two glass retaining bolts on regulator assembly.
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B. Remove door glass carefully. Hold glass from both its inner and outer surfaces. While tilting it toward hinge
side of door, pull it out from outside door frame.
11. Remove two nuts on outside door handle from access hole.
12. Remove outside door handle.
13. Remove three screws on door lock assembly.
14. Remove door lock assembly from access hole.

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15. Remove six nuts on window regulator assembly.
16. Remove window regulator assembly from access hole.

17. Remove wire harness from access hole towards hinge side of door.
18. Remove outside molding around window opening.
19. Remove door checker assembly.
A. Remove one bolt on checker pin assembly.
B. Remove checker pin assembly from access hole.
20. Remove door :
A. Remove bolts on both hinges.
B. Remove door.
Installation
1. Install door.
A. Position door on vehicle properly.
B. Install bolts on both hinges.
Tighten door hinge bolts to

13~22 lb·ft (18~30 N·m, 1.8~3.0 kg·m)
2. Install door checker pin assembly.

A. Position checker pin assembly through access hole.
B. Install one bolt.
3. Install outside molding around window opening.
4. Position wire harness from hinge side of door.
5. Position regulator assembly.
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6. Install six nuts on window regulator assembly.
Tighten six nuts to

78~113 lb·in (9~13 N·m, 90~130 kg·cm)
7. Position door lock assembly from access hole.

8. Install three screws on door lock assembly.
9. Position outside door handle.

10. Install two nuts on outside door handle from access hole.
11. Connect outside door handle rod of door lock assembly to outside door handle.
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12. Install glass piece carefully.
A. Use lubricant around window opening edges.
B. Hold glass from both its inner and outer surfaces. While tilting it towards hinge side of door, push it in from
outside door frame and place on glass mounting bracket of regulator assembly.
Make sure that glass edges are properly fitted into window edges.
13. Install two glass mounting bolts on window regulator.
Tighten two bolts to

17~26 lb·in (2~3 N·m, 20~30 kg·cm)
14. Make glass adjustments as necessary.

15. Install quarter glass.
16. Install center channel.
17. Install glass run channel.
18. Install plastic screen on door frame, make sure to pull out door lock knob rod and inside door handle rod of
door lock assembly from plastic screen.
A. Connect two control rods of door lock assembly.
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20. Install trim. Refer to "Trim" in this section.
21. Install outside belt weatherstrip.

22. Move window glass to maximum upper position.
Body (Interior and Exterior) > Interior > Crash Pad > Components and Components Location
Components
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Body (Interior and Exterior) > Interior > Crash Pad > Repair procedures
Removal
1. Remove console.
2. Remove driver air bag module. Refer to Group RT, Driver Air Bag Module.
3. Remove steering wheel, turn signal assembly, and upper/lower column covers. Refer to Group ST, Steering
System.
4. Remove two mounting bolts on either side of steering column, which hold instrument panel and steering column
together. Lower steering column to floor level.
5. Remove hood release handle lock nut, hood release handle and cable assembly nut.
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6. Remove instrument cluster
A. Remove three screws and instrument cluster housing.

B. Remove four bolts from instrument cluster.
C. Disconnect electrical connector for rear of unit.
7. Remove center panel ventilation control panel.
8. Remove radio.
A. Remove four mounting screws from radio.
B. Disconnect electrical connector for rear of radio.

C. Remove antenna cable for rear of radio.
D. Remove radio.
9. Remove glove box.
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10. Remove four mounting bolts and side cover from left/right side of T-bar.
11. Remove four mounting bolts from bottom of instrument panel.
12. Disconnect all connectors between instrument panel and vehicle bulkhead electrical wire harness.
13. Remove instrument panel.
Installation
1. Mount instrument panel into position.
Make sure steering column is mounted correctly through T-bar with electrical wire harness in position before
attempting to position instrument panel in place. If this is not done, column cannot be positioned correctly.
2. Connect linking connectors between vehicle electrical wire harness and instrument panel.
Each connector is keyed so and electrical harness connector mates with correct instrument panel connector.
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3. Install four mounting bolts to left/right side of instrument panel as shown.
Tighten bolts to
13~19 lb·ft (18~25 N·m, 1.8~2.7 kg·m)
4. Install four mounting bolts on left/right side of T-bar.
Tighten bolts to
13~19 lb·ft (18~25 N·m, 1.8~2.7 kg·m)
5. Install glove box.

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6. Install radio.
A. Install antenna cable to rear of radio.

B. Connect electrical connector to rear of radio.
C. Install four mounting screws to radio.
7. Install cencer panel ventilation control panel.
8. Install instrument cluster.
A. Connect electrical connector for rear of unit.

B. Install four instrument mounting bolts.
C. Install three screws and instrument cluster housing
9. Install hood release handle. Refer to "Hood Release Handle" in this section.
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10. Install two mounting bolts, one on either side of steering column, which hold instrument panel and steering
column together.
Tighten bolts to
13~19 lb·ft (18~26 N·m, 1.8~2.7 kg·m)
11. Install steering wheel, turn signal assembly and upper/lower column covers. Refer to group ST, Steering System.
12. Install driver air bag module. Refer to Group RT, Driver Air Bag Module.
13. Install console. Refer to "Console" in this section.
14. Install negative cable onto battery terminal.
Body (Interior and Exterior) > Interior > Roof Trim > Description and Operation
Headliner is a cloth cushion that serves as a buffer between passengers and top of vehicle. It also covers thermal and
acoustic insulation in top of vehicle and wiring or dome light. Both headliner and insulation are replaceable.
Body (Interior and Exterior) > Interior > Roof Trim > Components and Components Location
Components
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Body (Interior and Exterior) > Interior > Roof Trim > Repair procedures
Removal
1. Unscrew two mounting screws from sunvisors.
2. Remove sunvisors and sunvisors retaining clips.
3. Remove assist handle covers, unscrew mounting screws.
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4. Remove three assist handles.
5. Gently remove lens assembly on interior and map light.

6. Remove light bulb.
7. Remove two mounting screws.
8. Disconnect power connector and remove interior and map light.
9. Remove A, B and C pillar trims. Refer to "Trim" in this section.

10. Remove seven fasteners.
11. Remove geadliner.
12. Reverse remove procedure.
Body (Interior and Exterior) > Interior > Interior Trim > Components and Components Location
Components
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Body (Interior and Exterior) > Interior > Interior Trim > Repair procedures
Trunk side trim (5 Door)
Removal
1. Remove two fasteners on trunk end trim.
2. Remove trunk end trim.
3. Remove two screws and one fastener from trunk side trim.
4. Remove one screw from striker.
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5. Remove two mounting screws from holder.
6. Disconnect electrical connector.
Installation
1. Position trunk side trim.
2. Connect electrical connector.
3. Install holder and, striker to trunk side trim.
4. Install trunk end trim.
Trunk end trim
Removal
1. Remove two fasteners.
2. Unfasten trunk end trim.

Installation
1. Position trunk end trim.
2. Install two fastener to trunk end trim.
A pillar trim
Removal
1. Unfasten A-pillar trim with a trim removal tool.
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2. Remove A-pillar trim.
Installation
1. Position A-pillar trim.
2. Press A-pillar trim into fasten clips.
B-pillar lower trim
Removal
1. Remove lower mounting bolt from safety belt anchor.
2. Remove front and Rear scuff plate. Refer to "Front, Rear scuff plate" in this section.
3. Unfasten B-pillar lower trim with a trim removal tool.
4. Remove B-pillar lower trim.
Installation
1. Position B-pillar lower trim.
2. Press B-pillar lower trim in to fasten clips.
3. Install lower mounting bolt to seat belt anchor.
4. Install front and rear scuff plate.
B-pillar upper trim
Removal
1. Removal lower mounting bolt from safety belt anchor.
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2. Remove front and rear scuff plate. Refer to "Front, Rear scuff plate" in this section.
3. Unfasten B-pillar lower trim with a trim removal tool.

4. Remove B-pillar lower trim.
5. Remove upper mounting bolt from safety belt anchor.
6. Remove B-pillar upper trim with a trim removal tool.
Installation
1. Position B-pillar upper trim.
2. Install safety belt anchor :
A. Install one bolt on seat belt anchor.
Tighten mounting bracket bolt to

29~40 lb·ft (40~55 N·m, 4.0~5.5 kg·m)
B. Fasten safety belt.
3. Position B-pillar lower trim.

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4. Press B-pillar lower trim.
5. Install safety belt anchor.

29~40 lb·ft (40~55 N·m, 4.0~5.5 kg·m)
C-pillar trim (4 Door)

Removal
1. Remove rear seat cushion and seat back. Refer to "Seat" in this section.
2. Remove Package trim. Refer to "Package trim" in this section.
3. Remove tire house trim. Refer to "Tire house trim" in this section.
4. Unfasten C-pillar trim.
5. Remove C-pillar trim.
Installation
1. Position C-pillar trim and press in.
2. Install tire house trim. Refer to "Tire house trim" in this section.
3. Install Package trim. Refer to "Package trim" in this section.
4. Install rear seat back and seat cushion. Refer to "Seat" in this section.
C-pillar (5 Door)
Removal
3. Remove tire house trim.
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4. Remove upper anchor bolt from seat belt.
5. Remove two screws from C-pillar trim.

6. Unfasten C-pillar trim.
7. Remove C-pillar trim.
Installation
1. Position C-pillar trim and press in.
2. Install to screws to C-pillar trim.
3. Install upper anchor bolt to seat belt.
4. Install tire house trim.
5. Install trunk side trim.
6. Install trunk end trim.
Front door trim
Removal
1. Remove inner garnish.
2. Remove one screw on inside door handle.

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3. Remove three screws from front door trim.
4. Unfasten front door trim with a trim removal tool.

5. Disconnect electrical connector for rear of unit.
6. Remove front door trim by lifting front door trim up.
Installation
1. Place front door trim.
2. Connect electrical connector to rear of unit.
3. Install three screws to front trim.
4. Install one screw to inside door handle.
5. Install inner garnish.

Front scuff plate
Removal
1. Remove four fasteners on front scuff plate.
2. Unfasten front scuff plate with trim removal tool.
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3. Remove front scuff plate.
Installation
1. Position front scuff plate.
2. Press in front scuff plate in to fasten clips.
3. Install four fasteners to front scuff plate.
Rear door trim
Removal
1. Remove one screw on inside door handle.
2. Remove two screws from right side and bottom side of rear door trim.
3. Unfasten rear door trim with trim removal tool.

4. Disconnect electrical connector for rear of unit.
5. Remove rear door trim by lifting rear door trim up.
Installation
1. Install rear door trim.
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3. Install one screw on inside door handle.
4. Install two screws at right side and bottom side of rear door trim.
Rear hatch trim

Removal
1. Remove hi-mounting brake light assembly. Refer to "Exterior right" in this section.
2. Remove two mounting screws and cover from assist handle.
3. Remove assist handle.
4. Unfasten rear hatch trim.

5. Remove rear hatch trim.
Installation
1. Position rear trim.
2. Install assist handle.
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3. Install high-mounted brake light assembly.
Rear scuff plate

Removal
1. Remove two fasteners from rear scuff plate.
2. Unfasten rear scuff plate.
3. Remove rear scuff plate.
Installation
1. Position rear scuff plate.
2. Press in rear scuff plate.
3. Install two fasteners to rear scuff plate.
Package trim
Removal
2. Remove tire house trim. Refer to "Tire house trim" in this section.
3. Remove two child restraint anchorage.
4. Remove four screws on Package trim.
5. Unfasten Package trim.
6. Remove Package trim.
Installation
1. Position Package trim.
2. Install four screws and two child restraint anchorage.
3. Install tire house trim.
4. Install hi-mounted brake light assembly.
Tire house trim (4 Door)
Removal
1. Remove rear seat cushion and seatback. Refer to "Seat" in this section.
2. Remove two fasteners on rear scuff plate.
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3. Remove rear scuff plate.
4. Remove three fasteners.
Installation
1. Position tire house trim.
2. Install three fasteners.
3. Install rear scuff plate.
4. Install rear seat cushion and seatback. Refer to "Seat" in this section.
Tire house trim (5 Door)
Removal
1. Remove trunk end trim, trunk side trim and Rear scuff plate. Refer to "Trim" in this section.
2. Remove cover from tire house trim.
3. Remove one screw.
Installation
1. Position tire house trim.
2. Install onescrew and cover to tire house trim.
3. Install rear scuff plate, trunk side trim and trunk end trim. Refer to "Trim" in this section.
Body (Interior and Exterior) > Bumper > Front Bumper > Description and Operation
Front and rear bumpers consist of three parts; bumper face, energy absorbing foam, and bumper reinforcement. The
bumper face is made of polypropylene and the absorption medium is styrofoam. Reinforcement is constructed of
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metal with energy absorbing foam placed between bumper face and the reinforcement.
Body (Interior and Exterior) > Bumper > Front Bumper > Components and Components Location
Components
Body (Interior and Exterior) > Bumper > Front Bumper > Repair procedures
Inspection
1. Inspect front bumper face for damage and check that front bumper is securely mounted.
2. Inspect front bumper for missing attaching hardware.
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Removal
1. Remove headlight assembly.
2. Remove two bolts and four fasteners from top of the bumper.
3. Remove four fasteners from under cover.

4. Remove four fasteners from bottom of bumper
5. While pulling right mud guard, remove two screw from side of bumper.
6. Remove two bolts from the left-hand bumper support bracket.

7. Repeat for the right side.
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8. Remove bumper assembly.
9. Install front bumper in reverse order of removal.
Tighten bumper mounting bolts to

23~34 lb·ft (32~47 N·m, 3.2~4.7 kg·m)
Body (Interior and Exterior) > Bumper > Rear Bumper > Description and Operation
Front and rear bumpers consist of three parts; bumper face, energy absorbing foam, and bumper reinforcement. The
bumper face is made of polypropylene and the absorption medium is styrofoam. Reinforcement is constructed of
metal with energy absorbing foam placed between bumper face and the reinforcement.
Body (Interior and Exterior) > Bumper > Rear Bumper > Components and Components Location
Components (4 Door)
Page 82 of 99
Body (Interior and Exterior) > Bumper > Rear Bumper > Repair procedures
Inspection
1. Inspect rear bumper face for damage and check that it is securely mounted.
2. Inspect rear bumper for missing attaching hardware.
Removal
1. Remove three screws that secure left rear mud flap to mud guard.
2. Remove right mud flap.
3. Remove three screws that secure right rear mud flap to mud guard.
4. Remove one screw from right side of bumper.
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5. Repeat for left side.
6. Remove two nuts from left side in trunk.

7. Repeat for right side.
8. Remove eight fasteners from top of bumper.
9. Remove two bolts from left rear bumper stay.
10. Repeat for right side.
11. Remove rear bumper.
Tighten bumper mounting bolts to

23~34 lb·ft (32~47 N·m, 3.2~4.7 kg·m)
Body (Interior and Exterior) > Seat & Power Seat > Front Seat > Description and Operation
Front seat consists of a seat back and a cushion. Both items are replaceable or serviceable. Both seats can be
reclined or adjusted front-to-rear by two levers, reclining lever and adjusting lever. Head restraint can also be
adjusted or removed.
Seat adjuster lever is under right or left front corner of front seats. Pulling up this lever unlocks seat, allowing it to
slide forward or backward on atrack attached to vehicle floor. Track assembly and seat adjuster lock are
replaceable items.
Reclining lever is placed on door side of either seat. If this lever is pulled up and pressure is placed on seatback,
Page 84 of 99
seatback will recline. If no pressure is applied, seat will spring forward past vertical driving position. If pressure is
applied to seatback, it will recline to actual driving position and then lock. Reclining adjuster is a replaceable items.
Driver's seat is also equipped with lifter levers. This is controlled by levers on left side of driver's side seat cushion.
Lifter control levers are replaceableitems.
Body (Interior and Exterior) > Seat & Power Seat > Front Seat > Components and Components
Location
Components
Body (Interior and Exterior) > Seat & Power Seat > Front Seat > Repair procedures
Page 85 of 99
Removal
1. Pull reclining lever and let seatback spring forward.
2. Pull seat adjuster and push seat all of the way back.
3. Remove front two mounting bolts.
4. Move seat forward.

5. Remove rear mounting bolt and nut.
6. Remove seat.
Tighten bolts to
28~38 lb·ft (39~51 N·m, 3.9~5.2 kg·m)
Inspection
1. Check that seat adjuster and reclining lever move smoothly.
2. Look under seat and visually check seat adjuster for wear or damage.
3. Apply grease to all exposed moving parts.
Disassembly
Front seatback
1. Remove seat from vehicle.
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2. Remove reclining lever knob.
3. From under seat, push in tabs holding screw caps and then remove caps.
4. Remove two screws on seat side cover.
5. For driver's seat, remove lift knob cover, unscrew one mounting screw and remove lift knob.
6. Remove side cover.

7. Remove headrest and pull off holding catches. Replace catches.
8. Remove hog rings on seatback cover.

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9. Slide seat trim up and off seatback.

Front seat cushion cover
Disassembly
1. Remove reclining lever.
2. Remove hog rings on underside of seat cushion.
3. Pull cover off of foam cushion.
Front seat cushion cover

Reassembly
1. Place cover over foam cushion.
2. Install hog rings.
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3. Install reclining lever and seatback.
Headrest
Disassembly
1. Pull headrest up until it locks.
2. Release tab and pull headrest off seat.
Headrest
Reassembly
1. Insert headrest in holes and push down until it locks.
2. Release lock and adjust position for comfort.
Reclining knuckle
Disassembly
1. Follow seatback cover removal steps 1-8.
2. Pull up trim until upper two knuckle mounting bolts are exposed.
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3. Remove upper two hex head bolts and remove seatback.
4. Pull knuckle lever and push seat into reclining position.

5. Remove two lower knuckle hex head bolts.
6. Remove reclining knuckle.
Tighten knuckle bolts to

25~41 lb·ft (34~56 N·m, 3.5~5.7 kg·m)
Body (Interior and Exterior) > Seat & Power Seat > Rear Seat > Description and Operation
5 Door
The rear seat consist of two separate seatbacks and a seat cushion.
Seat cushion is mounted on vehicle frame by two bolts.
Two seatbacks are attached to vehicle frame by mounted hinge bushing and brackets.
Seatbacks of rear seat are locked to vehicle frame by seatback strikers.
4 Door
The rear seat consist of seatback and seat cushion.
The seatback is mounted on vehicle frame by three bolts.
The seat cushion is mounted on vehicle frame by three bolts.
Body (Interior and Exterior) > Seat & Power Seat > Rear Seat > Components and Components
Location
Components
Page 90 of 99
Body (Interior and Exterior) > Seat & Power Seat > Rear Seat > Repair procedures
Removal
Page 91 of 99
1. Remove two mounting bolts as shown in figure to release cushion, then pull seat cushion out.
2. Remove three mounting bolt from bottom of seatback.

3. Remove seatback.
Installation
Install in reverse order of removal.
Tighten seat mounting bolts to

16~22 lb·ft (22~31 N·m, 2.2~3.1 kg·m)
Body (Interior and Exterior) > Seat Belt > Front Seat Belt > Description and Operation
Safety belt system consists of five restraints. Outboard passengers (front and rear) have both shoulder and lap safety
belts. Inboard passenger (rear) has only a lap safety belt. Driver's safety belt is equipped with a warning light on the
instrument panel and an audible chime to remind driver to fasten safety belt. Warning ceases after approximately 60
seconds. There are no warnings on other passengers' belts. Retractors are securely mounted to body. Buckles are
also securely mounted to floor.
Body (Interior and Exterior) > Seat Belt > Front Seat Belt > Components and Components Location
Components
Page 92 of 99
Body (Interior and Exterior) > Seat Belt > Front Seat Belt > Repair procedures
Inspection (Front safty belts)
1. Inspect buckle assembly mounting to ensure that it is secure.
2. Inspect anchor assembly mounting to ensure that it is secur.
3. Remove B-pillar lower trim. Refer to "Tirm" in this section.
4. Inspect retractor assembly mounting to ensure that it is secure.
5. Install B-pillar lower trim.
6. Extend safety belt fully to ensure its motion is smooth and easy.
7. Retract safety belt fully to ensure its motion is smooth and easy.
8. Buckle safety belt. Pull firmly on each side of buckle to ensure that it is secure.
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9. Press buckle release button to ensure that it releases correctly and returns to its original position.
Do not disassemble either buckle or retractor assemblies. They are not repairable.
10. Inspect safety belt reminder system with driver's safety belt retracted. Turn ignition key to "ON"position. Safety
belt icon on warning and indicator panel will light up and a chime will be heard. Lighted icon and chime indicate
that driver's safety belt is not buckled. Chime will not be heard after 5~6 seconds. Turn ignition key to "LOCK"
position. Safety belt icon and chime will extinguish. Turn key to "ON" position. Just as before, safety belt icon
will light up and chime will be heard. Buckle driver's safety belt. Safety belt icon and chime will extinguish. Turn
key to "LOCK" position and remove key.
If a safety belt is not functioning and cannot be immediately repaired, warn the customer not to use that
seating position. If the customer must use that seating position, encourage the customer to use a substitute
vehicle until the proper repairs can be made. If the customer refuses, refer the matter to the Service
Manager.
Disassembly (Front buckle assembly)

1. Remove screw cover near bottom of assembly.
2. Remove one bolt from mounting bracket.
3. Install one bolt through mounting bracket.
Tighten mounting bolt to

29~40 lb·ft (40~55 N·m, 4.0~5.5 kg·m)
4. Install screw cover.
Removal
1. A pretensioner functiens one time only. Be sure to replace the pretensioner seat belt after it is deployed.
2. Do not attempt to disassemble or repair the seat belt pretensioner. If it malfunctions, replace it with a new
pretensioner seat belt.
3. Be cautions in handling a pretensioner seat belt, and do not expose it to water or oil. If crushed, damaged, or
deformed, replace it with a new one.
4. Connect the battery only after the installation of the pretensioner seat belt has been correctly completed.
5. Removal of pretensioner retractor:
a. Turn ignition switch "OFF"
b. Disconnect negative battery cable.
c. Wait for about 1 minute.
d. Disconnect gas generator connector.
e. Remove retractor screw.
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1. Remove one bolt from mounting bracket and remove bracket.
2. Retract belt slowly as far as it will go.

3. Unsnap captive shoulder belt anchor bolt cover from bottom and lift up.
4. Remove one anchor bolt.
5. Remove B-pillar lower trim panel.

6. Remove one bolt and one sheet metal screw to remove retractor assembly.
Installation
Page 95 of 99
1. Install one bolt and one sheet metal screw to attach retractor assembly.

29~40 lb·ft (40~55 N·m, 4.0~5.5 kg·m)
EXERCISE CARE TO INSTALL BELT SO THERE ARE NO TWISTS IN IT. A TWISTED BELT
MAY BE HARMFUL TO A PASSENGER IN A SERIOUS ACCIDENT. A TWISTED BELT
ALTERS DISTRIBUTION OF FORCE RESULTING FROM SUDDEN ECELERATION.
2. Install belt guide.
3. Install B-pillar upper trim.

4. Install B-pillar lower trim.
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5. Install anchor bolt.
Tighten anchor bolt to

29~40lb·ft (40~55 N·m, 4.0~5.5 kg·m)
6. Install anchor bolt cover.

7. Install one bolt through lap belt mounting bracket.
Tighten bolt to
29~40lb·ft (40~55 N·m, 4.0~5.5 kg·m)
Body (Interior and Exterior) > Seat Belt > Rear Seat Belt > Description and Operation
Safety belt system consists of five restraints. Outboard passengers (front and rear) have both shoulder and lap safety
belts. Inboard passenger (rear) has only a lap safety belt. Driver's safety belt is equipped with a warning light on the
instrument panel and an audible chime to remind driver to fasten safety belt. Warning ceases after approximately 60
seconds. There are no warnings on other passengers' belts. Retractors are securely mounted to body. Buckles are
also securely mounted to floor.
Body (Interior and Exterior) > Seat Belt > Rear Seat Belt > Components and Components Location
Components
Page 97 of 99
Body (Interior and Exterior) > Seat Belt > Rear Seat Belt > Repair procedures
Inspection (Rear safty belt)
1. Inspect three buckle assembly mountings to ensure that they are secure. (This is done from rear of vehicle)
2. Inspect remaining belt's mounting to ensure that it is secure. (This is done from rear of vehicle)
3. Pull safety belts to rear between seatback and cushion.
4. Remove seat cushion.
5. Inspect outboard lap belt mountings to ensure that they are secure.
6. Disconnect fasteners of C-pillar trim from body and pull C-pillar trim down completely.
7. Fold rear seatback forward for front side of seat cushion.
8. Remove package tray.
9. Inspect retractor assembly mountings to ensure that they are secure.
If a safety belt is not functioning and cannot be immediately repaired, warn the customer not to use that
seating position. If the customer must use that seating position, encourage the customer to use a substitute
vehicle until the proper repairs can be made. If the customer refuses, refer the matter to the Service
Manager.
Disassembly (Rear buckle)

1. Pull safety belts to rear through seats.
2. Fold seat forward and secure.
3. Remove one bolt from rear buckle assembly mounting bracket.
4. Install mounting bolt through bracket.

29~40 lb·ft (40~55N·m, 4.0~5.5 kg·m)
5. Feed buckle between seatback and cushion without any twists.
Removal
Page 98 of 99
1. Remove rear seat cushion.
2. Remove one bolt from lap belt mounting bracket.

3. Retract belt slowly as far as belt will go.

5. Remove three mounting bolts from rear seat back.
6. Remove seat back.
7. Remove package trim. Refer to "Trim" in this section.
8. Remove C-pillar trim. Refer to "Trim" in this section.
9. Remove two mounting bolt from belt retractor.
10. Remove seat belts retractor.
Installation
1. Install retractor mounting bolt and sheet metal screw.

29~40 lb·ft (40~55 N·m, 4.0~5.5 kg·m)
Exercise care to install belt so there are no twists in it. A twisted belt may be harmful to a passenger in a
serious accident. A twisted belt alters distribution of force resulting from sudden deceleration.
2. Install C-pillar trim.
3. Install package trim.
Page 99 of 99
4. Install high-mounted brake light assembly.
5. Install rear seat back.
6. Install one bolt through lap belt mounting bracket.

29~40 lb·ft (40~55 N·m, 4.0~5.5 kg·m)
7. Install rear seat cushion.

Page 1 of 49
RIO(BC) > 2005 > G 1.6 DOHC > Body Electrical System
Body Electrical System > General Information > Troubleshooting

Specifications
Multifunction switch
Items Specifications
Rated Voltage DC 12V
-30 °C ~ +80 °C (-22 ~ + 176
Operating temperature range
°F)
Rated load
Dimmer & passing switch High : 120 W
Low : 110 W
Passing : 120 W
Lighting switch Lighting : 0.2 A
Turn signal switch & lane change 0.2 A (Relay load)
Wiper switch Low, int : 6.0 A (Motor load)
High : 6.5 A (Motor load)
Washer switch 3.8 A (Motor load)
Instruments and warning system

Illumination 3.0w x 4EA
Warning Bulb wattage
Color
lamps (w)
Turn signal
1.4 Green
(LH, RH)
1.4 Blue
High beam
1.4 Red
Pre tension
1.4 Amber
Rear fog
1.4 Amber
Rear defroster
1.4 Red
Door ajar
1.4 Amber
O/D OFF
1.4 Red
Air bag
1.4 Amber
Engine check
1.4 Red
Oil pressure
1.4 Red
Parking brake
1.4 Red
Battery charge
1.4 Amber
Tail gate open
1.4 Amber
ABS
1.4 Red
Seat belt
3.0 Amber
Low fuel
A/T
1.4 Red
R
1.4 Green
P, N, D, 2, 1
Body Electrical System > General Information > Specifications

Page 2 of 49
Service specifications
Indicators and gauges
Page 3 of 49
Lighting system
Items Bulb wattage (w)
Head lamp 60W / 55W (High / Low)
Front turn signal lamp 28W
Front position lamp 8W
Front fog lamp 27W
Rear combination lamps
Tail/stop lamp 8W / 27W
Back up lamp 27W
Turn signal lamp 27W
License plate lamp 5W
Room lamp 10W
Over head lamp (Map
10W
lamp)
Luggage compartment 5W
High mount stop lamp 27W
Troubleshooting
Instrument and warning system
Page 4 of 49
Symptom Possible cause Remedy
Fuse blown Check for short and replace fuse
Tachometer does not operate Tachometer faulty Check tachometer
Wiring faulty Repair if necessary
Fuel gauge faulty Check gauge
Fuel gauge does not operate
Fuel sender faulty Check fuel sender
Wiring faulty Repair if necessary
Bulb burned out Replace bulb
Low fuel warning lamp does not light
Fuel level sensor faulty Check sensor
Wiring or ground fraulty Repair if necessary
Water temperature gauge does not Water temperature gauge faulty Check gauge
operate Water temperature sender faulty Check sender
Wiring or ground faulty Repair if necessary
Oil pressure warning lamp does not Bulb burned out Replace bulb
light Oil pressure sender faulty Check sender
Low brake fluid warning lamp does Brake fluid level warning switch
Check switch
not light faulty
Parking brake switch faulty Check switch
Fuse blown Check for connection
Open door warning lamp does not Bulb burned out Replace bulb
light Door switch faulty Check switch
Seat belt warning lamp does not light
Buckle switch faulty Check switch
Lighting system
Page 5 of 49
One lamp does not light Bulb burned out Replace bulb
(all exterior) Socket, wiring or ground faulty Repair if necessary
Fuse blown - Low beam Check for short and replace fuse
Fuse blown - high beam Check for short and replace fuse
Head lamps do not light
Head lamp relay faulty Check relay
Lighting switch faulty Check switch
Tail lamp fuse blown Replace fuse and check for short
Fusible link blown Replace fusible link
Tail lamps do not light Tail lamp relay faulty Check relay
Lighting switch faulty Check switch
Fuse blown Replace fuse and check for short
Stop lamp switch faulty Adjust or replace switch
Stop lamps do not light
Stop lamp relay faulty Replace relay
Stop lamp switch faulty Adjust or replace switch
Stop lamps stay on
Stop lamp relay faulty Replace relay
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
Turn signal switch faulty Check switch
one side
Flasher faulty Check flasher
Turn signal lamps do not operate
Turn signal switch faulty Check switch
Hazard warning lamps do not Flasher faulty Check flasher
operate Hazard switch faulty Check switch
Lamps' wattages are smaller or
Replace lamps
Flasher rate too slow or too fast larger than specified
Defective flasher Replace flasher
Page 6 of 49
Back up lamps do not light up Back up lamp switch faulty Check switch
Overhead console lamp does not Fuse blown Check for short and replace fuse
light up Wiring or ground faulty Repair if necessary
Windshild wiper
Wiper fuse blown Check for short and replace fuse
Wipers do not operate or return Wiper motor faulty Check motor
to off position. Wiper switch faulty Check switch
ETACS Module faulty Check ETACS Module
Wipers do not operate in INT Wiper switch faulty Check switch

position Wiper motor faulty Check motor
Wiring or ground fautly Repair if necessary
Power window
Fuse blown Check for short and rplace fuse
Clean and retighten the ground
Poor ground
terminal mounting bolt
No windows operate from the main
switch on the driver's door Defective power window main Check the switch
switch Replace if necessary
Open circuit in wires or loose or
Repair or replace
disconnected connector
Defective power window main
Check for driver's window switch
switch
Driver's side window does not
Defective motor or circuit breaker Replace the motor
operate
Check the harness and the connector
Defective power window subswitch Replace the switch
Passenger's side window does not Defective motor or circuit breaker Replace the motor
operate
Wiring faulty or disconnected
Repair if necessary
connector
Power door mirror

Page 7 of 49
Fuse blown Check the circuit and replace fuse
Clean and retighten the gound
Poor ground
terminal mounting bolt
No mirrors operate Check the switch
Defective mirror switch
Replace if necessary
Repair or replace
Check the switch
Defective mirror switch
One mirror does not operate Defective mirror actuator Replace the actuator
Open circuit wires or loose or
Repair or replace
Body Electrical System > Multifunction switch > Multi Function Switch > Components and Components
Location
Components
Page 8 of 49
Body Electrical System > Multifunction switch > Multi Function Switch > Repair procedures
Removal and installation
Prior to removing of the multi function switch assembly in vehicles equipped with air bags, be careful to follow the
following:
Page 9 of 49
• Never attempt to disassemble or repair the air bag module or clock spring. If faulty, replace it.
• Do not drop the air bag module or clock spring or allow contact with water, grease or oil. Replace if a dent,
crack, deformation or rust is detected.
• The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward. Do
not place anything on top of it.
• Do not expose the air bag module to temperatures over 93°C(200°F).
• After deployment of an air bag, replace the clock spring with a new one.
• Wear gloves and safety glasses when handing an air bag that has been deployed.
• An undeployed air bag module should only be disposed of in accordance with the procedures mentioned in the
restraints section.
• When you disconnect the air bag module-clock spring connector, take care not to apply excessive force.
• The removed air bag module should be stored in a clean, dry place.
• Prior to installing the clock spring, align the mating mark and “NEUTRAL” position indicator of the clock
spring, and after turning the front wheels to the straight-ahead position, install the clock spring to the column
switch. If the mating mark of the clock spring is not properly aligned, the steering wheel may not completely
rotate during a turn, or the flat cable within the clock spring may be broken obstructing normal operation of the
SRS and possibly leading to serious injury to the vehicle's driver. To inspect the clock spring, refer to the
restraints section.
Inspection
Check the continuity between the terminals while operating the switch.
Lighting switch
Dimmer and passing switch
Turn signal and lane change switch

Page 10 of 49
Wiper & washer switch
Body Electrical System > BCM (Body Control Module) > ETACS Module > Schematic Diagrams
Circuit diagram
Page 11 of 49
Etacs pin NO. and description

Page 12 of 49
Pin No. Connector "A" Pin No. Connector "B"
1a B+ 2a SEAT BELT SW
1b DOOR WARNING LAMP 2b S/BELT W/LAMP
CLUSTER OVER SPEED
1c IG 1 2c
(MIDDLE EAST)
DRIVER ACT. SW
1d P/WINDOW RELAY 2d
(UNLOCK)
1e ACC 2e HOOD SW
1f ALTERNATOR -L 2f HORN RELAY
1g KEYLESS SW 2g RKE RECEIVER
1h N.C 2h HAZARD RELAY
1i TNS SW 2i DRIVER DOOR SW
TRUNK SW (TAIL GATE
1j TNS RELAY 2j
SW)
1k H/LAMP SW 2k ASSIST DOOR SW
1l N.C 2l ROOM LAMP
1m RR.DEF SWITCH 2m RR.DOOR SW
ASSIST DOOR LOCK SW
1n RR.DEF RELAY 2n
(UNLOCK)
1o RR.FOG SW 2o N.C
1p RR.FOG RELAY 2p DOOR LOCK RELAY
REAR DOOR ACTUATOR
2q
SWITCH (L/R)
2r DOOR UNLOCK RELAY
TRUNK KEY UNLOCK
2s
SWITCH
2t GND
Body Electrical System > BCM (Body Control Module) > ETACS Module > Repair procedures
Inspection
This is installed at the lower of A-pillar.
While operating the components, check whether the operations are normal with timing chart.
Page 13 of 49
Etacs fuction
1. Rear window defogger and side mirror defogger.
Time specification
T1 : 20±3min.
2. Seat belt warning
Time specification
T1 : 6 ± 1.5 sec.
3. Buglar alarm
(1) Horn operates ON/OFF for 0.5 second while it is armed.
(2) Arm/disarm is operated by only the remote keyless entry.
(3) If any of entrances aren't opened for 30 second in disarm state.
If will generate the door lock output, and it is armed.
(4) Upon receiving the TX lock signal in the arm state, it doesn't generate lock output signal, but it generates the
hazard lamp output 1 time for 1 second.
(5) Upon receiving the TX unlock signal in the disarm state, it generates unlock output signal, hazard lamp output
twice.
Page 14 of 49
4. Decayed room lamp
Time specification
T1 : 4-5 sec.
T2 : 20 ± 5 min.
(1) Upon the door open with the keyless switch OFF, the room lamp turns on for T2.
The room lamp declines to 75% at once when the door close.
(2) Upon the door switch OFF with the ACC is OFF the room lamp declines 75% to 0% for T1.
Upon the door switch OFF with the ACC is ON the room lamp turns on for T1.
5. Ignition key reminder
6. Battery saver.
7. Power window timer
Time specification
T : 30 ± 5 sec.
Page 15 of 49
8. Lightr ajar
Alarm occurs while the door opened when the TNS switch is ON and IG switch is ON.
9. Central door lock / unlock
10. Key reminder unlock
Time specification
T1 : less than 0.1 sec
T2 : 1.0 sec.
T3 : 0.5 sec.
T4 : Max 0.5 sec.
Page 16 of 49
11. Remote keyless entry system
(1) Door lock
Time specification
T1 : 1.0 ± 0.2 sec.
(2) Door unlock
Time specification
T1 : 1.0 ± 0.2 sec.
Page 17 of 49
12. Remote keyless entry code saving
(1) Store the transmitter code by using Hi-scan pro.
(2) Connector pin arrangment.
Body Electrical System > Fuses And Relays > Relay Box (Engine Compartment) > Components and
Components Location
Components
Page 18 of 49
ICM Relay
Page 19 of 49
Relay box (Room)

Page 20 of 49
Body Electrical System > Fuses And Relays > Relay Box (Engine Compartment) > Repair procedures
Inspection
1. ICM relay is installed at the lower of A-piller, and general relay is installed at the lag bracket of audio.
2. Check for a burnt fusible link with an ohmmeter.
3. If a fusible link burns out, there is a short or some other problem in the circuit. Carefully determine the cause and
correct it before replacing the fusible link.
The fusible link will burn out within 15 seconds if a higher than specified current flows through the circuit.
Body Electrical System > Fuses And Relays > Fuses > Components and Components Location
Specification
Page 21 of 49
Body Electrical System > Fuses And Relays > Fuses > Repair procedures
Inspection
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.
Never use a fuse of higher capacity than specified.
Inspection of fuses
When a fuse is blown, there are two probable causes. The two causes can easily be determined by a visual check
after removing the fuses.
1. Fuse blown due to over-current.
Prior to replacing the fuse with a new one, check the circuit for a short and the related parts for abnormal
conditions. Only after the correction of a short or replacement of abnormal parts, should a fuse with the same
ampere rating be installed.
Page 22 of 49
2. Fuse blown due to repeated on-off current.
Normally, this type of problem occurs after a fairly long period of use, and is less frequent than #1 above. In this
case, you may simply replace with a new fuse of the same capacity.
A blade type fuse is identified by the numbered value in amperes. If the fuse is blown, be sure to replace a
fuse with the same ampere rating. If a fuse of higher capacity than specified is used, parts may be damaged
and a danger of fire exists. To remove or insert a fuse, use the fuse puller in the fuse box.
Body Electrical System > Indicators And Gauges > Instrument Cluster > Schematic Diagrams
Circuit diagram
Page 23 of 49
Body Electrical System > Indicators And Gauges > Instrument Cluster > Components and Components
Location
Specification
Page 24 of 49
Page 25 of 49
Specification
No. Item Bulb
Color
wattage(w)
1 Engine check 1.4W Amber
2 Door ajar 1.4W Red
3 Oil pressure 1.4W Red
4 Tail gate open 1.4W Amber
5 Seat belt 1.4W Red
6 - - -
7 Charge 1.4W Red
8 - - -
9 Parking brake 1.4W Red
10 ABS 1.4W Amber
Immobilizer
11 1.4W Amber
Check
12 - - -
13 High beam 1.4W Blue
14 Air bag 1.4W Red
15 Rear fog 1.4W Amber
16 O/D OFF 1.4W Amber
17 Rear defogger 1.4W Amber
18 Fuel low 3.0W Red
19 Pre tension 1.4W Red
Turn signal
20 1.4W Green
(LH, RH)
P, N,
D, 2, 1.4W Green
21 A/T 1
R 1.4W Red
Body Electrical System > Indicators And Gauges > Instrument Cluster > Repair procedures
Inspection of components
Speedometer
1. Adjust the pressure of the tires to the specified level.
2. Drive the vehicle onto a speedometer tester. Use wheel chocks as appropriate.
Page 26 of 49
3. Check if the speedometer indicator range is within the standard values in the service specifications.
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.
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.
When removing or installing the tachometer, be careful not to drop it or subject it to severe shock.
Revolution (RPM) 1,000 2,000 3,000 4,000 5,000 6,000 7,000 Remark
+6 +7.5
Tolerance (%) +6 +6 +6 +6 +6 Gasoline
-12 -1.5
Fuel gauge
1. Remove the instrument cluster.
Page 27 of 49
2. Check the fuel gauge by changing the resistance between the terminals.
Apply battery voltage to the terminal 1f, ground the terminal 1b, and connect the resistance to the terminal 2n and
then check that the pointer is moved as shown in below table.
Resistance (Ω) Gauge level
95 E(Empty)
32.5 2/1
6.5 F(Full)
Temperature gauge
1. Remove the instrument cluster.
2. Check the temperature gauge by changing the resistance between the terminals.
3. Apply battery voltage to the terminal 1f, ground the terminal 1b, and connect the resistance to the terminal 2c and
then check that the pointer is moved as shown in below table.
Temperature
Resistance (Ω) Angle ( °)
[ °F (°C)]
122 (50) 180.5 -30
185(85)~221(105) 48.7~26.5 -5 ~ 5
over 250 (125) 15.9 30
Body Electrical System > Power Door Locks > Power Door Lock Actuators > Repair procedures
Inspection
1. Disconnect the actuator connector from the wiring harness.
Page 28 of 49
2. Apply battery voltage (12V) to each terminal as shown in the table and verify that the actuator operates correctly.
Body Electrical System > Power Door Mirrors > Power Out Side Mirror Switch > Repair procedures
Inspection
1. Remove the power door mirror switch from the door trim panel.
2. Check for continuity between the terminals in each switch position according to the table.
If continuity is not as specified, replace the power door mirror switch.
Body Electrical System > Power Door Mirrors > Power Door Mirror Actuator > Repair procedures
Inspection
1. Disconnect the power door mirror connector from the harness.
Page 29 of 49
2. Apply battery voltage to each terminal as shown in the table and verify that the mirror operates properly.
Mirror heating inspection
Body Electrical System > Power Windows > Power Window Motor > Repair procedures
Inspection
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.
Page 30 of 49
Body Electrical System > Power Windows > Power Window Switch > Schematic Diagrams
Circuit diagram
Body Electrical System > Power Windows > Power Window Switch > Repair procedures
Inspcetion
Power window main switch
1. Remove the switch from the door trim panel.
Page 31 of 49
2. Check for continuity between the terminals. If continuity is not as specified in the table, replace the power
window switch.
Door lock switch
Power window sub switch

Page 32 of 49
Body Electrical System > Rear Glass Defogger > Rear Glass Defogger Printed Heater > Repair
procedures
Inspection
Wrap tin foil around the end of the voltmeter test lead to prevent damaging the heater line. Apply finger pressure
on the tin foil, moving the tin foil along the grid line to check for open circuits.
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.
Page 33 of 49
4. To check for open circuits, slowly move the test lead in the direction that the open circuit seems to exist. Try to
find a point where a voltage is generated or changes to 0V. The point where the voltage has changed is the open-
circuit point
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. 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).
After repairing, clean the glass with a soft dry cloth or wipe along the grid line with a slightly moistened
cloth.
Page 34 of 49
Body Electrical System > Windshield Wiper/Washer > Front Wiper Motor > Components and
Components Location
Component
Body Electrical System > Windshield Wiper/Washer > Front Wiper Motor > Repair procedures
Inspection
Speed operation check
1. Remove the connector from the wiper motor.
2. Attach the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 3.
Page 35 of 49
3. Check that the motor operates at low speed.
4. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 3.
5. Check that the motor operates at high speed.
Automatic stop operation check

1. Operate the motor at low speed.
2. Stop the motor operation anywhere except at the off position by disconnecting terminal 3.
3. Connect terminals 4 and 5.
4. Connect the positive (+) lead from the battery to terminal 4 and the negative (-) lead to terminal 3.
5. Check that the motor stops running at the off position.
Adjustment
1. Starting with passenger side arm, place wiper arms on pivot shaft.
2. Install nut and tighten.
Tighten nut to
13~16 lb·ft (18~22 N·m, 1.8~2.2 kg·m)
You should nut run windshield wipers on a dry windshield.

3. Install nut cover and check arm movement across windshield. Wiper arms should stop 1.6 inch (41mm) (Driver
side) and 1.6 inch (40mm) (Passenger side) from lower edge of windshield.
Page 36 of 49
Body Electrical System > Windshield Wiper/Washer > Front Washer Motor > Components and
Components Location
Components
Body Electrical System > Windshield Wiper/Washer > Front Washer Motor > Repair procedures
Inspection
1. With the washer motor connected to the reservoir tank, fill the reservoir tank with water.
2. Apply the battery voltage to the terminal a and ground the terminal b or c to see that the washer motor runs and
water sprays from the front or rear nozzles.
Page 37 of 49
3. Check that the motor operates normally.
Adjustment (Washer nozzle)

1. Spray should center on driver and passenger sides of front windshield. If off-line, adjust by slightly turning the
nozzle.
2. If clogged or restricted, use a needle or wire to clear nozzle exit.
Body Electrical System > Rear Wiper/Washer > Rear Wiper Motor > Components and Components
Location
Component
Page 38 of 49
Body Electrical System > Rear Wiper/Washer > Rear Wiper Motor > Repair procedures
Adjustment (Washer nozzle)
Page 39 of 49
1. Set the washer nozzle on the specified spray position.
Body Electrical System > Rear Wiper/Washer > Rear Washer Switch > Repair procedures
Inspection
1. Check the continuity between the terminals while operating the switch.
Body Electrical System > Lighting System > Repair procedures

Head lamp aiming instructions
The headlamps should be aimed with the proper beam-setting equipment, and in accordance with the equipment
manufacturer's instructions.
If there are any regulations pertinent to the aiming of headlamps 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 headlamp aiming. If beam-setting 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 headlamp centers) and a horizontal line (Horizontal
line passing through center of headlamps) on the screen.
4. With the headlamp and battery in normal condition, aim the headlamps so the brightest portion falls on the
horizontal and vertical lines.
Make vertical and horizontal adjustments to the lower beam using the adjusting wheel.
Front fog lamp
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.
Page 40 of 49
1. Turn the low beam on without the driver aboard.

The cut-off line should be projected in the allowable range (shaded region).
Page 41 of 49
2. Turn the high beam lamp on without the driver aboard.
3. Turn the front fog lamp on without the driver aboard.

Fog lamp switch

Page 42 of 49
1. Check for the continuity between the terminals while operating the switch.
Body Electrical System > Hazard Lamp Switch > Repair procedures
Hazard switch inspection
1. Check for the continuity between the terminals while operating the switch.
Flasher unit inspection

1. Remove the flasher unit from the relay box.
2. Connect 2-turn signal lamps between terminal 1 and 2.
3. Apply the battery voltage to the terminal 2 and ground the terminal 3.
4. Check the blinking frequency.
If abnormal, replace the flasher unit.
Blinking frequency : 60~120 times/minute
Body Electrical System > Daytime Running Lights > DRL Control Module > Repair procedures
Inspection
Circuit diagram
Page 43 of 49
Operation check
Check that the lights operate according to the following timing chart.

1. It is installed at the lower of A-pillar.
Page 44 of 49
Body Electrical System > Troubleshooting > 33

DIAGNOSTIC TROUBLE CODE: 33/34 POWER SUPPLY LOW/HIGH
Before inspection; These faults are concerned with the operating voltage of the ACU. Therefore, check the battery
voltage first and check it under the engine cranking for additional checking on charging device. "Air bag(10A)" fuse
also should be checked.
1 Disconnect airbag diagnostic unit connector S-01. Yes Go to step 3.
Turn the ignition switch to ON position.
Is battery voltage (9~12V) present at the terminal No Go to next step.
5 (W/G) of harness connector S-01?
2 Turn ignition ignition switch to OFF position. Yes Replace wire harness between S-01 and X-27.
Disconnect X-27 and then turn the ignition switch
to ON position. No Replace wire harness between "AIRBAG (10A)"
Is battery voltage (9~16) present at the terminal 2 fuse and X-27.
(W/G) of X-27?
3 Check for continuity between the terminal 6 (B) of Yes Temporarily install a normal ACU. Go to
S-01 and ground. Diagnostic Trouble Codes and Associated
Is continuity present? Procedures. If problem is corrected, replace
ACU.
No Replace harness between S-01 and ground.

DIAGNOSTIC TROUBLE: 35 WARNING LIGHT SHORT
1 Disconnect airbag control unit connector S-01. Yes Go to next step.
Is ground present at the terminal 7 (Y) of harness No Temporarily install a normal ACU. Go to
connector S-01?
Diagnostic Trouble codes and Associated
Procedures. If problem is corrected, replace
ACU.
2 Disconnect connector X-27. Yes Go to next step.
Is ground present at the terminal 7(Y) of S-01?
No Replace wire harness between S-01 and X-27.
3 Disconnect instrument cluster connector C-01 Yes Replace lamp socket or instrument cluster.
from instrument cluster.
Is ground present at the terminal B11 (Y) of C- No Replace wire harness between S-01 and X-27.
01?
For the faults concerned with warning light Mode 5, the warning light will go out approximately 10 seconds after the
occurred faults are corrected.

DIAGNOSTIC TROUBLE CODE: 36 WARNING LIGHT OPEN
Page 45 of 49
1 Disconnect airbag control unit connector S-01. Yes Go to next step.
Is there an open circuit between the terminal 7 (Y)
No Temporarily install a normal ACU. Go to
of S-01 and the terminal B11 (Y) of instrument
Diagnostic Trouble Codes and Associated
cluster C-01? Procedures. If problem is corrected, replace
ACU.
2 Is there an open circuit between the terminal 1C Yes Repair or replace lamp bulb, socket, and circuit
(Y) of C-01 and the terminal B11 (Y) of C-01? print in instrument cluster.
No Replace wire harness between S-01 and X-27.
3 Is there an open circuit between the terminal 1 (Y) Yes Replace wire harness between X-27 and S-01.
of X-27 and the terminal 7 (Y) of S-01? No Replace wire harness between C-01 and X-27.

DIAGNOSTIC TROUBLE CODE: 53 DRIVER MODULE SHORT TO GROUND
1 Disconnect airbag control unit connector S-01 Yes Replace harness between S-01 and S-09.
and clock spring assembly connector S-09.
Is ground present at the terminal 10 (R) or/and 11 No Go to next step.
(Y/R) of S-01?
2 Disconnect connector S-02 from driver airbag Yes Replace clock spring assembly.
module.
Is ground at the terminal 2 (Y/R) or 3 (R) of clock No Replace driver airbag module.
spring connector S-09? (Refer to Driver Airbag Module.)

DIAGNOSTIC TROUBLE CODE: 54 DRIVER MODULE SHORT TO BATTERY
1 Disconnect airbag control unit connector S-01 Yes Replace wire harness between S-01 and S-09.
and clock spring assembly connector S-09.
Is battery voltage present at the terminal 10 (R) No Go to next step.
or/and 11 (Y/R) of S-01?
2 Disconnect connector S-02 from driver airbag Yes Replace clock spring assembly.
module.
Is battery voltage at the terminal 2 (Y/R) or 3 (R) No Replace driver airbag module.
of clock spring connector S-09? (Refer to Driver Airbag Module.)

DIAGNOSTIC TROUBLE CODE: 55 DRIVER MODULE SHORT
Page 46 of 49
1 Disconnect connector S-02 from driver airbag Yes Go to next step.
module.
Is there short between the terminal 2 (Y/R) and No Replace driver airbag module.
terminal 3 (R) of clock spring S-02? (Refer to Driver Airbag Module)
2 Disconnect connector S-09 from clock spring Yes Replace airbag harness between S-01 and S-09.
assembly.
Is there a short circuit between the terminal 2 No Replace clock spring assembly.
(Y/R) and terminal 3 (R) of airbag harness S-09?

DIAGNOSTIC TROUBLE CODE: 56 DRIVER MODULE OPEN
1 Disconnect airbag control unit connector S-01 Yes Go to next step.
and driver airbag module connector S-02.
Is there an open circuit between the terminal No Go to step4.
11(Y/R) of S-01 and terminal 2(Y/R) of S-02?
2 Disconnect connector S-05 from clock spring Yes Replace airbag harness between S-01 and S-09.
assembly.
Is there an open circuit between the terminal 11 No Go to next step.
(Y/R) of S-01 and terminal 2(Y/R) of S-09?
3 Is there an open circuit between terminal B of S- Yes Replace clock spring assembly.
02 and 2(Y/R) of S-09?
No Go to next step.
4 Connect connector S-09 to clock spring Yes Go to next step.
assembly.
Is there an open circuit between the terminal 10 No Replace driver airbag module.
(R) of S-01 and terminal C (R) of S-02? (Refer to Driver Airbag Module.)
5 Disconnect connector S-09 from clock spring. Yes Relpace airbag harness between S-01 and S-09.
Is there an open circuit between the terminal
10(R) of S-01 and terminal 3(R) of S-09? No Go to next step.
6 Is there an open circuit between terminal 2(Y/R) Yes Replace clock spring assembly.
of S-02 and terminal 3(R) of S-09? No Replace driver airbag module.
(Refer to Driver Airbag Module.)

DIAGNOSTIC TROUBLE CODE: 57 PASSENGER MODULE SHORT TO GROUND
and passenger airbag module connector S-03.
Is ground present at the terminal 14 (G/Y) or 13 No Replace passenger airbag module.
(G/R) of S-01? (Refer to Passenger Airbag Module.)
Page 47 of 49

DIAGNOSTIC TROUBLE CODE: 58 PASSENGER MODULE SHORT TO BATTERY
Is battery voltage present at the terminal 14 (G/Y) No Replace passenger airbag module.
or 13(G/Y) of S-01? (Refer to Passenger Airbag Module.)

DIAGNOSTIC TROUBLE CODE: 59 PASSENGER MODULE SHORT
1 Disconnect connector S-02 from passenger airbag Yes Replace wire harness between S-01 and S-03.
module.
Is there short between the terminal 14 (G/Y) or No Replace passenger airbag module.
13 (G/R) of S-01? (Refer to Passenger Airbag Module.)

DIAGNOSTIC TROUBLE CODE: 60 PASSENGER MODULE OPEN
1 Disconnect airbag control unit connector S- 01 Yes Replace harness between S-01 and S-03.
(G/Y) of S-01 and terminal 2 (G/Y) of S-03?
2 Is there an open circuit between the terminal 13 Yes Replace harness between S-01 and S-03.
(G/R) of S-01 and terminal 3 (G/R) of S-03? No Replace passenger module.
(Refer to Passenger Airbag Module.)

DIAGNOSTIC TROUBLE CODE: 61 DRIVER PRETENSIONER SHORT TO GROUND
Page 48 of 49
and driver pretensioner connector S-07.
Is ground present at the terminal 1 (LG) or/and 2 No Go to next step.
(O) of S-01?
2 Disconnect connector S-07 from driver Yes Replace wire harness between S-01 and S-07.
pretensioner.
Is ground at the terminal 1 (LG) or/and 2 (O) of No Replace driver pretensioner.
pretensioner connector S-07?
Body Electrical System > Troubleshooting > P1693

TROUBLESHOOTING PROCEDURE FOR DTC
MIL request circuit malfunction
No. P1693
[Related items] • Open or short to chassis ground between TCM signal and
ECM
• Short to battery between TCM and ECM
• Message timeout from TCM
• Faulty TCM

1 Turn ignition to OFF and disconnect ECM Yes Go to step 2.
connector and TCM connector.
Measure resistance of MIL request circuit
between ECM harness connector and TCM No Open circuit between ECM harness connector
harness connector. and TCM harness connector.
• Specifications: below 1Ω Repair as necessary.
Does each resistance indicate continuity circuit?
2 ECM connector and TCM connector are still Yes Go to step 3.
disconnected.
Measure resistance between ECM harness
connector and chassis ground at MIL request No Short to chassis ground between ECM harness
circuit. connector and TCM harness connector.
• Specifications: infinite Repair as necessary.
Does each resistance indicate open circuit?
3 Turn ignition to ON. TCM and ECM connectors Yes Go to step 4.
are still disconnected.
Measure voltage of MIL request circuit between No Short circuit to battery between ECM harness
ECM harness connector and chassis ground. connector and TCM harness connector.
• Specifications: below 0.5V Repair as necessary.
Is each voltage within specifications?
4 Thoroughly check for loose, bent or corroded Yes Go to step 5.
connectors at ECM and TCM connectors. No Check TCM related fault code by SCAN TOOL.
Are connectors okay? Repair as necessary.
Page 49 of 49
5 Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehicle with SCAN
TOOL connected and monitor for pending codes.
Body Electrical System > Troubleshooting > P1800

Engine torque signal malfunction
Diagnostic trouble code Engine torque signal malfunction
P1800
Details 1. Short circuit to ground or open circuit.
2. Short circuit to battery voltage
Possible Damaged wiring or connectors between engine control module and

cause (ECM) transaxle control module (TCM)

pins OK?
No Go to next step.
3 Are connectors and wiring between ECM and Yes Go to next step.
TCM.
further.
Page 1 of 68
RIO(BC) > 2005 > G 1.6 DOHC > Brake System
Brake System > General Information > Special Service Tools

SPECIAL SERVICE TOOLS
Brake System
Tool
Illustration Use
(Number and Name)
0K130 430 019 Used to remove and install brake pipe.
Flare nut wrench
0KK30 430 017 Used to assemble disc pad.

Disc brake expander
0K370 430 018 Used to adjust push rod gap.

Brake adjust gauge
0KK30 140 001 Used to measure brake fluid pressure.

Oil pressure gauge &
adapter
Anti-Lock Brake System

Page 2 of 68
Tool
Illustration Use
(Nunber and name)
0K2CA 089 HSP Used to diagnose anti-lock brake
Hi-scan pro system.
0K670 990 AA0 Used to remove the sensor rotor.

Bearing installer set
0K130 430 019 Used to remove and install brake pipe.

Flare nut wrench
0K370 430 018 Used to adjust push rod gap.

Adjustment gauge
Brake System > General Information > Troubleshooting

Troubleshooting guide
Condition Possible source Action
Brake Warning Lamp Low fluid level FILL system. CHECK for leaks.
in Instrument Cluster Leaking master cylinder primary piston cup. OVERHAUL or REPLACE master
ON
cylinder.
Parking brake not fully released. FREE up and ADJUST parking brake.
REPLACE defective parts.
Parking brake wiring grounded. REPAIR parking brake wiring.
Parking brake switch grounded. REPLACE parking brake switch.
Low Pedal Rear brake self-adjuster not operating CHECK self-adjusting mechanism. REPAIR
properly. or REPLACE defective parts.
Caliper piston or slide pins sticking. REPAIR or REPLACE caliper or slide pins.
Page 3 of 68
Loose wheel bearings. DISASSEMBLE front spindles, INSPECT
bearings and ADJUST.
Pedal Goes to Floor Leak in hydraulic system. REPAIR leak. CHECK entire hydraulic
(Excessive Pedal system. REFILL and BLEED.
Travel)
Improper adjustment of pedal play. ADJUST pedal.
Air in system. BLEED brakes. CHECK for leaks.
Worn master cylinder piston cups or scored OVERHAUL or REPLACE master
cylinder bore. cylinder.
Disc brake "knock back" (Pads push caliper CHECK rotor runout, MACHINE or
piston back into caliper. Caused by REPLACE rotor. ADJUST front wheel
excessive rotor lateral runout or loose wheel bearings.
bearings.).
Worn brake pads. REPLACE brake pads.
Brakes Grab Linings contaminated by grease or brake REPLACE linings. REPAIR cause of
fluid. contamination.
Brake shoes bent, distorted, cracked or REPLACE brake linings.
loose on platform.
Loose backing plate. TIGHTEN rear bearing hub attaching bolts.
REPLACE if worn or bent.
Loose caliper slide pins or anchor bolts. TIGHTEN slide pins or bolts. CHECK for
hole elongation.
Hot spotted drums or rotors. REPLACE drums or rotors. CHECK
pads/shoes.
Binding wheel cylinders or caliper pistons. OVERHAUL or REPLACE wheel cylinders
or calipers.
Frozen or incorrectly adjusted parking brake REPAIR or REPLACE frozen components.
components.
Brakes Drag Frozen or incorrectly adjusted parking brake REPAIR or REPLACE frozen components.
components.
Broken or weak rear brake return springs. REPLACE springs.
Caliper or wheel cylinder pistons frozen. OVERHAUL or REPLACE calipers or
wheel cylinders.
Brake pedal binding at pivot points. EPAIR or REPLACE brake pedal bushings
or pedal assembly.
Brake On/Off(BOO) switch incorrectly ADJUST Brake On/Off(BOO) switch.
adjusted, not letting pedal return.
Power booster binding push rod adjustment REPLACE binding power booster.
or binding assist unit.
Master cylinder compensating ports plugged. UNPLUG compensating ports using
compressed air. REPLACE if obstruction
cannot be removed.
Poor Braking Leak in hydraulic system. REPAIR leak. CHECK entire hydraulic
Page 4 of 68
system. REFILL and BLEED.
Air in system. BLEED brakes. CHECK for leaks.
Worn / damaged brake pad. REPLACE brake pad.
Foreign material on brake pad. CLEAN or REPLACE brake pad.
Caliper piston malfunction. EPLACE caliper piston.
Master cylinder malfunction. REPAIR or REPLACE master cylinder.
Power brake booster malfunction. REPLACE power brake booster.
Check valve (vacuum hose) malfunction. REPLACE check valve and vacuum valve.
Dual proportioning valve malfunction. REPLACE dual proportioning valve.
Damaged vacuum hose. REPLACE vacuum hose.
Damaged flexible hose. REPLACE flexible hose.
Brake(s) Pull to One Worn/damaged brake pad. REPLACE brake pad.
Side
Foreign material on brake pad. CLEAN or REPLACE brake pad.
Abnormal wear or distortion of rotor. REPAIR or REPLACE rotor.
Caliper piston malfunction. REPLACE caliper piston.
Improper wheel alignment adjustment. PERFORM wheel alignment adjustment.
REFER to Section 54.
Improper tire air pressure. INFLATE tire to proper air pressure.
Loose or damaged dust cover mounting bolt. TIGHTEN or REPLACE dust cover
mounting bolt.
Improper wheel bearing preload adjustment. ADJUST preload or REPLACE wheel
bearing.
Brakes Do Not No brake pedal play. ADJUST brake pedal play.
Release
Improper push rod clearance adjustment. ADJUST push rod for proper clearance.
Master cylinder return port clogged. CLEAN return port on the master cylinder.
Caliper piston malfunction REPLACE caliper piston.
Excessive rotor runout. REPLACE rotor.
Brake pad not returning properly. CHECK and REPLACE brake pad if
necessary.
Improper wheel bearing preload adjustment. ADJUST preload or REPLACE wheel
bearing.
Abnormal Noise or Worn / damaged brake pad. REPLACE brake pad.
Vibration During Loose caliper mounting bolt. TIGHTEN caliper mounting bolt.
Braking
Insufficient grease on sliding parts. APPLY grease where necessary.
Foreign material or scratches on rotor CLEAN rotor contact surface.
contact surface.
Damaged rotor contact surface. REPLACE rotor.
Low or Hard Pedal Lack of vacuum to the power booster. REPAIR vacuum supply to power booster.
Page 5 of 68
Vacuum check valve restricted. TEST and REPLACE check valve as
necessary.
Restricted vacuum hose. REPAIR or REPLACE hose as necessary.
Groaning Noise Dry or rough brake cable holders. LUBRICATE cable and cable holders.
Brake Pedal Pulsates Brake drums out-of-round. REPLACE drums.
Disc rotors have excessive lateral runout. MACHINE rotors, REPLACE if necessary.
Loose wheel bearings. INSPECT and ADJUST wheel bearings.
Bent front / rear spindles. REPLACE spindle.
Bent or distorted hub mounting flange. REPLACE hub.
Brake Noise Worn brake linings. REPLACE linings.
Bent, cracked brake lining platforms on REPLACE linings. REPLACE backing
backing plate. plate.
Foreign objects in linings. REPLACE linings, CHECK drums for
scoring.
Cracked or heat checked drums or rotors. REPLACE drums or rotors. CHECK pads /
shoes.
Broken or loose rear brake hold down or REPLACE hold-down or return springs.
return springs.
Dry or rough backing plate slide pads. SAND and LUBRICATE slide pads.
Loose or missing disc brake anti rattle REPAIR or REPLACE anti-rattle springs.
springs.
Loose caliper mounting bolts. TIGHTEN mounting bolts, CHECK for hole
elongation.
Brake System > General Information > Specifications

SPECIFICATIONS
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Item Specifications
General System MGH-20
Type 4-Sensors and 4-Channels
Mode ABS+EBD
HCU Type Diagonal Split
Hydraulic control method Hold/ Rise/ Dump (3Mode)
Type of pump Radial pistons (2 pistons)
Type of motor 4-pole DC motor
Type of solenoid valve 4 inlet valve,
4 outlet valve
ECU Operation voltage DC 10~ 16V
Operation temperature -40 ~ 110 °C
ABS Type Electromagnetic induction
sensor
Resistance 1.3~1.5kΩ
Air gap Front 0.027±0.016 in (0.7±0.4 mm)
Rear 0.027±0.016 in (0.7±0.4 mm)
W/Lamp ABS Operation
12V
EBD (Brake Lamp) voltage
Consume
1<200mA
current
SPECIFICAFIONS
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Brake System > Brake System > Description and Operation

PRINCIPLE
1. The principle is approximate control of brake force near the required liquid pressure distribution curve(ideal
braking distribution curve)by way of adding a logic to ABS ECU instead of the existing P-valve.
2. Rear liquid pressure is controlled so that rear slip ratio will always be less than or same as that of front, having
calculated the slip ratio from each wheel speed sensor at braking time.
3. Therefore rear wheel locking does not precede that of front wheel.
4. Consequently brake force improves as rear brake liquid pressure can be enlarged in amount of parts of as shown
by deceleration liquid pressure in the figure below.
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5. And eventually whole brake force improvement is realized as brake force can be controlled by liquid pressure
distribution curves required of wheel according to friction material dispersion.
Brake System > Brake System > Components and Components Location
Structural view
Page 9 of 68
Brake System > Brake System > Brake Booster > Components and Components Location
Component
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Take the following steps after the installation:

• Add a fluid and bleed the air.
• Check all parts for the fluid leakage.
• Adjust and check the brake pedal operation.
• Make an on-vehicle check of the unit.
Brake System > Brake System > Brake Booster > Repair procedures
REMOVAL
1. Disconnect the fluid level warning connector.
2. Remove the brake pipes.
3. Remove the master cylinder
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4. Disconnect the vacuum supply hose from the power brake unit.
5. From inside the vehicle, remove the cotter pin securing the clevis pin.
6. Remove the clevis pin from the clevis.
7. Have a second technician support the brake booster in the engine compartment.
8. Remove the four brake booster mounting nuts securing the brake booster to the bulkhead.
9. Remove the brake booster.
10. Remove the gasket between the brake booster and the bulkhead.
INSTALLATION
Lubricate the clevis pin with white lithium grease.

To install, reverse the removal procedure.
Tighten the four brake booster mounting nuts.
Tightening torque :
18.6~25.5 N·m (1.9~2.6 kg·m, 13.7~18.8 lb·ft)
INSPECTION
Power brake unit function check (Simple method)
Step 1
1. With the engine stopped, depress the pedal a few times.
2. With the pedal depressed, start the engine.
3. If immediately after the engine starts the pedal moves down slightly, the unit is operating.
Step 2
1. Start the engine.
2. Stop the engine after it has run for 1 or 2 minutes.
3. Depress the pedal with the usual force.
4. If the first pedal stroke is long and becomes shorter with subsequentstrokes, the unit is operating.
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5. If a problem is found, inspect for damage of the check valve or vacuum hose and examine the installation. Repair
if necessary, and inspect it once again.
Step 3
2. Depress the pedal with the usual force.
3. Stop the engine with the pedal held depressed.
4. Hold the pedal down for about 30 seconds.
5. If the pedal height does not change, the unit is operating.
6. If there is a problem, check for damage to the check valve or vacuum hose, and check the connection. Repair if
necessary and check once again.
If the nature of the problem is still not clear after the 3 steps above, follow the more detailed check described in
the "Method-using tester" below.
(Method-using tester)
Connect the SST, vacuum gauge A, and pedal depression force gauge B as shown in the figure. After bleeding the
air from the SST, conduct the test as described in the 3 steps below.
Use a commercially available vacuum gauge and pedal depression force gauge.
A) Checking for vacuum loss Unloaded condition

2. Stop the engine when the vacuum gauge reading reaches 66.7 kPa (500 mmHg, 19.7 inHg).
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3. Observe the vacuum gauge for 15 seconds. If the gauge shows 63.3~66.7 kPa (475~500 mmHg, 18.7~19.7
inHg), the unit is operating.
Loaded condition
2. Depress the brake pedal with a force of 196 N (20 kg, 44 lb).
3. With the brake pedal depressed, stop the engine when the vacuum gauge reading reaches 66.7 kPa (500 mmHg,
19.7 inHg).
4. Observe the vacuum gauge for 15 seconds. If the gauge shows 63.3~66.7 kPa (475~500 mmHg, 18.7~19.7
inHg), the unit is operating.
B) Checking for hydraulic pressure

1. If with the engine stopped (vacuum 0 kPa (0 mmHg, 0 inHg)) the fluid pressure is within the specification, the unit
is operating.
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2. Start the engine. Depress the brake pedal when the vacuum reaches 66.7 kPa (500 mmHg, 19.7 inHg). If the
fluid pressure is within the specification, the unit will operate.
Check valve
The check valve is pressed into the vacuum hose. The arrow on the hose indicates the direction of hose installation
(toward booster).
1. Remove the clamps and remove the hose (with the internal check valve).
2. Apply a suction and pressure to the hose from the engine side. Verify that air flows only toward the engine. If the
air passes in both directions or not at all, replace the vacuum hose (along with the check valve).
Brake System > Brake System > Master Cylinder > Repair procedures
INSTALLATION
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1. Position the master cylinder on the brake booster. Refer to check push rod length.
Piston to push rod clearance Standard type
A. Place the SST on the master cylinder. Turn the adjusting bolt until it bottoms in the push rod hole in the piston.
B. Apply 19.7 inHg (500 mmHg) vacuum to the power brake unit with a vacuum pump.
C. Invert the adjustment gauge used in Step 1 and place it on the power brake unit.
D. Measure the clearance between the end of the gauge and the push rod of the power brake unit. If it is not 0 in
(0 mm), loosen the push rod locknut and turn the push rod to make the adjustment.
By making the above adjustment, the clearance between the push rod and piston (after installation of
the brake master cylinder to the power brake unit) will be as shown in the table below.
Vacuum applied to unit Push rod-to-piston clearance

0 inHg 0.016~0.024
(0 mmHg) in (0.4~0.6 mm)
Approx. 19.7 inH 0.004~0.016
(500 mmHg) in (0.1~0.4 mm)
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2. Install the master cylinder attaching washers and nuts. Tighten the master cylinder attaching nuts.
Tightening torque :
9.81~15.7 N·m (1.0~1.6 kg·m, 7~12 lb·ft)
3. Tighten the brake pipe flare nut with the SST.
Tightening torque :
13~22 N·m (1.3~2.2 kg·m, 10~16 lb·ft)
4. Connect the low fluid level sensor wiring.

5. Bleed the brakes.
Brake System > Brake System > Proportioning Valve > Components and Components Location
1. Remove the brake pipe shown in the figure.
2. Remove the bolt.
3. Remove the proportioning valve.
4. Install in the reverse order of removal.
5. After the installation, add a brake fluid, bleed air and check for the fluid leakage.
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Brake System > Brake System > Proportioning Valve > Repair procedures
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1. Connect the SST to the brake pipes with adapters as shown in the figure.
Adapter and flare nut tightening torque :

12.8~21.5 N·m (130~220 kg·cm, 113~190 lb·in)
Disconnect and connect the brake pipes with SST.
2. Bleed the air from the brake system.

3. Depress the brake pedal until the front brake pressure equals to A; then record the rear brake pressure A'.
4. Depress the brake pedal again, apply the additional pressure until the pressure equals to B; then record the
pressure B'.
Fluid pressure
• Do not attempt to adjust the proportioning valve.

• After the inspection, bleed the air from the brake system and check for the fluid leakage.
• If the measurements are not within the specification, replace the valve assembly.
Brake System > Brake System > Brake Line > Repair procedures
Air bleeding
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1. Jack up the vehicle and support it with a safety stands.
The brake fluid reservoir must be kept 3/4 full during air
bleeding.
2. Remove the bleeder cap and attach a vinyl hose to the bleeder plug.
3. Place the other end of the vinyl tube in a clear container.
4. One person should depress the brake pedal a few times, and then hold it in the depressed position.
5. A second person should loosen the bleeder screw, drain out the fluid, and retighten the screw with the SST.
Be sure the pedal remains depressed until the bleed screw is tightened.
6. Repeat Steps 4 and 5 until no air bubbles are seen.
7. Check for the correct brake operation.

8. Verify that there is no fluid leakage. Clean away any spilled fluid with rags.
9. After bleeding the air, add a brake fluid to the reservoir up to the specified level.
Tightening torque :
5.9~8.8 N·m (60~90 kg·cm, 52~78 lb·in)
Air bleeding must be started from the bleeder screw furthest from the master cylinder.
Brake pipe
Check for cracks, damage, and corrosion of the brake pipe.Replace the pipe or flare nut if necessary.
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Flexible hose (Removal)

Check for scars, cracks, and swelling of the flexible hose. Replace the hose if necessary.
1. Remove the brake pipe with the SST.
2. Disconnect the clip and remove the flexible hose from the bracket.
Flexible hose (Installation)

1. Fix the flexible hose in the bracket and install the clip.
2. Connect the flexible hose to the brake pipe and tighten the flare nut with the SST.
Verify that the hose is not twisted.

Verify that the hose does not contact other parts when the vehicle bounces or when the steering wheel is
turned fully right or left.
Tightening torque :
13~22 N·m (1.3~2.2 kg·m, 9~16 lb·ft)
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3. Depress the brake pedal several times, and inspect for leakage of the brake lines and system.
Brake System > Brake System > Brake Pedal > Components and Components Location
Component
Page 22 of 68
Brake System > Brake System > Brake Pedal > Repair procedures
Brake pedal height
Inspection
Verify that the distance from the center on the pedal pad to the dash lower panel mat is as specified.
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Specification : 6.69~6.93 in (170~176mm)
Adjustment
1. Disconnect the stop light switch connector.
2. Loosen the locknut B and turn the switch A until it does not contact the pedal.
3. Loosen the locknut D and turn the rod C to adjust the height of the brake pedal.
4. Tighten the stop light switch until it contacts the pedal then turn it an additional 1/2 turn. Tighten the locknuts B
and D.
Tightening torque :
23.5~34.3 N·m (2.4~3.5 kg·m, 17.4~25.3 lb·ft)
5. Verify the operation of the stoplights.

Pedal play
Inspection
1. Depress the pedal a few times to eliminate the vacuum in the system.
2. Gently depress the pedal by hand and check the free play (until resistance is felt).
Free play : 0.16~0.28 in (4~7 mm)
Adjustment
1. Loosen the locknut D and turn the rod C to adjust the free play.
2. Verify the pedal height and the stoplight operation.
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3. Tighten a lock nut D.
Tightening torque :
23.5~34.3 N·m (2.4~3.5 kg·m, 17.4~25.3 lb·ft)
4. Check the height of pedal and the lightening of stop lamp after the adjustment.
Pedal-To-floor clearance (Inspection)
Verify that the distance from the floor panel to the center of the pedal pad is as specified when the pedal is
depressed with a force of 490.33 N (50 kg) MIN.
Pedal-to-floor clearance : 2.76in (70mm)
If the distance is less than specified, check for the following problems:
1. Air in brake system
2. Malfunction of automatic adjuster (rear drum brakes)
3. Worn shoes or pads
REMOVAL
1. Disconnect the negative battery cable.
2. Remove the split pin from the brake pedal clevis pin and remove the pin.
3. Remove the pivot bolt attaching nut, lockwasher, and spring washer.
4. Remove the spacer from the pivot bolt.
5. Slide the pivot bolt to the right and remove.
6. Remove the brake pedal, brake pedal return spring, and spacers.
7. If necessary, remove the brake pedal bushings, foot pad, and stop bumper.
Installation
1. If necessary, install the brake pedal stop bumper, foot pad, and bushings.
2. Position the brake pedal spacer and slide the pivot bolt through to hold it in position.
3. Position the return spring on the brake pedal.
4. Position the clutch pedal, if equipped, and slide the pivot bolt through to hold it in position.
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5. Install the clutch pedal spacer, if equipped.
6. Install the pivot bolt attaching washers and nut.
7. Install the brake pedal clevis pin and split pin.
8. Connect the negative battery cable.
Brake System > Brake System > Front Disc Brake > Components and Components Location
Components
Components
Page 26 of 68
Brake System > Brake System > Front Disc Brake > Repair procedures
REMOVAL
1. Raise front of vehicle and properly support it.
2. Remove front wheels.
3. Remove two bolts and remove caliper.
4. Remove brake pads and guide plate.
5. Measure brake pad thickness.
Minimum brake pad thickness : 0.08 in (2.0 mm)
6. Prepare to catch any brake fluid. Disconnect brake hose using a flare nut wrench.
7. Remove two bolts and supporting plate.
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8. Measure rotor thickness at four or more places.
Minimum rotor thickness : 0.86 in (22 mm)
9. Mount a dial indicator and measure runout at the outer braking contact edge of the rotor.
Minimum runout : 0.002 in (0.06 mm)
Excessive runout could be caused by a loose wheel hub bearing.

10. To remove rotor, remove two mounting screws with an impact driver.
11. Resurface of replace rotor as required.
REMOVAL
1. Disconnect the low fluid level sensor wiring connector.
2. Disconnect the brake pipes from the master cylinder and ABS control unit by using SST(0K130 430 019). Cap
the tubes and plug the master cylinder ports and ABS control unit ports to prevent the entry of contaminants.
3. Remove the two master cylinder attaching nuts and washers.
4. Remove the master cylinder from the mounting studs on the brake booster.
INSTALLATION
1. Mount a new or repaired rotor on hub and fasten with two mounting screws.
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2. Install the supporting plate, and install the guide plate to the supporting plate.
Tightening torque :
57~75 lb·ft (78~102 N·m, 8.0~10.4 kg·m)
3. Connect the brake hose to the caliper using a flare nut wrench.
Tightening torque :
9~13 ib·ft (13~18 N·m, 1.3~1.8 kg·m)
4. Push the piston back into the caliper bore by using SST.
5. Position brake pads in supporting plate cavity and install caliper onto supporting plate.
6. Install two bolts.
Tightening torque :
61~68 lb·ft (83~93 N·m, 8.5~9.5 kg·m)
7. Bleed system (Refer to Air bleeding).

8. Inspect system for any leaks.
Disc brake pad

1. Check facing for oil or grease abnormal wear, cracks, and deterioration or damage from heat.
Measure thickness of lining.
Specified thickness : 0.39 in (10 mm)

Minimum : 0.08 in (2.0 mm)
2. Visually check for damage or wear on the guide plate.
Disc plate
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1. Measure thickness of disc plate.
Standard : 0.94 in (24 mm)

Minimum : 0.86 in (22 mm)
2. Measure runout at 0.32~0.47 in (8~12 mm) inside from outer edge of contact surface of disc pad.
Runout : 0.002 in (0.06 mm) Max.
• There must be no wheel bearing looseness.

• Measurement location is outer edge of disc plate surface.
DISASSEMBLY
1. Loosen the bleeder screw and drain the brake fluid out of the caliper. Install the bleeder screw.
2. Remove the piston boot.
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3. Position a block of wood or a roll of shop towels between the piston and the caliper.
NOT USE AN EXCESSIVE AMOUNT OF AIR PRESSURE TO REMOVE THE PISTON.

EXCESSIVE PRESSURE CAN FORCE THE PISTON OUT OF THE CALIPER BORE WITH
ENOUGH FORCE TO CAUSE PERSONAL INJURY. NEVER ATTEMPT TO CATCH THE
PISTON BY HAND AS IT COMES OUT OF THE CALIPER BORE.
A compressed air can be used as an alternative to removing the caliper piston.

Apply the air pressure through the fluid inlet port. Apply only enough pressure to ease the piston out of the
bore.
4. Remove the piston.

5. Remove the piston seal from the caliper bore. Use a plastic or wooden stick to remove the seal.
6. Remove the bleeder screw.

7. Remove the bushing and the pin bolts.
Do not use petroleum based solvent, kerosene, or gasoline for cleaning caliper parts. Their use as a
cleaning agent can leave residues which can damage the rubber seals.
8. Wash the parts in clean denatured alcohol and dry with a compressed air.
REASSEMBLY
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1. Install the piston seal.
Lubricate the piston seal with the rubber grease and install it in the caliper.
2. Lubricate the piston with brake fluid and partially install the piston.
3. Lubricate the dust piston with the rubber grease then install it on the piston.
4. Press the piston into the caliper until it bottoms in the bore.
5. Install the bleeder screw.

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6. Install the bushing and new pin boots.
7. Lubricate the inside surface of the bushings with the rubber grease contained in the overhaul kit.
Brake System > Brake System > Rear Drum Brake > Components and Components Location
Components
Wheel cylinder
Page 33 of 68
Components
Brake System > Brake System > Rear Drum Brake > Repair procedures
REMOVAL
1. Raise and support the vehicle after releasing the parking brake
2. Remove the wheel and tire.
3. Remove the hub cap.
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4. Use a small cape chisel to raise the staked edge of the lock nut.
Use carefully not to damage the groove and threads of

spindle.
5. Remove the drum, washer and bearings as an assembly from the spindle.
6. Remove the brake shoe hold-down springs and pins.
7. Remove the brake shoe assembly.

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8. Remove the parking brake cable from the brake shoe assembly.
9. Remove the wheel cylinder brake pipe.

10. Remove the wheel cylinder attaching bolt.
11. Remove the anti-rattle spring from brake shoe assembly.
12. Remove the operating lever after removing the return spring.
13. Remove the parking brake operating lever retainer.
INSTALLATION
1. Clean the backing plate with an approved vacuum cleaner.
2. Lubricate the contact face of the backing plate and brake shoes.
Be careful not to attach grease to lining surface.
3. Install the wheel cylinder to the backing plate.

4. Install the wheel cylinder brake pipe.
5. Install the parking brake operating lever after installing the brake shoe assembly.
Lubricate the contact face of strut and adjust lever.
6. Put the parking brake cable into the operating lever.
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7. Position the brake shoe assembly to the wheel cylinder.
8. Install the brake shoe hold-down pin and spring clip.

9. Set the self-adjuster to the fully released position.
10. Place a screwdriver against the adjuster cam and push it to the released position.
11. Install the drum, washer and bearing to the spindle.
12. Push the brake pedal several times to the self-adjuster.
13. Firmly fix the lock nut to the groove.
14. Install the hub cap.
INSPECTION
1. Inspect the inside of the brake drum for scratches and uneven or abnormal wear.
2. Repair minor damage or replace if damage is excessive.
3. Measure the inside diameter of the brake drum using Brake Drum Micrometer or equivalent.
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4. The standard inner drum diameter is 7.87 inches (200 mm).
The maximum diameter is 7.91 in (201 mm).
Be sure to check the drum-to-shoe contact after repairing or replacing the brake
drum.
5. Check the brake linings for peeling, cracks, or extremely uneven wear.
6. If the brake lining thickness is less than 0.04 inch (1.0 mm), replace the brake shoes.
DISASSEMBLY
1. Remove the dust boots and discard.
2. Remove the pistons and the return spring.
3. Remove the piston seals and discard.
4. Remove the bleeder screw and the ball seal.
Do not use petroleum based solvent, kerosene, or gasoline for cleaning wheel cylinder parts. Their use as a
cleaning agent can leave residues which can damage the rubber seals.
5. Wash the parts in clean denatured alcohol and dry with compressed air.
REASSEMBLY
1. Install the seals on the pistons.
2. Lubricate the wheel cylinder bore and pistons with the specified brake fluid.
3. Install the return spring, pistons, and dust boots.
4. Install the ball seal and the bleeder screw.
Brake System > Parking Brake System > Parking Brake Assembly > Components and Components
Location
COMPONENT
Page 38 of 68
Brake System > Parking Brake System > Parking Brake Assembly > Repair procedures
ADJUSTMENT
1. Ensure the parking brake lever is in the fully released position.
2. Raise the vehicle and ensure the rear wheels are free to turn.
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3. Adjust the cable length with adjuster nut so that the number of sector notch is 5~7 when pulling force of 10kg.
The rear brakes should lock when the parking brake lever is pulled upward 5~7 notches.
4. Do not attach parking cable with 90° or more twist.

5. Check the operation of the parking brake.
REMOVAL
1. Remove the parking brake console after loosening console bolt.
2. Disconnect the indicator lamp switch connector.

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3. Loosen the cable adjust nut.
4. Remove the parking brake lever after loosening two nuts and a bolt.
5. Disconnect the front cable from the rear cable by loosening attaching pin.
6. Remove the rear cable attaching bracket.
7. Remove the two rear seat hinge attaching bolts.
8. Remove the rear seat.

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9. Remove the side-door trim push reatiners.
10. Remove the rear carpet push retainers and carefully pull the carpeting forward to expose the parking brake
cable cover.
11. Remove the parking brake cable cover attaching nut.

12. Remove the parking brake cable cover.
13. Raise and support vehicle.
14. Remove the rear wheel and tire assemblies.
15. Remove the rear brake drum and shoe assemblies.
(refer to rear drum brake)
16. Remove the parking brake cable from the brake shoe assembly.
17. Loosen the parking brake cable attaching nut and bolt.
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18. Pull the end of the cable through the body hole and romove from the vehicle.
19. Remove the parking brake cable from the back plate.
INSTALLATION
1. Position the end of the cable through the body hole.
2. Put the parking brake cable into the back plate.
3. Install the parking brake cable on the brake shoe assembly.
4. Install the drum assembly (refer to rear drum brake)
5. Install the parking brake cable attaching nut and bolt.
Tightening torque:
19~26 N·m (19~26 kg·m, 14~19 lb·ft)
6. Install the wheel and tire assemblies.

7. Lower the vehicle.
8. Install the parking brake cable cover.
Tightening torque:
19~26 N·m (19~26 kg·m, 14~19 lb·ft)
9. Install the rear cable attaching bracket.
Tightening torque:
19~26 N·m (19~26 kg·m, 14~19 lb·ft)
10. Install the rear cable attaching bracket.

11. Install the rear carpet and rear side-door trim.
12. Install the rear seat.
Tightening torque:
19~26 N·m (19~26 kg·m, 14~19 lb·ft)
13. Secure the cable with the pin after connecting the front cable with the rear cable.
14. Install the parking brake lever.
Tightening torque:
19~26 N·m (19~26 kg·m, 14~19 lb·ft)
15. Route the end of the cable through the parking brake lever and then properly tighten the cable adjuster nut.
16. Install the parking brake indicator lamp switch.
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17. Install the parking brake console.
Check that the stroke is within specification.

Check that the parking brake warning lamp illuminates when pulling the brake lever back one
notch.
Brake System > ABS(Anti-Lock Brake System) > Schematic Diagrams

WIRING DIAGRAM
Page 44 of 68
Brake System > ABS(Anti-Lock Brake System) > Description and Operation
DESCRIPTION AND OPERATION
HECU(Hydraulic & Electrical Control unit)
The ABS control unit performs the following functions.
• Controls the ABS
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• Calculates vehicle speed
• Self-diagnostics: Stores malfunction codes, performs ABS control unit self-diagnosticand fail-safe functions with
two separated microprocessors.
The ABS control unit continuously checks locking of each wheel and controlseach valve to adjust brake fluid
pressure if required. The ABS control unitalso checks that components are working properly and stops ABS if a
malfunctionis detected. Then, it is operated as a standard brake system.
SPEED SENSOR
Structure
The speed sensor detects wheel rotation and consists of a permanent magnet and pickup coil. Sensors for the front
wheelsare attached to drive shaft and rear hub spindle for the rear wheel.
Operation
Since teeth of sensor rotor change magnetic field of sensor, it generates alternative voltage. This voltage is
proportional to rotating speed and its period can be changed. It can sense speed of wheel by detecting period.
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WARNING LAMP
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1. ABS warning lamp
(1) It is turned on for three seconds at time of ON of ignition Key and turns off afterwards.
(2) It is extinguished at start of operation.
(3) It is lighted if system abnormality arise.
(4) It is lighted during self-diagnosis.
(5) During its lighting, ABS control is interrupted and only ordinary brake operateds in same way as ABS, TCS
noninstalled vehicle.
(6) It is lighted when ECU connector is removed.
2. EBD (electronic brake-force distribution) warning lamp
(1) It is lighted at time of ON of ignition Key.
(2) It is extinguished at start of operation.
(3) It is lighted when parking brake switch is ON.
(4) It is lighted when brake oil is deficient.
(5) It is lighted when EBD control is infeasible.
A. When there is trouble at soloid valve.
B. When there is trouble in more than one sensor.
C. When there is trouble in ECU.
D. In case of high voltage.
HYDRAULIC CONTROL UNIT (HCU)
Brake System > ABS(Anti-Lock Brake System) > Components and Components Location
STRUCTURAL VIEW
Page 48 of 68
Brake System > ABS(Anti-Lock Brake System) > Troubleshooting

TROUBLESHOOTING GUIGDE
SELF-DIAGNOSIS
HECU (ABS)starts self-diagnostic functions after the ignition is switched ON. HECU detects failure for each circuit
and component by comparing condition of the system with limited condition set inside HECU, HECU stores the
failure code and then outputs the four-digit malfunction code to the diagnostic scan tool (Hi/Scan pro) when the
ABS data link connector is connected.
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SELF-DIAGNOSIS PROCEDURES(WITH THE DIAGNOSTIC SCAN TOOL)
1. With the ignition switch OFF, connect the diagnostic scan tool (Hi-scan pro) to the data link connector located
under side of master vacuum in engine compartment.
2. Make sure the ignition switch is in the on position, and then choose correct vehicle and model, proceed to
diagnostic data link menu item.
3. Choose the inspection item after initializing the unit.
4. Press malfunction code detection No.1 and diagnostic scan tool will display any malfunction code found.
A malfunction code is a four digit number which is continuously outputs until the failure code is erased by
the diagnostic scan tool.
5. From the list of failure codes, verity the failed part and repair it according to self-diagnosis procedures.
6. After repair, erase all malfunction codes stored in HECU (ABS) by selecting inspection item (No.4).
HOW TO ERASE MALFUNCTION CODE (with the diagnostic scan tool)

HECU(ABS) has an automatic malfunction code erasing function as below.
1. After the failures have been serviced, confirm the vehicle functions properly.
2. Press the enter key in malfunction code erase item (No.4) among the inspection items of the diagnostic scan tool
(Hi-scan pro).
HOW TO USE DIAGNOSIS AND TROUBLESHOOTING
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THE MANAGEMENT OF FAILURE DETECTED

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No Description
1 System down.
Both the ABS and the EBD function are inhibited and the ABS and the EBD warning lamps is activated.
In this failure, the valve relay and all solenoids are prevented from being switched on.
2 Only the ABS function is inhibited.
The ABS warning lamp is activated and the EBD warning lamp not activated.
3 Sensor failure outside the ABS control cycle
1. Only one wheel failure: take the same action as management.
2. More than two wheels failure : take the same action as management.
4 Sensor failure inside the ABS control cycle
1. One front wheel failure: inhibit the ABS control of the Failed-wheel and maintain the ABS control of
normal wheel. Afterthe controller completes the ABS control, take the same action as the management .
2. Rear wheel failure: inhibit ABS control of both front wheels and the pressure of rear wheel is decreased.
After the controller completes the ABS control, take the same action as the management.
3. More than two wheels failure: take the same action as the management.
5 Low operating voltage
1. Outside the ABS control cycle: inhibit the ABS control of front wheels and allow the ABS control of rear
wheel, deactivating the motor. And the ABS warning lamp is directly switched on. When the voltage
recover to the normal operating range, enable ABS function and ABS function and ABS warning lamp is
switched off and erase the error code of low voltage.
2. Inside the ABS control cycle: inhibit the ABS control of front wheels and allow the ABS control of rear
wheel, deactivating the motor. The ABS warning lamp is directly switched on and the state keeps
continuously. The error code is always stored.
6 Motor failure inside the ABS control cycle.
1. Inhibit the ABS control of front wheels and allow the ABS control of rear wheel, deactivating the
motor(in only motor failure). After the controller completes the ABS control, take the same action as the
management 2.
Detect mode
A: Initial check
B: Outside the ABS control cycle
C: Inside the ABS control cycle
D: Diagnosis mode
E: Failure mode
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS
Failure Failure Management/ Detect mode
No Condition for Detection Error code
Location Cause A B C D E
1.1 Sensor Short to The wheel velocity is below FL: C1200 3 3 4 3 3
(wiring, GND, 7Km/h and the offset voltage FR: C1203 3 3 4 3 3
harness, Short to of the sensor is outside the RL: C1206 3 3 4 3 3
exciter, batt, Open permitted range(2.15~3.5V). RR: C1209 3 3 4 3 3
ECU) If this condition is continued
for more than 140msec.
1.2 Speed The wheel deceleration of [- FL: C1201 - 3 4 3 3
Jump 100(-25km/h) for 7ms] FR: C1204 - 3 4 3 3
causes the controller to start RL: C1207 - 3 4 3 3
Page 52 of 68
monitoring this failure and to RR: C1210 - 3 4 3 3
compare the wheel velocity
with the vehicle velocity from
next cycle. When its
difference of -100g is
continued for morethan
140msec, controller
recognize the failure.
1.3 LARGE This monitoring is performed FL: C1202 - 3 4 3 3
AIR GAP for the period that the FR: C1205 - 3 4 3 3
minimum velocity risesfrom RL: C1208 - 3 4 3 3
2km/h to 10km/h RR: C1211 - 3 4 3 3
1. When the minimum wheel
velocity is 2km/h and the
velocity of other wheel
sexceed 10km/h with the
acceleration of >0.4g, the
controller start comparing
the velocity of other
wheels except the min.
wheel. If their difference is
below 4km/h and
continued for 140msec.
2. Except case 1), when the
min. wheel velocity is
2km/h and the max. wheel
velocity exceeds 10km/h,
the condition is continued
for 20sec.
1.4 Sensor Wrong 1. Max. wheel velocity FL: C1201 - 3 4 3 3

(wiring, Exciter exceeds 20km/h and the FR: C1204 - 3 4 3 3
harness, wheel velocity is 40% of RL: C1207 - 3 4 3 3
exciter, max. wheel velocity. If RR: C1210 - 3 4 3 3
ECU) this condition is lasted for
1min.
2. Max. wheel velocity
exceeds 40km/h and the
wheel velocity is 60% of
max. wheel velocity. If
this condition lastes for
30sec.
1.5 Long term 1. During the ABS control FL: C1202 - - 4 - -

ABS cycle, if the wheel velocity FR: C1205 - - 4 - -
mode of 2km/h lasts for RL: C1208 - - 4 - -
morethan 12sec. RR: C1211 - - 4 - -
2. If the ABS control cycle
is continued for more than
36sec.
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2.1 Valve relay Open When the valve relay is C2112 1 1 1 1 -
(wiring switched on, the reference
harness, voltage of valve relayis
ECU) outside the permitted range,
which is continued for
56msec.
2.2 Short When the valve relay is 1 - - - 1
switched off, the reference
voltage of valve relayis over
the criterion, which is
3 Solenoid Open, 1. When the valve relay is C1604 1 1 1 1 1
valve(ECU, Short, switched off, the drain
wiring Leakage voltage of the solenoid
harness) Current drive MOSFET is over
2. When the valve relay is
switched on and a
solenoid off, the drain
voltage of the solenoid
drive MOSFET is under
3. When the valve relay and
a solenoid are switched
on, the drain voltage ofthe
solenoid drive MOSFET
is over the criterion, which
is continued for 56msec.
4.1 Motor Motor When the motor relay is C2402 - 2 2 2 -

relay, motor relay or switched on, the reference
(wiring fuse open, voltage of motor is underthe
harness, motor criterion, which is continued
ECU) short to for 49msec.
GND
4.2 Motor The controller starts - 2 2 2 -
lock monitoring the motor voltage
for 84msec from the time
when the motor relay is
switched off. If the motor
voltage is under the criterion
for 49msec, after 1.8sec
from driving the motor off,
the motor is reactivated for
1sec and the above check is
performed again. In second
check, when themot or
Page 54 of 68
voltage is under the criterion
for 49msec, the controller
recognizes the failure.
4.3 Motor The controller starts 2 2 - 2 2
short to monitoring the motor after
BATT 1.8sec from the time when
the motor relay is switched
off. If the motor voltage is
over the criterion for
200msec.
4.4 Motor The controller starts 2 2 - 2 2
open monitoring the motor after
1.8sec from the time when
the motor relay is switched
off. If the motor voltage is
outside the permitte drange
for 200msec.
5.1 Power Low 1) When V(IGN)<9.4V is C1102 5 5 5 5 5
supply voltage continued for 500msec.2) If
the voltage reaches to more
than 9.6V, the controller
recovers to normal state.
3) When V(IGN)<7.2V is 1 1 1 1 1
detected during state 1).4) If
the voltage reaches to more
than 7.5V, the controller
recovers to state 1).
5.2 Over 1) When V(IGN)>16V is C1101 1 1 1 1 1
voltage continued for 500msec, or
when V(IGN)>18V is
2) If the voltage recovers
normal operating range, the
controller is reset.
6.1 ECU EEPROM After the master processor C1604 1 1 1 1 1
failure writes the pre-defined data
to EEPROM, read the data
and compare each other. If
they differ from each other.
6.2 ECU If the master/slave processor 2 2 - 2 2
failure detects abnormal operation
in RAM, status
register,interrupt, timer, A/D
converter and cycle time.
CONNECTOR TERMINAL LIST

Page 55 of 68
Connector Terminal
No Mark Terminal Specification Note
Name
4 IGN+ Power Over voltage range: 16.5±0.5V<V<20V
source via Operating voltage range:9.5±0.5V<V<16.5±0.5V
Ignition
Switch Low voltage range:8.0<V<9.5±0.5V
terminal
System down range:V<7.5±0.5V
Max. current: I<300mA

8 GND1 Ground Max. current(total of 2 terminals):I<60A Inside control
24 GND2 terminal
18 BRAKE Brake lamp Input voltage(low): -1.00<V(IL)<2.75V
Switch input Input voltage(high): 5.00<V(IH)<16.0V
terminal
1 FL+ Wheel Min. sensor voltage: V(s)>130mVpp
19 FR+ sensor Resistance: 1100±50%
5 RL+ Input Output range: 30~2000Hz
23 RR+ terminal Inductance: 0.7H ±50%
Permissible offset voltage range:2.15V<V(offset)<3.5V
2 FL-
20 FR-
6 RL-
22 RR-
16 ABS ABS
Warning warning Max. current: I<200mA
lamp lamp output Saturation voltage, at I=200mA:Vsat<1.5V
terminal
7 Diagnosis Diagnosis Input voltage: V(IL)<0.3VBVV(IH)<0.7VBV VB: Ignition voltage
interface
terminal Output voltage: V(IL)<0.2VBVV(IH)<0.8VBV
9 Batt1 Battery Max. current (inside control): I<30A
power Max. current (outside control): I<20mA
Source 1
terminal
(valve
power
source)
25 Batt2 Battery Inside control Max. rush current : I<100A(t<100msec) T: the running time of
power motor
Source 2 Max. current : I<30A(t>100msec)Dark current: I<0.3mA
terminal
BASIC INSPECTION
VISUAL OBSERVATION
Page 56 of 68
Step Inspection Actions
1 Check if parking brake is working properly. Yes Go to next step.
No - Repair or replace lever/cable.
- Inspect parking brake switch.
- Check operation.
- Turn adjusting nut.
2 Check if brake fluid level in the reservoir tank is between Yes Go to next step.
"Max" and " Min".
No Fill up brake fluids.
3 Check if brake fluids leak on all hydraulic lines. Yes Replace corresponding part.
No Go to next step.
4 Check if ABS fuse is fully seated and intact. Yes Go to next step.
- Opened or shorted
- Connection No Replace it.
5 Check if following component is fully seated and intact. Yes Check functions.
- ABS sensor
- Hydraulic control unit (ABS)
- Brake fluids reserve tank No Connect it again.
Repair or replace it.
- Stop lamp switch
- ABS warning module
Checking functionality
Page 57 of 68
Step Inspection Actions
1 Verify if ABS warning lamp turns on for 2 to 3 Yes Go to next step.
seconds when ignition is switched ON.
No Check ABS warning lamp and wiring harness.
2 - Verify if brake warning lamp(EBD warning Yes Go to next step.

lamp) turns off when parking brake is released.
- Verify if brake warning lamp turns on for 2 to
No - Check level of brake fluids.
3 seconds when ignition is switched ON. After
parking brake is released. - Inspect brake pipes, hoses, wheel cylinder,
seal and leak at master cylinder.
- Brake warning lamp (EBD warning lamp)
can turn on with ABS warning lamp at the
same time when ABS is defective.
- Although parking brake is released, brake
warning lamp can turn on intermittently
when ignition is switched on.
3 Retrieve malfunction codes using diagnostic tool Yes Go to corresponding detail inspection.
(Hi-scan pro). No Go to next step.
4 Go to step 3 again after driving vehicle, and Yes Go to corresponding detail inspection.
retrieve malfunction codes.
No - Check each connector and connections.
- System OK.
DIAGNOSTIC TROUBLE CODE INSPECTION

Page 58 of 68
DTC Trouble location Symptom
Battery voltage over
C1101 >16V
volt
Battery voltage low
C1102 <9.0V
volt
C1200 FL wheel sensor Open or short to GND/Battery
C1201 -Range/ Performance Speed jump or damaged exciter
C1202 -No signal Air-gap error or wrong excite
C1203 FR wheel sensor Open or short to GND/Battery
C1204 -Range/Performance Speed jump or damaged exciter
C1206 RL wheel sensor Open or short to GND/Battery
C1207 -Range/ Performance Speed jump or damaged exciter
C1209 RR wheel sensor Open or short to GND/Battery
C1210 -Range/Performance Speed jump or damaged exciter
C1604 ECU hardware ECU internal or valve failure
C2112 Valve relay, Fuse Valve relay or fuse failure
Open or short to battery, motor relay,
C2402 Motor- Electrical
fuse
Brake System > ABS(Anti-Lock Brake System) > ABS Control Unit > Components and Components
Location
COMPONENT
Page 59 of 68
Brake System > ABS(Anti-Lock Brake System) > ABS Control Unit > Repair procedures
Removal
1. Disconnect the negative battery cable from the battery.
2. Pull up the locker to remove the unit connector.
3. Disconnect the brake lines using a flare nut wrench. Be prepared to catch escaping brake fluid. Temporarily seal
open brake lines with plastic caps or equivalent.
4. Remove hydraulic control unit bracket bolts and nut on the vehicle remove unit bracket.
5. Temporarily seal open brake line ports with plastic plugs or equivalent.
6. Store the hydraulic control unit in a protective container while it is being serviced.
INSTALLATION
1. Install Hydraulic Control Unit into position and tighten the bolts and nut.
2. Reconnect brake lines.
3. To hydraulic control unit and connect Hydraulic Control Unit connector. Be certain connectors are fully mated.
4. Bleed the brake system.
Page 60 of 68
Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Repair procedures
REMOVAL
2. Remove the ABS sensor from the knuckle assembly.
3. Remove the ABS sensor wire from the attaching clip.

4. After removeing trim, remove the ABS sensor and connector in the engine room.
DISASSEMBLY
1. Remove the drive shaft assembly from the vehicle.
2. Remove the sensor rotor with SST(0K670 990 AA0).
INSTALLATION
1. Install ABS sensor and connector.
Tightening torque:
6~8 lb·ft (8~12N·m, 0.8~1.2 kg·m)
2. Install trim.
3. Install the ABS sensor to the attaching clip.
4. Install the ABS sensor to the knuckle assembly.
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5. Connect the negative battery cable to the battery.
A shield wire is used to prevent interruption of the input signal from the ABS sensor. Return the wire to its
original position after repair.
REASSEMBLY
1. Remove the sensor rotor with SST(0K670 990 AA0).
Inspection
1. Measure the resistance of the ABS sensor.
Resistance: 1.3~1.5 KΩ
2. Replace ABS sensor if necessary.

INSPECTION
1. Check rotor for damage.
2. Check if gap between rotor and sensor meets the specified value.
Gap: 0.027±0.016 in (0.7±0.4 mm)
3. Replace the sensor rotor if necessary.

Page 62 of 68
Brake System > ABS(Anti-Lock Brake System) > Rear Wheel Speed Sensor > Repair procedures
ABS sensor (Rear)
Removal
2. Loosen the rear shock absorber attaching bolt.
3. Remove the ABS sensor from the back plate.
4. Remove the ABS sensor wire from the attaching clip.

5. After removing the rear seat and rear side door-trim, remove the ABS sensor and connector.
Installation
1. Install the ABS sensor and connect.
2. Install the rear seat and rear side door trim
3. Install the ABS sensor wire attaching trim.
4. Put the ABS sensor into the back plate and install the ABS sensor.
Tightening torque:
8~12 N·m (0.8~1.2 kg·m, 6~8 lb·ft)
Page 63 of 68
5. Install the rear shock absober attaching bolt.
Tightening torque:
78~98 N·m (8.0~10.0 kg·m, 58~72 lb·ft)
6. Connect the negative battery cable from the battery.
Disassembly/Reassembly
1. Remove the rear brake drum from the vehicle.
2. Remove the sensor rotor by using the SST (0K670 990 AA0).
3. Install the sensor rotor by using suitable tool.
Inspection
1. Check rotor for damage.
2. Check if gap between rotor and sensor meets the specified value.
Gap : 0.027±0.016 in (0.7±0.4 mm)
3. Remove the sensor rotor if necessary.
Brake System > Troubleshooting > C1101

VOLTAGE OUT OF RANGE
Page 64 of 68
DTC No. C1101, C1102 Voltage out of range (Under and
Probable cause
over voltage)
[Comment] • Malfunction of wiring harness or
The voltage of the HECU power supply drops lower or rises higher connector
then specified value. • alfunction of HECU
If the voltage returns to the specified value, this code is no longer
outpurt.
If battery voltage drops or rises during inspection, this code will be outputas well. If the voltage returns to standard
value, this code is no longeroutput.

INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES
Wheel speed sensor
DTC No. C1200, C1203, C1206, C1209
Probable cause
Wheel speed sensor open or short GND circuit
[Comment] • Malfunction of wheel speed sensor
The HECU determines that an open or short circuit occurs in more • Malfunction of wiring harness or
than one line of wheel speed sensors. connector
• Malfunction of HECU
Page 65 of 68

SPEED JUMP OR WRONG EXCITER
DTC No. C1201, C1204, C1207, C1210
Probable cause
(Speed jump or wrong exciter)
[Comment] • Improper installation of wheel
A wheel speed sensor outputs an abnormal signal speed sensor
(other than an open short-circuit) • Malfunction of wheel speed sensor
• Malfunction of rotor
• Malfunction of wheel bearing
• Malfunction of wiring harness or
connector
Page 66 of 68

AIR GAP ERROR
DTC No. C1202, C1205, C1208, C1211 (Air gap error) Probable cause
[Comment] • Malfunction of wheel speed sensor
A wheel speed sensor outputs an abnormal signal • Iproper installation of wheel speed
sensor
• Malfunction of rotor
• Malfunction of wiring harness or
connector
Page 67 of 68

ECU HARDWARE
DTC No. C1604 ECU Hardware (Error valve failure) Probable cause
[Comment] • Malfunction of wiring harness
The HECU always monitors the solenoid valve drive circuit. • Malfunction of hydraulic unit
It determines that there is an open or short-circuit in the solenoidcoil • Malfunction of HECU
or in a harness : When no current flows in the solenoid even though
the HECU turns on it, and vice versa.

VALVE RELAY
DTC No. C2112 Valve relay (Including fuse failure) Probable cause
[Comment] • Malfunction of valve relay
When the ignition switch is turned to ON, the HECU switches the • Malfunction of wiring harness or
valverelay off and on during the initial check. In that way, the HECU connector
comparesthe signals sent to the valve relay with the voltage in the • Malfunction of HECU
valve power monitorline. That is how to check if the valve relay is • Malfunction of hydraulic unit
operating normally. The HECUalways checks if current flows in the
valve power monitor line, too.
It determines that there is an open circuit when no current flows.
Ifno current flows in the valve power monitor line, this diagnosis
code is output.
Page 68 of 68
Whenever reading the diagnosis codes using the ABS warning lamp, thisdiagnosis code will be output.

PUMP-MOTOR
DTC No. C2402 Electrical (Pump-motor) Probable cause
[Comment] • Malfunction of wiring harness or
When the motor power line is normal but no signal is inputed to connector
themotor monitor line when the motor power line is faulty. • Malfunction of hydraulic unit
Because force-driving of the motor by means of the actuator test willdrain the battery, the engine should be started
and left to run for a whileafter testing is completed.
Page 1 of 14
RIO(BC) > 2005 > G 1.6 DOHC > Clutch System
Clutch System > General Information > Special Service Tools

Tool
Illustration Use
(Number and Name)
0K130 111 002 To prevent the flywheel from turning
Ring gear brake
0k130 171 013 To remove the pilot bearing

Bearing puller
0k130 160 010 Used to fix clutch disc centering

Clutch disc centering
tool
Clutch System > General Information > Components and Components Location
The transaxle input shaft is linked to the engine through a mechanical clutch consisting of a Belleville spring-type pressure
plate, and a 7.87in (200mm) friction disc for A6 engines. After it has passed through the clutch disc splines, theinput
shaft is supported in the flywheel on a small, fully sealed ball bearing.
The holding force which is exerted by the pressure plate against the clutch disc is released by a pedal-operated cable
linked to a release lever, release fork, and release bearing.
The clutch pedal is suspended, with the brake pedal, from a support bracket welded to the body. Both pedals hang from
the support bracket on a common pivot bolt secured in position by a nut and two washers.
From the top of the clutch pedal, the cable extends to a release lever at the transaxle. The clutch system operates as
follows:
• When the clutch pedal is pressed, the cable and release lever rotate a shaft that enters the transaxle clutch housing
and connects to the clutch release fork.
• As the shaft rotates, the fork slides the release bearing along the transaxle bearing support until it contacts and
releases the pressure plate.
• When the pedal is released, springs attached to the support bracket and release lever return the clutch release
components to the normal applied position.
Clutch pedal free play is adjusted where the cable passes through the release lever. A nut on the threaded end of the
cable is used to reposition the pin that engages the release lever. Repositioning the pin adjusts pedal free play by
lengthening or shortening the cable.
Page 2 of 14
COMPONENTS
Page 3 of 14
Components(continued)
Page 4 of 14
Clutch System > General Information > Troubleshooting

TROUBLESHOOTING GUIDE
Page 5 of 14
Trouble Possible cause Remedy
Slippage Facing worn excessively Replace
Facing surface hardened or contaminated with Repair or replace
oil
Clutch cover deformed Repair or replace
Diaphragm spring damaged or fatigued Replace
Excessive clutch pedal play Adjust
Clutch pedal not functioning smoothly Repair or replace
Flywheel warped Repair or replace
Clutch cable not functioning smoothly Replace
Poor Excessive deflection and deformity of clutch Replace
disengagement disc
Clutch disc spline worn or rusted Replace or remove the rust
Oil on the facing surface Clean or replace
Diaphragm spring fatigued Replace
Excessive clutch pedal play Adjust
Clutch judders Oil on facing surface Clean or replace
when engaging
Torsion spring fatigued Replace
Facing surface hardened or deformed Repair or replace
Facing rivets loose Replace
Diaphragm spring fatigued Replace
Clutch cover excessively warped Replace
Flywheel surface hardened or warped Repair or replace
Engine mount loose or fatigued Refer to Section EM
Clutch pedal Pedal shaft not properly lubricated Lubricate or replace
does not
Cable not properly lubricated Lubricate or replace
function
smoothly Cale kinked Repair or replace
Noise Release bearing damaged Replace
Poor lubrication of release bearing sleeve Lubricate or replace
Worn sliding part of release fork Replace
Torsion spring fatigued Replace
Pedal freeplay insufficient Adjust
Excessive crankshaft end play Refer to Section EM
Clutch System > General Information > Specifications

SPECIFICATION
Page 6 of 14
Clutch System > Clutch System > General Information

SERVICE ADJUSTMENT PROCEDURE(PEDAL FREEPLAY)
1. Depress the pedal lightly by hand and measure the freeplay, and ensure that it is within the specification.
Pedal freeplay :
0.35~0.59 in (9~15 mm)
2. Depress the release lever and pull the pin away from the lever, then adjust the clearance A by turning the adjust nut B.
Standard clearance :
0.06~0.10 in (1.5~2.5 mm)
3. After the adjustment ensure that when the clutch is disengaged, the distance between the dash lower panel and the
upper center of the pedal pad is within the specification.
Disengagement height : (Without carpet)

3.28 in (83.2mm) min.
Clutch System > Clutch System > Troubleshooting

SERVICE ADJUSTMENT PROCEDURE(PEDAL HEIGHT)
1. Disconnect the clutch cable at the transaxle release lever to eliminate the possibility that the clutch cable is affecting
pedal height.
2. Measure the distance from the upper center of the pedal pad to the dash lower panel and ensure the distance is within
the specification.
Pedal height : (Without Carpet)

7.677in (195mm)
Page 7 of 14
3. Inspect the clutch pedal mounting for damaged, worn, or missing parts.
4. To adjust the pedal height, loosen the lock nut A and turn the clutch switch until the lower pedal is at the specified
height.
5. Tighten the lock nut A.
Tightening torque :
10~13 Ib·ft(14~18 N·m, 1.4~1.8 kg·m)
Clutch System > Clutch System > Clutch Cover And Disc > Repair procedures
REMOVAL (PRESSURE PLATE AND CLUTCH DISC)
Do not allow oil or grease to contaminate the clutch disc facing Even a trace of oil or grease may cause clutch
grabbingor slipping. Handle the disc by its edges and do not touch the facing.
1. Remove the transaxle. Refer to Section MT.
2. If the pressure plate will be reused, paint or scribe the alignment marks on the pressure plate and flywheel for
assembly reference.
Loosen the pressure plate bolts one turn at a time to release the pressure plate spring tension evenly. A failure
to release the tension evenly could cause distortion of the pressure plate.
3. Remove the pressure plate bolts, the pressure plate, and the clutch disc. While loosening the bolts, use SST to
prevent turning of the flywheel.
INSTALLATION
Page 8 of 14
1. Position the clutch disc on the flywheel and hold it in position with SST.
Use the marks which were made during removal for the alignment
reference.
2. Position the pressure plate on the flywheel and install the pressure plate bolts.
Tighten the bolts evenly and alternately to prevent distortion of the pressure
plate.
3. Tighten the pressure plate bolts.
Tightening torque :
13~20 Ib·ft (18~26 N·m, 1.8~2.7 kg·m)
4. Remove the clutch alignment tool.
Before installing the transaxle, clean the clutch disc splines on the input shaft and coat them with a light film of a
Clutch Grease, or equivalent.
5. Install the transaxle. Refer to Section MT.
INSPECTION(PRESSURE PLATE AND CLUTCH DISC)

Check the following parts, and repair or replace those if necessary
CLUTCH COVER
Page 9 of 14
1. Check the contact surface of the clutch disc for scorings, cracks, or discoloration.
Minor scoring or discoloration should be removed with a sandpaper.
2. Inspect the diaphragm spring for damage, or damage to the cover.

CLUTCH DISC
1. Check the facing surface for hardening or oil contamination.
Use sandpaper if the contamination is minor.
2. Inspect for looseness of the facing rivets.

3. To inspect for a worn coutch disc, measure the depth to the rivet heads with a slide caliper.
Depth : 0.012 in (0.3 mm) min.
4. Inspect the run-out of the clutch disc.
Lateral run-out : 0.027 in (0.7 mm) max.

Vertical run-out : 0.039 in (1.0 mm) max.
5. Inspect for wear or rust on the splines, Remove any minor rust.
Clutch System > Clutch System > Clutch Pedal > Components and Components Location
CLUTCH ASSEMBLY
Page 10 of 14
Clutch System > Clutch System > Clutch Pedal > Repair procedures
CLUTCH PEDAL
Removal
1. Loosen the cable adjuster nut at the transaxle release lever until the cable can be disengaged from the lever.
2. Remove the clip securing the cable case to the pedal support bracket.
3. Pull upward on the cable and disengage it from the hook on the pedal.
4. Remove the attaching nut, lockwasher, and flatwasher from the end of the pivot bolt.
5. Slide off the clutch pedal and return spring from the pivot bolt.
6. If necessary, remove the pedal pad, stop bumper, and bushings from the pedal.
Apply a grease (lithium base, NGLI No. 2) to the bushings and pivot
points.
Installation
To install, reverse the removal procedure.
Clutch cable
Removal
1. Loosen the cable adjuster nut at the transaxle release lever until the cable can be disengaged from the lever.
2. Remove the bolts attaching the cable routing bracket to the transaxle.
3. Remove the clip which is securing the cable case to the pedal support bracket.
Page 11 of 14
4. Pull upward on the cable and disengage it from the hook on the pedal.
5. If necessary, loosen the attaching nut and remove the routing bracket.
6. Remove the cable through the hole in the bulkhead.
INSPECTION
Check the following parts and replace if necessary.
1. Worn or damaged bushings.
2. Twisted or bent clutch pedal.
3. Worn or damaged pedal pad.
4. Damage to the inner or outer cable.
5. Function of the cable.
Installation
To install, reverse the removal procedure. Adjust the clutch pedal free play. Refer to the procedures in this section.
Clutch System > Clutch System > Clutch Release Bearing > Repair procedures
Removal
2. Remove the release fork attaching bolt.
3. Remove the release bearing.
Installation
Page 12 of 14
1. Apply a light film of Lubricant XG-1-C, or equivalent, on the following areas:
A. The sliding surface on the transaxle bearing support
B. The release fork where it contacts the bearing
C. The front of the bearing where the pressure plate release spring contacts
Fill only the groove and remove all the excess grease from the bearing hub. If the excess grease remains in the
hub, it can be forced onto the clutch disc splines where it may contaminate the clutch friction surfaces.
2. Fill the groove in the release bearing hub with a Lubricant XG-1-C, or equivalent. Also, apply a light film of
lubricanton the release fork contact area. The lubricant areas are shown in the right illustration.
3. Install the release bearing.

4. Install the release fork attaching bolt. Tighten the attaching bolt.
Tightening torque :
26~30 Ib·ft (35~41 N·m, 3.6~4.2 kg·m)
RELEASE FORK / LEVER

REMOVAL
Page 13 of 14
2. Remove the release fork attaching bolt (Reamer bolt).
3. Remove the release bearing.
4. Remove the release lever return spring.
5. Slide the release lever upward out of the release fork and remove the fork.
6. Slide the release lever out of the transaxle clutch housing.
7. Remove the release lever bushings from the transaxle clutch housing.
RELEASE FORK / LEVER
I NSTALLATION
Apply a light film of Lubricant XG-1-C, or equivalent, to the inside of the bushing before installing.
1. Install the release lever bushings.

2. Install the release bearing. Refer to the Release Bearing installation procedure for the proper lubrication of the
bearing.
3. Position the release fork and install the release lever.
4. Install the release lever return spring.
5. Align the bolt holes in the release fork and lever shaft.
Page 14 of 14
6. Install the release fork attaching bolt and tighten.
Tightening torque :
26~30 Ib·ft (35~41 N·m, 3.6~4.2 kg·m)
INSPECTION
The clutch release bearing is sealed, and should not be washed in solvent.
1. Turn bearing while applying force in axial direction.
If bearing sticks or has excessive resistance, replace it.
Page 1 of 37
RIO(BC) > 2005 > G 1.6 DOHC > Driveshaft and axle
Driveshaft and axle > General Information > Special Service Tools
Tool
Illustration Use
(Number and Name)
0K670 321 019 For removal of ball joint
Ball joint puller
0K130 331 016 For adjustment of wheel bearing

Spacer selector preload
0K201 270 014 For prevention of transaxle oil

Transaxle side gear holder leak
0K130 331 AA0A For removal of wheel hub

Wheel hub puller
0K670 990 AA0 For removal of sensor rotor

Bearing puller set
Page 2 of 37
Driveshaft and axle > General Information > Description and Operation
The halfshafts are the mechanical link that transfer the engine torque from the transaxle and differential to the front
wheels. At the transaxle end, the halfshafts are splined to the differential side gears. Disengagement of the shaft from
the gear is prevented by an expanding spring steel circlip. Duringthe installation, the clip compresses around the shaft
as it enters the gear. Once through the differential gear, the clip expands into a counterbore machined into the back
side of the gear.
The wheel end of the halfshafts are splined to the wheel hubs which are supported on the opposed tapered wheel
bearings. Disengagement of the shaft from the wheel hub is prevented by a washer and an attaching nut.
A backlash between the wheel hub and halfshaft is eliminated by the splines. The wheel hub splines are machined
straight while the halfshaft splines are machined with a slight helical cut.
Constant Velocity (CV) joints are installed at both ends of the halfshafts.
Two different types of CV joints are used. The inboard CV joints are repairable tripod CV joints. The outboard CV
joints are non-repairable Birfield CV joints.
Tripod CV joints are used to prevent the transfer of engine vibration through the halfshafts to the vehicle
body.Additional reduction of vibration is provided by a dynamic damper installed approximately in the middle of the
right halfshaft.
CV joints are necessary because the halfshaft is required to transmit torque while compensating for front suspension
movement. As the suspension moves, the CV joints allow the halfshaft to change length and operate smoothly
through varying angles.
For the necessary flexibility, Birfield CV joints use ball bearings positioned by a cage. The tripod CV joint uses three
balls mounted on needle bearings and a spider. In both types of joints, the outer race is machined into the CV joint
housing.
The tripod CV joints can be disassembled and serviced. Other than the CV joint boot, the outboard Birfield CV
joint is serviced only as an assembly with the shaft.
Driveshaft and axle > General Information > Troubleshooting

Trouble Possible cause Remedy
Broken ball-joint Replace
Faulty operation of
Broken tri-pod joint Replace
driveshaft
Worn or seized joint Replace
Insufficient grease in ball-joint or spline Replenish or replace
Abnormal noise from
Excessive backlash on spline Replace
driveshaft
Worn joint Replace
Incorrect front wheel bearing preload adjustment Adjust or replace
Bent steering linkage Refer to Section ST
Fatigued coil spring Refer to Section SS
Lower arm bushing worn or damaged Refer to Section SS
Steering wheel pulls. While Bent knuckle arm Replace
driving on a straight and
level road, the steering Bent lower arm or loose mounting Refer to Section SS
wheel pulls to one side Incorrect toe-in adjustment Refer to Section SS
Improper tire air pressure Refer to Section SS
Page 3 of 37
Unevenly worn tires (difference in wear between left and
Refer to Section SS
right tires)
Brake dragging Refer to Section BR
Incorrect wheel bearing preload adjustment Adjust or replace
Bent steering linkage Refer to Section ST
Joint in steering system worn or damaged Refer to Section ST
Incorrect steering pinion preload adjustment Refer to Section ST
Fatigued coil spring Refer to Section SS
Unstable handling
Shock absorber malfunction or looseness Refer to Section SS
Incorrect toe-in adjustment (front or rear) Refer to Section SS
Wheel bent or unbalanced Refer to Section SS
Incorrect front wheel bearing preload adjustment Adjust
Incorrect steering pinion preload adjustment Refer to Section ST
Excessive steering wheel
Rack and pinion worn Refer to Section ST
play
Joint in steering system worn or damaged Refer to Section ST
Incorrect front wheel bearing preload adjustment
Adjust
(excessively loose)
Tires are excessively worn Incorrect toe-in adjustment Refer to Section SS
or worn unevenly
Unbalanced wheel(s) Refer to Section SS
Abnormal noise from axle Malfunction of wheel bearing Replace
Driveshaft and axle > General Information > Specifications

Specifications
Driveshaft and axle
Page 4 of 37
Driveshaft and axle > Driveshaft Assembly > Components and Components Location
Component
Driveshaft and axle > Driveshaft Assembly > Repair procedures

Page 5 of 37
Inspection
Boot
Check the boots on the driveshaft for cracks, damage, grease leakage or loose boot bands. If any damage is found,
replace the boot.
Spline looseness
Turn the drivshaft by hand and check that the spline and joint are not excessively loose.
If a damage is found or joint is loose, replace or repair.
Twisted or cracked
Check that the driveshaft is not twisted or cracked. Replace if necessary.
Removal
1. Jack up the front of the chassis and support it with a safety stands.
Page 6 of 37
2. Drain the transaxle oil.
3. Remove the front wheel and tire assemblies.

4. Raise the nut tab and loosen the driveshaft lock nut, but do not remove it.
When loosening the nut, lock the hub by applying brakes.
5. Remove the tension rod mounting nuts.
6. Remove the ball joint clamp bolt and nut from the lower arm.
Page 7 of 37
7. Pry down the lower arm and disconnect the ball-joint.
Be careful not to damage the ball-joint dust boot.
8. Remove the stabilizer bar from the control link after loosening the control link nut.
(Refer to section SS-Suspension system)
9. Separate the driveshaft from the transaxle.
Separate the shaft by pulling the hub outward. Do not use too much force at once, increase the force
gradually. (If the shaft is pulled out too quickly, the oil seal may be damaged.)
10. Remove the driveshaft lock nut and discard.

Page 8 of 37
11. Pull the driveshaft out of the wheel hub.
Be especially careful not to damage the oil seal at this

time.
12. Pull the driveshaft out of the transaxle. Discard the circlip.
13. Install the differential side gear holder into the transaxle to fix the side gear.
Installation
1. Install a new circlip on the inboard halfshaft end.
2. Lubricagte the inboard end of the halfshaft with grease.
3. Install the inboard end of the halfshaft into the differential side gear.
Insert the halfshaft carefully so as not to damage the oil seal.
4. Lubricate the outboard end of the halfshaft with grease.

Page 9 of 37
5. Insert the outboard end of the halfshaft into the wheel hub.
Insert the halfshaft carefully so as not to damage the oil

seal.
6. Install a new halfshaft attaching nut onto the halfshaft and finger-tighten.
7. Push up the lower arm and reconnect the ball joint.
Use caution to avoid damaging the ball joint dust

boot.
8. Install the clamp nut and bolt on the lower arm.

9. Install a new driveshaft lock nut. Tighten to the specified torque and stake the lock nut, ensuring that it seats into
the groove in the driveshaft.
Driveshaft lock nut :

116~174 lb·ft (157~234 N·m, 16~24 kg·m)
Knuckle to lower arm ball-joint :
40~50 lb·ft (54~68 N·m, 5.5~6.9 kg·m)
10. Install the stabilizer bar to the control link.
Tightening torque :
32~45 lb·ft (43~60.8 N·m, 14.4~6.2 kg·m)
Page 10 of 37
11. Install the tension rod mounting bracket nuts and tighten.
Tightening torque :
87~108 lb·ft (118~147 N·m, 12~15 kg·m)
12. Install the front wheel.
• After installation, pull the front hub outward to check that the driveshaft does not come
out.
• Do not stake the lock nut with a pointed tool.
• Check that the wheel hub can be turned smoothly by hand.
13. Refill the transaxle with the specified grade and quantity of transaxle oil.
Driveshaft and axle > Driveshaft Assembly > Front Driveshaft > Components and Components
Location
Component
• Clamp the shaft in a vice. Use protectors in the vice to avoid damage.
• Do not allow dust or foreign material to enter the joint during disassembly or assembly.
• Do not disassemble the ball-joint at the wheel side. Do not wipe off the grease if there is no problem.
• Do not remove the clip used to secure the tripod joint to the differential side gear if there is no problem. If the
clip is removed, replace it with a new one.
Page 11 of 37
Driveshaft and axle > Driveshaft Assembly > Front Driveshaft > Repair procedures
Disassembly
1. Clamp the halfshaft in a vise. Do not allow the vise to contact the boot or its clamps.
2. Remove the large boot clamp. Side cutters can be used to cut the clamp. After removing the clamp, roll the boot
back over the shaft.
Page 12 of 37
3. Remove the wire ring bearing retainer.
4. Mark the matching mars on the spider and tripod housing
Mark with a paint, do not use a punch.
5. Remove the outer race.
6. Make the matching marks on the drive shaft end and spider.
7. Remove the tripod joint snap ring.
Page 13 of 37
8. Tap the boss with a hammer and rod to remove the spider assembly
Do not tap on the rollers.
If the boot is to be reused, wrap the halfshaft splines with a tape before removing it from the
shaft.
If necessary, remove the small boot clamp and the CV joint boot from the halfshaft.
Inspection
Check the following parts :
1. Twisted or cracked driveshaft.
2. Worn splines.
3. Excessively loose joint.
Page 14 of 37
4. Cracked or damaged boots.
Assembly
1. Install the tripod assembly on the halfshaft.
2. Tap the assembly onto the shaft by using a hammer and brass drift.
3. Install the tripod assembly retaining ring.

4. Fill the CV joint outer race with 3.5 oz (100 mg) of the specified grease.
5. Install the outer race over the tripod joint and install the wire ring bearing retainer.
6. Position the CV joint boot. Make sure the boot is fully seated in the grooves in the shaft and outer race.
7. Extend or compress the joint as necessary until the distance between the CV joint boot clamp grooves measures
2.66 in (67.5 mm).
Page 15 of 37
8. Insert a dulled screwdriver blade between the boot and the outer bearing race to allow trapped air to escape
from the boot.
9. Install new boot clamp(s). wrap the clamps around the boots in a clockwise direction, pull tight with pliers, and
bend the locking tabs to secure in position.
• Always use new bands.

• Bands should install so that their pointed ends initially point in forward direction of rotation.
10. Using a boot band tool, place pincer jaws in closing hooks of boot band.
11. Secure clamp by drawing closing closing hooks together.
12. After assembling the driveshaft, check to make sure the hoint parts move smoothly in the directions indicated by
the arrows. Check the boots for grease leaks or damage.
Driveshaft and axle > Front Axle Assembly > Description and Operation
Description
The front wheel mounting area on each side of the vehicle is located at the junction of various drive, steering,
braking, and suspension components. The outboard length of the halfshaft is the front wheel drive member. The
steering knuckle is the steering, suspension, and support member for the wheels. As a steering member, the knuckle
is connected to the steering gear tie rod end. As a suspension member, the knuckle is connected to the control arm
and MacPherson strut. As a support member, the knuckle contains the wheel hub bearings. The brake components
associated with the front hubs include the disc brake caliper, which is mounted on the steering knuckle, and the disc
brake rotor.
Page 16 of 37
The wheel hub is supported in the steering knuckle on opposed tapered roller bearings. A press fit secures the
bearing inner races to the hub and the outer races in the steering knuckle. Bearing preload is set using a selective
spacer that is installed in the steering knuckle between the inner and outer bearings and the races.
The halfshaft, which is splined to the hub, is secured to the hub with a staked nut and a large flat washer. Whenever
the nut is loosened, it must be replaced with a new nut.
Driveshaft and axle > Front Axle Assembly > Components and Components Location
Component
Page 17 of 37
Driveshaft and axle > Front Axle Assembly > Repair procedures
Inspection (Wheel bearing end play)
Page 18 of 37
1. Raise the front of the vehicle and check the looseness of front wheel bearings by rocking the tires at the top and
bottom.
End play : 0 in (0 mm)
2. Spin the tire quickly by hand and check that the tire turns smoothly without any abnormal noise from the bearing.
Do not confuse the looseness of the lower arm ball-joint. If any abnormal looseness or noise is found,
adjust the preload.
3. Remove the wheel, and remove the front disc caliper assembly and hang it from the shock absorber.
4. Set dial gauge against the wheel hub, then push and pull the wheel hub in the axial direction and measure the axial
play of the wheel bearing. If the play exceeds the specification, adjust the preload or replace the bearing.
Axial play : 0 in (0 mm)
Removal
1. Raise the front of the vehicle and support it with a safety stands.
2. Remove the wheel.
Page 19 of 37
3. Raise the nut tab and remove the driveshaft locknut. Discard the locknut, regardless of condition.
Use care not to damage the groove and threads in the driveshaft end.
When loosening the nut, lock the hub by applying the brakes.
4. Remove the cotter pin and the tie rod end attaching nut. Discard the cotter pin, regardless of condition.
5. Separate the tie-rod end from the knuckle with the SST.
If it is difficult to separate, hit the knuckle with a

hammer.
6. Remove the caliper assembly from the knuckle. Do not allow the caliper to hang freely by its flexible hose.
Suspend the assembly by rope or wire from the Macpherson strut.
Page 20 of 37
7. Remove the ABS speed sensor and the wheel speed sensor #(RH side).
8. Remove the disc rotor.

9. Remove the clamp bolt and nut. Push the lower arm downward to separate the knuckle and the ball-joint.
10. Remove the bolts and nuts which couple the knuckle and the shock absorber.
11. Separate the front hub and the knuckle from the driveshaft.
Installation
1. Mount the front hub and knuckle to the driveshaft.
2. Mount the knuckle to the lower arm ball-joint and to the shock absorber.
Page 21 of 37
3. Tighten the mounting bolts and nuts.
Tightening torque :
Knuckle to shock absorber
76~90 lb·ft (103~122 N·m, 10.5~12.5 kg·m)
Knuckle to lower arm ball-joint
40~50 lb·ft (54~68 N·m, 5.5~6.9 kg·m)
4. Install the disc rotor.
Tightening torque :
7.2~10.8 lb·ft (9.8~14.7 N·m, 1.0~1.5 kg·m)
5. Install the disc brake caliper assembly.
Tightening torque :
57~75 lb·ft (78~101 N·m, 8.0~10.4 kg·m)
6. Position the caliper hose in the strut routing bracket and install the retaining clip.
Page 22 of 37
7. Use a new driveshaft lock nut, tighten it to the specified torque and stake it securely into the groove.
Tightening torque :
116~174 lb·ft (157~235 N·m, 16.0~24.0 kg·m)
• Do not use a sharp edge tool for staking. If the nut cracks even slightly during staking, replace it with
another new one.
• Check that the wheel hub turns freely by hand.
8. Install the tie-rod end to the knuckle and tighten the nut.
Tightening torque :
32~41 lb·ft (47~52 N·m, 3.8~5.3 kg·m)
Use a new cotter pin.

9. Install a new cotter pin through the tie rod end attaching nut and the tie rod ball stud.
If the openings in the nut and the hole in the tie rod ball stud fail to line up, tighten the nut slightly just to the point
of alignment. Never loosen the nut.
Tightening torque :
65~87 lb·ft (88~118 N·m, 0.8~1.2 kg·m)
10. Install the ABS speed sensor and the wheel speed sensor.
Tightening torque :
6~8 lb·ft (8~12 N·m, 0.8~1.2 kg·m)
11. Install the wheel and tighten the wheel lug bolts.
Page 23 of 37
Driveshaft and axle > Front Axle Assembly > Front Hub - Axle > Components and Components
Location
Wheel hub/knuckle assembly
• Do not remove the dust cover unless necessary for repairs.

• Do not confuse the inner bearing with the outer bearing.
Component
Driveshaft and axle > Front Axle Assembly > Front Hub - Axle > Repair procedures
Disassembly
1. Remove the knuckle assembly.
Page 24 of 37
2. Remove the wheel hub assembly by using the SST.
3. Remove the outer bearing, outer oil seal, outer bearing race and spacer from the wheel hub by using the SST.
Hold the hub to prevent it from falling.
4. Discard the oil seal, regardless of condition.

5. Disassemble the knuckle assembly.
Remove the race gradually and

carefully.
6. Remove the oil seal (inner) with a screwdriver.
7. Remov e the wheel bearing (inner).
8. Remove the bearing race (inner) with the SST and a hammer.
Tap on the bearing race (inner) only.
Do not remove the dust cover if it is not necessary.

Do not reuse the dust cover if it is removed once.
Page 25 of 37
9. Mark the dust cover and knuckle for the proper reassembly.
10. Remove the dust cover with a chisel.
Inspection
Wash the disassembled parts before inspecting. Replace any damaged parts. Minor rust should be removed with a
fine sandpaper.
1. Abnormal wear, damage or seizure of bearing.
Replace the bearing as a set (inner and outer

races).
2. Cracks or damage of the knuckle. Scoring or rust of the bearing bore.
3. Damaged dust cover or poor fit with knuckle.
4. Cracks or damage of the hub. Scoring or rust of the bearing bore. Wear at the oil seal contact surface.
Assembly
If the bearings or knuckle have been replaced, the bearing preload must be checked before assembly. If
necessary, refer to the procedure in this Section.
1. If the dust shield was removed, install a new one by using the Dust Shield Replacer or equivalent.
Page 26 of 37
2. Install the bearing races in the steering knuckle.
3. Pack the bearings with the Lubricant lithium grease. Pack the hub area as shown in the figure.
4. Place the inner bearing into the steering knuckle bore so that it rests in a level position.
5. Lubricate the lip of the new inner oil seal. Apply a sufficient amount of lubricate to the cutting parts along the edge
of seal lip.
6. Install the new inner oil seal in the bore.

Page 27 of 37
7. Place the original bearing preload spacer, or the spacer selected from the bearing preload check procedure in the
steering knuckle bore.
8. Position the outer bearing in the steering knuckle bore.
9. Lubricate the lip of a new outer oil seal.
10. Install the new outer oil seal in the steering knuckle bore.
11. Support the inner wheel bearing with a suitable tool and press the wheel hub by 2500kg below force into the
knuckle assembly by using the press.
12. Install the new inner oil seal in the steering knuckle bore.
13. Install the knuckle assembly.
Adjustment of wheel bearing preload

1. Insert the two wheel bearings and removed spacer into the steering knuckle and attach the SST.
2. Secure the bottom of the SST.
3. Tighten the nut of the SST to the specified torque.
Tightening torque :
116~173 lb·ft (157~235 N·m, 16~24 kg·m)
When tightening, tighten it with 49 N.m (5 kg-m, 36 lb-ft) step by step to prevent applying the excessive
preload.
4. Rotate the steering knuckle to seat the wheel bearings.

5. Remove the SST from the bench vice and clamp the knuckle in the vice so that the SST can turn in the bearings.
Page 28 of 37
6. Measure the wheel bearing preload with the SST and a torque wrench.
Wheel bearing preload :

5.64~8.68 lb·in (0.64~0.98 N·m, 6.5~10 kg·cm)
7. If the preload is not within the specification, select the proper spacer from the table to adjust it.
Increase the spacer thickness to reduce the preload and decrease it to increase the preload. When a
spacer is changed by1rank, the preload changes 0.2 to 0.4 N·m (2.0~4.0 kg·cm, 1.7~3.5 lb·in) The rank
marking is stamped on the outer periphery of the spacer.
Mark Thickness (in(mm)) Mark Thickness (in (mm))

1 0.2474 (6.285) 12 0.2648 (6.725)
2 0.2490 (6.325) 13 0.2663 (6.765)
3 0.2506 (6.365) 14 0.2679 (6.805)
4 0.2522 (6.405) 15 0.2695 (6.845)
5 0.2538 (6.445) 16 0.2711 (6.885)
6 0.2554 (6.485) 17 0.2726 (6.925)
7 0.2570 (6.525) 18 0.2742 (6.925)
8 0.2585 (6.565) 19 0.2758 (7.005)
9 0.2600 (6.605) 20 0.2774 (7.045)
10 0.2616 (6.645) 21 0.2789 (7.085)
11 0.2631 (6.685)
8. Remove the SST.

Wheel bearing (outer & inner), oil seal (outer), and spacer
Completely fill the shaded area shown in the figure with lithium
grease.
Page 29 of 37
Driveshaft and axle > Rear Axle Assembly > Rear Hub - Carrier > Description and Operation
Description
The rear wheels and brake drums are supported on the opposed tapered roller bearings. The bearing inner races
ride on a spindle attached to the torsion beam.
The outer bearing races are pressed into a hub that is an integral part of the brake drum. Contamination of the
bearing lubricant is prevented by a sealon the inboard side and a grease cap on the outboard side.
The brake drum/hub bearing assembly is attached to the spindle with a nut.
The nut and washer are used to hold the bearings and hub in position on the spindle and set the bearing preload.
Component
Driveshaft and axle > Rear Axle Assembly > Rear Hub - Carrier > Repair procedures
Removal
1. Raise the rear of the vehicle and support it with a safety stands.
Page 30 of 37
3. Remove the hub cap.
4. Use a small cape chisel to raise the staked edge of the lock nut.
Use care not to damage the groove and threads of

spindle.
5. Remove the drum, washer and bearings as an assembly from the spindle.
If it is difficult to remove the brake drum, increase the shoe

clearance.
6. Remove the rear brake shoe assembly and brake pipe.
7. Remove the sensor rotor by using SST (for ABS).

Page 31 of 37
8. Remove the bearing oil seal. Discard the seal.
9. Remove the inner bearings from the bearing hub.
If the bearings are to be reused, they should be tagged so that they can be installed in their orignal
positions.
10. Remove the inner and outer bearing outer races by using SST.
11. Remove the wheel speed sensor (for ABS).
12. Remove the spindle attaching nuts.
13. Remove the backing plate and then support the backing plate with the wire, and remove the spindle.
Page 32 of 37
14. Remove the serration bolt by using a press.
• Do not remove the serration bolt if it is not

necessary.
• Do not reuse the serration bolt if it is removed
once.
Installation
1. Install new serration bolts by using a press.
2. Install wheel speed sensor (for ABS).

3. Install the backing plate.
4. Install the spindle attaching nuts.
Tightening torque :
32~45 lb·ft (43~61 N·m, 4.4~6.2 kg·m)
5. Tighten the wheel speed sensor (for ABS).
Tightening torque :
13~19 lb·ft (17.6~26.5 N·m, 1.8~2.7 kg·m)
Page 33 of 37
6. Install the rear brake assembly and brake pipe.
(Refer to BR Gr-Brake system)
7. Install the outer bearing race by using a hammer.
Tap in until the outer race is fully seated in the hub.
8. Position the inner bearing in the bearing hub.

9. Lubricate the oil seal lip with a lithium grease.
10. Install an oil seal.
11. Install the sensor rotor by using a flat plate to press it is (for ABS).
• Use a new oil seal, and coat the lip with grease in the middle of the right
halfshaft.
• Do not hit the oil seal directly with a hammer.
12. Completely fill the area shaded in the figure with a lithium grease.
13. Position the brake drum bearings and hub assembly on the spindle.
Page 34 of 37
14. Keep the drum which is centered on the spindle to prevent a damage to the oil seal and spindle threads.
15. Install the outer bearing.

16. Install the washer.
17. Install new lock nut.

18. Adjust the bearing preload.
Bearing preload :
5.6~8.6 lb·ft (0.63~0.98 N·m, 6.5~10 kg·cm)
19. Fix lock nut to the groove firmly.
Inside loosening of lock nut :

more 14.4 lb·ft (19.6 N·m, 2 kg·m)
Page 35 of 37
20. Install hub cap.
Inspection (bearing)
Check the following and replace if necessary.
1. Abnormal wear, damage or seizure of bearing.
Replace the bearing as a set (inner and outer races).
2. Damaged hub cap.

3. Wear or rust of oil seal? contact surface.
4. Crack or damage of rear hub spindle.
Inspection (brake drum)
1. Wear or damage on the brake drum.
Remove the minor rust with a sandpaper.
Installation (bearing preload)

1. Make sure the parking brake is fully released.
2. Remove the wheel and tire assembly.
3. Remove the grease cap.
Page 36 of 37
4. Rotate the brake drum to make sure there is no brake drag.
5. Seat the bearings by tightening the nut after raising the nut tap.
Tightening torque :
18~22 lb·ft (25~29 N·m, 2.5~2.9 kg·m)
6. Loosen the nut slightly until it can be turned by hand.

Before the b earing preload can be set, the amount of seal drag must be measured and added to the required
preload.
7. Use a pull scale and measure the oil seal drag.
8. Pull the scale squarely. Take the oil seal drag value when the wheel hub starts to turn, and record it.
9. Add the oil seal drag value in the previous step to the specified value of 0.6~1.9 lb (2.6~8.5 N, 0.26~0.87 kg).
This is regarded as the standard earing preload.
10. Turn the nut slowly to adjust to the standard bearing preload while checking with the pull scale.
11. Firmly fix the lock nut to the groove.
Page 37 of 37
12. Install the hub cap.
13. Install the wheel and tire assembly.
Tightening torque :
65~87 lb·ft (88~118 N·m, 9.0~12.0 kg·m)
Page 1 of 14
RIO(BC) > 2005 > G 1.6 DOHC > Emission Control System
Emission Control System > General Information > General Information

SPECIFICATIONS
Components Function Remarks
Crankcase Emission System HC reduction
Positive Crankcase Ventilation (PCV) Variable flow rate type
valve
Evaporative Emission System HC reduction
Evaporative emission canister
EVAP Canister Purge Solenoid Valve Duty control solenoid valve
Exhaust Emission System
MFI system (air-fuel mixtrue control CO, HC, NOx reduction Heated oxygen sensor
device) CO, HC, NOx reduction feedback type
Three-way catalytic converter Monolithic type
SERVICE STANDARD
Evaporative emission canister purge
solenoid valve
26Ω [at 20°C (68°F)]
Coil resistance
TIGHTENING TORQUE
N·m kg·cm Ib·ft
Positive Crankcase Ventilation 80 -
8 - 12 6-8
Valve 120
TROUBLESHOOTING
Symptom Probable cause Remedy
Engine will not start or hard to Vacuum hose disconnected or damaged Repair or replace
start Malfunction of the EVAP Canister Purge Repair or replace
Solenoid Valve
Rough idle or engine stalls Vacuum hose disconnected or damaged Repair or replace
Malfunction of the PCV valve Replace
Malfunction of the evaporative emission Check the system; if there is a
canister purge system problem, check related
components parts
Excessive oil consumption Positive crankcase ventilation line clogged Check positive crankcase
ventilation system
Emission Control System > General Information > Description and Operation
Component description table
Page 2 of 14
Component Function Remark
Maintains pressure in the fuel tank and regulates Located in the evaporative system lines
Check valve
vapor flow to the evaporative emissions canister next to the fuel tank
Evaporative
Stores fuel tank vapors (engine stopped) -
emission canister
Positive crankcase Sends blow-by gas in crankcase into intake
ventilation (PCV) manifold (dynamic chamber) for blow-by gas re- Actuated by intake manifold vacuum
valve circulation
Evaporative
Controls fuel vapor from evaporative emission For purge control
canister purge
canister to intake manifold(dynamic chamber) Actuated by ECM purge control signal
solenoid valve
Resonance Reduces intake air suction noise and increases
-
chamber engine torque
Restricts fuel from entering the evaporative system
Rollover valve Located on the fuel tank
in a vehicle rollover
On-board refueling
Prevents fuel vapor from fuel tank leaking to air in
vapor recovery Located on fuel tank
event of refueling
(ORVR) valve
Three way catalytic converter (TWC) monitoring

To comply with clean air regulations, vehicles are equipped with catalytic converters. These converters reduce the
emissions of hydrocarbons, oxides of nitrogen and carbon monoxide. Normal vehicle operation or engine misfire can
cause a catalyst to decay. A meltdown of the ceramic core can cause a reduction of the exhaust passage resulting in
an increase in vehicle performance and deteriorate engine performance, driveablity and fuel economy.
The catalyst uses dual oxygen sensor to monitor the efficiency of the converter because as a catalyst deteriorates, its
oxygen storage capacity and its efficiency are both reduced. By monitoring the oxygen storage capacity of a catalyst,
its efficiency can be indirectly calculated. The upstream (front) HO2 Sensor is used to detect the amount of oxygen
in theexhaust gas before it enters the catalytic converter. A low voltage indicates a high oxygen content (lean air
mixture) A high voltage indicates a low content of oxygen (rich mixture).
When the front HO2 Sensor detects a lean condition, there is an abundance in the oxygen in the exhaust has. A
functioning converter would store this oxygen so it can use it for the oxidation of HC and CO. As the converter
absorbs the oxygen, there will be a lack of oxygen downstream of the converter. The output of the downstream
(rear) HO2 Sensor will indicate limited activity in this condition. As the converter loses the ability to store oxygen,
the condition can be detectedfrom the operation of the rear HO2 Sensor. When the catalyst efficiency drops, no
chemical reaction takes place. This means the concentration of oxygen will be the same downstream (rear) as
upstream (front). The output voltage of the rear HO2 Sensor copies the voltage of the front HO2 Sensor. The only
difference is a time lag (monitored by the ECM) between the switching of the HO2 Sensors.
To monitor the system, the lean-to-rich switches of front to rear HO2 Sensors is counted. The ratio of rear switches
to front switches is used to determine whether the catalyst is operating properly. An effective catalyst will have fewer
rear switches than it has front switches, that is, a ratio closer to zero. For a totally ineffective catalyst, this ratio will
be one-to-one indicating that no oxidation occurs in the catalytic converter.
The system must be monitored so that when catalyst efficiency deteriorates and exhaust emissions increase to over
the legal limit, the MIL will illuminate.
Page 3 of 14
Emission Control System > Crankcase Emission Control System > Positive Crankcase Ventilation
(PCV) Valve > Repair procedures
Inspection
1. Warm up engine to normal operating temperature.
2. Run engine at idle.
3. Disconnect PCV valve ventilation hose from cylinder gead cover.
4. Block PCV valve opening.
5. Verify that vacuum is felt.
6. Remove PCV valve.
7. Blow through valve from port "A" and verify that air comes out of port "B".
8. Blow through valve from port "B" and verify that no air comes out of port "A".
9. Replace the PCV valve if necessary.
Emission Control System > Evaporative Emission Control System > Description and Operation
Evaporative emission control system
The evaporation control system prevents the emission of fuel tank vapor into the atmosphere. When fuel evaporates
in thefuel tank, the vapors pass through vent hoses or tubes to a charcoal filled evaporative canister. The canister
temporarily holds the vapors. The ECM allows intake manifold vacuum to draw vapors into the combustion
chambers during certain operating conditions.
Fuel tank
The fuel tank is located under the rear of the vehicle. The fuel pump, fuel level sending unit and fuel tank pressure
sensor are installed on the upper part of the fuel tank.
Fuel filler cap
A ratchet tightening device on the threaded fuel filler cap reduces the chances of incorrect installation, which would
Page 4 of 14
prevent sealing fuel vapors. After the gasket on the fuel filler cap and the fill neck flange contact each other, the
ratchet produces a loud clicking noise indicating the seal has been set.
Evaporative emissions canister
A maintenance free, EVAP canister is used on the Rio located under the right side of the vehicle near the fuel tank.
TheEVAP canister is filled with granules of an activated carbon mixture. Fuel vapors enter into the EVAP canister
are absorbed by the charcoal granules. Fuel tank pressure vents into the EVAP canister and are temporarily held in
the canister until they can be drawn into the intake manifold.
Canister close valve
The Canister Close Valve (CCV) closes off the air inlet to the Evaporative Emissions Canister for the Evaporative
Emissions System leak detection inspection function. The CCV also prevents fuel vapors from escaping from the
Evaporative Emissions Canister when the vehicle is not operating.
Purge solenoid valve
This valve is actuated by the purge control signal from the ECM and controls fuel vapor from the EVAP Canister to
the intake manifold.
Fuel tank pressure sensor
The Fuel Tank Pressure Sensor (FTPS) is an integral part of the monitoring system. The FTPS checks Purge
Solenoid Valve operation and leak detection in the Evaporative Emissions System by monitoring pressure and
vacuum levels in the fuel tank during and between Purge Solenoid Valve operating cycles.
EVAP system monitoring: Leakage detection
The evaporative system is monitored by a pressure test. The canister close valve and fuel tank pressure sensor are
used to close the system and observe tank pressure respectively.
Monitoring conditions
The leak test is conducted when the vehicle is stopped during an idle condition.
Monitoring process
The canister close valve and the EVAP canister purge control valve are closed and an increase in fuel tank pressure
caused by fuel evaporation occurs(compensation gradient). Afterwards, the canister close valve and the purge
control valve are opened. The canister close valve will be shut if the purge control valve reached its final duty cycle.
Page 5 of 14
1. Gross leak detection

A gross leak is assumed if negative pressure is built-up below a certain threshold. In this case, the EVAP canister
purge control valve is closed and the canister close valve is opened. Then, the diagnosis is completed.
2. Small leak detection
The EVAP canister purge control valve is closed as soon as the maximum vacuum level is achieved. The rate of
vacuum losswill be corrected by the above compensation gradient. A small leak is assumed if this corrected rate
of vacuum loss is above a certain threshold. Then, the canister close valve is opened and the diagnosis is
completed.
MIL illumination
If either a rough leak or a small leak is detected for two driving cycles, then a defective evaporative system is
assumed and the MIL is illuminated.
Emission Control System > Evaporative Emission Control System > Repair procedures
INSPECTION
2. Disconnect vacuum hose from EVAP canister purge valve side of hose.
3. Verify that no vacuum is felt at EVAP canister purge control solenoid valve.
4. If not as specified, check EVAP canister purge valve operation.
5. If valve is operating properly, reinstall vacuum hose.
Emission Control System > Evaporative Emission Control System > Canister > Repair procedures
CANISTER CLOSE VALVE INSPECTION
1. Measure canister close valve resistance.
Resistance:
Approximately 24Ω ± 1.5 at 68°F(20°C)
2. If not as specified, replace the canister close valve.

Page 6 of 14
Emission Control System > Evaporative Emission Control System > Purge Control Solenoid Valve
(PCSV) > Repair procedures
Inspection
1. Disconnect vacuum hoses from EVAP canister purge solenoid valve.
2. Verify that no air flows through valve.
3. Disconnect valve connector and apply 12 volt battery voltage as shown in figure.
4. Verify that air flows through valve.
5. If no air flows, replace the valve.
6. Reinstall valve connector.
7. Reconnect vacuum hoses.
Emission Control System > Exhaust Emission Control System > Description and Operation
EXHAUST EMISSION CONTROL SYSTEM
Exhaust emissions (CO,HC,NOx) are controlled by a combination of engine modifications and the addition of
special control components.
Modifications to the combustion chamber, intake manifold, camshaft and ignition system form the basic control
system.
These items have been integrated into a highly effective system which controls exhaust emissions while maintaining
good driveability and fuel economy.
AIR/FUEL MIXTURE CONTROL SYSTEM [Multiport Fuel Injection (MFI) System]
The MFI system is a system which uses the signals from the heated oxygen sensor to activate and control the
injector installed in the manifold for each cylinder, thus precisely regulating the air/fuel mixture ratio and reducing
emissions.
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.
Page 7 of 14
Emission Control System > Troubleshooting > P0420
Main catalyst efficiency deterioration (bank1)
No. P0420
[Related items] • Manifold catalytic converter deteriorated
If any codes relating to HO2S sensor. MAFS, injectors, a P0171~P0172

are present, do all repairs associated with them before proceeding with
this troubleshooting procedure.

1 Connect SCAN TOOL to data link connector or Yes Do all repairs associated with those codes before
OBD-II check connector. proceeding this procedure.
Turn ignition to ON and check other DTCs.
Are DTC P0300~P0304, P0116, P0125,
P0130~P0134, P0030~P0032, P0136~P0140, No Go to step 2.
P0036~P0038, P1168, and/or P0171~P0172
set?
2 Start engine and warm up to operating Yes Replace catalytic converter.
temperature.
Using SCAN TOOL monitor both front HO2S
and rear HO2S signals. No Go to step 3.
Do both signals switch lean to rich and rich to
lean?
3 Release fuel pressure and attach fuel pressure Yes Go to step 4.
gauge to service port on fuel rail.
Start an engine and warm up to operating
temperature.
Check for fuel pressure at idle. No Check fuel delivery system.
• Fuel pressure at idle: 46~51 psi
(320~350kPa, 3.2~3.5kg/cm²)
Is fuel pressure within specification?
4 Check exhaust system for leaks, cracks, loose Yes Go to step 5.
connection (especially exhaust manifold, catalyst
around rear HO2S, etc). No Repair or replace as necessary.
Is exhaust system okay?.
5 Check for any split, disconnected or perforated Yes Go to step 6.
vacuum hoses.
Also, check PCV valve for proper operation. No Replace faulty vacuum hoses or PCV.
Are vacuum hoses and PCV okay?
6 Check for fuel injector operation. Yes Go to step 7.
Are fuel injectors working normal and dispensing
proper volume? No Repair as necessary.
7 Check intake system for leaks, cracks, loose Yes

Page 8 of 14
connection as following items:
• Throttle body gasket Replace catalytic converter as necessary.
• Gasket between intake manifold and surge
tank
• Seals between intake manifold and fuel No Repair or replace as necessary.
injectors
• Seals between surge tank and PCV valves
Is intake system okay?

Diagnostic trouble code EVAP emission control system purge solenoid valve stuck
No. P0441 opened
[Related items] • Purge solenoid valve stuck opened

Turn ignition to ON and check other DTC.
Is DTC P0443, P0444 or P0445 set? No Go to step 2.
2 Turn ignition to OFF and disconnect vacuum hose Yes Go to step 2.

from PCSV.
Start engine and put a finger on the open end of
vacuum hose. No Repair or replace vacuum hose as necessary.
Is intake manifold felt?
3 Turn ignition OFF and disconnect hose leading Yes Problem is intermittent or was repaired and engine
from PCSV to intake manifold at PCSV. Draw a control module memory was not cleared. Check
vacuum at nipple and verify PCSV holds vacuum. terminal connections at ECM and PCSV.
Turn ignition to ON and jumper a wire to chassis
ground at PCSV control terminal (should hear a
faint click from PCSV). Vacuum should bleed off. No Temporarily install a known good PCSV and
Repeat this procedure 4 or 5 times to ensure check for proper operation. If problem is
PCSV reliability. corrected replace PCSV.
Is PCSV working properly?

Page 9 of 14
EVAP emission control system small leak detected (1mm)
No. P0442
EVAP emission control system large leak detected
No. P0455
EVAP emission control system small leak detected (0.5mm)
No. P0456
[Related items] • Fuel filler cap loose or missing
• Fuel filler cap o-ring missing or damaged
• Faulty or damaged fuel filler pipe
• Leaking, disconnected or plugged fuel vapor lines
• Fuel in lines due to faulty Rollover Valve (RV), On-Board Refueling Vapor
Recovery Valve (ORVR valve)
• Canister close valve clogged, stuck open or closed
• Improperly installed purge solenoid valve (PCSV)
• PCSV stuck open or closed
• Faulty fuel tank pressure sensor
• Leaking canister or catch tank
If any codes relating to FTPS, CCV, or PCSV circuits are present, do all
repairs associated with those codes before proceeding with this
troubleshooting procedure.

Turn ignition to ON and check any other DTCs.
Is DTC P0440, P0441, P0443, P0444, P0445,
P0447, P0448, P0451, P0452, P0453, or P0454 No Go to step 2.
set?
2 Using SCAN TOOL proceed EVAP leakage Yes Problem is intermittent or was repaired and engine
test. control module memory was not cleared. Check
Is EVAP system okay? terminal connections at ECM and PCSV.
No Go to step 3.
3 Check fuel filler cap for being tightly installed, has Yes Go to step 4.
o-ring seal installed and is in good condition.
Verify cap releases vacuum at specified values
(approximately 2psi pressure and approximately No Replace fuel filler cap.
1.5 inches hg vacuum).
Are cap, o-ring and release pressures OK?
4 Check fuel filler pipe for cracks, damage and o- Yes Go to step 5.
ring seat for deformation.
Is fuel filler pipe OK? No Replace fuel filler pipe.
5 Thoroughly check all fuel vapor hoses and hose Yes Go to step 6.
clamps between:
Page 10 of 14
1) canister and rollover/ORVR valves
2) canister and CCV
3) canister and PCSV
4) PCSV and intake manifold No Replace all cracked/damaged hoses or loose
(At this point, also verify arrow on PSV is pointing clamps.
towards intake manifold. If it is not, reverse
installation).
Are vapors hoses and clamps ok?
6 Turn ignition to OFF and remove FTPS access Yes Go to step 7.
plate.
Remove FTPS from tank unit. Turn ignition to ON
(engine OFF) and monitor FTPS output voltage No Temporarily install a known good FTPS and
with SCAN TOOL. check for proper operation. If problem is
• Specifications: 2~3V corrected replace FTPS.
Is voltage within specification?
7 Turn ignition OFF and disconnect hose leading Yes Go to step 8.
from PCSV to intake manifold at PCSV. Draw a
vacuum at nipple and verify PCSV holds vacuum.
ground at PCSV control terminal (should hear a No Temporarily install a known good PCSV and
faint click from PCSV). Vacuum should bleed off. check for proper operation. If problem is
Repeat this procedure 4 or 5 times to ensure corrected replace PCSV.
PCSV reliability.
Is PCSV working properly?
8 Turn ignition OFF and disconnect hose connecting Yes Go to step 9.
CCV to canister. Blow air into hose removed
from canister and verify air escapes.
ground at CCV control terminal. Blow an air into No Temporarily install a known good CCV and
hose and verify air does not escape from port. check for proper operation. If problem is
Repeat this procedure 4 or 5 times to ensure corrected replace CCV.
CCV reliability.
Is CCV working properly?
9 Thoroughly check fuel gas leaks, cracks, damages Yes Go to step 10.
of the following items:
• Fuel filler cap
• Fuel vent valve (ORVR)
• Fuel cut valve (Rollover valve)
• FTPS No Repair or replace as necessary.
• EVAP hoses
• Canister
Are the above items okay?

Page 11 of 14
Diagnostic trouble code EVAP emission control system purge solenoid valve circuit
No. P0444 open
Diagnostic trouble code EVAP emission control system purge solenoid valve circuit
No. P0445 short
[Related items] • Open or short between main relay and purge solenoid valve
• Open or short between purge solenoid valve and ECM
• Faulty purge solenoid valve

1 Thoroughly check PCSV for loose, bent, Yes Repair as necessary.
corroded, contaminated, deteriorated or damaged
connectors. No Go to step 2.
Is any problem present?
2 Turn ignition to OFF and disconnect PCSV Yes Go to step 3.
connector.
Turn ignition to ON and measure voltage of
PCSV power circuit between PCSV harness No Open circuit or short circuit to chassis ground
connector and chassis ground. between PCSV harness connector and main relay.
• Specification: approximately B+ Repair as necessary.
3 Turn ignition to OFF. Yes Check PCSV for poor terminal contacts due to
PCSV connector is still disconnected. oxidation, bent deformed, or misplaced terminals.
Measure resistance between PCSV battery Repair as necessary.
power and signal terminal.
• Specification: approximately 24~28Ω @ No Temporarily install a known good PCSV and
20°C check for proper operation. If problem is
Is resistance within specification? corrected, replace PCSV.

connector.
Measure resistance of PCSV signal circuit
between PCSV harness connector and ECM No Open circuit between PCSV harness connector
harness connector. and ECM harness connector.
• Specification: below 1Ω Repair as necessary.
Does resistance indicate continuity circuit?
5 ECM connector PCSV connector is still Yes Temporarily install a known good PCSV and
disconnected. check for proper operation. If problem is
Measure resistance between PCSV harness corrected, replace PCSV.
connector and chassis ground at PCSV signal
circuit. No Short circuit to chassis ground between PCSV
Measure resistance between PCSV battery harness connector and ECM harness connector.
voltage circuit and signal circuit. Short circuit between PCSV battery power circuit
• Specification: infinite and signal circuit.
Does resistance indicate open circuit? Repair as necessary.
6 Return vehicle to original condition. Clear all Diagnostic Trouble Codes. Verify by driving vehicle with
SCAN TOOL connected and monitor for pending codes.
Page 12 of 14

EVAP emission control system vent circuit open
No. P0447
EVAP emission control system vent circuit shorted
No. P0448
[Related items] • Open or short to chassis ground between main relay and
CCV
• Open or short to battery between CCV and ECM
• Short to chassis ground between CCV and ECM
• Faulty CCV

1 Thoroughly check CCV for loose, bent, Yes Repair as necessary.
2 Turn ignition to OFF and disconnect CCV Yes Go to step 3.
connector.
Measure voltage between CCV power terminal No Temporarily install a known good CCV and
and signal terminal. check for proper operation.
• Specification: 23~26Ω at 20°C (68°F) If problem is corrected, replace CCV.
Is resistance within specification?
3 Turn ignition to ON and measure voltage of CCV Yes Go to step 4.
power circuit between CCV harness connector
and chassis ground. No Open circuit or short circuit to chassis ground
• Specification: approximately B+ between CCV harness connector and main relay.
Is voltage within specification? Repair as necessary.

connector.
resistance of CCV signal circuit between CCV No Open circuit between CCV harness connector
harness connector and ECM harness connector. and ECM harness connector.
5 Measure resistance between CCV harness Yes Temporarily install a known good CCV and
connector and chassis ground at CCV signal check for proper operation.
circuit. If problem is corrected, replace CCV.
• Specification: infinite No Short circuit to chassis ground between CCV
Does resistance open circuit? harness connector and ECM harness connector.
Page 13 of 14

Diagnostic trouble code EVAP emission control system pressure sensor circuit
No. P0451 range/performance problem
EVAP emission control system pressure sensor low input
No. P0452
EVAP emission control system pressure sensor high input
No. P0453
EVAP emission control system pressure sensor intermittent
No. P0454
[Related items] • Open or short to battery between FTPS and ECM
• Short to chassis ground between FTPS and ECM
• Poor connections between FTPS and ECM
• Misplaced, loose or corroded terminals
• Faulty FTPS

1 Connect SCAN TOOL to data link connector or Yes Problem is intermittent or was repaired and engine
OBD-II check connector and loosen fuel cap. control module memory was not cleared. Check
Using SCAN TOOL monitor FTPS voltage terminal connections at ECM and FTPS.
signals.
• Specification: 2.2~2.8V No Go to step 2.
2 Thoroughly check FTPS for loose, bent, Yes Repair as necessary.
Is any problem present?.
3 Turn ignition to ON and measure voltage of FTPS Yes Go to step 4.
reference power circuit between FTPS harness
No If voltage is above specification, short circuit to
connector and chassis ground.
battery.
• Specification: 4.8~5.2V If voltage is below specification, open circuit or
Is voltage within specification? short circuit to chassis ground.
4 Turn ignition to OFF and disconnect ECM and Yes Go to step 5.
FTPS connectors.Turn ignition to ON.
Measure voltage of FTPS signal circuit between No Short circuit to power between FTPS harness
FTPS harness connector and chassis ground. connector and ECM harness connector.
Is voltage within specifications?
5 Turn ignition to OFF and disconnect ECM and Yes Go to step 6.
FTPS connectors.
Measure resistance of FTPS signal circuit
between FTPS harness connector and ECM
harness connector.
Page 14 of 14
harness connector. No Open circuit between FTPS harness connector
Measure resistance of FTPS ground circuit and ECM harness connector.
between FTPS harness connector and ECM Repair as necessary.
harness connector.
• Specifications: below 1Ω
6 Measure resistance between FTPS harness Yes Temporarily install a known good FTPS and
connector and chassis ground at FTPS signal check for proper operation.
circuit and FTPS ground circuit. If problem is corrected, replace FTPS.
• Specifications: infinite No Short circuit to chassis ground between FTPS
Does each resistance open circuit? harness connector and ECM harness connector.
Page 1 of 37
RIO(BC) > 2005 > G 1.6 DOHC > Engine Electrical System
Engine Electrical System > Ignition System > General Information

TIGHTENING TORQUES
Item Torque
Ignition coil bolt 11.5~16.6 lb-ft (15.6~22.6
N·m, 1.6~2.3kg-m)
Spark plugs 18~22 lb-ft (25~30 N·m,
2.5~3.0 kg-m)
Engine Electrical System > Ignition System > Description and Operation
General description
This vehicle incorporates DLI(Distributorless ignition) system in order to increase the rarge of ignition timing and
distributor voltage and to decrease electric wave noise. The components of this system are:
• Ignition Coil
• Camshsft Position Sensor
• ECM
• Spark Plug Wires and Spark Plugs
Ignition system operation
Page 2 of 37
In a conventional ignition system, the ignition coil produces a high voltage current and the distributor then relays this
current, at the required time, to each spark plug. In the distributorless ignition system, two sensors, the camshaft
position sensor and the crankshaft position sensor, tell the Engine Control Module(ECM) which cylinder is ready to
fire. The ECM then sends an ignition signal to an electronic ignition coil. This ignition coil then produces and sends a
high voltage current to the proper spark plug.
Distributorless ignition is a "wasted-spark" system in which two spark plugs fire simultaneously. One cylinder fires at
TDC on the compression stroke, while the other fires at TDC of the exhaust stroke.
The cylinders are grouped together by firing order. For example, firing order is 1-3-4-2. Cylinders 1 and 4 are in the
same position, while cylinders 2 and 3 are 180 behind. Plugs 1 and 4 fire together, as do the plugs in cylinders 2 and
3.
This means that an ignition spark is fired in one cylinder while at the same time a "waste" spark is fired in the
companion cylinder.
Because of dualed plug firing, if an inductive tachometer is connected to a plug wire, it will indicate an engine RPM
that is twice the actual speed (i.e., 1,600 RPM, instead of 800 RPM).
Electronic spark advance system
Ignition Timing is determined and set within the ECM based on signals from various sensors and switches.
Optimum performance is gained with this system. The ECM varies ignition timing according to engine speed, intake
air amount, coolant temperature and other conditions.
• Timing specification at idle is: 8±5° BTDC

• Timing is not adjustable
Ignition system components
The mechanical, rotating high-voltage distributor mechanism has been replaced by static electronically controlled
components. These components are described below.
Ignition coils
Two ignition coils are used in this system. The engine locates them directly above the #2 and #4 spark plugs. The
coil resistance is identical for these two coils, and there is no maintenance required for them. If determined to be
faulty, they must be replaced.
Spark plug cable

The spark plug cable connect the two ignition coils to the spark plugs. Their function is basically the same as on the
previous system. Because of their shorter length, the DLI spark plug cable enhance the ignition systems delivered
voltage. In addition, they reduce the wave interference from one high tension wire to another.
Spark plugs
The spark plugs provide the air gap necessary to produce an arc from the electrical energy coming in from the
ignition coil. This arc then ignites the fuel/air mixture in the cylinder, producing power.
Ignition timing
Ignition timing can be thrown off for two reasons: A problem with a sensor, which will be detected by ECM or a
misalignment of camshaft to crankshaft. This last problem indicates a problem with timing belt, which is covered in
Group EM, Engine. There is no need to adjust engine timing after replacement of a coil.
Page 3 of 37
Check procedure
1. Warm engine and let idle.
2. Turn all other electrical systems OFF.
3. Connect timing light to high-tension lead number one.
4. Check that ignition timing mark on crankshaft pulley aligns with timing mark on engine block.
Engine Electrical System > Ignition System > Troubleshooting

TROUBLE SHOOTING
Problem Possible Cause Action
Engine light "ON" Check engine control module. Repair as
Engine control module detects fault in system
required
Engine runs rough Spark plug failure Check, clean or replace plugs
High-tension lead arcing to ground Replace high-tension leads
Ignition coil(s) faulty Check/replace ignition coil(s)
CMP sensor faulty Check/replace sensor
CKP sensor faulty Check/replace sensor
Engine fails to start, Fuse failure Check/replace IGN fuse
starter turning Low battery current Check charging system
Ignition coil(s) failure Check/replace coil(s)
CMP sensor failure Check/replace sensor
CKP sensor failure Check/replace sensor
Engine Electrical System > Ignition System > Specifications

SPARK PLUG AND IGNITION COIL
Engine Electrical System > Ignition System > Ignition Coil > Repair procedures
Inspection
Voltage check
2. Disconnect ignition coil connector.
3. Turn ignition switch to "ON"
Page 4 of 37
4. Measure voltage between terminal ECU and B+ at ignition coil connector.
Voltage: approximately 12 Volts
5. If no voltage, check main fuse, ignition switch and wire harness.

Resistance check
1. Using an ohmmeter, check resistance of primary coil. Connect one lead of ohmmeter to positive (+) terminal and
other lead to each negative (-) terminal.
If not within specification, replace coil. Remember that unit has two coil assemblies, so both must be checked.
Primary coil resistance:

0.45~0.55Ω @ 68°F (20°C)
2. Using an ohmmeter, check resistance of the secondary coil. If not within specification, replace coil. Remember
that you must check resistance of both top and bottom secondary coil. If one is out of specification replace the
whole unit.
Secondary coil resistance:

10.9~13.3kΩ @ 68°F (20°C)
REMOVAL
1. Disconnect battery cable.
Page 5 of 37
2. Disconnect high-tension leads.
3. Disconnect ignition coil connectors.
4. Remove four ignition coil mounting bolts.
5. Remove ignition coils.
INSTALLATION
1. Position two coils above No.2 and No.4 spark plugs, and firmly push down to connect.
2. Insert and tighten four ignition coil mounting bolts.
Tightening torque:
11.5~16.6 lb-ft (15.6~22.6 N·m, 1.6~2.3 kg-m)
3. Reconnect ignition coil connectors.

4. Reattach high tension leads. Leads are marked for correct connection.
5. Reconnect battery cable.
Engine Electrical System > Ignition System > Spark Plug > Repair procedures
REMOVAL
Do not attempt any maintenance on spark plugs if engine is hot.

1. Disconnect negative battery terminal.
2. Carefully remove high-tension leads.
3. Use compressed air to blow any dirt or debris from around spark plug hole.
4. Check that spark plug fits squarely in spark plug socket and remove spark plug.
INSTALLATION
1. Install spark plug into cylinder head.
Tightening torque:
18~22 Ib-ft (25~30 N·m, 2.5~3.0 kg-m)
2. Reconnect high-tension leads.

3. Reconnect negative battery cable.
INSPECTION
1. Reconnect negative battery cable.
2. Connect spark plug to high-tension lead.
Page 6 of 37
3. Hold spark plug with insulated pliers 0.2 to 0.39 inch (5~10 mm) from a ground.
Do not touch vehicle body during following instructions.

4. While holding spark plug, have a second person crank engine. Verify that a strong blue spark jumps from spark
plug to ground.
5. If there is no spark or the spark is weak, check for, and implement correction:
A. Carbon deposits. Clean out or replace plug.
B. Oil fouling. Correct oil problem, replace plug.
C. Worn or burnt electrode. If present, replace plug.
D. Broken or burned ceramic insulator. If present replace plug.
E. Damaged spark plug ring. If so, replace ring.
F. Improper spark plug gap. Regap if possible, otherwise replace plug.
Plug Gap : 0.039~0.043 in (1.0~1.1 mm)
Engine Electrical System > Ignition System > Spark Plug Cable > Repair procedures
Inspection
1. Disconnect from coil and spark plugs.
2. Check for breaks in insulation.
3. Check inside high-tension lead connectors for corrosion or carbon deposits.
Page 7 of 37
4. Connect high-tension lead to an ohmmeter and check resistance.
Resistance : 4.48~6.72 kΩ per 3.28 ft (1m)
5. Replace if defective.
Engine Electrical System > Charging System > Troubleshooting

Symptom-related diagnostic procedure
Generator
1 Check battery voltage. Yes Go to next step.
Specification: Above 12.4V
No Check battery.
2 Start engine and check if generator warning light Yes Go to step 4.
goes out. No Go to next step.
3 Check if voltage at generator terminals are correct Yes Check wiring harness between battery and
terminal B.
No • Check wiring harness.

• Replace generator.
4 1. Connect an ammeter (80A minimum) between Yes Charging system normal.

terminal B and terminal B harness connector.
2. Start engine.
3. Turn all electrical loads ON and depress brake
pedal.
Page 8 of 37
4. Check if output current is 65A or more at 2,500-
3,000 rpm.
No Go to next step.
Do not ground terminal B.
5 Check drive belt tension OK? Yes Replace generator.

No Adjust drive belt tension.
Engine Electrical System > Charging System > Repair procedures

On-vehicle service
Generator Inspection
Before testing the generator, perform the following checks:
1. Inspect the battery condition.
2. Inspect condition of battery cable and terminals, battery posts, connections at engine block, starter solenoid and
relay.
3. Inspect all fuses in both the engine compartment fuse/relay box and the passenger compartment fuse box.
4. Inspect the generator mounting bolts for tightness.
5. Inspect the generator drive belt condition and tension.
6. Inspect connections at generator field, battery output and ground terminals. Check ground connection at engine.
Charging system resistance check
This tests will indicate the amount of voltage drop across the generator output wire, from the generator output (B+)
terminal to the battery positive post. They will also show the amount of voltage drop from the ground (-) terminal on
the generator to the negative battery post. Refer to the Rio Electrical Troubleshooting Manual for connector and
terminal information.
1. Engage the parking brake, make sure the transaxle is in PARK (A/T) or NEUTRAL (M/T) and start the engine.
2. Set blower control to the maximum position.
3. Turn on headlights and set in high-beam position and turn the vehicle interior lamps on.
4. Bring the engine speed up to 2400 RPM and hold.
5. Touch the DVOM(Digital Voltage and Ohm Meter) negative lead directly to the positive battery post.
6. Touch the DVOM positive lead to the B+ output terminal stud on the generator (not the terminal mounting nut).
The outputvoltage should be no higher than 0.6V. If the voltage is higher than 0.6V, touch the DVOM positive
lead to the terminalmounting stud nut and then to the wiring connector. If the voltage is now below 0.6V, look for
dirty, loose or poor connection.
7. Touch the DVOM negative lead directly to the negative battery post.
Page 9 of 37
8. Touch the DVOM positive lead to the ground terminal stud on the generator case (not the terminal mounting nut).
The voltage should be no higher than 0.3V. If the voltage is higher than 0.3V touch the DVOM positive lead to
the terminal mounting stud nut and then to the wiring connector. If the voltage is now below 0.3V, look for dirty,
loose or poor connection.
A voltage drop test can be performed at each (-) connection in this circuit to locate the excessive
resistance. This test can also be performed between the generator case and the engine. If test voltage is
higher than 0.3V, check for corrosion at the generator mounting points or loose generator mounting.
Current output test
This test will determine if the charging system can deliver its minimum test current (amperage) output. A volt/amp
tester equipped with both a battery load control and an inductive type pickup clamp (ammeter probe) will be used
for this test. Refer to the operating instructions supplied with the tester.
1. Engage the parking brake, make sure the transaxle is in PARK (A/T) or NEUTRAL (M/T) and start the engine.
2. Bring the engine speed up to 2500 RPM and hold.
This load test must be performed within 15 seconds to prevent damage to test
equipment.
3. Slowly adjust the rheostat control (load) on the tester to obtain the highest amperage reading. Do not allow the
voltage to drop below 12V.
On certain brands of test equipment, this load will be applied automatically. Refer to the operating
instructions supplied with the test equipment.
4. The ammeter reading must meet the minimum amps specifications listed on the specifications chart.
5. Turn the load control knob on the tester to the OFF position but continue to hold the engine speed at 2500
RPM. If all circuitry is okay, the amperage should drop below 15 to 20 amps. This may take several minutes with
all electrical accessories OFF. If amperage does not drop, refer to the Electrical Troubleshooting Manual and
check circuitry.
6. Remove the volt/amp tester. If the minimum amperage requirements could not be met, test the generator. If the
generator tests okay, check the charging system circuitry (refer to the Electrical Troubleshooting Manual).
Drive belt
Inspection
1. Check drive belt and pulley for wear, cracks, and fraying. Replace if necessary.
Page 10 of 37
2. Measure drive belt tension with a tension gauge.
Tesion
3. Measure deflection by applying moderate pressure (22 Ib [98 N]) midway between pulleys. Adjust if necessary.
Deflectio
Engine Electrical System > Charging System > Specifications

SPECIFICATION
BATTERY
GENERATOR
Page 11 of 37
Engine Electrical System > Charging System > Alternator > Schematic Diagrams
Circuit diagram
Engine Electrical System > Charging System > Alternator > Repair procedures
REMOVAL
1. Remove negative battery cable.
2. Open B terminal cover cap.
3. Remove B terminal nut.
4. Remove B terminal lead.
Page 12 of 37
5. Disconnect generator connector.
6. Loosen pivot bolt B and tensioner mounting bolt A. Do not remove.
7. Relieve tension on drive belt by rotating adjustment bolt C.

8. Remove drive belt from generator pulley.
9. Remove tensioner mounting bolt and belt tensioner.
10. Remove generator pivot bolt.
11. Loosen bolt at base of adjusting bracket and rotate the bracket up.
12. Lift generator from engine compartment.
REPLACEMENT
1. Position generator on engine.
2. Install pivot bolt(leave loose).
3. Rotate bracket into position on top of generator.
4. Place belt tensioner into position on adjustment bracket.
5. Install tensioner mounting bolt (leave loose)
6. Place drive belt on generator pulley.
7. Adjust belt tension by rotating adjustment bolt C.
Allowable deflection:
New belt: 0.22-0.28 in (5.5-7.0 mm)
Old belt: 0.24-0.28 in (6.0-7.0 mm)
Page 13 of 37
8. Tighten tensioner bolt.
Tighten tensioner bolt to

14-19 Ib-ft (19-26 N·m, 1.9~2.6 Kg-m)
9. Tighten pivot bolt and bracket bolt.
Tighten pivot and bracket bolt to

28-38 Ib-ft (38-51 N·m, 3.8~5.3 Kg-m)
10. Connect generator L and S terminal connectors.

11. Connect B terminal lead.
12. Install and tighten B terminal nut.
13. Close B terminal nut cover.
14. Install air intake inlet pipe and tighten end clamp.
15. Connect top hose to air intake inlet pipe.
16. Install front air intake inlet pipe bolts.
• Be sure battery connections are not reversed. This will damage rectifier.
• Do not use highvoltage testers, such as a megger.They will damage the
rectifier.
• Remember that battery voltage is always applied to alternator B terminal.
• Do not ground L terminal while engine is running.
• Do not start engine while L and S terminals are disconnected from generator.
Disassembly
Insert protective material in the jaws of the vise.

1. Remove four cap screws from rear housing.
Page 14 of 37
2. Use a 200-watt soldering iron to heat the rear of bearing box to allow the bearing to be removed from rear
housing.
If bearing box is not heated, bearing cannot be pulled out of rear housing. The rear bearing and rear
housing fit together very tightly.
3. Use a flat-blade screwdriver to separate front housing from stator.

Page 15 of 37
4. Place rotor in a vise and loosen locknut, then disassemble pulley, rotor, and front housing.
5. If necessary, remove front bearing using a socket and a hand press or vise.
6. Remove rear bearing with a bearing puller.
7. Remove B terminal nut and insulating bushing.

8. Remove five screws holding the rectifier and brush holder.
9. Separate rear bracket and stator.

Page 16 of 37
10. Use a soldering iron to remove solder from rectifier and stator leads, and then remove IC regulator.
Disconnect quickly. If soldering iron is used for more than 5 seconds, rectifier may be damaged by
heat.
11. Replace brushes. Remove solder from pigtail, and then remove brush.
Reassembly
1. Assemble brush, and solder pigtail so that wear limit line of brush projects 0.079~0.118 in (2~3 mm) out of
brush holder.
Page 17 of 37
2. Assemble regulator, and solder with rectifier and stator leads.
Disconnect quickly. If solderings iron is used for more than 5 seconds, rectifier may be damaged by
heat.
3. Assemble rear bracket and stator.
4. Tighten screws holding rectifier and brush holder.
Tightening torque:
1.5~4.0 Ib-ft (2.0~5.4 N·m, 0.2~0.55 kg-m)
5. Tighten B terminal nut and insulating bushing.
6. Assemble rear bearing and stopper spring.
Make sure groove on bearing rim is facing slip ring

side.
Page 18 of 37
7. Assemble front bearing. Using a socket which exactly fits outer race of bearing, carefully push in front bearing.
Use a hand press or a vise.
INSPECTION
Rotor
1. Measure resistance between slip rings with a ohmmeter. If it is not within standard resistance, replace rotor.
Standard resistance: 3.5~4.5Ω
2. Check for continuity between slip ring and core with a circuit tester. Replace rotor if there is continuity.
3. If slip ring surface is rough, smooth with a lathe or fine sandpaper.

Stator
Page 19 of 37
1. Check for continuity between stator coil leads with a circuit tester.
2. Replace stator if there is no continuity.

3. Check for continuity between stator coil leads and core with a circuit tester.
4. Replace stator if there is continuity.

Rectifier
1. Check for continuity between each diode with an ohmmeter.
Page 20 of 37
2. Replace if necessary.
Bearing.
1. Check for abnormal noise, looseness, insufficient lubrication, etc.
2. Replace bearing(s) if there is any abnormality.
Engine Electrical System > Charging System > Battery > Description and Operation
Battery Recharging
Slow charging
1. It is not necessary to remove vent caps to perform a slow charge.
Quick charging
Page 21 of 37
1. Remove battery from vehicle and remove vent caps to perform a quick charge.
• Before performing maintenance or recharging battery, turn off all accessories and stop
engine.
• Negative cable must be removed first and installed last.
• Set battery in water when quick charging to prevent overheating battery.
Engine Electrical System > Charging System > Battery > Repair procedures
Inspection
Any of the following conditions can result in abnormal battery discharging:

1. Corroded or loose battery posts and terminal clamps.
2. A loose or worn generator drive belt.
3. Electrical loads that exceed the output of the charging system. This can be due to equipment installed after
manufacture or repeated short trip use.
4. Slow driving speeds (heavy traffic conditions) or prolonged idling with high-amperage draw system in use.
5. A faulty circuit or component causing excessive ignition-off draw or "parasitic" draw.
6. A faulty or incorrect charging system component.
Page 22 of 37
7. A faulty or incorrect battery. Before testing, visually inspect the battery for any damage (a cracked case or cover,
loose posts, etc.) that would cause the battery to be faulty.
• IF A BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS OR LOW

ELECTROLYTE LEVEL, DO NOT TEST, ASSIST-BOOST OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY OR DEATH COULD
OCCUR.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT
SMOKE, USE FLAME, OR CREATE SPARKS NEAR THE BATTERY. PERSONAL INJURY
OR DEATH COULD OCCUR.
• THE BATTERY CONTAINS SULFURIC ACID WHICH IS POISONOUS AND CAUSTIC.
AVOID CONTACT WITH THE SKIN, EYES OR CLOTHING. IN THEEVENT OF CONTACT,
FLUSH WITH WATER AND CONTACT A PHYSICIAN IMMEDIATELY. KEEP OUT OF
THE REACH OF CHILDREN.
• IF THE BATTERY IS EQUIPPED WITH REMOVABLE CELL CAPS, BE CERTAIN THAT
EACH OF THE CELL CAPS IN IS PLACE AND TIGHT BEFORE THE BATTERY IS
RETURNED TO SERVICE. PERSONAL INJURY AND/OR VEHICLE DAMAGE COULD
OCCUR.
Electrolyte level
1. Check whether or not the electrolyte level lies between "UPPERLEVEL" line and "LOWER LEVEL" line.
2. If low, add distilled water to "UPPER LEVEL" line. Do not overfill.
Hydrometer (Specific-gravity) test
The hydrometer tests battery state-of-charge by measuring the specific gravity of the electrolyte. This test cannot be
performed on maintenance-free batteries with non-removable cell caps. Specific gravity is a comparison of the
density of the electrolyte to the density of pure water. Pure water has a specific gravity of 1.000, and sulfuric
(battery) acid makes up approsimately 35% of the electrolyte by weight, or 24% of its volume. In a fully charged
battery the electrolyte will have a temperature-corrected specific gravity of 1.260 to 1.290. However, a specific
gravity of 1.235 or above is satisfactory for battery load testing and/or return to service.
1. Measure specific gravity with a hydrometer. Refer to the instructions supplied with the hydrometer for
recommendations on the correct use of the hydrometer.
Battery open-circuit voltage test
A battery open-circuit voltage (no load) test will show the state of charge of a battery. This test can be used in
placeof the hydrometer test. Before proceeding with this test, make sure the battery is completely charged.
1. Before measuring the open-circuit voltage, the surface charge must be removed from the battery. Turn on the
headlights for fifteen seconds, then allow up to five minutes for the battery voltage to stabilize.
2. Disconnect and isolate both battery cables, negative cable first.
3. Using a DVOM(Digital Voltage and Ohm Meter) connected to the battery post, measure the open-circuit
voltage. Refer to the Open-Circuit Voltage table. This voltage will indicate the battery state-of-charge, but will
not reveal its cranking capacity. If the open-circuit voltage reading is 12.4V or greater, perform the load test.
Battery load test
1. Disconnect and isolate both battery cables, negative cable first. Make sure the battery top and posts are clean.
2. Connect a suitable VAT Tester to the battery posts. Check the open-circuit (no load) of the battery. Open-
circuit voltage must be 12.4V or greater.
3. Apply a 300 Amp load to the battery for fifteen seconds to remove the surface charge from the battery, then
allow the battery to stabilize for five minutes.
4. Apply a load equal to 50% of the CCA rating of the battery. After approximately fifteen seconds, check the
loaded voltage reading, then remove the load.
Page 23 of 37
5. The voltage drop will vary with the battery temperature at the time of the load test.
Battery ignition off draw test

The battery draw test refers to power being drained from the battery with the ignition switch in the OFF position. A
normal electrical system will draw from five to twenty-five milliamps (0.005 to 0.025 ampere) with the ignition OFF
and allnon-ignition controlled circuits working properly. The 0.025 ampere is needed to enable the memory
functions of the vehicle to function.
1. Verify that all electrical accessories are OFF. Turn off all lamps, remove the ignition key and close all doors.
3. Set a DVOM(Digital Voltage and Ohm Meter) to its highest amperage scale and connect the DVOM between
the disconnected negative battery cable and the negative battery post.
4. If the amperage reading is higher that 0.025 ampere, remove each fuse until the amperage reading becomes
within specifications, this will isolate each circuit and identify the source of the draw. If the amperage reading
remains high after disconnecting each fuse, unplug the connector from the generator. If the amperage reading
becomes within specifications, check the charging system.
5. After appropriate repairs have been made, retest the system.
Voltage drop test
The voltage drop test will determine if there is excessive resistance in the battery terminal connections or the
batterycables. When performing these tests, remember that the voltage drop is giving an indication of the resistance
between the two points at which the DVOM probes are attached. For example, when testing the resistance of the
battery positive cable, connect one of the DVOM leads to the positive battery cable clamp and the the other cable
connector at the starter solenoid. If you probe the positive battery terminal post and the cable connector at the
starter solenoid, you are actually reading the combined voltage drop in the positive battery cable clamp-to-terminal
post connection and the positive battery cable.
1. Connect the positive lead of the DVOM to the negative battery terminal post.
2. Connect the negative lead of the DVOM to the negative battery terminal cable clamp.
3. Turn the ignition switch to the start meter and observe the DVOM. If voltage is detected, correct the poor
contact between the cable clamp and the terminal post.
4. Connect the positive lead of the DVOM to the positive battery terminal post.
5. Connect the negative lead of the DVOM to the positive battery terminal cable clamp.
6. Turn the ignition switch to START and observe the DVOM. If voltage is detected, correct the poor contact
between the cable clamp and the terminal post.
7. Connect the voltmeter to measure between the positive battery terminal post and the starter solenoid battery
terminal stud.
8. Turn the ignition switch to START and observe the reading on the DVOM. If the reading is above 0.2V, clean
and tighten the battery cable connection at the solenoid and repeat the test. If the reading is still above 0.2V,
replace the faulty positive battery cable.
9. Connect the DVOM to measure between the negative battery terminal post and a good clean ground on the
engine block.
10. Turn the ignition switch to START and observe the DVOM. If the reading is above 0.2V, clean and tighten the
battery cable connection on the engine block and repeat the test. If the reading is still above 0.2V, correct the
faulty negative battery cable.
Page 24 of 37
11. Connect the DVOM positive lead to the starter housing. Connect the DVOM negative lead to the negative
battery terminal post.
12. Turn the ignition switch to START and observe the DVOM. If the reading is above 0.2V, correct the poor
starter to engine block ground contact.
Engine Electrical System > Starting System > Troubleshooting

Symptom-related diagnostic procedure
1 Will not crank-starter motor does not operate
1 Check if engine cranks with fully charged battery. Yes Check charging system.
No Go to next step.
2 Check if battery voltage is supplied at B terminal. Yes Go to next step.
No Check wiring harness.
3 Check if battery voltage is supplied at S terminal Yes Replace starter unit.

with clutch pedal depressed (M/T), car in park
(A/T), and ignition switch in START position.
No • Check transmission range switch (A/T)

(Refer to Section AT.)
• Check ignition switch.
• Check wiring harness.
2 Will not crank-starter motor spins

1 Check if drive pinion is pulled out while cranking. Yes Remove starter and check flywheel ring gear teeth
(Click heard when pulled out.) and starter drive pinion teeth.
No Replace starter unit.

Page 25 of 37
3 Cranks slowly
1 Check if engine cranks normally when fully charged. Yes Check charging system.
No Go to next step.
2 Check starter cable connection for looseness and Yes Repair or replace connection.
corrosion.
No Check for seized motor armature. Repair or

replace as necessary.
4 Generator warning lamp illuminates with engine running

1 Check for correct battery voltage at idle. Yes Check wiring harness between generator L
terminal and generator warning lamp.
Specification: 14.1~14.7V No Check charging system.
5 Discharged battery
1 Check charging system. Yes Turn ignition switch ON and check dark
current as shown.
Dark current: Below 20mA

Engine Electrical System > Starting System > Specifications

Starter
Page 26 of 37
Engine Electrical System > Starting System > Starter > Components and Components Location
Component
Engine Electrical System > Starting System > Starter > Repair procedures
Cold cranking test
1. Connect a DVOM(Digital Voltage and Ohm Meter) tester to the battery terminals.
Refer to the operating instructions for the tester being used.
2. Make sure the parking brake is fully engaged. If the vehicle is equipped with an automatic transaxle, place the
shift selector in the PARK position. If the vehicle is equipped with a manual transaxle, place the gearshift lever in
the NEUTRAL position.
3. Make sure that all accessories are turned off.
4. Turn the ignition switch to START and observe the cranking voltage and current draw.
Page 27 of 37
5. If the voltage reading is below 9.6 volts, remove the starter for bench testing. If the starter bench test is okay,
refer to section EM for further diagnosis of the engine. If the starter bench test is not okay, replace the starter.
6. If the voltage reading is above 9.6V and the current (amperage) draw is below specifications, go to the
BATTERY VOLTAGE DROP TEST.
7. If the voltage reading is 12.5V or more and the starter doesn't turn, go to the SOLENOID TEST.
8. If the voltage reading is 12.5V or more and the starter turns very slowly, go to the BATTERY VOLTAGE
DROP TEST.
A cold engine will increase the starter current (amperage) draw reading and reduce the battery voltage
reading.
INSPECTION
Solenoid
1. Check for continuity between S and M terminals with ohmmeter. Replace solenoid if there is no continuity.
2. Check for continuity between S terminal and solenoid body with ohmmeter. Replace solenoid if there is no
continuity.
3. Check continuity between M and B terminal with ohmmeter. Replace solenoid if there is continuity.
Brush and brush holder

1. Check continuity between each insulated brush and plate with ohmmeter. Replace brush holder if there is
continuity.
Page 28 of 37
2. Replace spring if There is no continuity.
Field coil
1. Check for continuity between M terminal wire and brushes with ohmmeter. Replace yoke assembly if there is no
continuity.
2. Check continuity between M terminal wire and yoke with ohmmeter. Replace yoke assembly if there is
continuity.
3. Check if field coil is loose. Replace yoke assembly if necessary.
Armature
1. Check continuity between commutator and core with ohmmeter. Replace armature if there is continuity.
Page 29 of 37
2. Check continuity between commutator and shaft with ohmmeter. Replace armature if there is continuity.
Solenoid test
1. Remove the starter.
2. Check for continuity between the solenoid terminal and the field coil terminal. If there is continuity, go to next
step.If there is no continuity, repair/replace the faulty components and retest.
3. Check for continuity between the solenoid terminal and the solenoid case. If there is continuity, check the Starter
Relay, Park/Neutral Position Switch, Clutch Pedal Position Switch and Ignition Switch. Refer to the Rio
Electrical Troubleshooting Manual. If there is no continuity, repair/replace the faulty components and retest.
Removal
2. Remove four upper intake manifold support bracket bolts.
3. Disconnect S terminal connector.
4. Disconnect B terminal connector.
5. Remove starter.
Disassembly
1. Remove nut from M terminal.
Page 30 of 37
2. Remove field wire from M terminal.
If pinion depth shims are found between solenoid and drive end housing, remove them and set
aside.
3. Remove solenoid screws and magnetic switch.
4. Remove solenoid plunger spring.
5. Disengage plunger from lever and remove plunger.

Page 31 of 37
6. Remove bolts from rear cover. Separate motor assembly from drive end housing. Also separate motor assembly
from planetary gear set, if present.
7. Remove lever from drive pinion.
8. Drive stopper from snap ring using a deep well socket or similar tool.
9. Remove snap ring from its groove in pinion shaft.

10. Remove stopper and drive pinion from pinion shaft.
11. Remove two brush plate screws and rear cover.

12. Remove armature from field coil housing.
Page 32 of 37
13. Remove armature washers from the end of the armature.
Reassembly
1. Reassemble armature washers to the end of armature.
2. Reassemble armature in field coil housing.
3. Reassemble rear cover and tighten two brush plate screws.
Tightening torque:
1.7~3.2 Ib-ft (2.4~4.4 N·m, 0.24~0.44 kg-m)
4. Reassemble drive pinion and stopper on pinion shaft.

5. Place snap ring on its groove in pinion shaft.
6. Reassemble stopper.
Page 33 of 37
7. Reassemble lever on drive pinion.
8. If present, reassemble planetary gear set to motor assembly.

9. Reassemble motor assembly in drive end housing.
10. Place bolts in rear cover and tighten.
Tightening torque:
2.8~5.2 Ib-ft (3.8~7.1 N·m, 0.39~0.72 kg-m)
11. Engage plunger in lever.
12. Insert solenoid plunger spring.

Page 34 of 37
13. Reassemble magnetic switch and tighten solenoid screws.
Tightening torque:
3.0~5.6 Ib-ft (4.1~7.6 N·m, 0.42~0.77 kg-m)
14. Apply battery power to the S terminal and ground starter motor body. Pinion will eject outward and then stop.
15. Measure clearance (pinion gap) between pinion and stopper.
Pinion gap: 0.079 in (2.0 mm)
Be careful not to let electricity flow continuously for more than 10 seconds.
16. If pinion gap is not within specified range, adjust it by increasing or decreasing the number of washers used
between solenoid and drive housing. The gap will become smaller if the number of washers is increased
Do not use more washers than plates.
17. Connect field wire to M terminal.
Engine Electrical System > Troubleshooting > P0300

Page 35 of 37
Random misfire detected
No. P0300
Cylinder 1 misfire detected
No. P0301
No. P0302
No. P0303
No. P0304
[Related items] • Vacuum leak in air intake system
• CKPS circuit malfunction
• Ignition circuit malfunction
• Faulty ignition coil or plug wire
• Spark plug malfunction
• Low compression due to blown head gasket, leaking valve or piston ring
• Low/high fuel pressure due to faulty pressure regulator, restricted fuel lines,
plugged fuel filter or faulty fuel pump
• Fuel injector circuit malfunction
• Faulty fuel injector
If any injectors, HO2S, ECTS, and MAFS codes are present, do all
repairs associated with those codes before proceeding this
troubleshooting guide.

Turn ignition to ON and monitor DTCs.
Are any other codes set? No Go to step 2.

vacuum hoses. Also, check PCV valve for proper
operation. No Replace faulty vacuum hoses or PCV.
Are vacuum hoses and PCV okay?
3 Turn ignition to OFF and disconnect ignition coil Yes Go to step 4.
connector.
Turn ignition to ON and measure voltage of No Open circuit or short circuit to chassis ground
ignition coil battery voltage between ignition coil between ignition coil harness connector and main
harness connector and chassis ground. relay.
Is battery voltage within specifications?
4 . Yes Go to step 5.
.
Are ignition coils and plug wires OK? No Repair or replace as necessary.
Page 36 of 37
5 Disconnect CKP connector and measure Yes Thoroughly check for loose, bent or corroded
resistance between CKP terminal 2 and terminal 3 terminals between CKPS and ECM.
(800~900Ω at 20°C). Measure resistance between CKPS terminal 3
{measure distance from hosing to teeth on and chassis ground (1<Ω).
flywheel/torque converter (measurement "A") and Repair as necessary.
from mounting surface on sensor to sensor tip
(measurement "B") subtract "B" from "A" = air
gap}. No Repair as necessary.
Are air gap and resistance measurements within
specifications?
6 Release fuel pressure and attach fuel pressure Yes Go to step 7.
gauge to service port on fuel rail.
Start an engine and warm up to operating
temperature.
Check for fuel pressure at idle. No Check fuel delivery system.
• Fuel pressure at idle: 46~51 psi
(320~350kpa, 3.2~3.5kg/cm²)
Is fuel pressure within specification?
7 and plug condition. Yes Go to step 8.
Are spark plugs gapped properly and in good
condition? No Repair as necessary.
8 (no more than 10% between highest and lowest Yes Go to step 9.
cylinder)].
No Perform leak down test to determine source of
Is compression OK?
low compression and repair as necessary.
Engine Electrical System > Troubleshooting > P0560

Diagnostic trouble
code System voltage malfunction
No. P0560
Diagnostic trouble
code System voltage low input
No. P0562
Diagnostic trouble
code System voltage high input
No. P0563
[Related items] • Open or short between ECM and battery
• ECM internal faulty
Page 37 of 37
1 Turn ignition to OFF and disconnect ECM Yes Thoroughly check for poor connection, misplaced,
connector. corroded terminals at ECM connector.
Measure voltage of backup circuit between Repair as necessary.
battery and chassis ground. No Open circuit or short circuit to chassis ground
• Specification: approximately B+ between ECM harness connector and battery.
2 • Temporarily install a known good ECM and check for proper operation. If problem is corrected replace
ECM.
• Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehicle with
Page 1 of 77
RIO(BC) > 2005 > G 1.6 DOHC > Engine Mechanical System
Engine Mechanical System > General Information > General Information

COMPRESSION
If the engine exhibits low power, poor fuel economy, or poor idle, check thefollowing :
1. Ignition system
2. Compression
3. Fuel system
INSPECTION
1. Check that the battery if fully charged. Recharge it if necessary.
2. Warm up the engine to normal operating temperature.
3. Remove the center cover.
4. Disconnect the high tension lead and ignition coil.
5. Remove all spark plugs.
6. Connect a compression gauge to the No.1 spark plug hole.
7. Fully depress the accelerator pedal and crank the engine.

8. Record the maximum gauge reading.
9. Check each cylinder.
Compression Standard 1275
(kpa (kg/cm², psi)- (13, 184)
rpm) Difference between
98 (1, 14.2)
cylinders
10. If the compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder and
recheck the compression.
(1) If the compression increases, the piston, piston rings, or cylinder wall maybe worn.
(2) If the compression stays low, the valve may be stuck or seating improperly.
(3) If the compression in adjacent cylinders stays low, the cylinder head gasketmay be defective or the cylinder
head distorted.
Engine Mechanical System > General Information > Special Service Tools
Tool
Illustration Use
(Number and Name)
0K670 321 019
Ball joint puller
Page 2 of 77
0K670 321 019 Used to remove tie-rod end.
Ball joint puller
0K130 111 004 Used to disassemble and assemble timing

Coupling flange holder belt pulley.
0K130 111 002 Used to prevent engine rotation.

Ring gear Brake
0K130 160 010 Used to install clutch disc.

Clutch disc centering tool
0K130 990 007 Used to disassemble and assemble engine.

Engine stand
0KK30 101 001 Used to disassemble and assemble engine.

Engine stand hanger
0K993 120 001 Used to remove and install valve.

Valve spring lifter arm
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0K993 120 004 Used to remove and install valve.
Valve spring lifter pivot.
0K993 120 006 Used to remove valve seal.

Valve seal remover
0K2CA 120 AA0 Used to replace valve seal and valve spring.
Valve spring compressor
set
0KK30 140 001 Used to measure fuel pressure.

Oil pressure gauge
09221-FD100(A) Used to remove and install valve guide.

Valve guide remover
09221-FD100(B)
Valve guide installer
0K2CA 120 001 Used to replace valve seal and valve spring.
Valve spring compressor
hook
Engine Mechanical System > General Information > Troubleshooting

TROUBLESHOOTING GUIDE
ENGINE MECHANICAL SYSTEM
Page 4 of 77
Engine will not crank Battery, starting system or other electrical problems Refer to Starting system,
Charging system.
Liquid in combustion chamber Remove with suction gun,
then crank engine over with
spark plugs removed
Seized engine Repair
Engine cranks normally, but Fuel system malfunction Refer to Fuel system
does not start Ignition system malfunction Refer to Ignition system
Improper valve clearance Check HLA's
Restricted exhaust system Refer to exhaust system
Timing belt and/or related parts Inspect timing belt and
related parts; replace if
necessary
Low compression due to: stuck or burned valves; worn Perform a compression
piston, piston ring orcylinder; failed cylinder head gasket test, as outlined in this
section; repair engine
asnecessary
Camshaft worn Replace
Poor idle quality Fuel system malfunction Refer to Fuel system
Emission system malfunction Refer to Emission control
system
Ignition system malfunction Refer to Ignition system
Uneven cylinder compression Perform a compression
test, as outlined in this
section ; repair engine
asnecessary
Poor valve-to-valve seat contact Repair or replace
Broken valve spring Repair
Failed cylinder head gasket Replace
White exhaust smoke Usually caused by water vapor, which is a normal by- None required
product of combustionon cold days
Excessive white smoke with engine warmed up could be Repair or replace
caused by a failed cylinderahead or intake gasket. Could
also be a cracked block, cylinder head or
intakemanifold
Fuel system malfunction Refer to Fuel system
Black exhaust smoke
Emission system malfunction
Blue exhaust smoke Usually caused by oil burning in the combustion Replace
chambers from: worn rings,worn valve guides, worn
valve seals or failed cylinder head gasket
Valve train noise Worn valve guides Repair
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Low oil pressure Refer to Lubrication system
Broken valve spring Replace
Sticking valves Free valves
Camshaft worn or faulty Replace
Insufficient power Insufficient compression caused by:
1. Improper valve clearance Check HLA's
2. Leakage from valve seat Repair or replace
3. Seized valve stem Replace
4. Weak or broken valve spring Replace
5. Failed cylinder head gasket Replace
6. Cracked or distorted cylinder head Repair or replace
7. Sticking, damaged or worn piston ring Replace
8. Cracked or worn piston Replace
Fuel system malfunction Refer to Fuel system
Slipping clutch Refer to Clutch
Dragging brakes Refer to Brake system
Wrong tire size Refer to Wheels and tires
Restricted exhaust system Refer to Exhaust system
Abnormal combustion Improper valve clearance Check HLA's
Sticking or burned valve Replace
Weak or broken valve spring Replace
Carbon accumulation in combustion chamber Eliminate carbon
Engine knocks at idle when Loose or worn accessory drive belt/tensioner Check belts and tensioners
hot Replace if necessary
A/C compressor or generator bearing Replace
Improper oil viscosity Install proper oil viscosity
for expected temperatures
Excessive piston pin clearance Install new piston, pin and/
or connecting rod
Connecting rod clearance Check and replace rods if
necessary
Engine knocks at idle when Insufficient piston-to-bore clearance Hone and replace rods if
hot necessary
Faulty timing belt tensioner or guide Replace
Loose damper pulley Tighten or replace if
necessary
Slight noise at idle, Valve spring clicking on cap, off square or broken Repair or replace
becomes louder as engine
Excessive stem to guide clearance Repair
speed is increased
Excessive valve seat runout Repair
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Engine knocks when cold Excessive piston to wall clearance Replace pistons
Loose or broken damper pulley Tighten or replace
Knock increases with Excessive piston to bore clearance Replace piston
torque Bent connecting rod Replace
Engine has heavy knock Broken damper pulley Replace
when hot and torque is
Accessory belts too tight or damaged Adjust or replace belt
applied
Belt tensioned damaged Replace
Flywheel cracked or loose clutch plate Replace flywheel or clutch
plate
Excessive main bearing clearance Repair
Excessive rod bearing clearance Repair
Engine has light knock Improper timing Check timing
when hot and under light
Piston pin and/or connecting rod Replace piston pin and/or
load conditions
rod
Poor quality fuel Use recommended or
higher grade fuel
Exhaust leak at manifold Tighten bolts and/or
replace exhaust manifold
gaskets if necessary
Excessive rod bearing clearance Repair
Engine knocks during initial Improper oil viscosity Install proper oil viscosity
start up and lasts only a for expected temperatures
few seconds
TIMING BELT
Tooth is broken or Camshaft jamming Inspect camshaft by removing cylinder head
cracked cover
Repair or replace if necessary
Back surface is Tensioner jamming Remove tensioner and inspect
cracked and/or worn Replace if necessary
Engine overheating Inspect cooling system
Refer to engine cooling system
Interference with timing belt cover Remove timing belt cover and inspect
Side surface is worn Improper installation of timing belt Remove timing belt and reinstall
and / or frayed
Malfunction of timing belt guide plate Remove timing belt and inspect guide plate
Teeth are worn Poor belt cover sealing Remove timing belt cover and inspect
Coolant leak at water pump Inspect water pump
Page 7 of 77
Camshaft malfunction Inspect camshaft by removing cylinder head
cover
Repair or replace if necessary
Excessive belt tension Remove tensioner spring and inspect
Oil or coolant is on Poor oil sealing Inspect front oil seals
the belt Replace if necessary
Coolant leak at water pump Inspect water pump
Poor belt cover sealing Remove timing belt cover and inspect
HLA(HYDRAULIC LASH ADJUSTER)

1. Noise when engine is started immediately Oil leakage in Run engine at 2,000~3,000 rpm.
after oil is changed. oil passage If noise stops after 2 seconds - 10
2. Noise when engine is started after setting minutes*, HLA is normal.
approx. one day. If not, replace HLA.
* Time required for engine oil to
3. Noise when engine is started after Oil leakage in HLA
cranking for 3 seconds or more. circulate within engine includes
tolerance for engine oil condition and
4. Noise when engine is started after new
ambient temperature.
HLA is installed.
5. Noise continues more than 10 minutes. Insufficient oil pressure Check oil pressure
If lower than specification, check for
cause.
Oil pressure: 12.8 Psi
(88.26 kpa, 0.9 kg/cm²) - at idle
Faulty HLA Press down HLA by hand
If it does not move, HLA is normal.
If it moves, replace HLA.
Measure valve clearance.
If more than 0 mm (0 in), replace
HLA.
6. Noise during idle after high-speed running. Incorrect oil amount Check oil level.
Drain or add oil as necessary.
Deteriorated oil Check oil quality.
If deteriorated, replace with specified
type and amount of oil.
LUBRICATION SYSTEM
Page 8 of 77
Engine hard starting Improper engine oil Replace
Insufficient engine oil Add oil
Excessive oil Internal engine wear Refer to Engine Mechanical
Consumption Oil leak System
Repair
Oil pressure drop Insufficient oil Add oil
Oil leakage Repair
Worn and/or damaged oil pump gear Replace
Worn plunger (inside oil pump) or weak spring Replace
Clogged oil strainer Clean
Excessive main bearing or connecting rod bearing Refer to Engine Mechanical
clearance System
Warning lamp illuminates Oil pressure drop As described above
while engine is running Malfunction of oil pressure switch Refer to Body Refer to Body Electrical
Electrical System System
Malfunction of electrical system Troubleshooting manual
COOLING SYSTEM
Overheating Coolant level
Add
insufficient
Coolant leakage Repair
Radiator fins clogged Clean
Radiator cap
Replace
malfunction
Fan motor malfunction Replace
Thermostat
Replace
malfunction
Water passage
Clean
clogged
Water pump
Replace
malfunction
Corrosion Impurities in coolant Replace
Engine Mechanical System > General Information > Specifications

Specifications
Page 9 of 77
Engine Mechanical System > Timing System > Timing Belt > Components and Components Location
COMPONENT
Page 10 of 77
Engine Mechanical System > Timing System > Timing Belt > Repair procedures
REMOVAL
Page 11 of 77
2. Loosen power steering lock bolts and nuts accordingly and remove tension from power steering (P/S) and/or air
conditioning (A/C) compressor drive belt.
3. Remove P/S and/or A/C drive belt.

4. Loosen generator mounting bolts and adjusting bolt.
5. Remove generator bolts.
6. Remove water pump pulley.
7. Remove crankshaft pulley.
8. Remove upper and lower timing belt covers.
9. Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine.
10. Check that "I" mark on intake camshaft pulley is aligned with mark on seal plate and "E" mark on exhaust
camshaft pulley is aligned with mark on seal plate.
Do not move camshaft or crankshaft once timing marks have been correctly positioned.
11. Loosen tensioner pulley lock bolt.
12. Protect timing belt with a rag.
13. Remove tensioner pulley.
14. Remove timing belt.
Mark the direction of timing belt rotation (on the timing belt) for proper
reinstallation.
INSTALLATION
1. Install tensioner pulley.
Replace tensioner spring whenever timing belt is

replaced.
2. Pull tensioner pulley to its furthest point and tighten lock bolt.
Page 12 of 77
3. Check that timing mark on timing belt pulley is aligned with timing mark on engine.
4. Check that "I" mark on intake camshaft pulley is aligned with mark on seal plate and "E" mark on exhaust
If existing timing belt is being reused, install belt in proper rotation direction marked prior to removal.
5. Install timing belt onto timing belt pulley first, then idler pulley, exhaust camshaft pulley, intake camshaft pulley,
and tensioner pulley in that order.
6. Check that there is no looseness in belt between idler pulley and exhaust camshaft pulley or between intake and
exhaust camshaft pulleys.
7. Loosen tensioner pulley lock bolt and allow tensioner spring to apply tension to timing belt.
Do not add additional tension.

8. Tighten tensioner pulley lock bolt to specified torque.
Tightening torque:
28~38 lb-ft (38~51 N·m, 3.9~5.2 kg-m)
9. Rotate crankshaft two full revolutions (clockwise only) and align timing mark on timing belt pulley with timing
mark on engine block.
10. Check that "I" mark on intake camshaft pulley and "E" mark on exhaust camshaft pulley are aligned with marks
on seal plate.
11. If they are not aligned, remove timing belt and start process from tensioner installation.
Page 13 of 77
12. Measure timing belt deflection by applying moderate pressure midway between camshaft pulleys. If deflection is
not correct, repeat from tensioner installation.
Deflection pressure:
22 Ib. (98 N, 10 kg)
Deflection:
0.39~0.50 in. (11~13 mm)
13. Install lower and upper timing belt covers in that order.
Tightening torque:
5.8~8.0 Ib-ft (7.9~10.7 N·m, 0.8~1.1 kg-m)
14. Install timing belt guide plate and crankshaft pulley.
Tightening torque:
9.0~12.6 lb-ft (12.3~17.2 N·m, 1.3~1.8 kg-m)
15. Install water pump pulley.
Tightening torque:
9.0~12.6 lb-ft (12.3~17.2 N·m, 1.3~1.8 kg-m)
16. Install generator belt and adjust the tension.
17. Install P/S and/or A/C drive belt and adjust the tension.
INSPECTION
Never forcefully twist, turn inside out or bend timing belt. Do not allow oil or grease to come in contact with timing
belt.
1. Replace timing belt if it is contaminated with oil or grease.
Page 14 of 77
2. Check timing belt for uneven wear, fraying, peeling, cracking and hardening. Replace timing belt as necessary.
3. Bend timing belt into a "U" shape as shown in figure. Distance "A" must be at least 1.0 in (25 mm).
4. Inspect both idler pulley and tensioner pulley for uneven wear and smooth bearing operation.
5. Inspect camshaft pulleys and timing belt pulley for broken teeth or damage.
Replace any component that shows damage, excessive wear, or that appears prone to a possible
failure.
Engine Mechanical System > Cylinder Head Assembly > Camshaft > Components and Components
Location
COMPONENTS (DOHC)
Page 15 of 77
Engine Mechanical System > Cylinder Head Assembly > Camshaft > Repair procedures
DISASSEMBLY
1. Disconnect the breather hose and the PCV hose.
2. Remove the coolant pump pulley and crankshaft pulley.
Page 16 of 77
3. Remove the timing belt cover.
4. Loosen the timing belt tensioner pulley and temporarily secure it.
5. Remove the timing belt from the camshaft sprocket.
6. Loosen the center cover bolts and then remove the center cover.
7. Remove the ignition coil assembly.
8. Loosen the cylinder head cover bolts and then remove it.
9. Remove the camshaft pulley.
10. Remove the cam carrier assembly.

11. Remove the camshaft.
12. Remove the HLA.
INSPECTION
1. Set front and rear camshaft bearing journals on V-blocks.
2. Position a dial indicator on center bearing journal and zero dial.
3. Rotate camshaft in V-blocks and check runout.
Runout:
0.0012 in (0.03 mm) maximum
4. Check camshaft for uneven wear patterns, cracks, or damage.

Page 17 of 77
5. Measure cam lobe heights at two points as shown.
Lobe height
Intake, Exhaust
Standard: 1.6878 in (42.870 mm)
Minimum: 1.6877 in (42.868 mm)
6. Check camshaft bearing journal diameter (X and Y directions) on both sides (A and B) of journal as shown in
figure.
Standard diameter:
1.3370-1.3386 in (33.961-34.0 mm)
Minimum diameter:
1.0594 in (26.910 mm)
Out-of-round:
7. Replace camshafts if necessary.
8. Measure camshaft journal oil clearance with HLA's removed.

9. Remove all foreign material and oil from journals and bearing surfaces.
10. Set camshafts onto cylinder head.
11. Position Plastigauge on journals in axial direction.
12. Do not rotate camshafts.
Page 18 of 77
13. Install cam carrier assembly.
14. Install cam carrier bolts.
Tightening torque:
8.3~10.5 lb-ft (11.3~14.2 N·m 1.15~1.45 kg-m)
15. Loosen cam carrier assembly bolts.

16. Remove cam carrier assembly.
17. Measure oil clearances.
Oil clearance: 0.0014~0.0032 in (0.035~0.081 mm)

18. If oil clearance exceeds specification, replace cylinder head.

19. Install camshafts.
20. Place a dial indicator against end of camshaft.
21. Using a prying tool, move camshaft as far forward as possible.
22. Zero dial.
23. Using prying tool, move camshaft as far rearward as possible.
Page 19 of 77
24. Check gauge to determine how much end play is present.
End play: 0.0026~0.0054 in (0.067~0.137 mm)

Maximum: 0.0058 in (0.147 mm)
REASSEMBLY
1. Install the HLA.
2. Install the phase sensor target wheel to the intake camshaft.
The knock pin of camshaft and the white paint mark of target wheel must be symmetrical each other
centering around axis of camshaft when installing the target wheel.
3. Install the camshaft after lubricating the journal of camshaft with engine oil.
Page 20 of 77
4. Apply liquid sealant on the cam carrier as shown illustration.
Sealant type : HYLOGRIP 3000

Bead width : 0.0787 in (2 mm)
• Clean the foreign material from mating surface before applying sealant.
• Assembly procedure must be completed within 15 minutes after applying sealant.
5. Install the cam carrier assembly. Tighten the cam carrier bolts as shown illustration.
Tightening torque :
8.3~10.5 lb-ft (11.3~14.2 N-m , 1.15~1.45kg-m)
6. Install the camshaft oil seal. Be sure to apply engine oil to the external surface of the oil seal. Insert the oil seal
along the camshaft front end until the oil seal is fully seated.
7. Install the seal plate.

Page 21 of 77
8. Install the camshaft pulley.
Tightening torque :
55.0~77.4 lb-ft (74.5~104.9 N-m , 7.6~10.7 kg-m)
9. Check that “I” mark on intake camshaft pulley is aligned with mark on seal plate and “E” mark on exhaust
10. Install the cylinder head cover.
Tightening torque :
3.6~6.5 lb-ft (4.9~8.8 N-m , 0.5~0.9 kg-m)
11. Install the ignition coil.

12. Install the timing belt.
13. Tighten the timing belt tensioner pulley.
Tightening torque :
27.5~38.3 lb-ft (37.3~52.0 N-m , 3.8~5.3 kg-m)
14. Install the timing belt cover.
Engine Mechanical System > Cylinder Head Assembly > Valve > Components and Components
Location
Page 22 of 77
COMPONENT
Engine Mechanical System > Cylinder Head Assembly > Valve > Repair procedures
DISASSEMBLY
Page 23 of 77
1. Drain the coolant and disconnect the upper radiator hose.
2. Remove the breather hose (beween the air cleaner and the head cover).
3. Remove the air-intake hose.
4. Remove the vacuum hose, fuel hose and coolant hose
5. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion.
6. Remove the ignition coil.
7. Remove the power steering oil pump and bracket.
8. Remove the intake manifold.
9. Remove the heat protector and exhaust manifold assembly.
10. Remove the coolant pump pulley and the crankshaft pulley.
11. Remove the timing belt cover.
12. Remove the timing belt tensioner pulley.
13. Remove the timing belt.
14. Remove the head cover and cam carrier assembly.
15. Remove the cylinder head assembly. The cylinder head bolts should be removed by using Special Tool,
Cylinder Head Bolt Wrench, in the sequence as shown in the illustration in two or three steps.
16. Remove the gasket pieces from cylinder block top surface and cylinder head bottom surface.
Make sure that the gasket pieces do not fall in the engine
INSPECTION
1. Clean all components.
2. Remove gasket fragments, dirt, oil, grease, carbon, moisture, residue, and other foreign materials.
CYLINDER HEAD
1. Inspect cylinder head for damage, cracks, and leakage of oil and water. Replace cylinder head if necessary.
Page 24 of 77
2. Measure cylinder head mating surface in six directions as shown in figure.
Distortion:
Before resurfacing cylinder head, check following repair or replace cylinderhead if necessary
• Sunken valve seats.
• Damage at intake and exhaust manifold mating surfaces.
• Camshaft oil clearances and end play.
3. Grind cylinder head mating surface if distortion exceeds specification.
Distortion:
4. Check cylinder head height by measuring from cylinder deck surface to cylinderhead cover gasket surface.
5. If cylinder head height is not within specification, replace cylinder head.
Height:
5.031~5.039 in (127.8~128 mm)
6. Measure intake and exhaust manifold mating surface distortion at two directions shown in figure.
Distortion:
Page 25 of 77
7. If distortion exceeds specification, resurface or replace cylinder head.
Distortion:
REASSEMBLY
1. Clean all gasket surfaces of the cylinder block and the cylinder head.
2. Install a new cylinder head gasket onto the cylinder head assembly.
Apply sealant to the gasket and do not reuse the old cylinder head gasket.
A. Tighten cylinder head bolts in order shown.
Tightening torque:
36.1 lb-ft (49 N·m, 5 kg-m)
B. Loosen bolts in reverse of order shown.

C. Retighten cylinder head bolts in order shown.
Tightening torque:
18 lb-ft (25 N·m, 2.5 kg-m)
D. Mark cylinder head bolts for rotational reference.

E. Rotate cylinder head bolts 90° (1/4 Turn) in order shown.
• Do not rotate crankshaft without timing belt.

• Make sure that all pistons are positioned in the middle of cylinder before installing sylinder head.
• Two bolts (No.7 and No.8) are shorter than other bolts. Never install the two bolts in other position.
(for A6D)
• Do not reuse the old cylinder head bolts.
3. Install the timing belt tensioner pulley.

Page 26 of 77
4. Install the timing belt on the camshaft sprocket, marking sure that the tension side is tightened by turning the
camshaft sprocket in reverse, all timing marks are in alignment.
5. Adjust the timing according to "Timing Belt".
6. Install the rocker cover and tighten the bolts to the specififed torque.
Tightening torque:
Rocker cover bolt
3.6~6.5 lb-ft (5~9 N·m, 0.5~0.9 kg-m)
7. Install the timing belt cover.

8. Install the new intake manifold gasket and the intake manifold. Tighten the nuts and bolts to the specified torque.
9. Install the exhaust manifold gasket and the exhaust manifold. Tighten the exhaust manifold attaching nuts to the
specified torque.
10. Install the surge tank and tighten the nuts and bolts to the specified torque.
Tightening torque:
Manifold nuts and bolts (both intake and exhaust)
11~14 lb-ft (15~20 N·m, 1.5~2.0 kg-m)
Tightening torque:
Surge tank to inlet manifold nuts and bolts
11~14 lb-ft (15~20 N·m, 1.5~2.0 kg-m)
11. Install the power steering oil pump and bracket.

12. Install the ignition coil.
13. Install the air intake hose.
14. Connect the vacuum hose, fuel hose and water hose.
15. Install breather hose.
Engine Mechanical System > Cylinder Head Assembly > Cylinder Head > Repair procedures
Inspection
VALVE MECHANISM
1. Inspect each valve for following:
A. Damaged or bent valve stem
B. Rough or damaged face
C. Damaged or unevenly worn stem tip
Page 27 of 77
2. Resurface or replace valve as needed.
Margin thickness
Intake: 0.0394 in (1.0mm)
Exhaust: 0.0394 in (1.0mm)
3. Measure length of each valve.
Length
Intake: 3.7815 in (96.05 mm)
Exhaust: 3.7402 in (95.00 mm)
4. Measure diameter of each valve stem.
Diameter
Intake: 0.2152~0.2157 in (5.465~5.480 mm)
Exhaust: 0.2138~0.2146 in (5.430~5.450 mm)
Page 28 of 77
5. Measure inside diameter of each valve guide at points shown in figure.
Diameter intake and exhaust valve guide:

0.2165~0.2171 in (5.500~5.515 mm)
6. Calculate valve stem-to-valve guide clearance.

Subtract outer diameter of valve stem from inside diameter of respective valve guide.
Clearance
Intake valve:
0.0008~0.0020 in (0.020~0.050 mm)
Exhaust valve:
0.0020~0.0033 in (0.050~0.085 mm)
Max: 0.008 in (0.20 mm)
7. If clearance exceeds specification, replace valve, and/or valve guide.

Page 29 of 77
8. Measure protrusion height of each valve guide. Replace valve guide as needed.
Intake: 0.5039~0.5276 in (12.8~13.4 mm)

Exhaust: 0.5039~0.5276 in (12.8~13.4 mm)
Intake and exhaust valve guides are different.

Be sure to use correct valve guide.
VALVE SEAT
1. Inspect contact surface of each valve seat and valve face for following:
A. Roughness
B. Damage
C. Pitting
D. Cracks
2. Resurface valve seats with a 45° valve seat cutter. Resurface valve faces as needed.
3. Apply a coat of Dychem blue to valve face and valve seat and allow to dry.
4. Inspect valve seating by pressing valve against seat and rotating valve 360°.
A. If Dychem blue is not removed 360° around valve face, replace valve.
B. If Dychem blue is not removed 360° around valve seat, resurface valve seat.
Page 30 of 77
5. Measure seat contact width.
Width: 0.0382~0.0618 in (0.97~1.57 mm)
6. Complete seat-cutting process by lapping valve to seat using valve-lapping compound.
Clean valves thoroughly before reassembly, and insure that all traces of lapping compound has been
removed.
VALVE SPRING
1. Inspect each valve spring for cracks and damage.
2. Measure free length and out-of-square. Replace valve springs as needed.
Free length :
Standard : 1.5354 in (39.0 mm)
Limit : 1.5276 in (38.8 mm)
Out-of-square : 0.0402 in (1.02 mm)
Replacement
Valve seat ring
1. Cut away the inner face of the valve seat to reduce the wall thickness.
Page 31 of 77
2. Enlarge the cylinder head hole so that matches the specified cylinder head hole inner diameter of new valve seat
ring.
3. Heat the cylinder head to about 250°C (480°F) and press-fit an oversize seat ring for the cylinder head hole size.
4. Using lapping compound, lap the valve to the new seat.
Valve seat contact width :

0.0382~0.0618in (0.97~1.57mm)
VALVE SEAT RING OVERSIZE (1600cc)

Seat ring
Over size Size Cylinder head hole Seat ring
Item outer diameter (in
(in (mm)) mark inner diameter (in (mm)) height (in (mm))
(mm))
1.1961-1.1968 1.2000-1.2008 0.1858-0.1890
STD -
(30.38-30.40) (30.480-30.500) (4.72-4.80)
Intake
1.2079-1.2087 1.2118-1.2126 0.1976-0.2008
valve 0.012 (0.3) OS 30
(30.68-30.70) (30.780-30.800) (5.02-5.10)
seat ring
1.2197-1.2205 1.2236-1.2244 0.2094-0.2126
0.024 (0.6) OS 60
(30.98-31.00) (31.080-31.100) (5.32-5.40)
1.0819-1.0827 1.0858-1.0866 0.1858-0.1890
STD -
(27.48-27.50) (27.580-27.600) (4.72-4.80)
Exhaust
1.0937-1.0945 1.0976-1.0984 0.1976-0.2008
valve 0.012 (0.3) OS 30
(27.78-27.80) (27.880-27.900) (5.02-5.10)
seat ring
1.1055-1.1063 1.1094-1.1102 0.2094-0.2126
0.024 (0.6) OS 60
(28.08-28.10) (28.180-28.200) (5.32-5.40)
Valve guide
1. Using the special tool (09221-FD100(A)), withdraw the old valve guide toward the bottom of cylinder head.
2. Recondition the cylinder head hole so that it can match the newly press-fitted oversize valve guide.
Page 32 of 77
3. Using the special tool (09221-FD100(A), (B)), press-fit the valve guide. The valve guide must be press-fitted
from the upper side of the cylinder head.
Do not install a valve guide unless it is oversize.
4. After the valve guide is press-fitted, insert a new valve and check for proper stem-to-guide clearance.
5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as
necessary.
VALVE GUIDE OVERSIZE (1600cc)
Cylinder head hole Valve guide
Over size Size Valve guide protrusion
Item inner diameter (in outer diameter (in
(in (mm)) mark height (in (mm))
(mm)) (mm))
0.3740-0.3747 0.3753-0.3757
STD -
(9.500-9.518) (9.533-9.544)
0.002 (0.05) 0.3760-0.3767 0.3773-0.3777
5
Valve OS (9.550-9.568) (9.583-9.594) 0.5039-0.5276
guide 0.010 (0.25) 0.3839-0.3846 0.3852-0.3856 (12.8-13.4)
25
OS (9.750-9.768) (9.783-9.794)
0.020 (0.50) 0.3937-0.3944 0.3950-0.3954
50
OS (10.000-10.018) (10.033-10.044)
Engine Mechanical System > Engine And Transaxle Assembly > Engine And Transaxle Assembly >
Components and Components Location
COMPONENT I
Page 33 of 77
COMPONENT II
Page 34 of 77
COMPONENT III
Page 35 of 77
COMPONENT IV
Page 36 of 77
Engine Mechanical System > Engine And Transaxle Assembly > Engine And Transaxle Assembly >
Repair procedures
REMOVAL
1. Disconnect battery cables.
Page 37 of 77
2. Remove battery and battery tray.
3. Drain engine coolant.

4. Remove fresh air duct.
5. Remove upper and lower radiator hose.
6. Remove accelerator cable.

7. Disconnect fuel hose from fuel injector rail.
8. Remove heater hose.
9. Disconnect brake vacuum hose and purge control vacuum hose from dynamic chamber.
10. Disconnect injector connectors.
11. Disconnect electric connectors.
12. Remove transaxle linkage (A/T).

13. Remove manual transaxle linkage and extension bar (M/T).
14. Remove clutch release cylinder and pipe (M/T).
15. Disconnect transaxle range switch connector (A/T).
16. Disconnect solenoid valve connector (A/T).
Page 38 of 77
17. Disconnect ATF cooler hose (A/T).
18. Disconnect power steering pump hose.
19. Disconnect B-terminal and S-terminal connector from starter.
20. Disconnect generator B-terminal connector from generator.
21. Remove four A/C compressor bolts.

22. Remove both front wheels.
23. Disconnect front exhaust pipe and catalytic converter.
24. Remove both right and left tie rod ends from steering knuckles by removing one cotter pin and one nut each.
25. Remove bolt and nut from both right and left lower arm and separate lower arm from steering knuckles.
Page 39 of 77
26. Remove 2bolts and nuts from damper and separate damper from steering knuckles.
27. Gently pry both driveshafts from transaxle.

28. Support engine with engine hoist.
29. Remove four nuts and four bolts from engine mounting member.
30. Remove two bolts from No.1 engine mounting bracket.

31. Remove one nut from No.2 engine mounting rubber.
32. Remove four bolts from No.2 engine mounting bracket.
33. Remove two nuts from No.3 engine mounting rubber.
34. Lift engine and transaxle out as a unit.
INSTALLATION
1. Install engine and transaxle into engine compartment as a unit.
2. Install two nuts to No.3 engine mounting rubber.
Tightening torque:
49~69 Ib-ft (66~93 N·m, 6.8~9.5 kg-m)
3. Install No.2 engine mounting bracket bolts and install No.2 engine mounting rubber nut.
Tightening torque:
Nut:49~69 Ib-ft (66~93 N·m, 6.8~9.5 kg-m)
Bolts:28~38 Ib-ft (37~52 N·m, 3.8~5.3 kg-m)
Page 40 of 77
4. Install four engine mounting member bolts & nuts.
Tightening torque:
Nut:28~38 Ib-ft (37~52 N·m, 3.8~5.3 kg-m)
Bolts:52~69 Ib-ft (71~93 N·m, 7.2~9.5 kg-m)
5. Remove engine hoist.

6. Install new clips on driveshaft.
7. Push driveshaft and joint shaft into transaxle with opening of clips pointing upward.
8. Install damper to steering knuckles.
9. Install both right and left lower arm to steering knuckles.
10. Install both right and left tie rod ends to steering knuckles.
11. Install front exhaust pipe and catalytic converter.
Tightening torque:
27~38 Ib-ft (37.2~52 N·m , 3.8~5.3 kg-m)
12. Install A/C compressor.
13. Connect B-terminal connector to generator.

Page 41 of 77
14. Connect B-terminal and S-terminal connector to starter.
15. Connect power steering pump hose.

16. Connect ATF cooler hose(A/T).
17. Connect solenoid valve connector(A/T).
18. Connect transaxle range switch connector(A/T).
19. Install clutch release cylinder and pipe(M/T).
Tightening torque:
13.7~18.8 Ib-ft (18.6~25.5 N·m , 1.9~2.6 kg-m)
20. Install extension bar and manual transaxle linkage(M/T).
Tightening torque:
Extension bar: 27~38 Ib-ft
(37.2~52 N·m, 3.8~5.3 kg-m)
Manual transaxle linkage:
12~17 Ib-ft (16~23 N·m , 1.6-2.3 kg-m)
21. Install transaxle linkage(A/T).
Tightening torque:
23.1~34.0 Ib-ft (31.4~46.1 N·m, 3.2~4.7 kg-m)
Page 42 of 77
22. Connect electric connectors.
23. Connect injector connectors to injector rail.

24. Connect brake vacuum hose and purge control vacuum hose to dynamic chamber.
25. Install heater hose.
26. Connect fuel hose to injector rail.
27. Install accelerator cable.

28. Install upper and lower radiator hose.
29. Install fresh air duct.
30. Install battery tray and battery.
Tightening torque:
10~12 Ib-ft (13.5~16 N·m, 1.4~1.6 kg-m)
31. Fill engine coolant with specified type and amount.

32. Connect both battery cables.
33. Check and/or fill all fluids.
34. Test run engine perform an overall check.
Engine Mechanical System > Cylinder Block > Piston and Connecting Rod > Components and
Components Location
COMPONENT
Page 43 of 77
Engine Mechanical System > Cylinder Block > Piston and Connecting Rod > Repair procedures
DIASSEMBLY
1. Mark corresponding cylinder number on rod cap and connecting rod with a numbering stamp.
Mark connecting rods on same side and make a reference mark on block so that rods are installed in
correct position and direction. Failure to install rods properly with result in oil starvation, spun bearings, or
damaged internal engine components.
2. Rotate crankshaft so that cylinders No.2 and No.3 are at Bottom Dead Center (BDC) and repeat marking
procedure.
Page 44 of 77
3. Remove connecting rod nuts and gently loosen rod caps by tapping cap with a light plastic mallet.
4. Remove rod caps.
Coter connecting rod bolts to protect crankshaft

jounals
5. Push connecting rod and piston as far up into cylinder as possible. Using a wooden dowel, tap gently on piston to
release it from cylinder.
6. Repeat this procedure for each cylinder.

7. Mark tops of pistons with corresponding cylinder numbers they were removed from.
8. Using a piston ring expander, remove piston rings.
9. Hold piston upright and gently move connecting rod.

10. Release connecting rod and observe its movement.
Do not swing connecting rod widely. Constant, hard contact with piston will cause a bell-mouth condition
that will require piston replacement.
11. If connecting rod does not move freely, check piston pin bore and connecting rod for straightness and
deformation.
12. Remove piston pin clip from ends of piston pin bore.
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13. Tilt piston and allow piston pin to slide out into your hand. Piston pins may need to be pressed out.
Do not allow pins to drop to the ground.

14. Remove connecting rod from piston. Keep individual piston and piston pin together for reassembly.
INSPECTION
PISTON RING
1. Insert a new piston ring into a piston ring groove and check clearance between piston ring and ring end.
Clearance between ring and ring end
Standard : 0.0012-0.0028 in (0.03-0.07 mm)

Maximum : 0.0039 in (0.10 mm)
2. If clearance exceeds the maximum, replace piston.

3. Inspect piston rings for damage, abnormal wear, or breakage.
4. Replace piston rings if necessary.
5. Insert piston ring into cylinder by hand.
6. Square ring in cylinder by inverting a piston into cylinder and pushing ring to the bottom of its travel in cylinder.
Page 46 of 77
7. Place a feeler gauge in end gap and check end gap clearance.
End gap clearance

Ring A6 DOHC
Top ring 0.006~0.011 in
(0.15~0.30 mm)
Second ring 0.016~0.021 in
(0.40~0.55 mm)
Oil rail 0.008~0.027 in
(0.20~0.70 mm)
Maximum 0.039 in (1.0 mm)
REASSEMBLY
1. Select the piston which has the size mark which is identical with the size mark of the corresponding cylinder.
Piston outer diameter and cylinder bore inner diameter

Page 47 of 77
2. Insert connecting rod into piston and slide piston pin through piston and connecting rod.
Verify that piston and rod are assembled in same direction as they were prior to
disassembly.
3. Hold piston upright and move connecting rod back and forth. Check that rod moves freely.
4. Install three piece oil ring onto piston.
A. Apply clean engine oil to the oil ring expander and upper and lower oil rings.
B. Install expander onto piston so that expander ends face upward.
C. Install lower oil ring onto piston. Ring may be installed with either face upward.
D. Install upper oil ring onto piston. Ring may be installed with either face upward.
5. Check that oil ring expander separates upper and lower oil rings, and that oil ring assembly spins freely on piston.
6. Use a ring expander and install second ring.

Page 48 of 77
7. Use a ring expander and install top ring.
Top ring and second ring should be installed with "R" or "Y" mark facing
up.
8. Align piston ring gaps as shown.
9. Install a bearing into connecting rod.

10. Place rubber sleeves on connecting rod bolts to protect crankshaft from damage.
11. Check piston rings for correct end gap stagger.
12. Place piston with "F" mark facing front of engine block, then slip piston and connecting rod assembly into a
piston ring compressor.
13. Rotate crankshaft so that crank pin journal for specific cylinder is at its lowest point (bottom dead center).
14. Lower piston and connecting rod assembly until piston ring compressor makes contact with deck surface of
engine block.
Page 49 of 77
15. Using butt end of a hammer, tap the top of piston into cylinder and continue tapping until connecting rod makes
contact with crankshaft.
Follow this procedure for remaining piston and connecting rod assemblies.
16. Install a connecting rod bearing in each connecting rod cap.
17. Place a piece of Plastigauge(R) on crank pin journals.
18. Install connecting rod caps, aligning marks made previous to disassembly and torque to specification.
Tightening torque:
22~24 lb-ft (29~34 N·m, 3.0~3.5 kg-m)
• When installing the connecting rods, match marks made on the connecting rod and cap to reference
mark made on cylinder block to prevent oil starvation to the connecting rod bearings.
• When installing the piston assembly into cylinder bolck, position the piston between TDC and BDC,
then install the cylinder head in order to prevent pistons and valves from contacts which may cause
damage.
19. Loosen and remove connecting rod caps.

20. Check the connecting rod bearing clearance.
Oil clearance:
0.0010 ~ 0.0021 in (0.026 ~ 0.054 mm)
Page 50 of 77
21. If oil clearance exceeds maximum oil clearance specification, grind the crankshaft and use undersized connecting
rod bearings.
(1) Connecting rod bearing selection table
(2) Connecting rod bearing housing bore size

Code Connecting rod bearing housing bore size
1 1.6929-1.6931 in (43.000-43.006 mm)
2 1.6931-1.6934 in (43.006-43.012 mm)
3 1.6934-1.6935 in (43.012-43.016 mm)
(3) Connecting rod bearing thickness

Connecting rod bearing bearing thickness
Standard bearing Green 0.0593-0.0594 in
(1.506-1.509 mm)
Blue 0.0594-0.0595 in
(1.509-1.512 mm)
Red 0.0595-0.0596 in
(1.512-1.515 mm)
Undersize bearing 0.25 0.0642-0.0644 in
(1.631-1.635 mm)
0.50 0.0691-0.0693 in
(1.756-1.760 mm)
0.75 0.0741-0.0742 in
(1.881-1.885 mm)
22. Apply a coat of clean engine oil to connecting rod bearing in connecting rod cap.
23. Install connecting rod cap and torque to specification.
Tightening torque:
22~24 lb-ft (29~34 N·m, 3.0~3.5 kg-m)
Page 51 of 77
24. Insert a thickness gauge between connecting rod and crankshaft and check connecting rod side clearance.
Do not measure between connecting rod cap and crankshaft.
Side clearance:
0.0044~0.0103 in (0.110~0.262 mm)
25. If side clearance exceeds maximum side clearance specification, replace connecting rod and cap.
Engine Mechanical System > Cylinder Block > Crankshaft > Components and Components Location
COMPONENT
Page 52 of 77
Engine Mechanical System > Cylinder Block > Crankshaft > Repair procedures
DISASSEMBLY
1. Remove the timing belt, front case, flywheel cylinder head assembly and oil pan. For details, refer to respective
chapters,
2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps.
Mark the main bearing caps to permit reassembly in the original position and
direction.
4. Remove the main bearing caps and remove the crankshaft.
Keep the bearings in order by cap number.
Page 53 of 77
INSPECTION
1. Check crankshaft bearing and crank pin journals for damage and scoring.
2. Check oil holes for clogging.
3. Set crankshaft on V-blocks.
4. Measure crankshaft run-out at center journal. Replace crankshaft if it is not within specification.
Run-out : 0.0016 in (0.04 mm)
5. Grind crankshaft only if there is visible scoring, or if out-of-round is excessive.

6. Only grind crankshaft amount necessary to correct condition.
7. If a crankshaft must be ground 0.020 in (0.50 mm) or more, heat-treat crankshaft to ensure durability.
MAIN JOURNAL DIAMETER UNDERSIZES:
Bearing size Journal diameter
0.010 in (0.25 mm) 1.9562~1.9569 in
undersize (49.688~49.706 mm)
0.020 in (0.50 mm) 1.9464~1.9471 in
undersize (49.438~49.456 mm)
0.030 in (0.75 mm) 1.9365~1.9372 in
undersize (49.188~49.206 mm)
CRANK PIN JOURNAL DIAMETER UNDERSIZES:

Bearing size Journal diameter
0.010 in (0.25 mm) 1.5626~1.5632 in
undersize (39.690~39.706 mm)
0.020 in (0.50 mm) 1.5528~1.5534 in
undersize (39.440~39.456 mm)
0.030 in (0.75 mm) 1.5429~1.5435 in
undersize (39.190~39.206 mm)
MAIN BEARING AND CONNECTING ROD BEARINGS

Page 54 of 77
1. Check main and connecting rod bearings for peeling, scoring and other damage.
REASSEMBLY
1. Inspect journals and bearings for any foreign material. Clean crankshaft, oil holes, and main bearing journals
thoroughly, and dry components with compressed air.
2. Install grooved main bearings into saddles on engine block.
3. Install thrust bearings with oil groove facing crankshaft.
4. Set crankshaft on installed bearings.

5. Install remaining main bearings into main bearing caps.
6. Position Plastigauge on crankshaft journals.
7. Install main bearing caps along with lower main bearings according to cap number and ← mark.
8. Tighten main bearing cap bolts.
Tightening torque:
40~43 lb-ft (54~59 N·m, 5.5~6.0 kg-m)
Do not rotate crankshaft with Plastigauge on crankshaft journals.

Page 55 of 77
9. Remove main bearing caps and check bearing clearance.
The widest point of Plastigauge is the smallest clearance, and the narrowest point of Plastigauge is the
largest clearance.
10. If oil clearance exceeds specification, grind and polish crankshaft and use undersized main bearings.
Oil Clearance:
0.0007~0.0014 in (0.018~0.036 mm)
MAXIMUM: 0.0031 in (0.08 mm)
11. Lift crankshaft out of cylinder block and carefully remove Plastigauge from main bearings and crankshaft
journals.
12. Apply a light coat of engine oil on main bearings and install crankshaft by gently lowering it onto bearings.
13. Apply a light coat of oil on crankshaft main bearing journals and on main bearings on main bearing caps.
14. Install main bearing caps along with lower main bearings according to cap number and ← mark.
15. Tighten main bearing cap bolts according to the following procedure:
Tighten bolts in order shown
Tightening torque:
40~43 lb-ft (54~59 N·m, 5.5~6.0kg-m)
16. Rotate crankshaft to ensure it does not bind.

Page 56 of 77
17. Place a dial indicator against front of crankshaft and zero gauge.
18. Using a prying tool, move crankshaft forward and zero dial indicator.
19. Move the crankshaft toward the rear of block with prying tool and check the amount of movement on dial
indicator.
End Play:
0.0032~0.0111 in (0.080~0.282 mm)
20. If end play exceeds specification, grind crankshaft and install oversized thrust bearings, or replace crankshaft
and thrust bearings.
OVERSIZE THRUST BEARING WIDTH
Thrust bearing size Specification
Standard 0.0985~0.1003in
(2.500~2.550 mm)
Standard + 0.010 in (0.25 mm) 0.1034~0.1053 in
(2.625~2.675 mm)
Standard + 0.020 in (0.50 mm) 0.1083~0.1102 in
(2.750~2.800 mm)
Standard + 0.030 in (0.75 mm) 0.1132~0.1151 in
(2.875~2.925 mm)
21. Install the oil seal in the crankshaft rear oil seal case. Press fit the oil seal all the way in, being careful not misalign
it.
22. Install the rear plate and tighten the bolts.
23. Install the connecting rod caps. Refer to "Piston and Connecting Rods".
24. Install the flywheel, front case, oil pan and timing belt. For further details, refer to the respective chapters.
MAIN BEARING SELECTION

Page 57 of 77
1. Standard main bearing selection
2. Main bearing housing bore size

Code Main bearing housing bore size
2.1260-2.1262 in (54.000-54.006
A
mm)
2.1262-2.1265 in (54.006-54.012
·
mm)
2.1265-2.1267 in (54.012-54.018
C
mm)
3. Main journal shaft diameter

Code Main journal shaft diameter
1.9661-1.9663 in (49.938-49.944
A
mm)
1.9663-1.9665 in (49.944-49.950
·
mm)
1.9665-1.9668 in (49.950-49.956
C
mm)
Page 58 of 77
4. Main bearing thickness
Main bearing Thickness
Standard 0.0790-0.0791
bearing in
Yellow
(2.007-2.010
mm)
0.0791-0.0793
in
Green
(2.010-2.013
mm)
0.0793-0.0794
in
Brown
(2.013-2.016
mm)
0.0794-0.0795
in
Black
(2.016-2.019
mm)
0.0795-0.0796
in
Blue
(2.019-2.022
mm)
0.0796-0.0797
in
Red
(2.022-2.025
mm)
Undersize 0.0840-0.0841
bearing in
0.25
(2.133-2.137
mm)
0.0889-0.0891
in
0.50
(2.258-2.262
mm)
0.0938-0.0940
in
0.75
(2.383-2.387
mm)
Engine Mechanical System > Cooling System > Coolant > Repair procedures
INSPECTION
Page 59 of 77
• Never remove radiator cap while engine is hot.

• Wrap a thick cloth around radiator cap before removing.
• When removing radiator cap, loosen slowly to first stop and wait until pressure in radiator is released, then
completely remove.
LEVEL (ENGINE COLD)
1. Verify that there is no build-up of rust or scale around radiator cap or radiator filler neck.
2. Verify that coolant is free of contaminants. Replace coolant if necessary.
COOLANT QUALITY
1. Verify that there is no build-up of rust or scale around radiator cap or radiator filler neck.
2. Verify that coolant is free of contaminants. Replace coolant if necessary.
REPLACEMENT
• Never open radiator cap while engine is hot.

• Wrap a thick cloth around cap before loosening.
• Use caution when draining hot coolant.
• Do not use alcohol or methanol-based coolant.

• Use only demineralized water in coolant mixture.
1. Remove radiator cap and loosen drain plug.
2. Drain coolant into a suitable container.
3. Flush cooling system with water until all traces of color are gone; then let system drain completely.
4. Install drain plug.
5. Fill with proper mixture of ethylene glycol-based coolant.
Coolant Capacity: 6.0 liters (6.3 US qt, 5.3 lmp qt)
6. Run the engine with the radiator cap removed until the upper radiator hose is hot.
7. With the engine idling, add coolant to the radiator until it reaches the bottom of the filler neck.
8. Install the radiator cap.
9. Allow engine to cool and check coolant level.
Engine Mechanical System > Cooling System > Water pump > Components and Components Location
COMPONENT
Page 60 of 77
Engine Mechanical System > Cooling System > Water pump > Repair procedures
Removal
Do not disassemble water pump assembly.

If a problem is found, replace assembly as a unit.
2. Remove drive belt.
4. Remove power steering pump in order to remove water inlet pipe.
5. Remove components in the order shown in figure.
Engine Mechanical System > Cooling System > Thermostat > Components and Components Location
Page 61 of 77
COMPONENT
Remove components in the order shown in figure.
Engine Mechanical System > Cooling System > Thermostat > Repair procedures
INSPECTION
1. Visually check that thermostat is air tight.
2. Place a thermostat and a thermometer in water.
Page 62 of 77
3. Gradually heat water and check following.
Initial opening temperature:

189.5~191.3°F (87.5~88.5°C)
Full open temperature:
212°F (100°C)
Full open lift:
0.31 in (8.0 mm) min
INSTALLATION
1. Install thermostat into cylinder head with jiggle pin positioned up.
2. Install in the reverse of removal.
When installing thermostat gasket, make sure that printing side of gasket is facing toward cylinder
head.
Engine Mechanical System > Cooling System > Radiator > Components and Components Location
COMPONENT
Page 63 of 77
Engine Mechanical System > Cooling System > Radiator > Repair procedures
REMOVAL
2. Remove fresh air duct.
3. Drain coolant.
4. Remove components in the order shown in the figure.
Page 64 of 77
INSTALLATION
1. Install in the reverse order of removal.
2. After installation, fill engine coolant and check coolant leakage
LEAKAGE
1. Connect a coolant system pressure tester to the radiator filler neck.
2. Apply 15 psi (103 kPa, 1.05 kg/cm²) pressure to the system.
3. Verify that the pressure remains steady at 15psi (103 kPa, 1.05 kg/cm²).
4. If not, check system for coolant leakage.
Engine Mechanical System > Cooling System > Radiator Cap > Repair procedures
INSPECTION
RADIATOR CAP VALVE
1. Remove foreign material from radiator cap valve and the valve seat.
2. Attach radiator cap to a radiator cap tester. Apply pressure gradually to 15 psi (103 kPa, 1.05 kg/cm²).
3. Wait about 10 seconds. Verify that pressure has not decreased.

4. Replace radiator cap as necessary.
NEGATIVE PRESSURE VALVE
1. Pull negative pressure valve to open it. Verify that it closes completely when released.
2. Check for damage on contact surfaces, and for a cracked or deformed seal.
3. Replace radiator cap as necessary.
Page 65 of 77
Engine Mechanical System > Cooling System > Cooling Fan Motor Assembly > Components and
Components Location
COMPONENT
Remove components in the order shown in figure.
Engine Mechanical System > Lubrication System > General Information

OIL PRESSURE CHECK
1. Disconnect and remove oil pressure switch.
2. Install oil pressure gauge into oil pressure switch installation hole.
3. Warm engine to normal operating temperature.
Page 66 of 77
4. Run engine at idle and note gauge readings.
Oil pressure:
12.8 psi (88.26 kPa, 0.9 kg/cm²) above
5. If pressure is not within specification, check for cause, and repair.

6. Remove oil pressure gauge and install oil pressure switch.
Tightening torque:
8.7~13.0 lb-ft (12~18 N·m, 1.2~1.8 kg-m)
Engine Mechanical System > Lubrication System > Engine Oil > Repair procedures
REPLACEMENT
Be careful when draining because oil is hot and could cause personal injury.
1. Warm engine to normal operating temperature and turn engine off. Position a suitable container under oil pan.
2. Remove oil filler cap and oil pan drain plug.
3. Allow oil to be fully drained.
4. Install drain plug with new gasket.
Tightening torque:
22~30 lb-ft (29~41 N·m, 3.0~4.2 kg-m)
5. Refill engine with specified type and amount of engine oil.

6. Run engine and check for leaks.
Page 67 of 77
7. Check oil level and add oil if necessary.
Oil pan capacity:

3.2 U.S. qt (3.0 liters, 2.6 lmp qt)
8. Install oil filler cap.
Engine Mechanical System > Lubrication System > Oil Pan > Components and Components Location
COMPONENT
Page 68 of 77
Engine Mechanical System > Lubrication System > Oil Pan > Repair procedures
Installation
Page 69 of 77
1. Apply continuous sealant to mating surface as shown illustration.
Sealant type : LOCTITE 5900

Bead width : 0.1575 in (4 mm)
• Assembly procedure must be completed within 4 minutes after applying sealant.
2. Install the oil pan.
Tightening torque :
A : 7.2~8.7 lb-ft (9.8~11.8 N-m , 1.0~1.2kg-m)
B,C,D : 7.2~9.4 lb-ft (9.8~12.7 N-m , 1.0~1.3kg-m)
Engine Mechanical System > Lubrication System > Oil Pump > Components and Components Location
COMPONENT
Page 70 of 77
COMPONENT
Page 71 of 77
Engine Mechanical System > Lubrication System > Oil Pump > Repair procedures
REMOVAL
2. Drain engine oil.
3. Remove Drive belt.
Page 72 of 77
5. Remove components in the order shown in figure.
Installation
1. Apply continuous sealant to mating surface as shown illustration.
Sealant type : LOCTITE 5900

Bead width : 0.0394~0.0787 in (1~2 mm)
• Be careful for sealant not to enter the oil hole.
2. Install the oil pump.
Tightening torque :
13.7~18.8 lb-ft (18.6~25.5 N·m, 1.9~2.6 kg-m)
INSPECTION
1. Clean all components and clean off dust from all components.
2. Check all components with specifications and replace as necessary.
Component Specification
Oil pump
Side clearance 0.0039 in (0.10 mm)
Tooth tip coearance 0.0071 in (0.18 mm)
Outer roter to pump body
0.0078 in (0.20 mm)
clearance
Engine Mechanical System > Lubrication System > Oil Filter > Repair procedures
REPLACEMENT
1. Raise vehicle.
2. Remove oil filter with oil filter wrench. If rubber seal is stuck to engine, remove it.
3. Apply a small amount of clean engine oil to rubber seal of new filter.
4. Install oil filter and turn it by hand until rubber seal contacts base.
5. Tighten filter 1-1/6 turns with filter wrench.
6. Start engine and check for leaks.
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7. Turn engine off, and wait 5 minutes. Check oil level and add oil if necessary.
Oil filter capacity:

0.21 U.S. qt (0.20 liter, 0.18 lmp qt)
Engine Mechanical System > Intake And Exhaust System > Air Cleaner > Components and
Components Location
INTAKE SYSTEM
Remove components in the order shown in above figure.
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Engine Mechanical System > Intake And Exhaust System > Air Cleaner > Repair procedures
ACCELERATOR CABLE
1. Depress the accelerator pedal to the floor and check that the throttle valve is fully opened.
Adjust with nut (A) , if necessary.
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2. Measure the free play of the accelerator cable.
Free play: 0.16~0.28 in (4~7 mm)
Engine Mechanical System > Intake And Exhaust System > Front Exhaust Pipe > Components and
Components Location
COMPONENT
Remove components in the order shown in above figure.
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Engine Mechanical System > Intake And Exhaust System > Front Exhaust Pipe > Repair procedures
INSTALLATION
Install front exhaust as follows:
1. Tighten (A) temporarily
2. Tighten (B) temporarily
3. Tighten (A) fully
4. Check the connection between the pipe of (B) and bracket
5. Tighten (B) fully
Engine Mechanical System > Troubleshooting > P0128

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Engine coolant thermostat open stuck
No. P0128
[Related items] • Thermostat stuck opened
• After engine start-up, the elapsed time before feedback operation is initiated
is too long
(engine coolant temperature sensor input is insufficient for closed loop
operation)
• Poor connections between ECTS and ECM
• Contaminated, deteriorated ECTS

1 Remove thermostat and check that thermostat is Yes Go to step 2.
stuck.
No Temporarily install a known good thermostat and
Is thermostat okay? check for proper operation.
If problem is corrected, replace thermostat.
OBD-II check connector and turn ignition to ON. proceeding this procedure.
Are any DTC relating ECTS and/or IATS set? No Go to step 3.
3 Start engine and allow engine to idle until engine Yes Problem is intermittent or was repaired and engine
reaches operating temperature. control. module memory was not cleared. Check
Using SCAN TOOL and monitor ECT signals. terminal connections at ECM and ECTS.
• 3.6~3.8V (2.31~2.59 kΩ) @ 20°C (68°F)
• 1.2~1.5V (0.31~0.33 kΩ) @ 80°C (176°F) No Go to step 4.
Is signal within specifications?
4 Check ECTS for contamination, deterioration or Yes Clean ECTS with cleaner before installing. If
damage. damaged or deteriorated, replace.
Is ECTS contaminated, deteriorated or damaged? No Go to step 5.

connectors at ECM and ECTS connectors.
With ignition OFF, disconnect ECM and ECTS
connectors. Measure resistance between ECTS No Repair as necessary.
and ECM on all two circuits.
Is resistance all below 1 ohm?
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RIO(BC) > 2005 > G 1.6 DOHC > Fuel System
Fuel System > General Information > Schematic Diagrams

ENGINE CONTROL SYSTEM
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Fuel System > General Information > Special Service Tools

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Tool
Illustration Use
(Number and Name)
0K2CA 089 HSP Used for diagnosis and DTC retrieval and
Hi-scan pro erasing.
0K2A1 131 AA1 Used for measuring fuel pressure.

Fuel pressure gauge
Fuel System > General Information > Description and Operation

Component description table
Component Function Remark
A/C relay Controls battery power to compressor magnetic
Control condenser fan relay and
clutch and condenser fan relay according to
compressor magnetic clutch
vehicle conditions
A/C switch Controls battery power to A/C DEF switch and
Normal open type
grounds A/C DEF switch
Air cleaner Filters air entering throttle body
Camshaft
Detects number 1 cylinder TDC and sends the
positin(CMP) Installed at rear of cylinder head (bank 1)
signal to ECM
sensor
Crankshaft position Detects crankshaft angle from flywheel rotation
SGT signal
(CKP) sensor and sends signal to ECM
Data link Centalized service connector for on-board For on-board diagnosis and
connector (DLC) diagnosis service/inspection
EGI main relay Normal open type
Supplies battery power to electrical devices
Controlled by ECM
Engine control Detects the following:
module (ECM) 1. A/C operation 1. A/C switch
2. Air/fuel ratio (oxygen concentration) 2. Oxygen sensor
3. Vertical chassis movement 3. Chassis acceleration sensor
4. Ignition ON signal 4. Ignition switch
5. Engine coolant temperature 5. Engine coolant temperature sensor
6. Engine speed 6. Crankshaft position (CKP) sensor
(SGT signal)
7. In-gear condition (A/T only) 7. Transaxle range switch (A/T)
8. Intake air amount 8. Mass air flow sensor
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9. Intake air temperature 9. Intake air temperature sensor
10. No. 1 piston TDC(compression stroke) 10. Camshaft position (CMP) sensor
(SGC signal)
11. Throttle valve opening angle 11. Throttle position sensor
12. Vehicle speed 12. Vehicle speed sensor
13. Fuel tank pressure 13. Fuel tank pressure sensor
14. Engine knocking 14. Knock sensor
Controls operation of following:

1. A/C 1. A/C relay
2. Self-diagnosis function 2. Hi-scan pro & MIL
3. Fuel injection system 3. Injector
4. Ignition control system 4. Ignition coil
5. Idle speed control 5. Idle air control valve
6. Purge control system 6. Evaporative canister purge valve
7. Fuel pump control 7. Fuel pump relay
8. Cooling fan control 8. Cooling fan control relay
Engine coolant
Detects engine coolant temperature and sends
temperature (ECT) -
signal to ECM
sensor
Fuel filter (high Filters fine dirt particles in fuel discharged from the
-
pressure side) fuel pump
Fuel filter (low
Filters fuel in fuel tank -
pressure side)
Fuel injector Injects fuel into intake port Controlled by signals from ECM
Fuel pressure
Adjusts fuel pressure supply to injectors Controlled by intake manifold vacuum
regulator
Fuel pump Supplies fuel from fuel tank to fuel under pressure Actuated by fuel pump relay installed
Fuel pump relay Controls battery power to fuel pump Normal open type
Actuated by ECM fuel pump control signal or by
jumping data link connector terminal 1 to battery
Fuel tank pressure Detects vapor leakage and monitors purge valve
Located on the fuel tank
sensor operation
Heated oxygen Detects oxygen density in exhaust gas and sends
Located in exhaust manifold
sensor(front) signal to ECM for air/fuel mixture adjustment
Heated oxygen Detects oxygen density in exhaust gas and sends
TWC converter verification
sensor (rear) signal to ECM
Idle air For idle speed control
Supplies intake air to engine, bypassing throttle
control(ISC) valve Actuated by ECM idle speed control
valve
signal
Ignition coils Supplies secondary voltage to spark plugs Mounted directly above spark plugs
Ignition control
Controls operation of ignition coils Incorporated into ECM
module
Ignition switch Starts engine and controls battery power to
-
electrical devices
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Intake manifld Supplies intake air to all cylinders -
Knock sensor Detects detonation in the combustion (chambers) The ECM will retard ignition timing hased
and sends signal to ECM on input signal
Main relay Supplies current to output devices and ECM -
Mass air flow Detects amount of intake air and sends signal to
-
(MAF) sensor ECM
Starter Starts engine by rotating flywheel ring gear -
Three way catalytic Reduces HC, CO and NO in exhaust through
For exhaust gas emissions reduction
converter chemical reaction
Throttle body Controls intake air amount -
Throttle position Detects throttle valve opening angle and sends
Installed on throttle body
sensor signal to ECM
Transaxle control Controls functions of transaxle for better Located below instrument panel behind
module performance and shift quality lower trim panel left
Transaxle range For idle speed control load/no load
Detects shift lever position and sends to ECM
switch determination
VICS valve Controls shift lever position and sends to ECM -
Fuel System > General Information > Repair procedures

IGNITION TIMING AND IDLE SPEED
Ignition timing
1. Apply parking brake.
3. Turn OFF all electrical loads.
4. Connect timing light to number one spark plug wire.
A rubber inspection plug has been provided in the plastic coil cover(center of the cylinder head cover)
directly over the number one (1) spark plug wire. Remove the inspection plug and connect the inductive
pick-up of your tachometer or timing light to the number one (1) spark plug wire. If your tachometer/timing
light inductive pick-up is too large, the coil cover will have to be removed.
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5. Verify that ignition timing marks on crankshaft pulley and timing mark on timing belt cover are aligned.
Ignition timing: BTDC 6° ± 5° (at idle speed)
Ignition timing is not adjustable.
6. If timing is not within the specified range, replace the ECM.

Idle speed
1. Apply parking brake.
3. Turn OFF all electrical loads.
4. Connect inductive tachometer to number one (1) spark plug wire or connect tachometer pick-up lead to terminal
'O' in the data link connector (DLC). In case of using scan tool connect Hi-scan pro to the DLC.
The base idle speed is not adjustable. The idle speed is automatically controlled by the engine control
module. Incorrect idle speed indicates a potential problem with the IAC system or an intake manifold leak.
5. Check that idle speed is within specified range.
Idle speed (transaxle in "NEUTRAL") : 750 ± 50 rpm
This is a "wasted spark" ignition system, some tachometers will indicate twice the actual engine
speed.
6. Disconnect tachometer from DLC or spark plug wire.

7. Turn off engine.
Fuel System > General Information > Specifications

Specifications
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Fuel System > Engine Control System > Schematic Diagrams

Emission control diagram
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Fuel System > Engine Control System > Description and Operation
Diagnostic trouble codes retrieval procedure
1. Connect the Hi-scan pro to the Data Link Connector (DLC).
2. Turn the ignition switch ON.
3. Retrieve any DTC in ECM memory.
Clearing diagnostic trouble codes
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1. Connect the Hi-scan pro to the Data Link Connector(DLC).
2. Turn the ignition switch ON.
3. Erase any DTC stored in ECM.
Data link connector 20 pin layout

PIN NO. TERMINAL FUNCTION
a Fuel pump test
b Power supply (B+)
d Cooling fan test
f Air bag unit
h ABS unit
Communication diagnosis terminals for Hi-scan
k
pro (K-Line)
m Fail code output terminal for A/T vehicle
n Test ground for A/T vehicle
o Power supply for IG ON
p Engine fail code output terminal
q Spark plug timing adjust
r Ground
s Ground
t Engine monitor terminal
Data link connector 16 pin layout

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PIN NO. TERMINAL FUNCTION
4 Ground
5 Ground
Communication diagnosis terminal
7
(K-Line)
16 Power supply (ECU 10A)
General description
OBD-II overview
The goal of the On Board Diagnostics-II(OBD-II) regulation, which was mandated by the Environmental Protection
Agency (EPA), is to ensure proper emission system operation for the life of the vehicle by providing the vehicle with
an "on-board" diagnostic system which is capable of continuously monitoring the efficiency of the emission control
system.
To achieve this goal, OBD-II diagnostics monitors emissions-related components and systems for deterioration and
identifies an emissions-related malfunction before the driver notices a problem with the vehicle. The Engine Control
Module (ECM) monitors many different circuits in the fuel injection, ignition, emission and engine systems. If the
ECM senses a problem with a monitored circuit often enough to indicate an actual problem, it stores a Diagnostic
Trouble Code in the ECM memory. If the code applies to a non-emissions related component or system and the
problem is repaired or ceases to the exist, the ECM cancels the code after a predetermined number of drive cycles.
Certain criteria must be met before the ECM stores a DTC in memory. The criteria may be a specific range of
engine RPM, engine temperature, and/or input voltage to the ECM. Keep in mind though that the ECM might not
store a DTC for a monitored circuit even though a malfunction has occurred. This may happen because one of the
DTC criteria for the circuit has not been met. For example, lets say the DTC criteria requires the ECM to monitor
the circuit only when the engine operates between 750 and 2000 RPM. Suppose the sensors output circuit shorts to
ground as a result of engine torque when the engine operates above 2400 RPM (resulting in 0 volt input to the
ECM). Since the condition happens at the engine speed above the maximum threshold, in this case 2000 RPM, the
ECM will not store a DTC.
As a functional test, the MIL (check engine) illuminates at key ON before engine cranking. Whenever the ECM sets
a DTC that affects vehicle emissions, it sends a signal to illuminate the MIL. There are some monitors that may take
consecutive trips, with a detected fault, before the MIL is illuminated. This is also known as "PENDING" codes.
Also the MIL flashes when the ECM detects an active engine misfire, then shuts off fuel to the affected cylinder.
OBD-II diagnostics supports not only the standard test mode of OBD-II (Mode 01~Mode 07) but also an
advanced test Mode (Mode 22: Supported PID -analog inputs and outputs, digital inputs and outputs). All of these
diagnostic test modesare supported using Hi-Scan Pro through the DLC.
The ECM executes the following key monitoring for OBD-II:
• Primary emission control system/components
• Heated oxygen sensors (includes heater)
• Catalyst
• Fuel system
• Evaporative emission system
• Misfire
• Comprehensive components (input and output)
Heated oxygen sensor monitoring
System description
Effective control of exhaust emission is achieved by an oxygen "feedback system" to the ECM. This "feedback" is
accomplished with the HO2 Sensors. Once the HO2 Sensor reaches operating temperature, the sensor generates a
voltage signal to the ECM that is inversely proportional to the amount of oxygen in the exhaust. This voltage signal is
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used by the ECM to calculate the fuel injector pulse width to maintain the ideal 14.7 to 1 Air Fuel (A/F) ratio. This is
the ideal mixture because at this ratio, the catalyst works best to remove hydrocarbons (HC), carbon monoxide
(CO) and nitrogen oxide (NOX) from the exhaust.
Monitoring process
To achieve the requirements of the HO2S Monitoring diagnosis, diagnostic tests have been designed to monitor the
following:
• Heater voltage and current
• Period of front HO2S reaction
• Other parameter (Tv) to monitor sensor aging
· Heater voltage and current
The voltage readings taken from the HO2 Sensor are very temperature sensitive and are not particularly accurate
below 300C. For this reason, heating of the HO2 sensor is necessary to allow the engine crontroller to shift to
closed loop control as soon as possible. The heating element used to heat the HO2 Sensor must be tested to ensure
that it is heating thesensor properly.
· Period of front HO2 reaction

The ECM is supplied with information regarding the oxygen content of the exhaust gases by the front HO2S. The
signal is used to compute the injection period. The front HO2S monitors the contaminated exhaust gases. This, in
time, causes aging of the device and a change in the signal. To monitor the front HO2S responsiveness, the response
period of the upstream oxygen sensor signal is compared with a lower and upper threshold. This comparison is done
in an applicable range of engine speed and load with the engine at operating temperature. If the actual mean value of
the period is outside of the lower and upper period thresholds the diagnostic trouble code is set.
· Other parameter (Tv) to monitor sensor aging
The sensor aging is monitored by comparing the front and rear HO2S and also using the correction value (Tv) which
determines the mean value of the lean/rich shift necessary for optimal air/fuel ratio-control. With the help of this
information, the ECM can make allowance for aging of the front HO2S in its injection period calculations. When the
parameter-Tv is above or below the specific limits, the ECM will set the diagnostic trouble code HO2S Slow
Response by aging.
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· MIL illumination
If any fault relating to HO2S is detected, then the MIL is only turned ON if the same fault is again detected during a
second drive cycle.
Symptom related diagnostic procedure
Using this section
Introduction
Most of the fuel and emission control system is electrically controlled, often making it difficult to diagnose problems
in the system, especially intermittent problems.
Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a driveability
complaint. The customer is often a good source of information on such problems, especially intermittent ones.
Through talks withthe customer, one can find out what the symptoms are and under what conditions they occur.
Work flow
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Diagnostic index
Symptom diagnosis charts

Further describes the symptom.
Confirm that the chart addresses the actual symptom before beginning troubleshooting
This describes the possible point of malfunction.
This shows the order of troubleshooting. Proceed with troubleshooting as indicated.
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This describes an inspection to determine the malfunction of parts quickly.
This recommends the appropriate action to take as a result (Yes/No) of the check.
Diagnostic symptom index
No. Troubleshooting item Descriotion
1 Will not crank or cranks slowly Refer to engine electrical system
Cranks normally but Engine cranks at normal speed but shows no sign of
2 No combustion
will not start firing
Partial combustion Engine cranks at normal speed but shows only partial
3
Engine cold combustion and will not continue to run
Partial combustion after Engine starts normally when cold, but will not start after
4
warm-up running and hot soaked
Cranks normally but Engine cranks at normal speed but requires excessive
5 Always
hard to start cranking time before starting
Same condition as No. 5 after running and cold ; restarts
6 When engine is cold
normally after warm-up
Same condition as No. 5 after running and hot soaked;
7 After warm-up
starts normally when cold
8 Rough idle (Low idle Always Engine stalls or vibrates excessively at idle
speed/engine stalls at
Engine stalls or vibrates excessively at idle during warm-
9 idle) Before warm-up
up
Engine runs normally at idle during warm-up but vibrates
10 After warm-up
excessively or stalls after warm-up
Engine stalls or vibrates excessively at idle when A/C
11 When A/C ON
ON
Engine stalls or vibrates excessively only just after
12 Rough idle/engine stalls just after starting
starting (acceleration from idle)
13 High idle speed after warm-up Idle speed excessive after warm-up
14 Idle moves up and down/idle hunting Engine speeds up and down periodically at idle
Engine unexpectedly stops running while decelerating or
after deceleration
16 Engine stalls suddenly (intermittent) Engine intermittently stops running
Flat spot occurs just after accelerator depressed or mild
17 Stumbles/hesitates on acceleration
jerking occurs during acceleration
Unexpected change in engine speed which is usually
repetitive
Performance poor under load when throttle valve wide
19 Lack of power open
Maximum speed reduced
20 Poor acceleration Performance poor while accelerating
Engine runs rough while decelerating and abnormal
21 Runs rough on deceleration/backfire
combustion occurs in exhaust system
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Abnormal combustion accompanied by audible "pinging"
22 Knocking
noise
23 Fuel odor Gasoline odor in cabin
24 High oil consumption Oil consumption excessive
Hi-scan pro tool does not indicate diagnostic trouble
25 MIL always ON
code but MIL always ON
26 MIL always ON Hi-scan pro tool indicates malfunction
Blower fan operates but magnetic clutch does not
27 A/C does not work
operate
Driveability definitions
Stumble : Mild jerking during acceleration.
Hesitation : Delay increase in engine speed occurring just after the accelerator pedal is depressed.
Surge : Continuous soft jerking during cruise.
Precautions for symptom diagnosis
Fuel system pressure release
The fuel system remains under pressure when the engine is not running. Release fuel system pressure before
disconnectingany fuel line to reduce the chance of personal injury or fire damage to vehicle components. Fuel is
explosive. An emptyfuel tank can still contain explosive gases. Supply adequate ventilation to the work area. Do
not smoke, and keep sparks and open flames away. Refer to fuel system pressure release procedure.
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Fuel system monitoring

System description
The determination of how much fuel to deliver to the engine is the calculation of injector pulse width. Basic injection
duration (injector pulse width) is determined by:
• Engine load (MAF sensor)
• Engine Speed (SGT)
• Short fuel trim correction factor
• Long fuel trim correction factor
Fuel trim is monitored to meet the OBD-II requirements
1. Short fuel trim (FT)
Short FT is a temporary correction to fuel delivery which changes with every cycle of the front Heated Oxygen
Sensor. Under normal conditions, it fluctuates rapidly around its ideal value of 0% correction and is set to 0%
during open loop operation.
Short FT is a parameter of the OBD-II serial data stream and can be displayed by a scan tool. The normal range
of short FT is ±25%, but under normal operating conditions it rarely goes beyond ±10%. Short FT responds to
changes in front HO2Soutput. If basic injection duration results in a lean air/fuel ratio, Short FT responds with
positive corrections (+1% to +25%) to add fuel and enrich the mixture. If basic injection is too rich, Short FT
responds with negative corrections(-1% to -25%) to subtract fuel and lean the mixture.
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2. Long Fuel Trim
Long FT is a data parameter on the OBD-II data streams. It is a more permanent correction to fuel delivery
because it ispart of the basic injection duration calculation. Long FT changes slowly, in response to Short FT. It's
normal range is±25%, positive values indicating rich correction and negative values indicating lean correction.
Unlike Short FT which affects injection duration calculation in closed loop only, the Long FT correction factor
affects the basic injection duration calculation in open and closed loop. Because Long FT is stored in a non-
volatile RAM and isnot erased when the ignition is switched OFF, the fuel system is able to correct for variances
in engine and fuel conditions even during warm-up and wide open throttle conditions.
Monitoring process
The ECM monitors the averages of long term and short term fuel trim. If these fuel trim values reach and stay at their
maximum limits (±25%) for a defined period of time, a diagnostic trouble code is set.
MIL illumination
When the fuel trim value exceeds the failure thresholds, then the MIL is only turned ON if the same fault is detected
during a second drive cycle.
Misfire monitoring
System description
Misfire is monitored by evaluating fluctuations of the angular velocity of the crankshaft position sensor. The
crankshaft position sensor allows the ECM to monitor crankshaft speed variations during each cylinder power
stroke. When all cylinders of an engine are firing evenly, the crankshaft speeds up evenly with each power stroke.
During a misfire, crankshaft speed decreases in that cylinder. Kia OBD-II engines use a 60 minus 2 tooth crankshaft
position sensor to measure crankshaft speed and position. The ECM uses this information to determine if a misfire
occurs, which cylinder it is occurring in, and the degree of misfire. If a significant misfire is detected, a DTC is
stored. The MIL in the instrument panelwill illuminate, informing the driver of a malfunction.
Monitoring conditions
The misfire monitoring begins as soon as 2.9 to 50 ignitions pass after engine start. It is disabled while the ECM
detects a sudden change of engine speed or load. The misfire monitoring covers the full range of engine operation.
Monitoring process
A new function for pre-filtering of sensor wheel segment duration signal is introduced to Sephia in order to enlarge
themisfire monitoring range. The sensor wheel segment duration is pre-filtered by this function and then the filtered
valueis used to calculate the engine roughness which is compared with the reference value to detect misfiring. With
this function, it is possible to eliminate the influence of the crankshaft-synchronous oscillations on the detection of
misfire.These oscillations can be caused by sensor wheel tolerance or crankshaft torsional vibration. The misfire
monitoring ofSephia covers nearly the full range of engine operation in case of random or continuous misfire, and for
symmetrical misfire.
MIL illumination
The MIL is illuminated when a misfire is detected which can cause the damage of catalyst or exhaust emission higher
than 1.5 times certification standard (I/M failure).
The MIL flashes while a catalyst damaging misfire is being detected.
Comprehensive components monitoring
Any input or output components that can affect emissions or any input or output component used to monitor any
other monitored component/system is monitored.
The lack of circuit continuity and rationality, and out-of-range values to ensure proper operation of the input devices,
are monitored for proper response to ECM commands.
ENGINE CONTROL COMPONENTS
The Engine Control Module (ECM) operates the fuel system. It regulates ignition timing, air fuel ration, emission
control devices, charging system, idle speed control, air conditioning clutch engagement, etc. The ECM has the
ability to adapt to changing operating conditions.
The ECM receives input signals from various switches and sensors. Based on these inputs, the ECM regulates
various engine and vehicle operations through different system components also known as ECM Outputs. On the
other hand, the sensors and switches that provide inputs to the ECM are ECM Inputs. For example, the ECM
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adjusts ignition timing based upon inputs it receives from sensors that react to: engine RPM, engine coolant
temperature, throttle position, transaxle gear, vehicle speed, etc. The ECM adjusts idle speed based on inputs it
receives from sensors that react to: throttle position, vehicle speed, transaxle gear, etc.
Mass air flow sensor
The Mass Air Flow (MAF) Sensor is the most direct method of measuring engine load because it measures the
mass of air intake. This is also known as a “hot-wire” sensor because it depends on the measurement of current
flowing through heated wires to measure air flow. The hot wire is heated to specific temperature differential above
incoming air. Two wires inside the MAF Sensors are exposed to a portion of the airflow entering the engine:
The ambient temperature wire or “cold wire” isn’t heated so this wire is the temperature of the surrounding air and
serves as the reference temperature. The hot wire is heated by the MAF to be a certain amount above the ambient
air. As soonas air flows over the wire, both wires are cooled. The control circuits then apply more voltage to keep
the hot wire atthe original temperature differential. This creates a voltage signal monitored by the ECM. The greater
the air flow andwire cooling, the greater the signal.
Engine coolant temperature sensor
The Engine Coolant Temperature (ECT) Sensor provides an input voltage to the ECM relating to coolant
temperature. The ECM uses this input signal along with inputs from other sensors to determine injector pulse width
and ignition timing. As coolant temperature varies the ECT Sensor’s resistance changes. The change in resistance
results in a different input voltage to the ECM. When the engine is cold, the ECM will operate in Open Loop cycle.
It will demand slightly richer air/fuel mixtures and higher idle speeds until normal temperatures are reached.
Fuel System > Engine Control System > Troubleshooting

DTC CONTENT MIL
P0101 Mass or Volume Air Flow Circuit Range/Performance Problem O
P0102 Mass or Volume Air Flow Circuit Low Input O
P0103 Mass or Volume Air Flow Circuit High Input O
P0112 Intake Air Temperature Circuit Low Input O
P0113 Intake Air Temperature Circuit High Input O
P0116 Enigne Coolant Temperature Circuit Range/Performance Problem O
P0117 Enigne Coolant Temperature Circuit Low Input O
P0118 Enigne Coolant Temperature Circuit High Input O
P0125 Insufficient Coolant Temperature For Closed Loop Fuel Control O
P0128 Coolant Thermostat Stuck O
P0121 Throttle Position Sensor Circuit Range/Performance Problem O
P0122 Throttle Position Sensor Circuit Low Input O
P0123 Throttle Position Sensor Circuit High Input O
P0130 HO2S Circuit Malfunction (Bank 1, Sensor 1) O
P0131 HO2S Circuit Low Voltage (Bank 1, Sensor 1) O
P0132 HO2S Circuit High Voltage (Bank 1, Sensor 1) O
P0133 HO2S Circuit Slow Responsive (Bank 1, Sensor 1) O
P0134 HO2S Circuit No Activity Detected (Bank 1, Sensor 1) O
P0030 HO2S Heater Circuit Malfunction (Bank 1, Sensor 1) O
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P0031 HO2S Heater Circuit Low Input (Bank 1, Sensor 1) O
P0032 HO2S Heater Circuit High Input (Bank 1, Sensor 1) O
P0136 HO2S Circuit Malfunction (Bank 1, Sensor 2) O
P0137 HO2S Circuit Low Input (Bank 1, Sensor 2) O
P0138 HO2S Circuit High Input (Bank 1, Sensor 2) O
P0139 HO2S Circuit Slow Responsive (Sensor 2) O
P0140 HO2S Circuit No Activity Detected (Sensor 2) O
P0036 HO2S Heater Circuit Malfunction (Bank 1, Sensor 2) O
P0037 HO2S Heater Circuit Low Input (Bank 1, Sensor 2) O
P0038 HO2S Heater Circuit High Input (Bank 1, Sensor 2) O
P0171 Fuel System Too Lean O
P0172 Fuel System Too Rich O
P0261 Cylinder 1 - Injector Circuit Low Input O
P0262 Cylinder 1 - Injector Circuit High Input O
P0300 Random Misfire Detected O
P0301 Cylinder 1 - Misfire Detected O
P0325 Knock Sensor Circuit Malfunction O
P0335 Crankshaft Position Sensor Circuit Malfunction O
P0340 Camshaft Position Sensor Circuit Malfunction O
P0420 Main Catalyst System Efficiency Below Threshold (Bank 1) O
P0441 EVAP Emission Control System Purge Control Valve Stuck Opened O
P0442 EVAP Emission Control System - Smal Leak (1.0 mm) O
P0455 EVAP Emission Control System - Large Leak O
P0456 EVAP Emission Control System - Small Leak Detected (0.5 mm) O
P0444 EVAP Emission Control System - Purge Control Valve Circuit Open O
P0445 EVAP Emission Control System - Purge Control Valve Circuit Shorted O
P0447 EVAP Emission Control System - Vent Control Circuit Open O
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P0448 EVAP Emission Control System - Vent Control Circuit Shorted O
EVAP Emission Control System - Pressure Sensor Range/Performance
P0451 O
Problem
P0452 EVAP Emission Control System - Pressure Sensor Low Input O
P0453 EVAP Emission Control System - Pressure Sensor High Input O
P0454 EVAP Emission Control System - Pressure Sensor Intermittent O
P0501 Vehicle Speed Sensor Range/Performance O
P0506 Idle Control System RPM Lower Than Expected O
P0507 Idle Control System RPM Higher Than Expected O
P0560 System Voltage Malfunction O
P0562 System Voltage Low Input O
P0563 System Voltage High Input O
P0605 Internal Control Module ROM Error (ECM-Selftest Failed) O
P0650 Malfunction Indicator Lamp Circuit Malfunction O
P1166 HO2S - Controller Adaptation Diagnosis Malfunction O
P1505 Idle Air Control Valve Opening Coil Signal Low Input O
P1506 Idle Air Control Valve Opening Coil Signal High Input O
P1507 Idle Air Control Valve Closing Coil Signal Low Input O
P1508 Idle Air Control Valve closing Coil Signal High Input O
P1586 AT/MT Encoding Malfunction O
P1529 TCU Request for MIL ON/Freeze Frame to ECM via CAN O
P1693 MIL Request Circuit Malfunction O
TROUBLESHOOTING
DIAGNOSTIC TROUBLE CODE TABLE
DTC Diagnostic items Trouble area MIL
P0101 Mass or Volume Air Flow Circuit • Dirty air cleaner O
Range/Performance Problem • Air leak in intake system
• Vacuum leak in intake system
• Improper PCV valve
• Contaminated, deteriorated or damaged MAFS
• Faulty MAFS or TPS
• Poor connections at ECM, MAFS, or TPS
P0102 Mass or Volume Air Flow Circuit Low • Open or short to ground between MAFS signal and O
Input ECM
• Open or short to ground between MAFS reference
power and main relay
• Faulty MAFS
Page 25 of 125
P0103 Mass or Volume Air Flow Circuit High • Short to battery between MAFS signal and ECM O
Input • Open between MAFS ground and ECM
• Faulty MAFS
P0112 Intake Air Temperature Circuit Low • Short to ground between IATS signal and ECM O
Input • Faulty IATS
P0113 Intake Air Temperature Circuit High • Open or short to battery between IATS signal and O
Input ECM
• Open between IATS ground and ECM
• Faulty IATS
P0116 Engine Coolant Temperature Sensor • After engine start-up, the elapsed time before O
Circuit Range/Performance Problem feedback operation is initiated is too long (engine
coolant temperature sensor input is insufficient for
closed loop operation)
• Foreign materials fouled, contaminated, deteriorated
ECTS
• Faulty ECTS
• Faulty thermostat
P0117 Engine Coolant Temperature Circuit Low • Short to ground between ECTS signal and ECM O
Input • Faulty ECTS
P0118 Engine Coolant Temperature Circuit High • Open or short to battery between ECTS signal and O
Input ECM
• Open between ECTS ground and ECM
• Faulty ECTS
P0125 Insufficient Coolant Temperature For • After engine start-up, the elapsed time before O
Closed Loop Fuel Control feedback operation is initiated is too long (engine
coolant temperature sensor input is insufficient for
closed loop operation)
• Foreign materials fouled, contaminated, deteriorated
ECTS
• Faulty ECTS
P0128 Coolant thermostat stuck • Thermostat stuck opened O
P0121 Throttle Position Sensor Circuit • Poor connections between TPS and ECM O
Range/Performance Problem • Misplaced, loose or corrodes terminals
• Contaminated, deteriorated TPS
• Faulty TPS
P0122 Throttle Position Sensor Circuit Low • Open or short to ground between TPS reference O
Input power and ECM
• Short to ground between TPS signal and ECM
• Faulty TPS
Page 26 of 125
P0123 Throttle Position Sensor Circuit High • Open or short to battery between TPS signal and O
Input ECM
• Open between TPS ground and ECM
• Faulty TPS
P0130 HO2S Circuit Malfunction • Open or short to battery between front HO2S and O
(Bank 1, Sensor 1) ECM
• Short to ground between front HO2S and ECM
• Short between front HO2S wires
• Faulty front HO2S
• Poor connections between front HO2S and ECM
• Misplaced, bent, loose or corroded connector
terminals
P0131 HO2S Circuit Low Input • Short to ground between front HO2S signal and O
P0132 HO2S Circuit High Input • Open or short to battery between front HO2S signal O
(Bank 1, Sensor 1) and ECM
P0133 HO2S Circuit Slow Responsive • Abnormal combustion O
(Bank 1, Sensor 1) • Improper fuel pressure
• Front and rear HO2S connections reversed
• Faulty fuel delivery system
• Leak in intake system
• Leak in exhaust system
P0134 HO2S Circuit No Activity Detected • Open or short between HO2S signal terminal and O
• Contaminated, deteriorated or aged HO2S
terminals
P0030 HO2S Heater Circuit Malfunction • Open or short to battery between front HO2S heater O
• Short to ground between front HO2S heater and
ECM
• Open or short to chassis ground between front
HO2S heater and main relay
• Incorrect front HO2S heater resistance
• Faulty front HO2S heater
P0031 HO2S Heater Circuit Low Input • Open or short to ground front HO2S heater signal O
• Open or short to ground front HO2S heater battery
Page 27 of 125
P0032 HO2S Heater Circuit High Input • Short to battery between front HO2S heater signal O
P0136 HO2S Circuit Malfunction • Open or short to chassis ground between rear O
(Bank 1, Sensor 2) HO2S and ECM
• Short to battery between rear HO2S and ECM
• Short between rear HO2S wires
terminals
• Faulty rear HO2S
P0137 HO2S Circuit Low Input • Short to ground between rear HO2S signal and O
P0138 HO2S Circuit High Input • Open or short to battery between rear HO2S signal
(Bank 1, Sensor 2) and ECM O
P0139 HO2S Circuit Slow Responsive • Abnormal combustion O
(Bank 1, Sensor 2) • Improper fuel pressure
P0140 HO2S Circuit No Activity Detected • Open or short between rear HO2S signal terminal O
• Contaminated, deteriorated or aged rear HO2S
terminals
P0036 HO2S Heater Circuit Malfunction • Open or short to battery between rear HO2S heater O
• Short to ground between rear HO2S heater and
ECM
• Open or short to chassis ground between rear
HO2S heater and main relay
• Incorrect rear HO2S heater resistance
• Faulty rear HO2S heater
P0037 HO2S Heater Circuit Low Input • Open or short to battery between rear HO2S heater O
• Open or short to ground rear HO2S heater battery
Page 28 of 125
P0038 HO2S Heater Circuit High Input • Short to battery between rear HO2S heater signal O
P0171 Fuel System Too Lean (Bank 1) • Faulty fuel delivery system O
• Clogged fuel injectors
• Faulty fuel injectors
• Faulty MAFS
• Faulty TPS
P0172 Fuel System Too Rich • Faulty ignition system O
• EVAP canister purge valve malfunction
- Clogged fuel injectors
- Faulty fuel injectors
- Fuel pressure too high
- Fuel pressure regulator failure
• Faulty MAFS
• Faulty TPS
P0261 Cylinder 1 Injector Circuit Low Input • Open or short to ground between main relay and O
injector
• Open or short to ground between ECM and injector
P0262 Cylinder 1 Injector Circuit High Input • Short to battery between ECM and injector O
injector
injector
Page 29 of 125
injector
P0300 Random Misfire Detected • Vacuum leak in air intake system O
• CKPS circuit malfunction
P0301 Cylinder 1 Misfire Detected • Ignition circuit malfunction O
• Faulty ignition coil or plug wire
• Spark plug malfunction
P0302 Cylinder 2 Misfire Detected • Low compression due to blown head gasket, leaking O
valve or piston ring
P0303 Cylinder 3 Misfire Detected • Low/high fuel pressure due to faulty pressure O
regulator, restricted fuel lines, plugged fuel filter or
faulty fuel pump
P0304 Cylinder 4 Misfire Detected • Fuel injector circuit malfunction O
P0325 Knock Sensor Circuit Malfunction • Open or short to ground between knock sensor and O
(Bank 1) ECM
• Source of high resistance between knock sensor and
ECM
• Faulty knock sensor
P0335 Crankshaft Position Sensor Circuit • Open or short to ground between CKPS and ECM O
Malfunction • Short to battery between CKPS and ECM
• Short between CKPS wires
• Out of allowable air gap
• Faulty Target wheel tolerance
• Faulty CKPS
P0340 Camshaft Position Sensor Circuit • Open or short to ground between CMPS and ECM O
Malfunction • Short to battery between CMPS and ECM
• Short between CMPS wires
• Poor connection between CMPS connector &
harness connector
• Faulty CMPS
P0420 Main Catalyst Efficiency Below • Manifold(or warm-up) catalytic converter O
Threshold (Bank1) deteriorated
P0441 EVAP Emission Control System Purge O
• PSV stuck opened
Control Valve stuck opened
P0442 EVAP Emission Control System Small • Fuel filler cap loose or missing O
Leak (1mm) • Fuel filler cap o-ring missing or damaged
• Faulty or damaged fuel filler pipe
Page 30 of 125
P0455 EVAP Emission Control System Large • Fuel in lines due to faulty rollover valve, on-board O
Leak refueling vapor recovery valve or stuck closed CCV
• Canister close valve clogged, stuck open or closed
• Improperly installed purge solenoid valve
P0456 Evaporative Emission Control System- O
• PSV stuck open or closed
Small Leak Detected (0.5mm)
• Faulty fuel tank pressure sensor
• Leaking canister or catch tank
P0444 EVAP Emission Control System Purge • Open or short between main relay and purge O
Control Valve Circuit Open solenoid valve
• Open or short between purge solenoid valve and
P0445 EVAP Emission Control System Purge ECM O
Control Valve Circuit Short
• Faulty purge solenoid valve
P0447 EVAP Emission Control System Vent • Open or short to ground between main relay and O
Circuit Open CCV
• Open or short to ground between CCV and ECM
P0448 EVAP Emission Control System Vent • Short to battery between CCV and ECM O
Circuit Shorted
• Faulty CCV
P0451 EVAP Emission Control System • Poor connections between FTPS and ECM O
Pressure Sensor Range/Performance • Misplaced, loose, bent or corroded terminals
Problem • Contaminated, deteriorated or damaged FTPS
• Faulty FTPS
• Stuck closed CCV
• Blocked vapor hose between canister and CCV
P0452 EVAP Emission Control System • Open or short to ground between FTPS reference O
Pressure Sensor Low Input power and ECM
• Short to ground between FTPS signal and ECM
• Faulty FTPS
P0453 EVAP Emission Control System • Open or short to battery between FTPS signal and O
Pressure Sensor High Input ECM
• Open between FTPS ground signal and FTPS
• Faulty FTPS
P0454 Evaporative Emission Control System- • Open or short to ground between FTPS and ECM O
Pressure Sensor Intermittent • Short to battery between FTPS and ECM
• Poor connections between FTPS and ECM
• Foreign materials fouled FTPS
• Faulty FTPS
P0501 Vehicle Speed Sensor Circuit • Open or short to battery between VSS and ECM O
Range/Performance • Short to ground between VSS and ECM
• Open or short between VSS wires
• Faulty VSS
P0506 Idle Control System RPM Lower Than • Open or short between main relay and IACV O
Expected • Open or short between ECM and IACV
Page 31 of 125
• Intake system is plugged
• Carbon fouled throttle plate
• Faulty IACV
P0507 Idle Control System RPM Higher than • Short to ground between IACV and ECM O
Expected • Air leak in intake system
• Improperly adjusted accelerator cable
• Faulty IACV
• Faulty TPS
• Faulty PCV/PSV
P0560 System Voltage Malfunction • Open or short to ground between ECM and battery O
• Reverse battery cable connection (+/- reverse)
P0562 System Voltage Low Input O
• ECM internal faulty
P0563 System Voltage High Input • Faulty Alternator O
P0605 Internal Control Module ROM Error O

• Internal ECM malfunction
(ECM-Selttest Failed)
P0650 MIL Circuit Malfunction • Open or short to chassis ground between MIL and O
ECM
• Faulty MIL
P1166 HO2S Controller Adaptation Diagnosis • P1166 is case for HO2S (Bank1, Sensor 1) Signal O
Malfunction line open
• Fuel System (Fuel Tank/Pressure Regulator/Fuel
Pump/PSV) Failure
• Poor Connection to Fuel Line Hose/ Sealing/Cut
• Sealing Between Purge Valve and Fuel Tank
• Air Leakage in Exhaust System
• Ignition System (Ignition Coil, Spark Plug, Cable)
Failure
• Surge Tank and Intake Port Failure
P1505 Idle Air Control Valve Opening Coil • Open or short to ground between IACV and ECM O
Signal Low Input • Faulty IACV
P1506 Idle Air Control Valve Opening Coil • Short to battery between IACV and ECM O
Signal High Input • Faulty IACV
P1507 Idle Air Control Valve Closing Coil • Open or short to ground between IACV and ECM O
Signal Low Input • Faulty IACV
P1508 Idle Air Control Valve Closing Coil • Short to battery between IACV and ECM O
Signal High Input • Faulty IACV
P1586 AT/MT Encoding Malfunction • Poor connection to chassis ground at ECM O
• Open or short circuit between ECM AT/MT and
chassis ground
• Normal condition: AT-chassis ground, MT-open
P1529 TCU Request for MIL ON/Freeze
Frame to ECU via CAN
Page 32 of 125
P1529 TCU Request for MIL ON/Freeze • This is only a request from TCM to turn the MIL O
Frame to ECU via CAN ON. The fault code is stored in the TCM. The freeze
frame data is storedin the ECM under the P1529
request code. Be sure to retrieve freeze frame data
before clearing code P1529 from ECM.
P1693 MIL Request Circuit Malfunction • Open or short to chassis ground between TCM O
signal and ECM
• Short to battery between TCM and ECM
• Message timeout from TCM
• Faulty TCM
O : Means fault code memory and MIL ON

Symptom diagnosis chart(Cranks)
2 Cranks normally, but will not start (no combustion)
• Cranks normally, but no combustion
Description • Battery is OK
• Throttle valve closed while cranking
(Troubleshooting hint)
No fuel injection to engine because of fuel shortage or no ignition in all cylinders
1. No spark
• Ignition control malfunction
• Malfunction of ignition system component
2. No fuel injection
• Malfunction of fuel pump
• Malfunction of injector
3. Low fuel line pressure
4. Low engine compression pressure

1 Check for a strong blue spark plug with spark Yes Go to step 5.
plug wire disconnected. Is blue spark present?
No Go to next step.
2 Check that malfunction indicator light is illuminated Yes Malfunction indicator light is illuminated.
while ignition switch is ON. Check for causes. Refer to troubleshooting with
Does MIL stay on after engine start-up? diagnostic trouble codes.
No Go to next step.
3 Check ignition system. Check resistance of DLI Yes Go to next step.
coils.
Primary: approx. 0.6~0.8Ω

Secondary: 11~15kΩ No Replace ignition coils or repair wiring harness.
Check wiring harness between ECM and DLI

coil. Is resistance within specification?
4 Check spark plug wires. Yes
4 Check spark plug wires. Yes Page 33 of 125
Go to next step.
Resistance: 4.48~6.72 kΩ/m
No Replace spark plug wires.
Check for damage to spark plug wires. Are spark
plug wires OK?
5 Connect data link connector terminals Fuel pump Check if engine starts on this condition.
and B+ with a jumper wire and check operational - Check main relay or wiring harness if engine
Yes
sound of fuel pump. starts.
Does fuel pump operate? - Go to step 7 if engine does not start.
No Go to next step.
6 Check that battery voltage is applied on R/W wire Check continuity of fuel pump (between R/W and
Yes
of fuel pump connector B12 when ignition switch B).
is ON.
No Check main relay.
7 Crank engine and check operational sound of Yes Go to step 10.
injector.
No Go to next step.
8 Check that battery voltage is applied to injector Yes Go to next step.
connector when engine is running.
No Check wire between main relay and injector.
9 Check that the resistance of injector is Yes Go to next step.
13.5~15.5Ω. No Temporarily install a known good injector and
check for proper operation. If problem is
corrected, replace injector.
10 Connect data link connector terminals Fuel pump Yes Go to next step.
and B+ with a jumper wire and check fuel line
No High pressure:
pressure while ignition switch is ON. Disconnect return line from fuel filter side.
Blow through line towards tank.
Fuel line pressure:
If line is clear, try with new pressure regulator.
46~51 psi (320~350 kPa, 3.2~3.5 kg/cm²) If line is blocked, check for blockage in return line
and clean or replace as necessary.
Is fuel line pressure within specification?
Low pressure:
Clamp return line and check if pressure rises.
If pressure rises, replace pressure regulator.
If pressure does not rise, check fuel filter at fuel
delivery module.
If it is OK, measure fuel pump max pressure and
11 Check engine compression pressure. Yes Go to next step.
No Check engine condition:
Engine compression pressure:
- Wear of piston, piston ring and cylinder wall
184 psi (1275 kPa,13.0 kg/cm²) at 300 rpm
- Defect of cylinder head gasket
- Deformation of cylinder head
Is engine compression pressure within
- Improper valve clearance
specification? - Valve stuck to guide
12 Check condition of all spark plugs. Yes
Page 34 of 125
Go to next step.
Spark plug gap: 0.039~0.043 in (1.0~1.1 mm)
Check for excessive carbon deposit and correct No Clean or replace.

contact with spark plug wires.
Are spark plugs OK?
13 Check crankshaft position sensor. Yes Go to next step.
Is crankshaft position sensor OK? No Check crankshaft position sensor and related wire
harness.
14 Temporarily install a known good ECM and check for proper operation. If problem is corrected, replace
ECM.

3 Cranks normally, but won't start (partial combustion) - When engine is cold
• Cranks normally, but partial, not continuous, combustion occurs
• Fuel present in tank
1. Overrich air/fuel ratio
• Clogged air cleaner element
• Malfunction of mass air flow sensor
2. Overlean air/fuel ratio
• Incorrect fuel injection control (correction for engine coolant temperature)
• Low fuel line pressure
• Air leakage into intake system

1 Check that malfunction indicator light is Yes Malfunction indicator light is illuminated. Check
illuminated. for causes. Refer to troubleshooting with
Does the MIL remain on after engine start-up? diagnostic trouble codes.
No Go to next step.
2 Disconnect spark plug. Yes Go to next step.
Crank engine and check for spark at plug wire
terminal. Is spark OK? No Replace ignition coil or repair wiring harness.
No High pressure:
pressure while ignition switch is ON.
Disconnect return line from fuel filter side.
Fuel line pressure:
46~51 psi (320~350 kPa, 3.2~3.5 kg/cm²)
If line is blocked, check for blockage in return line
Low pressure:
Page 35 of 125
delivery module.
4 Do injectors operate while cranking engine? Yes Go to next step.
No Check that battery voltage is applied to injector
connector and check wire between main relay and
injector.
5 Check resistance of injectors.
Resistance: 13.5~15.5Ω
Replace injector.
No
6 Check condition of ISC valve. Yes Go to next step.
Check for open circuit between ISC valve and
ECM. No Open circuit or incorrect voltage:
Check battery voltage is applied to R/Y wire of - Repair wiring harness incorrect ISC valve
ISC valve with engine running. Check ISC valve resistance.
hose connection. Is ISC valve OK? - Replace ISC valve.
7 Check terminal voltage of manifold absolute Yes Go to next step.
pressure sensor, throttle position sensor, ignition
coils and engine coolant temperature sensor. No Repair as necessary.
Are sensors functioning properly?
8 Check MAF sensor and related DTC. Yes Go to next step.
Is MAF sensor OK?
No Temporarily install a known good MAF sensor
and check for proper operation. If problem is
corrected, replace MAF sensor.
9 Check that engine starts when engine coolant Yes Check engine coolant temperature sensor.
temperature sensor connector is disconnected. -If normal:check wiring harness between engine
Does engine start? coolant temperature sensor and ECM.
-If not normal: replace engine coolant temperature
sensor.
No Go to next step.
10 Check for air leakage at intake system Yes Repair or replace.
components.
No Go to next step.
No Check engine condition:
184 psi (1275 kPa,13.0 kg/cm²) at 300 rpm - Defect of cylinder head gasket
Is engine compression pressure within - Improper valve clearance
12 Check condition of all spark plugs. Yes Go to next step.
Page 36 of 125
Spark plug gap: 0.039~0.043 in (1.0~1.1 mm)
- Excessive carbon deposit. No Clean or replace.

- Contact with high spark plug wire.
Are spark plugs OK?
ECM.
symton diagnosis chart (cranks)

4 Cranks normally, but won't start (partial combustion) - After engine is warmed up
• After engine is left hot after running, cranking speed is OK
• Engine starts normally when engine is cold
• Correction for coolant temperature
• Fuel leakage at injector
2. Vapor lock occurs
• Fuel pressure decrease after engine stops

1 Warm up engine to normal operating temperature Yes
and stop engine. Connect data link connector Replace fuel with another brand.
terminal fuel pump and B+ with a jumper wire for
3 minutes while ignition switch in ON. Then check No Go to step 2.
that engine starts. Does engine start?
and B+ with a jumper wire and check fuel line No High pressure:
Fuel line pressure: If line is clear, try with new pressure regulator.
46~51 psi (320~350 kPa, 3.2~3.5 kg/cm²) If line is blocked, check for blockage in return line
Low pressure:
delivery module.
3 Plug fuel pressure regulator outlet and check that Yes
fuel pressure is retained while ignition switch is Replace fuel pressure regulator.
OFF.
No Check fuel pump pressure is kept.
Fuel line pressure:
Page 37 of 125
Fuel line pressure: - If normal: check fuel leakage from injector
25 psi (180 kPa, 1.8 kg/cm²) for 15minutes - If not normal: replace fuel delivery module
Is fuel line pressure retention within specification?

4 Check that engine starts when engine coolant Yes Check engine coolant temperature sensor.
temperature sensor connector is disconnected. - If nor normal: check wiring harness between
Does engine start? engine coolant temperature sensor and ECM
-If not normal: replace engine coolant temperature
sensor
No Go to next step.
5 Check that malfunction indicator light is Malfunction indicator light is illuminated. Check
illuminated. Is MIL illuminated? Yes for causes. Refer to troubleshooting with
diagnostic trouble codes.
No Go to next step.
coils and engine coolant temperature sensor. No Check for causes.
Are sensor terminals voltage correct?
ECM.

5 Cranks, normally, but hard to start - Always
• Cranks normally, but cranking time up to starting is excessively long
• Engine is normal while engine is idling (Refer to "Rough Idling", if not in good idling condition)
• Incorrect fuel injection control (correction for engine coolant temperature)
• Air leakage at intake system
3. Spark plugs not in good condition

1 Check if malfunction indicator light is illuminated Yes Malfunction indicator light is illuminated.
Is MIL illuminated for more than 3 seconds after diagnostic trouble codes.
ignition is turned ON? No Go to next step.
2 Check intake manifold vacuum while engine is Yes
idling. Go to next step.
Page 38 of 125
Vacuum: more than 18.9 inHg (480mmHg) No Check air leakage at intake system.
Is intake manifold vacuum within specification?

3 Check cleanness of air cleaner element. Yes Go to next step.
Is air cleaner element OK?
No Check air leakage at intake system.
4 Check if engine starts easily when throttle valve is Yes Check carbon deposit on throttle valve and go to
held one quarter open. step 6.
Does engine start easily? No Go to next step.
5 Check fuel line pressure while engine is idling. Yes Go to next step.
High pressure:
Fuel line pressure: Disconnect return line from fuel filter side.
46~51 psi (320~350 kPa, 3.2~3.5kg/cm²)
Is fuel line pressure within specification? If line is blocked, check for blockage in return line
No
Low pressure:
delivery module.
6 Check condition of ISC valve. Check for open
circuit between ISC valve & ECM. Measure Yes Go to next step.
Battery voltage is applied to R/Y wire engine
running. No Check for causes.
Check ISC valve hose connection. Is ISC valve
OK?
7 Connect data link connector terminals Fuel Pump Yes Check fuel pump relay.
and B+ with a jumper wire and check that engine - If normal, repair or replace wiring harness.
starts. - If not normal, replace relay.
Does engine start?
No Go to next step.
Is MAF sensor OK? No Temporarily install a known good MAF sensor
No Check engine condition.
Engine compression pressure: - Wear of piston, piston ring and cylinder wall
184 psi (1275kPa, 13.0 kg/cm²) at 300 rpm - Defect of cylinder head gasket
Is engine compression pressure within - Improper valve clearance
specification?
- Valve stuck to guide
10 Check spark plug condition. Yes
Page 39 of 125
Go to next step.
Spark plug gap: 0.039~0.043 in (1.0~1.1 mm).
Check for excessive carbon deposit and correct No Clean or replace.

contact with spark plug wires. Are spark plugs
OK?
ECM.

6 Cranks normally, but hard to start - When engine is cold
• Cranks normally, but cranking time up to starting is excessively long
• Battery is OK
Description
• Restart is normal after engine warmed up
• Engine is normal while engine is idling(Refer to "Rough Idling" if not in good idling condition)
• Contaminated air cleaner element
• Malfunction of injection control (correction for engine coolant temperature)

Is MIL illuminated longer than 3 seconds after diagnostic trouble codes.
ignition switch is turned ON?
No Go to next step.
Are sensors OK?
3 Check if engine starts easily when throttle valve is Yes Check carbon deposit on throttle valve and go to
held one quarter open. step 6.
Does engine start easily? No Go to next step.
4 Check vacuum in intake manifold while engine is Yes
Vacuum: more than 18.9 inHg (480mmHg) No Check air leakage at intake air system component.

Is air cleaner element OK? No Replace air cleaner element.
6 Connect data link connector terminal fuel pump Yes Go to next step.
Page 40 of 125
No High pressure:
Fuel line pressure:
46~51 psi (320~350 kPa, 3.2~3.5kg/cm²)
Low pressure:
delivery module.
ECM.

7 Cranks normally, but hard to start - After engine is warmed up
• After engine is left hot after running, cranks normally, but cranking time up to starting is
excessively long
• Starts normally when engine is cold
• Engine is normal while engine is idling(Refer to "Rough Idling", if not in good idling condition)
• Malfunction of fuel ratio calculation
• Fuel leakage from injector
2. Vapor lock

No Go to next step.
Are sensors OK?
3 After engine idling and turn ignition switch OFF. Yes Go to next step.
Check that fuel line pressure is retained.
No Plug outlet of fuel pressure regulator and turn
ignition switch OFF. Then check that fuel line
Fuel line pressure: more than 25 psi
Pressure is retained.
(180 kPa, 1.8 kg/cm²) for 15 minutes
- If normal: replace fuel pressure regulator
Page 41 of 125
- If not normal: check fuel pump pressure kept
Is fuel line pressure retention within specification?
Is fuel pump is normal, check fuel leakage from
injector?
4 Warm up engine to normal operating temperature Yes
and stop engine. Connect data link connector Replace fuel with another brand.
terminals fuel pump and B+ with a jumper wire for
3 minutes while ignition switch is ON. Then check No Go to next step.
that engine starts easily.
Does engine start easily?
ECM.
Symptom diagnosis chart(Idling)

8 Rough idling / engine stops while idling - always
Description • Engine starts normally, but engine stops or vibrates while idling
• Air leakage
• Malfunction if fuel injection control
2. Clogging or malfunction of one or more injector
3. Malfunction of mass air flow sensor
4. Malfunction of IAC valve or related wiring
5. Malfunction of spark plugs
7. Malfunction of throttle position sensor or related wiring

ignition switch is turned ON? No Go to next step.
Are sensors OK?
3 Check operating sound of injectors while engine is Yes Go to step 5.
idling.
Are injectors operating? No Go to next step.
4 Check that voltage is applied to injector Yes Go to next step.

connectors while engine is running (approx. 12V). No Check wiring harness between ECM and injector
Is voltage within specification? .
5 Check resistance of injector.
Page 42 of 125
?
Replace injector.
No
6 Ignition ON, throttle closed, measure voltage of Yes Go to next step.
throttle position sensor 3(L/O) (0.2~0.8V).
No Temporarily install a known good TP sensor and
check for proper operation.
If problem is corrected, replace TP sensor
and check for proper operation.
If problem is corrected, replace MAF sensor.
Engine compression pressure: No Check engine condition.

184 psi (1275kPa, 13.0 kg/cm²) at 300 rpm - Wear of piston, piston ring and cylinder wall
Is engine compression pressure within - Deformation of cylinder head
ECM.

9 Rough idling / engine stops while engine is idling - engine cold
Description • Engine speed is slow, engine stops or vibrates while warming up engine.
1. Insufficient intake air
• Malfunction of IAC valve
2. Malfunction of fuel injection control
• Malfunction of fuel injection control devices(correction for engine coolant temperature)
Page 43 of 125
2 Check intake manifold vacuum at dynamic Yes
chamber while engine is idling. Go to next step.
Vacuum: 18.9 inHg (480 mmHg) at idle No Check air leakage in intake system.

4 Check terminal voltage of manifold absolute Yes
Go to next step.
coils, engine coolant temperature sensor. No Check for causes.
Are sensors OK?
5 Check resistance of engine coolant temperature Yes Go to next step.
sensor.
Temporarily install a known good ECT sensor and
No check for proper operation.
If problem is corrected, replace ECT sensor.
ECM.

10 Rough idling / engine stops while engine is idling - After engine is warmed up
• Engine operation is normal while warming up engine, but engine stops or vibrates after warming
Description
up
1. Malfunction of IAC valve
• Air leakage
3. Malfunction of ignition system
• Malfunction of fuel injection control(correction for coolant temperature)

Page 44 of 125
Are sensors OK?
3 Check vacuum of intake manifold. Yes Go to next step.
Vacuum: more than 18.9inHg (480mmHg) at No Check for air leakage at intake system
idle component.
Is air cleaner element OK? No Replace air cleaner.
No High pressure:
46~51 psi (320~350 kPa, 3.2~3.5kg/cm²) Blow through line towards tank.
Low pressure:
delivery module.
6 Disconnect engine coolant temperature sensor Yes Replace engine coolant temperature sensor.
connector and check that engine condition
improves. No Go to next step.
Does engine condition improve?
7 Check operating sound of injector whileengine is Yes Go to step 10.
idling. Are injectors operating? No Go to next step.
8 Check resistance of injector. Yes Go to step 10.
Resistance: 13.5~15.5Ω No Temporarily install a known good injector and

Is resistance within specification? If problem is corrected, replace injector.
9 Check engine compression pressure. Yes
Go to next step.
184 psi (1275kPa, 13.0 kg/cm²) at 300 rpm

Page 45 of 125
No Check engine.
specification?
ECM.

11 Rough idling / engine stops while engine is idling - When A/C is in operation
• Engine stops or vibrates excessively when A/C is operating
Description
• Idling condition is normal when A/C is turned OFF
1. Malfunction of ISC control system
2. Malfunction of A/C operation switch
3. Malfunction of blower switch

No Go to next step.
2 Check air conditioner cut relay is ON/OFF when Yes Go to next step.
air conditioner switch and blower switch are
ON/OFF. No Malfunction of air conditioner switch, relay, or
Are A/C cut relay, blower switch and A/C switch
OK? blower switch.
3 Check for continuity between B04-24, B04-23 Yes Go to next step.

and B04-36 of ECM.
Does continuity exist? No Repair wiring harness.
ECM.

12 Abnormal idling / engine stops immediately after starting
• Starting is normal, but engine vibrates excessively or stops immediately after starting
Description (when accelerating from idling condition)
• Idling condition is normal on other conditions
1. Malfunction of ISC system
2. Air leakage at intake system
3. Malfunction of blower switch
Page 46 of 125
Is MAF sensor OK?
3 Check that voltage of throttle position sensor Yes Go to next step.
terminal is 0.2~0.8V and does not vary. No Temporarily install a known good TP sensor and
corrected, replace TP sensor.
4 Check for air leakage at intake system and Yes
vacuum at dynamic chamber while engine is idling. Go to next step.
Vacuum: more than 18.9 inHg (480mmHg) No Check intake system and dynamic chamber.

ECM.
Symptom diagnosis chart(Idle speed)

13 High idle speed after engine warmed up
Description • Excessively high idle speed after engine warmed up
Excessive intake air flow
1. Throttle valve not closed completely
2. Malfunction of idle speed control
• ISC valve stuck
• ISC valve connector disconnected
• Incorrect input signal from engine coolant temperature sensor
Page 47 of 125
1 Check that throttle valve is closed completely Yes Go to next step.
when accelerator pedal is released.
No Check correct installation and free operation of
Is throttle valve closed?
throttle linkage. If not normal, clean or adjust
linkage.
3 Disconnect engine coolant temperature sensor Yes Temporarily install a known good ECT sensor and
connector and check if engine condition improves. check for proper operation.
Does engine condition improves? If problem is corrected, replace ECT sensor.
No Go to next step.
4 Plug PCV hose connected with dynamic chamber Yes Check or replace PCV valve.
and check if engine speed decrease.
Does engine speed decrease? No Go to next step.
5 Check that voltage of throttle position sensor Temporarily install a known good TP sensor and
terminal 3(L/O) is 0.2~0.8V and does not vary. Yes check for proper operation.
If problem is corrected, replace TP sensor.
No Go to next step.
6 Check following ECM terminal voltage.
- ISC valve control Yes Go to next step.
- A/C switch input
- Park/neutral input No Replace as necessary.
Are voltage correct?
ECM.
Symptom diagnosis chart(Idle speed)

14 Variation of idle speed / Idle hunting
Description • Periodic engine speed increase and decrease while engine is idling
1. Malfunction of throttle position sensor system
2. Air leakage
3. Malfunction of ISC system
4. Fuel injection is irregular

No Go to next step.
Page 48 of 125
2 Check that voltage of throttle position sensor Yes Go to next step.
terminal 3(L/O) is 0.2-0.8V and does not vary. No Temporarily install a known good TP sensor and
Is voltage within specification? check for proper operation.
If problem is corected, replace TP sensor.
3 Check air cleaner element. Yes Go to next step.
4 Disconnect high tension cord and check equal Yes Go to next step.
engine speed decrease in all cylinders.
No Go to step 7.
5 Check following ECM terminal voltage.
• ISC valve control Yes Go to next step.
• A/C switch input
• Park/neutral input Check for causes.
No
Are voltage correct?
Is MAF sensor OK? No Temporaily install a known good MAF sensor and
7 Check operating sound of injector while engine is Yes Go to step 9.
idling. Are injectors OK? No Go to next step.
8 Check that approx. battery voltage is applied to Yes Go to next step.
injector connector terminals. No Check the wiring harness between ECM and
Is voltage within specification? injector.
9 Check resistance of injector. Yes
Go to next step.
Resistance : 13.5~15.5Ω
No
Replace injector.
10 Check spark plugs for proper operation. Yes Go to next step.
Are spark plugs OK? No Clean or replace.
11 Check engine compression pressure. Yes
Go to next step.
No Check for cause.
specification?
12 Check for fuel leakage from injectors. Do Yes Temporarily install al known good injector and
injectors leak? check for proper operation.
If problem is corrected, replace injector.
No Go to next step.
ECM.
Page 49 of 125
Symptom diagnosis chart(Engine)

• Engine stops unexpectedly during or after deceleration
Description
• Idling condition is normal
Engine speed decreases abruptly when accelerator pedal is released, which can cause connectors to come loose
1. Malfunction of idle air control
3. Malfunction of fuel cut control

No Go to next step.
2 Check throttle position sensor, ISC valve terminal Yes Go to next step.
voltage and related wiring harness. No Repair the wiring harness or replace defective
Are sensors OK?
component.
3 Check ECM terminal voltages for B04-35, B04- Yes Go to next step.
34, B04-17, B04-15 and B04-7.
Are voltage within specification? No Check for cause and repair as necessary.
4 Check contact condition of following connectors: Yes

-Throttle position sensor, manifold absolute Go to next step.
pressure sensor, ignition coils, injector, crankshaft
position sensor, ECM. No Repair or replace.
Are terminal connections OK?

ECM.
Symptom diagnosis chart(Engine)

16 Engine stalls suddenly (intermittent), sudden engine stop
• Engine stops suddenly and intermittently
Description
• Engine is normal until engine stops
1. Malfunction of ISC control system
3. Intermittent loosened electrical contact
Page 50 of 125
Is MIL illuminated longer than 3 seconds after is diagnostic trouble codes.
turned ON? No Go to next step.
2 Check contact condition of following connectors: Yes
-Throttle position sensor, manifold absolute Go to next step.
pressure sensor, ignition coils, injector, crankshaft
position sensor, ECM. No Repair or replace as necessary.
Are terminal connections OK?

3 Measure crankshaft position sensor and manifold Yes Go to next step.
absolute pressure sensor signals.
Are sensor signals OK? No Repair or replace.
34, B04-17, B04-15 and B04-7.
Are voltages OK? No Check for cause and repair as necessary.
ECM.
Symptom diagnosis chart(Stumble / Hesitation on acceleration)

17 Stumble / Hesitation on acceleration
• Vehicle seems to stop for a time immediately after pressing accelerator or rattles a little during
Description
acceleration
1. Lean air/fuel ration on acceleration
• Air leakage
• Malfunction of fuel injection control

2 Check vacuum in intake manifold while engine Yes
Vacuum: more than 18.9 inHg (480mmHg) No Check air leakage at air intake system and repair.

No Replace air cleaner element.
Page 51 of 125
4 Check if MAF sensor is OK. Yes Go to next step.
No Temporarily install a known good MAF sesor and
If problem is corrected,replace MAF sensor.
5 Check engine coolant temperature sensor and Yes Go to next step.
related DTC.
Is ECT sensors OK? No Replace the engine coolant temperature sensor.
6 Check throttle position sensor and related DTC.
Voltage between terminals:
Idling condition: 0.2~0.8V No Temporarily install a known good TP sensor and
Throttle valve full open: 4.0~4.8V check for proper operation.
Is TP sensors OK?
7 Disconnect injector connector one by one while Yes
engine in idling, and check equal engine speed Go to next step.
decrease for each cylinder.
Does engine speed decrease equally for all No Check injector.
cylinders?
8 Check correct installation and free operation of Yes Go to next step.
throttle linkage. No Adjust or replace joint or damaged linkage and
Is throttle linkage OK?
adjust deflection of throttle cable.
No High pressure:
Fuel line pressure:
46~51 psi (320~350 kPa, 3.2~3.5kg/cm²)
If line is clear, try new pressure regulator.
Low pressure:
delivery module.
10 Check air passage and vacuum hose installation. Yes Go to next step.
Are vacuum hoses OK? No Repair as necessary.
11 Check exhaust system clogging. Yes Repair or replace necessary.
Is exhaust system clogged?
No Go to next step.
ECM.
Symptom diagnosis chart(Surging while cruising)

Page 52 of 125
18 Surging while cruising
Description • Repeated engine speed variation occurs at all times
2. Misfire
3. Intermittent electrical connection
4. Lean air/fuel ratio

Vacuum: more than 18.9 inHg (480mmHg) No Check air leakage at air intake system and repair.

3 Check throttle position sensor and related DTC. Yes
Go to next step.
Is TP sensors OK?
4 Disconnect heated oxygen sensor connector and Yes Go to next step.
Is HO2S OK? No Replace front heated oxygen sensor.
5 Check that vehicle speed sensor signal input to Yes Go to next step.
ECM B02-18.
Is signal correct? No Repair wiring harness or vehicle speed sensor.
15, and B04-7. Are voltages OK? No Check for causes and repair.
7 Check correct installation and free operation of Yes Go to next step.
throttle linkage. No Adjust or replace joint or damaged linkage and
Is throttle linkage OK? adjust deflection of throttle body cable.
No High pressure:
Fuel line pressure:
46~51 psi (320~350 kPa, 3.2~3.5kg/cm²)
Page 53 of 125
Low pressure:
delivery module.
10 Check exhaust system clogging. Yes Repair as necessary.
Is exhaust system clogged?
No Go to next step.
ECM.
Symptom diagnosis chart(Lack of power)

19 Lack of power
• Lack of power at full throttle
Description • Lower maximum vehicle speed
• Idling speed is normal
• Throttle valve does not open fully
• Clogged intake air system
2. Lean air/fuel ratio
• Fuel line pressure decrease
• Malfunction of fuel injection
3. Malfunction of ignition

1 Check following items. Yes
- Clutch slippage Go to next step.
- Brake dragging
- Lack of tire air pressure No Repair as necessary.
- Improper tire size
Are these systems OK?
2 Is throttle valve open fully when depressing Yes Go to step 5.
accelerator pedal fully?
No Go to next step.
3 Check correct installation of throttle cable. Yes Go to next step.
Is throttle cable OK? No Repair or adjust throttle cable.
Page 54 of 125
4 Check correct operation of throttle body. Yes Go to next step.
Is throttle body OK? No Repair or replace throttle body.
5 Check that malfunction indicator light is illuminated Malfunction indicator light is illuminated.
while ignition switch is ON. Yes Check for causes. Refer to troubleshooting with
6 Check the camshaft position sensor and DTC Yes Go to next step.
related.
No Temporarily install a known good CMP sensor
Is CMP sensor OK? and check for proper operation.
If problem is corrected, replace CMP sensor.
Go to next step.
Is TP sensors OK?
Vacuum: more than 18.9 inHg (480mmHg) No Repair intake system or dynamic chamber.

9 Disconnect injector connector one by one while Yes
engine in idling, and check equal engine speed Go to next step.
decrease for each cylinder.
Does engine speed decrease equally for all No Check injector.
cylinders?
11 Keep engine idling and turn ignition switch OFF. Yes Go to next step.
Check that fuel line pressure is retained.
No Plug outlet of pressure regulator and turn ignition
switch OFF. Then check fuel line pressure is
Fuel line pressure: more than 25 psi
retained.
(180 kPa,1.8kg/cm²) for 15 minutes
- If normal: replace pressure regulator
- If not normal: check fuel pump
Is fuel pressure retention within specification?
If fuel pump is normal, check fuel leakage from
injector.
12 Does fuel line pressure increase when accelerating Yes Go to next step.
abruptly?
No Check fuel line and fuel filter clogging and repair if
Fuel line pressure: 48 psi (330 kPa, 3.3
kg/cm²) as necessary.
Page 55 of 125
13 Check the MAF sensor and related DTC. Yes Go to next step.
14 Check ignition system Yes
- Check resistance of DLI coil Go to next step.
Primary: 0.6~0.8Ω
Secondary: 11~15kΩ
- Check wiring harness between DLI coil and No Replace ignition coils or repair wiring harness.
ECM
Is ignition system OK?

15 Check spark plug wires. Yes Go to next step.
Are spark plug wires OK?
No Replace spark plug wires.
16 Check spark plug. Yes Go to next step.
Are spark plugs OK?
No Clean or replace.
No Check engine condition
184 psi (1275 kPa, 13.0 kg/cm²)at 300 rpm
specification? - Valve guide stuck
ECM.
Symptom diagnosis chart(Poor acceleration / Lack of power)

20 Poor acceleration / Lack of power
• Lack of power on acceleration
• Lack of power at full throttle
Description
• Lower maximum vehicle speed
• Idling speed is normal
1. Factors except engine malfunction
• Clutch slippage
• Brake dragging
• Lack of tire air pressure
• Improper tire size
• Overload
• Throttle valve does not open fully
• Intake system clogging
Page 56 of 125

1 Check following items. Yes
- Clutch slippage Go to next step.
- Brake dragging
- Lack of tire air pressure
- Improper tire size No Repair as necessary.
- Overload
Are the items OK?
No Go to next step.
Is throttle cable OK?
No Repair or replace throttle cable.
4 Check correct operation of throttle body. Yes Go to next step.
Is throttle body OK?
No Repair or replace throttle body.
5 Check that malfunction indicator light is illuminated Malfunction indicator light is illuminated.
while ignition switch is ON. Yes Check for causes. Refer to troubleshooting with
6 Check camshaft position sensor and connector. Yes Go to next step.
Is CMP sensor OK? No Replace camshaft position sensor or repair related
wire harness.
Go to next step.
Is TP sensors OK?
Vacuum: more than 18.9 inHg (480mmHg) No Check air leakage into intake system and repair as
necessary.
9 Disconnect injector connector one by one while Yes Go to next step.
engine is idling. Is there an equal engine speed
decrease for each cylinder? No Check injectors.

Page 57 of 125
No High pressure:
Fuel line pressure:
46~51 psi (320~350 kPa, 3.2~3.5kg/cm²) Blow through line towards tank.
Low pressure:
delivery module.
12 Does fuel line pressure increase when accelerating Yes
Go to next step.
abruptly?
No Check fuel line and fuel filter clogging and repair if
Fuel line pressure: 48 psi (330 kPa, 3.3
as necessary.
kg/cm²)
13 Check the MAF sensor and related DTC. Yes Go to next step.
14 Check ignition system Yes
- Check resistance of DLI coil Go to next step.
Primary: 0.6~0.8Ω
Secondary: 11~15kΩ
- Check wiring harness between DLI coil and No Replace ignition coils or repair wiring harness.
ECM
Is ignition system OK?

15 Check spark plug wires. Yes Go to next step.
Are spark plug wires OK? No Replace spark plug wires.
16 Check spark plugs. Yes
Spark plug gap: 0.027~0.031 in (0.7~0.8 mm) Go to next step.
- Excessive carbon deposit
- Contact with high tension cord No Clean or replace as necessary.
Are spark plug OK?
specification? - Valve guide stuck
ECM.
Page 58 of 125
Symptom diagnosis chart(deceleration/ backfire)

21 Rough engine running on deceleration/ backfire
• Rough engine running on deceleration and backfire
Description
• Transmission is normal
• Air cleaner element clogged
• Malfunction of fuel injection system(fuel cut control)
• Malfunction of throttle position sensor

No Go to next step.
Vacuum: more than 18.9 inHg (480mmHg) No Check air leakage into air intake system.

18, B05-6 and B05-4.
Are terminal voltages OK? No Check for cause and repair as necessary.
5 Check fuel injection system. Yes Go to next step.

Is fuel injection system OK? No Repair injection system as necessary.
6 Check mass air flow sensor and related DTC. Yes Go to next step.
Is MAF sensor OK?
7 Check throttle position sensor and DTC related to Yes
sensor. Go to next step.
- Voltage between terminals
When idling: 0.2~0.8V
When opening throttle valve fully : 4.0~4.8V No Temporarily install a known good TP sensor and
- Check that idling voltage return to specified check for proper operation.
valve when releasing after pulling accelerator If problem is corrected, replace TP sensor.
cable.
Is TP sensor OK?
Page 59 of 125
8 Check throttle body contamination. Yes Clean or replace as necessary.
Is throttle body contaminated? No Go to next step.
9 Check fuel leakage from injector. Yes Go to next step.
Do fuel injectors leak? No Clean or replace as necessary.
ECM.
Symptom diagnosis chart(Knocking)

22 Knocking
Description • Abnormal combustion occurs, accompanied by audible "pinging" noise
1. Improper ignition timing
2. Carbon deposit in cylinder
3. Engine overheat
• Incorrect fuel injection
• Fuel line pressure decrease on acceleration

No Go to next step.
No Go to next step.
Is throttle cable OK?
No Repair or replace throttle cable.
4 Check correct installation of throttle body. Yes Go to next step.
Is throttle body OK? No Repair or replace throttle body.
specification?
- Valve guide stuck
6 Check camshaft position sensor and related DTC. Yes Go to next step.
Is CMP sensor OK?
No Temporaily install a known good CMP sensor and
If problem is corrected, replace CMP sensor.
Page 60 of 125
No High pressure:
46~51 psi (320~350 kPa, 3.2~3.5kg/cm²)
Low pressure:
delivery module.
8 Check cooling system. Yes Go to next step.
Is cooling system OK? No Repair or replace.
ECM.
Symptom diagnosis chart(fuel odor)

23 Fuel odor
Description • Fuel odor in passenger compartment
1. Loose connection of fuel system or evaporative engine system
2. Malfunction of evaporative emissions system

1 Check damage or leakage of fuel system or Yes Repair or replace as necessary.
evaporative emission system.
Is system leaking or damaged? No Go to next step.
ignition switch ON? No Go to next step.
3 Warm up engine fully. After disconnecting vacuum Yes Go to step 6.
hose from evaporative emissions canister to purge
solenoid valve, check that vacuum is applied to it. No Go to next step.
Is vacuum applied?
4 Check operational sound of EVAP canister purge Yes Check vacuum hose clogging.
solenoid valve is normal.
Is EVAP canister purge valve OK? No Go to next step.
5 Check that vacuum is applied to vacuum hose Yes Check ECM terminal voltage.
after applying battery voltage to EVAP canister
purge valve. Is vacuum applied? No Replace EVAP canister purge valve.
Page 61 of 125
ECM.
Symptom diagnosis chart(High oil consumption)

24 High oil consumption
Description • High oil consumption
1. Malfunction of PCV valve
2. Malfunction of engine (oil leakage)

1 Check damage, removal, clogging or sticking of Yes Go to next step.
PCV hose, or ventilation hose fittings.
Is PCV system OK? No Repair or replace as necessary.
2 Check if there is air pressure or oil in ventilation Yes Go to next step.

hose. No Check engine condition:
Is ventilation hose OK? - Oil leakage
- Wear of valve seal
- Wear of valve stem
- Wear of valve guide
3 Check if vacuum is applied at PCV valve while Yes Check engine condition:
engine is idling. - Wear of piston ring groove
Is vacuum applied? - Malfunction of piston ring
- Wear of piston or cylinder
No Replace PCV valve.
Symptom diagnosis chart(MIL on continuously)

25 MIL on continuously
Description • Hi-scan pro tool does not display diagnostic trouble code, but MIL light on continuously
1. Short circuit of wiring harness
2. Malfunction of ECM

1 Disconnect wire (L/Y) from ECM and check that Yes Temporarily install a known good ECM and
MIL remains illuminated. check for proper operation.
Is MIL illuminated? If problem is corrected, replace ECM.
No Check short circuit from meter set to ECM.
Symptom diagnosis chart(MIL dose light illuminate)

Page 62 of 125
26 MIL dose light illuminate
Description • Hi-scan pro tool displays malfunction code, but MIL does not illuminate
1. Bulb is blown
2. Open circuit

1 Check MIL buib is OK. Yes Go to next step.
Is buib OK? No Replace bulb.
2 Ground ECM wire (L/Y) with a jumper wire and Yes Go to next step.
check if MIL illuminates. Does MIL illuminate?
No Repair wiring harness from ECM to meter set.
3 Check ECM connections. Yes Temporarily install a known good ECM and
Are ECM connections OK? check for proper operation. If problem is
corrected, replace ECM.
No Repair or replace ECM connector.
Symptom diagnosis chart(Air conditioner)

27 Air conditioner does not operate
Description • Blower motor operates, but magnetic clutch not engaged
1. Short or open circuit of wiring harness
2. Malfunction of air conditioner relay, air conditioner switch, magnetic switch
3. Malfunction of ECM

1 Check voltage of ECM terminal B04-24. Yes Go to next step.
Is voltage OK?
No Check for causes.
2 Check voltage of ECM terminal B04-23. Yes Check air condition system.
Is voltage OK?
No Temporarily install a known good ECM and
corrected, replace ECM.
Fuel System > Engine Control System > Repair procedures

On-vehicle service
Inspection
Component Connector Terminal Normal Ranges
TPS
Page 63 of 125
1-2 1.6-2.4Ω
1-3 0.71-1.38kΩ at close throttle
TPS 1-3 2.2-3.4kΩ at wide open
(Throttle Position Sensor) terminal 1 : ground
terminal 2 : power
terminal 3 : signal
1-3 13.24-16.83kΩ at -4°F(-20°C)

1-3 2.27-2.64kΩ at 68°F(20°C)
ECT
1-3 0.207-0.429kΩ at 176°F(80°C)
(Engine Coolant
Temperature sensor)
1-2 13.24-16.83kΩ at -4°F(-20°C)

1-2 2.27-2.64kΩ at 68°F(20°C)
ATS 1-2 0.207-0.429kΩ at 176°F(80°C)
(Air Temperature Sensor)
1-2 13.5-15.5Ω at 68°F (20°C)
INJECTOR
2-4 Whole sensor is in a temperature chamber

without heater power
3-7Ω at 68°F(20°C)
O2 Sensor
2-3 16.5-18.5kΩ at 68°F(20°C)

1-2 14.5-16.5kΩ at 68°F(20°C)
ISC terminal 1 : closing coil
(Idle Speed Control) terminal 2 : power supply (12V)
terminal 3 : opening coil
1-2 24-28Ω at 68°F(20°C)

CPSV
(Canister Purge control
Valve)
CCV
(Canister Close valve)
Page 64 of 125
1-2 23.0-26.0Ω at 68°F(20°C)
CCV
(Canister Close valve)
1-2 80-90Ω at 68°F(20°C)
POWER
RELAY
Fuel System > Engine Control System > Specifications

ECM TERMINAL VOLTAGE
CONNECTOR B-01
Terminal Signal Connected to Test condition Voltage
9 Power input Ignition switch Key ON B+
8 Power input Ignition switch Key ON B+
1 Ignition input Ignition switch Key ON B+
4 Ground Ground Constant <0.5V
6 Ground Ground Constant <0.5V
5 Ground Ground Constant <0.5
Data link
3 Diagnosis K-line - -
connector
7 Power Battery Constant B+
CONNECTOR B-02
Page 65 of 125
Canister close valve Non-operation B+
20 Canister close valve
control Operation <1v
Wheel speed sensor Wheel stop 0V or 5V
18 Wheel speed sensor
input Wheel rolling 1~2V (wave)
Wheel speed sensor
12 Wheel speed sensor Constant <1V
ground
Fuel tank pressure
9 Fuel tank Constant <1V
ground
Key ON/ENG OFF 5V
15 Fuel tank pressure input Fuel tank
Idle 2~3V
Key ON/ENG OFF 0.4V
17 HO2S down input HO2S down
Idle 0~1V
11 HO2S down ground HO2S down Constant B+
Key ON/ENG OFF B+
19 HO2S down heater HO2S down 6~8V (duty
Idle
48~52%)
CONNECTOR B-03
Key ON/ENG OFF B+
47 Fuel injection valve control Fuel injector No. 2
Idle B+(duty)
Key ON/ENG OFF B+
Idle B+(duty)
Key ON/ENG OFF B+
Idle B+(duty)
Key ON/ENG OFF B+
Idle B+(duty)
Key ON/ENG OFF B+
31 Engine RPM signal output Instrument cluster Idle 6-7V(duty
45~50%)
Key ON(throttle valve 1-2V(duty
close) 8~12%)
28 TPS signal output Transaxle control module
Key ON(throttle valve 8-12V(duty
open) 88~92%)
Idle 1-2V(duty
27 Torque signal output Transaxle control module
8~12%)
15 TPS voltage TPS Key ON B+
Page 66 of 125
EVAP purge solenoid EVAP purge solenoid Key ON/ENG OFF B+
42
valve valve Idle 10-12V(duty)
Key ON/ENG OFF 6-7V(duty
ISC valve output control 42~52%)
44 ISC valve
(closing) Idle 9-10V(duty
60~70%)
Key ON/ENG OFF 7-8V(duty
ISC valve output control 50~60%)
43 ISC valve
(opening) Idle 4-6V(duty
30~40%)
20 Knock sensor shield Knock sensor Constant <0.5V
33 Knock sensor ground Knock sensor Constant <0.5V
46 Knock sensor input Knock sensor Key ON 2-3V
Key ON 0.5V
36 MAF sensor input MAF sensor
Idle 0.6-0.8V
Constant <1V
23 MAF sensor ground MAF sensor
Idle 0-B+
Key ON/ENG OFF 0.4V
35 HO2S up input HO2S up
Idle 0-1V
22 HO2S up ground HO2S up Constant <1V
Key ON/ENG OFF B+
40 HO2S up heater control HO2S up Idle 6-8V(duty
48~52%)
16 Power output Tank pressure sensor Key ON 5V
CONNECTOR B-04
Key ON/cooling fan non-
B+
operation
33 Cooling fan relay control Cooling fan relay
Key ON/cooling fan
<1V
operation
A/C non-operation B+
36 A/C relay control A/C relay
A/C operation <1V
A/C non-operation B+
23 DPS signal input DPS
A/C operation <1V
A/C switch ON B+
24 A/C switch signal input A/C switch
A/C switch OFF <1V
Page 67 of 125
Key ON/switch operation <1V
25 Power steering switch input Power steering switch Key ON/switch non- B+
operation
Key ON/ENG OFF <1V
37 MIL control MIL (instrument cluster) Idle (DTC non-present) B+
Idle (DTC present) <1V
Key ON (P/N range) <1V
30 Park/Neutral signal input Transaxle control module
Key ON (other range) B+
Headlight switch signal Key ON/switch HEAD B+
26 Headlight switch
input Key ON <1V
Key ON <1V
34 Main relay control Main relay
Key OFF B+
Key ON (throttle valve 0.2~0.8V
close)
17 TPS signal input TPS
Key ON (throttle valve 4.0~4.8V
open)
7 TPS ground TPS Constant <1V
Camshaft position sensor Key ON/ENG OFF 0V or 5V
18 signal input Camshaft position sensor Idle 2-3V (duty
40~50%)
Camshaft position sensor Camshaft position sensor Constant <1V
8
ground
Intake air temperature Intake air temperature Key ON/ENG OFF 1-2V
11
sensor signal input sensor (at 20°C)
Intake air temperature Intake air temperature Constant <1V
1
sensor ground sensor
Key ON/ENG OFF B+
35 Fuel pump relay control Fuel pump
Idle <1V
Key ON/ENG OFF <0.5V
Crankshaft position sensor
20 Crankshaft position sensor Idle 2-3V(duty
signal input
40~50%)
Crankshaft position sensor Crankshaft position sensor Constant <1V
10
ground
29 Torque reduction control Transaxle control module - 9-10V
Engine coolant temperature Key ON/ENG OFF 1-2V
15 Engine coolant temperature
signal input (at 80°C)
Engine coolant temperature Constant <1V
5 Engine coolant temperature
ground
27 TCU MIL signal input Transaxle control module - 0V or 5V
Page 68 of 125
Vehicle stop 0V/5V
22 Vehicle speed sensor input Vehicle speed sensor
Vehicle rolling 2-3V
CONNECTOR B-05
Key ON/ENG
Ignition coil Ignition coil B+
4 OFF
control (cylinder no.1&4)
Idle B+(pulse)
Key ON/ENG
Ignition coil Ignition coil B+
6 OFF
control (cylinder no.2&3)
Idle B+(pluse)
Fuel System > Engine Control System > Mass Air Flow Sensor (MAFS) > Repair procedures
Removal
Do not drop or subject the sensor to shock.

Do not put objects inside the sensor.
1. Disconnect mass air flow sensor connector.
2. Loosen air intake hose retaining clamps on both sides of mass air flow sensor.
3. Disconnect air intake hose from mass air flow sensor.
4. Remove two bolts attaching mass air flow sensor to mounting bracket.
5. Remove mass air flow sensor.
Inspection
1. Attach mass air flow sensor to air intake hose and to mounting bracket.
2. Replace two bolts to retain mass air flow sensor to mounting bracket.
Tightening Torque: 69~96.3 Ib·in (7.8~10.8 N·m, 0.8~1kg·m)
3. Reconnect air intake hose to the mass air flow sensor.

4. Tighten bolts of retaining clamps on both sides of mass air flow sensor.
5. Reconnect mass air flow sensor connector to sensor.
6. Warm up engine to normal operating temperature and let engine idle.

7. Connect voltmeter between terminal 2 (G/L) and ground.
8. Verify that the voltage varies between 0.6V~0.8V.
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9. Rev up engine and verify that voltage varies between 3.0V~4.0V.
10. If voltage is not within specification, replace mass air flow sensor.
Fuel System > Engine Control System > Throttle Position Sensor (TPS) > Repair procedures
Inspection
1. Disconnect connector from throttle position sensor.
2. Connect ohmmeter between sensor terminals 1 and 2.
3. Verify that resistance increases linearly according to throttle angle.
Specification: 1.6~2.4kΩ(with throttle valve closed)
4. If resistance is not as specified, replace the throttle position sensor.

5. Connect throttle position sensor connector.
Voltage inspection
1. Verify that throttle is at the closed throttle position.
2. Turn ignition switch ON (engine OFF).
3. Connect voltmeter between terminals 2(L/G) and 1(W/G) on throttle position sensor connector. Check for 5V
reference voltage.
4. Connect the voltmeter between terminal 1(W/G) and terminal 3(L/O) on the TPS connector.
5. Measure the voltage at the fully open and fully closed position.
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6. If not as specified, replace throttle position sensor.
Specification :
Measuring condition Voltage (V)
Fully closed 0.2~0.8V
Fully open 4.0~4.8V
Fuel System > Engine Control System > Heated Oxygen Sensor (HO2S) > Repair procedures
Inspection of terminal voltage for front & rear heated oxygen sensor
2. Run engine at idle speed.
3. Connect a voltmeter between terminal 1 (LG/R) and ground.
4. Increase and decrease engine speed quickly several times.
5. Verify that meter reading varies between 0~1.0V.
Rear oxygen sensor voltage does not fluctuate as quickly as front oxygen
sensor.
6. If not as specified, inspect:
A. On-board diagnostic system
B. System inspection
C. Intake manifold vacuum
D. Fuel line pressure
7. If all systems are normal, replace the heated oxygen sensor.
Inspection of front & rear heated oxygen sensor heaters
1. Ensure ignition switch is OFF.
2. Disconnect heated oxygen sensor connector.
3. Connect ohmmeter between terminals 1 and 3 and measure resistance.
Specification: Approx. 3~7Ω(68°F{20°C})
4. If not as specified, replace heated oxygen sensor.
Tightening Torque: 22-36 lb·ft(30~49 N·m, 3~5 kg·m)

Page 71 of 125
5. Reconnect heated oxygen sensor connector.
Removal
1. Disconnect heated oxygen sensor connector.
2. With standard oxygen sensor socket, remove heated oxygen sensor and washer.
Installation
1. Install heated oxygen sensor and washer.
Tightening Torque:22-36 lb·ft(30~49 N·m, 3~5 kg·m)
2. Reconnect heated oxygen sensor connector.
Fuel System > Engine Control System > Knock Sensor (KS) > Repair procedures
Inspection
1. Disconnect knock sensor connector and remove knock sensor from vehicle. Mount knock sensor in the jaws of
a bench vise and connect a voltmeter between terminals 1 and 2.
2. Wrap on the bench vise sharply with a hammer and observe voltmeter.
3. Verify that a voltage spike (less than 1V) is output from the knock sensor.
4. If no voltage spike is observed, replace the knock sensor.
Removal
1. Remove intake manifold support bracket.
2. Disconnect wire harness.
3. Loosen bolt and remove sensor.
Installation
1. Install sensor and tighten bolt.
2. Install wire harness.
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3. Reinstall intake manifold support bracket.
Fuel System > Engine Control System > Injector > Repair procedures
inspection
Check operation
1. Warm up engine and let engine idle.
2. Listen for sound of each injector running by using sound scope or screwdriver.
Fuel is explosive. When working on fuel system, make sure to supply adequate ventilation to the work
area. Do not smoke, and keep sparks and open flames away.
Make sure the fuel injectors are firmly seated on the fuel rail to prevent movement and possible damage.
3. If no sound is heard, measure injector resistance.
4. If injector is OK, check wiring to injector and voltages of ECM terminals B03-47, 48, 49, and 50.
Fuel leakage test
1. Remove injectors together with fuel rail.
2. Secures injectors to fuel rail with wire.
3. Connect data link connector terminals FUEL PUMP and B+ with jumper wire.

5. Tilt injectors about 60 degrees and verify that no fuel leaks from the injector nozzles.
6. If fuel leaks, replace injector.
7. Turn ignition switch "OFF" and remove jumper wire.
VOLUME TEST
1. Remove injectors together with fuel rail.
2. Secure injectors to distributor pipe with wire.
3. Reconnect injector connectors.
4. Connect jumper wire to injector to ECM wires (BRN) and ground.
5. Turn ignition ON.
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6. Inspect injector volume with graduated container.
Injector volume : 1.9g/sec
If not as specified, replace injectors.
When reassembling fuel rail and injectors:

• Use new injector O-rings
• Apply a small amount of clean engine oil to each O-ring before installing
Injector resistance
1. Disconnect injector harness.
2. Measure resistance of each injector.
Resistance: 13.5~15.5Ω at 68°F (20°C)
3. If not within specification, replace injector.
Fuel System > Engine Control System > Main Relay > Repair procedures
Inspection
1. Remove cover from main fuse block.
2. Place a finger on main relay.
3. Verify that relay clicks when ignition switch is turned ON.
4. Verify that main relay clicks when ignition switch is turned ON and OFF.
5. Apply battery voltage (B+) to terminal 85 and ground terminal 86 of the relay.
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6. Check continuity of relay as shown.
B+ not
Terminals B+ applied
applied
No
30 - 87 Continuity
continuity
7. If not as specified, replace main relay.

8. Turn ignition switch OFF.
9. Replace the cover on main fuse block.
Fuel System > Engine Control System > Fuel Pump Relay > Repair procedures
Fuel pump relay inspection
Check operation
disconnectingany fuel line to reduce the chance of personal injury or fire damage to vehicle components.
Listen for fuel pump relay clicking as ignition switch is turned "ON".
Check continuity between relay terminals.
Terminal 85-86 Terminal 87-30
Apply B+ and ground Continuity
B+ and ground not
No continuity
applied
Fuel System > Engine Control System > Other Engine Control System Component > Repair procedures
Fuel tank pressure sensor inspection
1. Reconnect tank pressure sensor connector.
2. Vent fuel tank by removing fuel filler cap.
3. Turn ignition switch to ON position.
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4. Using voltmeter, measure voltage at all three(3) fuel tank pressure sensor terminals in the fuel tank sending unit
connector.
3(W)-2.0~3.0V
(Signal return voltage/base reading)
5. If signal voltage reads 5.0 volts, check the sensor ground wire.
1(BR)-0.0V(sensor ground)
2(L)-5.0V(reference voltage)
6. Disconnect hose from fuel tank at evaporative emissions canister.

7. Connect hand-held vacuumpump to hose.
8. Connect voltmeter between fuel tank ground and the W wire in the fuel tank sending unit connector.
9. With ignition switch in the ON position, verify that voltage goes down when vacuum is applied to when pressure
is applied.
10. Disconnect fuel tank pressure sensor connector, then remove the retainer nut, and remove fuel tank pressure
sensor from the tank.
11. Remove screw attaching fuel tank pressure sensor ground wire to the fuel tank sending unit mounting plate.
12. Measure fuel tank pressure sensor resistance.
1(BR)-3(W):5.0~6.0kΩ
1(BR)-2(L):2.5~3.0kΩ
2(L)-3(W):5.0~6.0kΩ
13. If not within specification, replace the fuel tank pressure.
Fuel System > Fuel Delivery System > Repair procedures

Releasing fuel system pressure
disconnectingany fuel line to reduce the chance of personal injury or fire damage to vehicle components.
1. Start engine.
2. Disconnect fuel pump connector located below rear seat cushion.
3. Let engine stall, then turn OFF ignition switch.
4. Reconnect fuel pump connector.
Fuel line handling
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Fuel is explosive. When working on fuel system make sure to supply adequate ventilation to the work area. Do not
smoke, and keep sparks and open flames away.
1. When disconnecting fuel hose quick connectors, use shop towels to absorb fuel, protecting equipment and
personnel.
Priming the fuel system
After fuel pressure has been released, system must be primed to avoid excessive cranking to restart the engine.
Follow steps below:
1. Connect data link connector terminals FUEL PUMP and B+ with a jumper wire.
2. Turn ignition switch ON for no longer than 10 seconds to pressurize system and check for fuel leaks. (Jumper
wire gets hot if it is left in for longer than 10 seconds.)
3. Turn ignition switch OFF and remove jumper wire.
Fuel pressure hold inspection
The fuel system remains under pressure when the engine is not running. Release fuel system pressure
before disconnectingany fuel line to reduce the chance of personal injury or fire damage to vehicle
components.
2. Release fuel system pressure.

3. Raise a vehicle.
4. Install SST(0K2A1 131 001A) to fuel filter as described below.
5. Connect negative battery terminal.

7. Turn ignition switch ON for 10 seconds to operate fuel pump.
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9. Inspect fuel pressure after 25 minutes.
Fuel pressure:
More than 25psi (180kPa, 1.8 kg/cm²)
10. If not as specified, check the following components: do following inspections:

A. Fuel pump
B. Pressure regulator
C. Injectors
Fuel line pressure inspection
2. Release fuel system pressure.
3. Raise a vehicle.
4. Install SST(0K2A1 131 001A) to fuel filter as shown.
8. Inspect the fuel line pressure.
Fuel line pressure:

46~51psi (320~350kPa, 3.2~3.5kg/cm²)
Pressure too high:

A. Check for restricted fuel return line
B. If line is clean, replace pressure regulato
Pressure too low:
A. Clamp return line and check if pressure risee
B. If pressure does rise, replace pressure regulator
C. If pressure does not rise, measure fuel pump maximum pressure
Fuel System > Fuel Delivery System > Fuel Tank > Components and Components Location
Components
Page 78 of 125
Fuel System > Fuel Delivery System > Fuel Tank > Repair procedures
Removal
2. Remove rear seat.
3. Remove fuel pump cover, and then disconnect fuel pump connector.
4. Remove components in the order shown in above figure.
Fuel System > Fuel Delivery System > Fuel Pump > Repair procedures
Page 79 of 125
Fuel pump operation
2. Remove fuel filler cap.

3. Turn ignition switch "ON".
4. Determine if fuel pump is running by listening for sound of it at fuel filler inlet.
5. Connect negative battery terminal.
The fuel system remains under pressure when the engine is not running. Release fuel system pressure
before disconnecting any fuel line to reduce the chance of personal injury or fire damage to vehicle
components.
6. Connect data link connect terminals FUEL PUMP and B+ with jumper wire.
8. Measure fuel pump maximum pressure.
Fuel pump maximum pressure:

65~94 psi(450~650 kPa, 4.5~6.5 kg·m)
9. If not within specification, replace fuel delivery module.
Fuel System > Fuel Delivery System > Fuel Line > Repair procedures
Quick connector Installation
Position quick connector to male pipe(direction "A") and push quick connector until retainer lock in and a click is
heard.
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Quick connector Removal
Release fuel system pressure before servicing any fuel system connection.
1. Push quick connector to direction "A".
2. Squeeze both sides of lock retainer and pull connection apart to direction "B".
Don's push and pull too hard.
Quick connector Inspection

Once installed, pull and push quick connector to direction "A" and "B" to make sure the connection is secure.
Don't press lock retainer.
Fuel System > Troubleshooting > P0030

Page 81 of 125
HO2S heater circuit malfunction (bank1, sensor1)
No. P0030
HO2S heater circuit low input (bank1, sensor1)
No. P0031
HO2S heater circuit high input (bank1, sensor1)
No. P0032
[Related items] • Open or short to battery between front HO2S heater and ECM
• Short to chassis ground between front HO2S heater and ECM
• Open or short to chassis ground between front HO2S heater and main
relay
• Incorrect front HO2S heater resistance

1 Visually inspect the HO2S circuit for exposed Yes Repair any concerns found in the visual inspection.
wiring, contamination, corrosion and proper
installation.
Were any concerns found during the visual No Go to step 2.
inspection?
2 Connect SCAN TOOL to data link connector or Yes Go to step 3.
OBD-II check connector.
No Problem is intermittent or was repaired and engine
control module memory was not cleared. Check
Are any DTC related to HO2S heater also set?
terminal connections at ECM and HO2S.
3 Turn ignition switch to OFF and disconnect Yes Go to step 4.
HO2S connector.
Start engine and allow an engine to idle until ECT
reaches operating temperature.
Measure voltage of HO2S heater battery voltage No Open circuit or short circuit to chassis ground
between HO2S harness connector and chassis between main relay and HO2S harness connector.
ground.
• Specification: approximately B+
Is measured voltage within specification?
connector and HO2S connector.
Measure resistance of HO2S heater signal circuit
between HO2S harness connector and ECM No Open circuit between HO2S harness connector
5 Measure resistance between HO2S heater signal Yes Go to step 6.
and battery power terminal.
Measure resistance between MAFS MAFS No Temporarily install a known good HO2S and
ground circuit. check for proper operation.
• Approximately 3~7Ω at 20°C (68°F) If problem is corrected, replace HO2S.
Is measured resistance within specification?
Page 82 of 125

HO2S heater circuit malfunction (bank1, sensor2)
No. P0036
HO2S heater circuit low input (bank1, sensor2)
No. P0037
HO2S heater circuit high input (bank1, sensor2)
No. P0038
[Related items] • Open or short to battery between rear HO2S heater and ECM
• Short to chassis ground between rear HO2S heater and ECM
• Open or short to chassis ground between rear HO2S heater and main
relay
• Incorrect rear HO2S heater resistance

1 Visually inspect the HO2S circuit for exposed Yes Repair any concerns found in the visual inspection.
wiring, contamination, corrosion and proper
installation.
Were any concerns found during the visual No Go to step 2.
inspection?
2 Connect SCAN TOOL to data link connector or Yes Go to step 3.
OBD-II check connector.
No Problem is intermittent or was repaired and engine
Turn ignition to ON and monitor DTCs. control module memory was not cleared. Check
Are any DTC related to HO2S heater also set?
terminal connections at ECM and HO2S.
HO2S connector.
Start engine and allow an engine to idle until ECT
Measure voltage of HO2S heater battery voltage No Open circuit or short circuit to chassis ground
between HO2S harness connector and chassis between main relay and HO2S harness connector.
ground.
Measure resistance of HO2S heater signal circuit
between HO2S harness connector and ECM No Open circuit between HO2S harness connector
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5 Measure resistance between HO2S heater signal Yes Go to step 6.
and battery power terminal. No Temporarily install a known good HO2S and
• Approximately 3~7Ω at 20°C (68°F) check for proper operation.
Is measured resistance within specification? If problem is corrected, replace HO2S.

Diagnostic trouble
code Torque reduction signal malfunction
P1780
Details 1. Short circuit in wiring.
2. Transaxle control module (TCM) malfunction
Possible 1. Short circuit in wiring.

cause 2. Transaxle control module (TCM) malfunction

pins OK? No Repair or replace.
module at terminal 51
Standard voltage:
Ignition switch ON: Approx. 5 No Go to next step.
Engine idle: Approx. 5

3 Are connectors and wiring between transaxle Yes Go to next step.
control module (TCM) and engine control module
(ECM). No Repair or replace connectors and wiring.
4 After diagnostic trouble code has been cleared, Yes Replace transaxle control module (TCM) and / or
does reinspection diagnostic trouble code appear. ECM.
further.

Page 84 of 125
Mass or volume air flow circuit low input
No. P0102
[Related items] • Open or short to ground between MAFS and ECM
• Open or short to ground between MAFS battery power and
engine main relay
• Faulty MAFS

OBD-II check connector. control module memory was not cleared. Check
Start engine and monitor MAFS voltage signals. terminal connections at ECM and MAFS.
• Specification: 0.2~0.8V @ idle
Is signal within specification? No Go to step 2.

MAFS connector.
Turn ignition switch to ON.
Measure voltage of MAFS battery power circuit No Open circuit or short circuit to chassis ground
between MAFS harness connector and chassis between MAFS harness connector and main
ground. relay. Repair as necessary.
MAFS connector.
Turn ignition switch to ON.
Measure voltage of MAFS reference 5V circuit No Open circuit or short circuit to chassis ground
between MAFS harness connector and chassis between MAFS harness connector and ECM
ground. connector.
• Specification: approximately 5V Repair as necessary.
connector.
Measure resistance of MAFS signal circuit
between MAFS harness connector and ECM No Open circuit between MAFS harness connector
5 ECM connector and MAFS connector is still Yes Temporarily install a known good MAFS and
disconnected. check for proper operation.
Turn ignition to OFF. If problem is corrected, replace MAFS.
Measure resistance between MAFS harness
connector and chassis ground at MAFS signal No Short circuit to chassis ground between MAFS
circuit. harness connector and ECM harness connector.
Measure resistance between MAFS signal circuit Short circuit between MAFS signal circuit and
and MAFS ground circuit. ground circuit.
• Specification: infinite Repair as necessary.
Page 85 of 125

Mass or volume air flow circuit high input
No. P0103
[Related items] • Short to battery between MAFS signal and
ECM
• Faulty MAFS

OBD-II check connector. control module memory was not cleared. Check
Start engine and monitor MAFS voltage signals. terminal connections at ECM and MAFS.
• Specification: 0.2~0.8V @ idle
Is signal within specification? No Go to step 2.

MAFS connector.
Measure resistance of MAFS ground circuit
between MAFS harness connector and ECM No Open circuit between MAFS harness connector
3 ECM connector and MAFS connector is still Yes Temporarily install a known good MAFS and
Turn ignition to ON. If problem is corrected, replace MAFS.
Measure voltage of MAFS signal circuit between
MAFS harness connector and chassis ground. No Short circuit to battery between MAFS harness
• Specification: below 0.5V connector and ECM harness connector.

Diagnostic trouble
code Intake air temperature circuit low input
No. P0112
[Related items] • Short to battery between MAFS signal and ECM
• Faulty MAFS
Page 86 of 125
Turn ignition to ON and monitor other DTCs.
Are any DTC relating to MAFS set? No Go to step 2.
reaches operating temperature. control module memory was not cleared. Check
Using SCAN TOOL and monitor IAT signals. terminal connections at ECM and MAFS.
• 2.3~2.9V (2.27~2.64 kΩ) @ 20°C (68°F)
3 Ignition OFF, IATS connector and ECM Yes Temporarily install a known good IATS and
connector is still disconnected. check for proper operation.
Measure resistance between IATS signal circuit If problem is corrected, replace IATS.
and ECTS ground circuit.
Measure resistance between IATS harness No Short circuit between IATS signal circuit and
connector and chassis ground at IATS signal ground circuit.
circuit. Short to chassis ground between IATS harness
• Specification: infinite connector and ECM harness connector.

Diagnostic trouble
code Intake air temperature circuit high input
No. P0113
[Related items] • Open or short to battery between IATS signal and ECM
• Open between IATS ground and ECM
• Faulty IATS
Page 87 of 125
OBD-II check connector proceeding this procedure.
Are any DTC relating to MAFS set? No Go to step 2.
Using SCAN TOOL and monitor IAT signals. terminal connections at ECM and MAFS.
• 2.3~2.9V (2.27~2.64 kΩ) @ 20°C (68°F)
3 Turn ignition to OFF and disconnect IATS Yes Go to step 4.
connector. Turn ignition to ON and measure
voltage of IATS signal circuit between IATS No Open circuit or short circuit to chassis ground
harness connector and chassis ground. between IATS harness connector and ECM
• Specification: approximately 5V harness connector.

connector.
Measure resistance of IATS ground circuit
between IATS harness connector and ECM No Open circuit between IATS harness connector
harness connector and ECM harness connector.
5 Turn ignition to ON. ECM connector is still Yes Temporarily install a known good IATS and
Measure voltage of IATS signal circuit between If problem is corrected, replace IATS.
IATS harness connector and chassis ground. No Short circuit to battery between IATS harness

Page 88 of 125
Diagnostic
trouble code Engine coolant temperature circuit range/performance problem
No. P0116
Diagnostic
trouble code Insufficient coolant temperature for closed loop fuel control
No. P0125
[Related items] • After engine start-up, the elapsed time before feedback operation is initiated is too long
(engine coolant temperature sensor input is insufficient for closed loop operation)
• Foreign materials fouled, contaminated, deteriorated ECTS
• Faulty ECTS
If any codes relating to ECTS are present, do all repairs associated with them before
this troubleshooting procedure.

OBD-II check connector proceeding this procedure.
Are any DTC relating to ECTS set? No Go to step 2.
Using SCAN TOOL and monitor ECT signals. terminal connections at ECM and ECTS.
• 3.6~3.8V (2.31~2.59 kΩ) @ 20°C (68°F)
3 Check ECTS for contamination, deterioration or Yes If ECTS is damaged or deteriorated, replace.
damage.
Is ECTS contaminated, deteriorated or damaged? No Go to step 4.
connectors at ECM connector and ECTS
connector.
With ignition OFF, disconnect ECM connector
and ECTS connector. No Open circuit between IATS harness connector
Measure resistance of all two circuits between and ECM harness connector.
ECTS harness connector and ECM harness Repair as necessary.
connector.
Does each indicate continuity circuit?
5 Remove thermostat and check that thermostat is Yes Temporarily install a known good IATS and
stuck or damaged. check for proper operation.
Is thermostat okay? If problem is corrected, replace ECTS.
Page 89 of 125
No Temporarily install a known good thermostat and
If problem is corrected, replace thermostat.

Diagnostic trouble
code Engine coolant temperature circuit low input
No. P0117
[Related items] • Short to ground between ECTS signal and ECM
• Faulty ECTS

Using SCAN TOOL and monitor ECT voltage terminal connections at ECM and ECTS.
signals.
• 2.3~2.9V (2.27~2.64 kΩ) @ 20°C (68°F)
2 Ignition OFF, disconnect ECTS connector and Yes Temporarily install a known good ECTS and
ECM connector. check for proper operation.
Measure resistance between ECTS signal circuit If problem is corrected, replace ECTS.
and ECTS ground circuit.
Measure resistance between ECTS harness No Short circuit between ECTS signal circuit and
connector and chassis ground at ECTS signal ground circuit.
circuit. Short to chassis ground between ECTS harness

Diagnostic trouble
code Engine coolant temperature circuit high input
No. P0118
[Related items] • Open or short to battery between ECTS signal and ECM
• Open between ECTS ground and ECM
• Faulty ECTS
Page 90 of 125

Using SCAN TOOL and monitor ECT voltage terminal connections at ECM and ECTS.
signals.
• 2.3~2.9V (0.27~2.64 kΩ) @ 20°C (68°F)
2 Turn ignition to OFF and disconnect ECTS Yes Go to step 3.
connector.
Turn ignition to ON and measure voltage of ECTS No Open circuit or short circuit to chassis ground
signal circuit between ECTS harness connector between ECTS harness connector and ECM
and chassis ground. harness connector.
connector.
Measure resistance of ECTS ground circuit
between ECTS harness connector and ECM No Open circuit between ECTS harness connector
4 Turn ignition to ON. Yes Temporarily install a known good ECTS and
Measure voltage of ECTS signal circuit between check for proper operation.
ECTS harness connector and chassis ground. If problem is corrected, replace ECTS.
• Specification: below 0.5V No Short circuit to battery between ECTS harness
Is voltage within specifications? connector and ECM harness connector.

Diagnostic trouble code Throttle position sensor circuit range/performance
No. P0121 problem
[Related items] • Open or short to chassis ground between TPS and ECM
• Short to battery between TPS and ECM
• Misplaced, loose or corrodes terminals
• Contaminated, deteriorated TPS
• Faulty TPS
Page 91 of 125
Are any DTC relating to TPS set? No Go to step 2.
Using SCAN TOOL, monitor TP voltage signals. terminal connections at ECM and ECTS.
• 0.3~0.9V (0.71~1.38 kΩ) @ idle
• 4.0~4.4V (2.2~3.4 kΩ) @ full open No Go to step 3.
3 Ignition ON and engine OFF. Yes Problem is intermittent or was repaired and engine
Using SCAN TOOL and monitor TP voltage control module memory was not cleared. Check
signals while slowly opening the throttle. terminal connections at ECM and TPS.
Does voltage signal increase?
No Temporarily install a known good TPS and check
for proper operation. If problem is corrected,
replace TPS.
4 Turn ignition to OFF and disconnect TPS Yes Go to step 5.
connector.
Turn ignition to ON and measure voltage of TPS No Open circuit or short circuit to chassis ground
reference voltage between TPS harness connector between TPS harness connector and ECM
and chassis ground. connector.
5 Thoroughly check TPS for loose, poor Yes Temporarily install a known good TPS and check
connection, bent, corrosion, contamination, for proper operation.
deterioration, or damage. If problem is corrected, replace TPS.
Is TPS okay?
No Clean TPS with cleaner before installing. If
damaged or deteriorated, temporarily install a
known good TPS and check for proper
operation.
If problem is corrected, replace TPS.

Throttle position sensor circuit low input
No. P0122
[Related items] • Open or short to ground between TPS reference power and
ECM
• Short to ground between TPS signal and ECM
• Faulty TPS
Page 92 of 125
Using SCAN TOOL, monitor TP voltage signals. terminal connections at ECM and TPS.
• 0.3~0.9V (0.71~1.38 kΩ) @ idle
• 4.0~4.4V (2.2~3.4 kΩ) @ full open No Go to step 2.
connector.
Turn ignition to ON and measure voltage of TPS No Open circuit or short circuit to chassis ground
reference voltage between TPS harness connector between TPS harness connector and ECM
and chassis ground. connector.
connector.
Measure resistance of TPS signal circuit between
TPS harness connector and ECM harness No Open circuit between TPS harness connector and
connector. ECM harness connector.
4 Ignition OFF, TPS connector and ECM Yes Temporarily install a known good TPS and check
connector is still disconnected. for proper operation.
Measure resistance between TPS signal circuit If problem is corrected, replace TPS.
and ground circuit.
Measure resistance between TPS harness No Short circuit between TPS signal circuit and
connector and chassis ground at TPS signal ground circuit.
circuit. Short to chassis ground between TPS harness

Diagnostic trouble
code Throttle position sensor circuit high input
No. P0123
[Related items] • Open or short to battery between TPS signal and ECM
• Open between TPS ground and ECM
• Faulty TPS
Page 93 of 125
Using SCAN TOOL, monitor TP voltage signals. terminal connections at ECM and TPS.
• 0.3~0.9V (0.71~1.38 KΩ) @ idle
• 4.0~4.4V (2.2~3.4 KΩ) @ full open No Go to step 2.
connector and ECM connector.
Measure resistance of TPS ground circuit
between TPS harness connector and ECM No Open circuit between TPS harness connector and
harness connector. ECM harness connector.
3 Turn ignition to ON. Yes Temporarily install a known good TPS and check
Measure voltage of TPS signal circuit between for proper operation.
TPS harness connector and chassis ground. If problem is corrected, replace TPS.
• Specification: below 0.5V No Short circuit to battery between TPS harness
Is voltage within specifications? connector and ECM harness connector.

Diagnostic trouble
code HO2S circuit malfunction (bank1, sensor1)
No. P0130
[Related items] • Open or short to battery between front HO2S and ECM
• Short to chassis ground between front HO2S and ECM
• Short between front HO2S wires
• Poor connections between front HO2S and ECM
• Misplaced, bent, loose or corroded terminals
Page 94 of 125
2 Warm up engine to normal operating temperature Yes Problem is intermittent or was repaired and engine
for more than 10 minutes. control module memory was not cleared. Check
Using SCAN TOOL, monitor HO2S signal terminal connections at ECM and HO2S.
waveform.
Does the HO2S signal switch lean to rich and rich No Go to step 3.
to lean over 6 times for 10 seconds?
Measure resistance of HO2S ground circuit
between HO2S harness connector and ECM
harness connector. No Open circuit between HO2S harness connector
Measure resistance of HO2S signal circuit and ECM harness connector.
between HO2S harness connector and ECM Repair as necessary.
harness connector.
• Specification: below 1Ω
4 Turn ignition to ON. ECM connector is still Yes Go to step 5.
disconnected.
Measure voltage of HO2S signal circuit between No Short circuit to battery between HO2S harness
HO2S harness connector and chassis ground. connector and ECM harness connector.
• Specification: below 0.5V Repair as necessary.
5 Ignition OFF, HO2S connector and ECM Yes Go to step 6.
connector is still disconnected.
Measure resistance between HO2S signal circuit
and ground circuit. No Short circuit between HO2S signal circuit and
Measure resistance between HO2S harness ground circuit.
connector and chassis ground at HO2S signal Short to chassis ground between HO2S harness
circuit. connector and ECM harness connector.
Does resistance indicate open circuit?
6 Thoroughly check HO2S for contamination, Yes If damaged or deteriorated, temporarily install a
deterioration or damage. known good HO2S and check for proper
Is HO2S contaminated, deteriorated or damaged? operation.
If problem is corrected, replace HO2S.
No Verify ECM and HO2S connectors are secure. If
connectors are okay, temporarily install a known
good HO2S and check for proper operation.
Page 95 of 125

Diagnostic trouble
code HO2S circuit low input (bank1, sensor1)
No. P0131
[Related items] • Short to ground between front HO2S signal and ECM

1 Turn ignition to OFF and disconnect HO2S Yes Go to step 2.
2 Connect HO2S connector and ECM connector. Yes Problem is intermittent or was repaired and engine
Warm up engine to normal operating temperature control module memory was not cleared. Check
for more than 10 minutes. terminal connections at ECM and HO2S.
Using SCAN TOOL, monitor HO2S signal
waveform.
Does the HO2S signal switch lean to rich and rich No Go to step 3.
to lean over 6 times for 10 seconds?

Page 96 of 125
HO2S circuit high input (bank1, sensor1)
No. P0132
[Related items] • Open or short to battery between front HO2S signal and
ECM

HO2S signal circuit between HO2S harness No Short circuit to battery between HO2S harness
connector and chassis ground. connector and ECM harness connector.
Using SCAN TOOL, monitor HO2S signal terminal connections at ECM and HO2S.
waveform. Does the HO2S signal switch lean to
rich and rich to lean over 6 times for 10 seconds? No Go to step 3.

Page 97 of 125
HO2S circuit slow responsive (bank1, sensor1)
No. P0133
[Related items] • Abnormal combustionl
• Improper fuel pressurel
If any misfire, purge solenoid valve, MAFS or HO2S heater codes are
present, do all repairs associated with those codes before proceeding this

2 Visually check for leak from exhaust system Yes Repair intake system leaks as necessary.
(especially between TWC converter and front
exhaust pipe). No Go to step 3.
Are any leaks present?
3 Visually check for leak from intake system. Yes Repair exhaust system leaks as necessary.
Are any vacuum leaks present? No Go to step 4.
4 Start engine after installing fuel pressure gauge at Yes Temporarily install a known good HO2s and
service valve in fuel rail. check for proper operation. If problem is
With engine running at operating temperature, is corrected, replace HO2S.
fuel pressure within specification?
No 1. If measured pressure is too high: Go to step 5.
Fuel pressure at idle: 46~51 psi 2. If measured pressure is too low: Go to step 6
(320~350kPa, 3.2~3.5kg/cm²)
5 Disconnect return line hose from fuel filter. Blow Yes Check for blockage in return line, clean or replace
through line towards tank. as necessary.
Is return line restricted?
No Repair pressure regulator.
6 Clamp a return line from fuel filter and check if Yes Replace fuel delivery module.
pressure rises.
No Check fuel filter at fuel pump. If it is OK, measure
Do fuel pressure rise?
fuel pump maximum pressure and repair as
necessary.
Page 98 of 125
HO2S circuit no activity detected (bank1, sensor1)
No. P0134
[Related items] • Open or short between front HO2S signal terminal and ECM
• Contaminated, deteriorated or aged front HO2S
• Misplaced, bent, loose or corroded connector terminals
If any misfire, purge solenoid valve or HO2S heater codes are present, do
all repairs associated with those codes before proceeding this

Using SCAN TOOL monitor HO2S signal. terminal connections at ECM and HO2S.
Does the HO2S signal switch lean to rich and rich
to lean over 6 times for 10 seconds? No Go to step 3.

harness connector.
4 Turn ignition to ON. Yes Go to step 5.
Measure voltage of HO2S signal circuit between
HO2S harness connector and chassis ground. No Short circuit to battery between HO2S harness
Is voltage within specifications? Repair as necessary.

Page 99 of 125
connector and chassis ground at HO2S signal
6 Thoroughly check HO2S for contamination, Yes Clean HO2S with cleaner before installing. If
deterioration or damage. damaged or deteriorated, temporarily install a
Is HO2S contaminated, deteriorated or damaged? known good HO2S and check for proper
operation.
OK, temporarily install a known good HO2S and
7 Visually check for leak from exhaust Yes Repair intake system leaks as necessary.
system.(especially between TWC converter and
front exhaust pipe) No Go to step 8.

HO2S circuit malfunction (bank1, sensor2)
No. P0136
[Related items] • Open or short to chassis ground between rear HO2S and
ECM
• Short to battery between rear HO2S and ECM
• Short between rear HO2S wires
Page 100 of 125

harness connector.
Measure voltage of HO2S signal circuit between
HO2S harness connector and chassis ground. No Short circuit to battery between HO2S harness

5 Thoroughly check HO2S for contamination, Yes Clean HO2S with cleaner before installing. If
deterioration or damage. damaged or deteriorated, temporarily install a
Is HO2S contaminated, deteriorated or damaged? known good HO2S and check for proper
operation.

Page 101 of 125
Diagnostic trouble
code HO2S circuit low input (bank1, sensor2)
No. P0137
[Related items] • Short to ground between rear HO2S signal and ECM


HO2S circuit high input (bank1, sensor2)
No. P0138
[Related items] • Open or short to battery between rear HO2S signal and
ECM
Page 102 of 125
HO2S signal circuit between HO2S harness No Short circuit to battery between HO2S harness

HO2S circuit slow responsive (bank1, sensor2)
No. P0139
[Related items] • Abnormal combustion
• Improper fuel pressure
If any misfire, purge solenoid valve, MAFS or HO2S heater codes are
present, do all repairs associated with those codes before proceeding this
Page 103 of 125
2 Visually check for leak from exhaust system Yes Repair intake system leaks as necessary.
(especially between TWC converter and front
exhaust pipe). No Go to step 3.
3 Visually check for leak from intake system. Yes Repair exhaust system leaks as necessary.
Are any vacuum leaks present?
No Go to step 4.
4 Start engine after installing fuel pressure gauge at Yes Temporarily install a known good HO2s and
service valve in fuel rail. check for proper operation. If problem is
With engine running at operating temperature, is corrected, replace HO2S.
fuel pressure within specification?
No 1. If measured pressure is too high: Go to step 5.
Fuel pressure at idle: 46~51 psi 2. If measured pressure is too low: Go to step 6
(320~350kPa, 3.2~3.5kg/cm²)
5 Disconnect return line hose from fuel filter. Blow Yes Check for blockage in return line, clean or replace
through line towards tank. as necessary.
Is return line restricted?
No Repair pressure regulator.
6 Clamp a return line from fuel filter and check if Yes Replace fuel delivery module.
pressure rises.
No Check fuel filter at fuel pump. If it is OK, measure
Do fuel pressure rise? fuel pump maximum pressure and repair as
necessary.

HO2S circuit no activity detected (bank1, sensor2)
No. P0140
[Related items] • Open or short between rear HO2S signal terminal and ECM
• Contaminated, deteriorated or aged rear HO2S
If any misfire, purge solenoid valve or HO2S heater codes are present, do
all repairs associated with those codes before proceeding this trouble
area.
Page 104 of 125
1 Connect SCAN TOOL to data link connector or OBD- Yes Do all repairs associated with
II check connector. those codes before proceeding
Turn ignition to ON and monitor other DTCs. this procedure.
2 Turn ignition to OFF and disconnect ECM connector Yes Go to step 3.
and HO2S connector.
Measure resistance of HO2S ground circuit between
HO2S harness connector and ECM harness connector. No Open circuit between HO2S
Measure resistance of HO2S signal circuit between harness connector and ECM
HO2S harness connector and ECM harness connector. harness connector.
Measure voltage of HO2S signal circuit between HO2S
No Short circuit to battery between
harness connector and chassis ground. HO2S harness connector and
• Specification: below 0.5V ECM harness connector.
4 Ignition OFF, HO2S connector and ECM connector is Yes Go to step 5.
still disconnected.
Measure resistance between HO2S signal circuit and No Short circuit between HO2S
ground circuit. signal circuit and ground circuit.
Measure resistance between HO2S harness connector Short to chassis ground between
and chassis ground at HO2S signal circuit. HO2S harness connector and
• Specification: infinite ECM harness connector.
5 Thoroughly check HO2S for contamination, Yes Clean HO2S with cleaner before
deterioration or damage. installing. If damaged or
Is HO2S contaminated, deteriorated or damaged? deteriorated, temporarily install a
known good HO2S and check
for proper operation.
If problem is corrected, replace
HO2S.
No Verify ECM and HO2S
connectors are secure. If OK,
temporarily install a known good
HO2S and check for proper
operation.
If problem is corrected, replace
HO2S.
6 Visually check for leak from exhaust system.(especially Yes Repair intake system leaks as
between TWC converter and front exhaust pipe) necessary.
No Go to step 7.
7 Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehicle with
Page 105 of 125

Fuel system too lean (bank1)
No. P0171
[Related items] • Faulty fuel delivery system
• Clogged fuel injectors
• Faulty fuel injectors
• Faulty MAFS
• Faulty TPS
If any codes relating to injectors, HO2S, ECTS or MAFS are stored, do

all repairs associated with those codes before proceeding with this

2 Using SCAN TOOL, monitor long-term on fuel Yes Problem is intermittent or was repaired and engine
trim data. control module memory was not cleared.
• Long-term: -12~12%
Is long-term within the specifications indicated? No Go to step 3.
3 Visually/physically inspect the following items: Yes Go to step 4.

• Throttle body gasket
tank
• Seals between intake manifold and fuel
injectors
• Seals between surge tank and PCV valves No Repair or replace as necessary.
• Crankcase ventilation valve and/or system for
leaks
• Contaminated fuel
• Air cleaner element for being restricted
• MAFS for proper installation and foreign
objects No Repair or replace as necessary.
• Exhaust system for leaks
Page 106 of 125
5 Check vacuum hoses for splits and proper Yes Go to step 6.
connections to engine dynamic chamber
(especially PCV, ISC hose, throttle body, intake
manifold, and brake booster). No Repair or replace as necessary.
Are connections OK?
6 With engine idling disconnect hose between Yes EVAP canister purge valve or circuit failure.
EVAP valve and canister. Check for vacuum at Repair according to DTC P0443 repair
EVAP valve. procedures.
Is vacuum available at purge valve when EVAP
valve is not operating? No Go to step 7.
7 After installing fuel pressure gauge to service port Yes Go to step 8.

on fuel rail, connect DLC F/P and B (B+) with a
No Low pressure:
jumper wire.
Clamp return-line and check if pressure rises:
• Fuel pressure at idle: 46~51 psi - If pressure rises: replace pressure regulator.
(320~350kpa, 3.2~3.5kg/cm²) - If pressure does not rise: check the strainer at
Is fuel line pressure correct with ignition switch the fuel pump.
ON?
High pressure:
Disconnect return-line from fuel filter side and
blow through line towards tank:
- If line is clear: replace fuel delivery module.
- If line is blocked: check for blockage in return
line and clear or replace as necessary.
If it is OK, check fuel.

8 Start engine and check for engine rpm decrease Yes Repair as necessary.
when disconnecting each injector connector in
sequence.
Measure the decreasing engine rpm of all 4
cylinders. No Go to step 9.
Is there any cylinder with no change in rpm or only
a small rpm change?
9 Remove spark plugs and inspect spark plug tips. Yes Check for engine mechanical failure. If it is OK,
Check for abnormal color of spark plug tips replace spark plugs.
compared to other cylinders.
Are any spark plugs with abnormal color No Go to step 10.
compared to other cylinders?
10 Check for ECM input signal from MAFS, HO2S, Yes Go to step 11.
TPS and other input signals.
Are input signals within specification? No Replace all failed parts.

Page 107 of 125
Fuel system too rich (bank1)
No. P0172
[Related items] • Faulty ignition system
• EVAP canister purge valve malfunction
- Clogged fuel injectors
- Faulty fuel injectors
- Fuel pressure too high
- Fuel pressure regulator failure
• Faulty MAFS
• Faulty TPS
If any injectors, front HO2S, ECTS, and MAFS codes are present, do all
repairs associated with those codes before proceeding this

2 Using SCAN TOOL, monitor long-term on fuel Yes Problem is intermittent or was repaired and engine
trim data. control module memory was not cleared.
• Long-term: -12~12%
Is long-term within the specifications indicated? No Go to step 3.

tank
• Seals between intake manifold and fuel
injectors
• Seals between surge tank and PCV valves No Repair or replace as necessary.
leaks
• Contaminated fuel
• Air cleaner element for being restricted
• MAFS for proper installation and foreign
objects
Page 108 of 125
objects No Repair or replace as necessary.
5 Check vacuum hoses for splits and proper Yes Go to step 6.
connections to engine dynamic chamber
(especially PCV, ISC hose, throttle body, intake
manifold, and brake booster). No Repair or replace as necessary.
Are connections OK?

No Low pressure:
jumper wire.
• Fuel pressure at idle: 46~51 psi - If pressure rises: replace pressure regulator.
(320~350kpa, 3.2~3.5kg/cm²) - If pressure does not rise: check the strainer at
Is fuel line pressure correct with ignition switch the fuel pump.
ON?
High pressure:
blow through line towards tank:
- If line is clear: replace fuel delivery module.
- If line is blocked: check for blockage in return
line and clear or replace as necessary.

when disconnecting each injector connector in
sequence.
Measure the decreasing engine rpm of all 6
cylinders. No Go to step 9.
Is there any cylinder with no change in rpm or only
a small rpm change?
10 Check for ECM input signal from MAFS, HO2S, Yes Go to step 11.
TPS and other input signals.
Are input signals within specification? No Replace all failed parts.
Page 109 of 125
Diagnostic trouble
code Cylinder 1 injector circuit low/high input
No. P0261/P0262
Diagnostic trouble
No. P0264/P0265
Diagnostic trouble
No. P0267/P0268
Diagnostic trouble
No. P0270/P0271
[Related items] • Open or short between main relay and injectors
• Open or short between ECM and injectors
• Short to battery between ECM and injectors

injector connector.
Measure resistance between injector terminal 1 No Temporarily install a known good injector and
and terminal 2. check for proper operation.
• 13.5~15.5 W at 20°C (68°F) If problem is corrected, replace HO2S.
Is measured resistance within specification?
injector connector.
With ignition ON and measure voltage of battery No Open circuit or short circuit to chassis ground
voltage between injector harness connector and between main relay and injector harness
chassis ground. connector.
3 Disconnect ECM connector and injector Yes Go to step 4.
connector.
Measure resistance between injector harness No Open circuit between injector harness connector
connector and ECM harness connector. and ECM harness connector.
Does resistance indicate continuity?
4 ECM connector and injector connector is still Yes Temporarily install a known good injector and
Measure resistance between injector harness If problem is corrected, replace injector.
connector and chassis ground at injector signal
circuit.
• Specification: infinite
Page 110 of 125
connector and chassis ground at injector signal
circuit. No Short circuit to chassis ground between injector
• Specification: infinite terminal 2 and ECM.
Does resistance indicate continuity? Repair as necessary.

Diagnostic trouble
code Knock sensor circuit malfunction (bank 1)
No. P0325
[Related items] • Open or short to GND between knock sensor and ECM
• Source of high resistance between knock sensor and ECM
• Faulty knock sensor

OBD-II check connector. control module memory was not cleared.
Turn ignition to ON and monitor KS voltage Check terminal connections at ECM and KS.
signals.
• Specifications: 2.0~3.0V No Go to step 2.
2 Start and run engine. Yes Check any other DTCs. If any DTCs is present,
Using SCAN TOOL monitor KS voltage signals do all repairs associated with those codes before
from idle to 3000rpm. proceeding next step.
Does voltage signal increase? No Go to step 3.
3 Thoroughly check KS and ECM for loose, bent, Yes Repair as necessary.
4 Turn ignition to OFF and disconnect KS Yes Go to step 5.
Measures resistance of KS signal circuit between
KS harness connector and ECM harness
connector. No Open circuit between KS harness connector and
Measure resistance of KS ground circuit between ECM harness connector and/or chassis ground.
KS harness connector and chassis ground. Repair as necessary.
Is each resistance within specification?
Measures voltage of KS signal circuit between
KS harness connector and chassis ground.
• Specification: below 0.5V
Does voltage within specifications?
Page 111 of 125
Measures voltage of KS signal circuit between
KS harness connector and chassis ground. No Short circuit to battery between KS harness
Does voltage within specifications? Repair as necessary.
6 Ignition OFF, KS connector and ECM connector Yes Temporarily install a known good knock sensor
is still disconnected. and check for proper operation.
Measures resistance between KS harness If problem is corrected, replace knock sensor.
connector and chassis ground at KS signal circuit. No Short circuit to chassis ground between KS
Measure resistance between KS signal circuit and harness connector and ECM harness connector.
ground circuit. Short circuit between KS signal circuit and ground
• Specifications: infinite circuit.

Crankshaft position sensor circuit malfunction
No. P0335
[Related items] • Open or short to chassis ground between CKPS and ECM
• Short to battery between CKPS and ECM
• Short between CKPS wires
• Out of allowable air gap
• Faulty Target wheel tolerance
• Faulty CKPS

1 Thoroughly check CKPS and ECM for loose, Yes Repair as necessary.
bent, corroded, contaminated, deteriorated or
damaged connectors. No Go to step 2.
2 Turn ignition to OFF and disconnect CKPS Yes Go to step 3.
connector.
CKPS power circuit between CKPS harness between CKPS harness connector and main
connector and chassis ground. relay.
connector.
Measure resistance of CKPS signal circuit
between CKPS harness connector and ECM
harness connector. No Open circuit between CKPS harness connector
Measure resistance of CKPS ground circuit and ECM harness connector and/or chassis
between CKPS harness connector and chassis ground.
Page 112 of 125
between CKPS harness connector and chassis
ground. Repair as necessary.
Measure voltage of CKPS signal circuit between
CKPS harness connector and chassis ground. No Short circuit to battery between CKPS harness
• Specifications: below 0.5V connector and ECM harness connector.
5 Tun ignition to OFF. Yes Go to step 6.

Measures resistance between CKPS harness
connector and ECM harness connector at CKPS No Short circuit to chassis ground between KS
signal circuit. harness connector and ECM harness connector.
Measure resistance between CKPS signal circuit Short circuit between CKPS signal circuit and
and ground circuit. ground circuit.
6 {measure distance from hosing to teeth on Yes Temporarily install a known good CKPS and
flywheel/torque converter (measurement "A") and check for proper operation.
from mounting surface on sensor to sensor tip If problem is corrected, replace CKPS.
(measurement "B") subtract "B" from "A" = air
No Remove CKPS, install CMPS correctly, and
gap}.
check CKPS for proper operation. If not,
Is air gap within specifications?
temporarily install a known good CKPS and
corrected, replace CKPS.

Camshaft position sensor circuit malfunction
No. P0340
[Related items] • Open or short to chassis ground between CMPS and ECM
• Short to battery between CMPS and ECM
• Short between CMPS wires
• Faulty CMPS
Page 113 of 125
1 Thoroughly check CMPS and ECM for loose, Yes Repair as necessary.
bent, corroded, contaminated, deteriorated or
damaged connectors. No Go to step 2.
2 Turn ignition to OFF and disconnect CMPS Yes Go to step 3.
connector.
CMPS power circuit between CMPS harness between CMPS harness connector and main
connector and chassis ground. relay.
connector.
Measure resistance of CMPS signal circuit
between CMPS harness connector and ECM
harness connector. No Open circuit between CMPS harness connector
Measure resistance of CMPS ground circuit and ECM harness connector and/or chassis
between CMPS harness connector and chassis ground.
ground. Repair as necessary.
Measure voltage of CMPS signal circuit between
CMPS harness connector and chassis ground. No Short circuit to power between CMPS harness
• Specifications: below 0.5V connector and ECM harness connector.
5 Tun ignition to OFF. Yes Go to step 6.

Measures resistance between CMPS harness
connector and ECM harness connector at CMPS No Short circuit to chassis ground between KS
signal circuit. harness connector and ECM harness connector.
Measure resistance between CMPS signal circuit Short circuit between CMPS signal circuit and
and ground circuit. ground circuit.
6 Turn ignition to OFF and disconnect CMPS Yes Temporarily install a known good CMPS and
connector. check for proper operation.
Check for CMPS installation.Is CMPS installed If problem is corrected, replace CMPS.
properly?
No Remove CMPS, install CMPS correctly, and
check CMPS for proper operation. If not,
temporarily install a known good CMPS and
corrected, replace CMPS.
Page 114 of 125
Vehicle speed sensor circuit malfunction
No. P0501
[Related items] • Open or short to battery between VSS and ECM
• Short to chassis ground between VSS and ECM
• Faulty VSS
If any codes relating to VSS circuits are present, do all repairs associated
with those problems before proceeding with this troubleshooting
procedure.

1 Turn ignition to ON. Yes Problem is intermittent or was repaired and engine
Using SCAN TOOL and monitor VSS signal. control module memory was not cleared. Check
• B+ at ignition ON terminal connections at ECM and VSS.
• 0~B+ at driving
No Go to step 2.
connector and VSS connector.
connector and ABS harness connector at VSS No Open circuit between ECM harness connector
signal circuit. and VSS harness connector.
3 ECM connector and VSS connector are Yes Go to step 4.
disconnected.
connector and chassis ground at VSS signal No Short circuit to chassis ground between ECM
circuit. harness connector and VSS harness connector.
4 Turn ignition to ON and measure voltage between Yes Check for poor terminal contacts due to
wheel speed sensor signal terminal and ground. oxidation, bent deformed, or misplaced terminals.
• B+ at ignition ON If OK, open circuit or short circuit between VSS
• 0~B+ at driving and ECM.
No Temporarily install a known good VSS and check
for proper operation.
If problem is corrected, replace VSS.
Page 115 of 125
Idle control system rpm lower than expected
No. P0506
[Related items] • Open or short between main relay and IACV
• Open or short between ECM and IACV
• Intake system is plugged
• Carbon fouled throttle plate
• Faulty IACV
If any codes relating to TPS, MAFS, fuel injector or IACV present, do all
repairs associated with them before proceeding with this troubleshooting
guide.

Are any other codes also set? No Go to step 2.
2 Check accelerator cable free play [0.040~0.120 Yes Go to step 3.

in (1.0~3.0 mm)].
Is accelerator cable free play within specification? No Adjust cable.
3 Start engine and allow engine to idle until engine Yes Go to step 4.
Using SCAN TOOL, monitor TP voltage signals.
• 0.3~0.9V (0.71~1.38 KΩ) @ idle No Do all repairs associated with TPS before
• 4.0~4.4V (2.2~3.4 KΩ) @ full open proceeding the next step.
4 Turn ignition to OFF and disconnect IACV Yes Go to step 5.
connector.
With ignition ON, measure voltage of IACV
battery voltage between IACV harness connector No Open circuit or short circuit to chassis ground
and chassis ground. between IACV harness connector and main relay.
• Specifications: approximately B+ Repair as necessary.
5 Turn ignition to OFF. Yes Go to step 6.
Measure resistance of IACV opening coil and
closing coil. No Temporarily install a known good IACV and
• Closing coil: 14.5~16.5Ω at 20°C (68°F) check for proper operation. If problem is
• Opening coil: 16.5~18.5Ω at 20°C (68°F) corrected replace IACV.
6 Remove IACV from throttle body and check for Yes Thoroughly check for loose, bent or corroded
excessive carbon deposits and sticking per terminals at all connectors in circuit.
following check.
Page 116 of 125
Connect IACV battery terminal to 12V power.
One at a time, momentarily ground IACV opening
coil signal terminal and closing coil terminal while
visually verifying valve closes when the closing coil
terminal is grounded and valve opens when
opening coil signal terminal is grounded. No Temporarily install a known good IACV and
Repeat numerous times to ensure valve reliability. check for proper operation. If problem is
Is IACV moving freely and is not carbon fouled? corrected replace IACV.
While IACV is removed, inspect throttle

body for obstructions in idle circuit ports.
Repair or replace as necessary.

connector.
Measure resistance of IACV opening coil signal
circuit between IACV harness connector and
ECM harness connector. No Open circuit between IACV harness connector
Measure resistance of IACV closing coil signal and ECM harness connector.
circuit between IACV harness connector and Repair as necessary.
ECM harness connector.
8 ECM connector and IACV connector is still Yes Go to step 9.
disconnected.
Measure resistance between IACV harness
connector and chassis ground at IACV opening
coil circuit. No Short circuit to chassis ground between IACV
Measure resistance between IACV harness harness connector and ECM harness connector.
connector and chassis ground at IACV closing Repair as necessary.
coil circuit.
• Specifications: infinite
9 Remove intake hose and inspect throttle plate for Yes Clean throttle body.
excessive carbon deposits.
Is throttle plate being held open with excessive No Go to step 10.
carbon deposits?

Page 117 of 125
Idle control system rpm higher than expected
No. P0507
[Related items] • Short to ground between IACV and ECM
• Air leak in intake system
• Improperly adjusted accelerator cable
• Faulty IACV
• Faulty TPS
• Faulty PCV/PSV
If any codes relating to TPS, PSV, MAFS, fuel injector or IACV are
present, do all repairs associated with them before proceeding with this
troubleshooting guide.

Are any other codes also set? No Go to step 2.
2 Check accelerator cable free play [0.040~0.120 Yes Go to step 3.

in (1.0~3.0 mm)].
Is accelerator cable free play within specification? No Adjust cable.
3 Start engine and allow engine to idle until engine Yes Go to step 4.
Using SCAN TOOL, monitor TP voltage signals.
• 0.3~0.9V (0.71~1.38 KΩ) @ idle No Do all repairs associated with TPS before
• 4.0~4.4V (2.2~3.4 KΩ) @ full open proceeding the next step.
connector.
5 Turn ignition to OFF. Yes Go to step 6.
Measure resistance of IACV opening coil and
closing coil. No Temporarily install a known good IACV and
• Closing coil: 14.5~16.5Ω at 20°C (68°F) check for proper operation. If problem is
• Opening coil: 16.5~18.5Ω at 20°C (68°F) corrected replace IACV.
Is each resistance within specification?
6 Remove IACV from throttle body and check for Yes Thoroughly check for loose, bent or corroded
excessive carbon deposits and sticking per terminals at all connectors in circuit.
following check.
Connect IACV battery terminal to 12V power.
Page 118 of 125
One at a time, momentarily ground IACV opening
coil signal terminal and closing coil terminal while
visually verifying valve closes when the closing coil
terminal is grounded and valve opens when
opening coil signal terminal is grounded. No Temporarily install a known good IACV and
Repeat numerous times to ensure valve reliability. check for proper operation. If problem is
Is IACV moving freely and is not carbon fouled? corrected replace IACV.
While IACV is removed, inspect throttle

body for obstructions in idle circuit ports.
Repair or replace as necessary.

connector.
ECM harness connector. No Open circuit between IACV harness connector
Measure resistance of IACV closing coil signal and ECM harness connector.
circuit between IACV harness connector and Repair as necessary.
8 ECM connector and IACV connector is still Yes Go to step 9.
disconnected.
connector and chassis ground at IACV opening
coil circuit. No Short circuit to chassis ground between IACV
Measure resistance between IACV harness harness connector and ECM harness connector.
connector and chassis ground at IACV closing Repair as necessary.
coil circuit.
• Specifications: infinite
vacuum hoses. Also, check PCV valve for proper
operation and purge solenoid valve for proper
installation and operation. No Replace faulty vacuum hoses, PCV or PSV
Are vacuum hoses, PCV and PSV okay?
tank
• Gasket between intake manifold and cylinder
head
• Seals between intake manifold and fuel No Repair or replace as necessary.
injectors
• Seals between surge tank and PCV valves
leaks
Page 119 of 125
Are the items okay?

Internal Control Module ROM Error (ECM-Selftest Failed)
No. P0605
[Related items] • Internal fault. There is no inspection of service possible for this diagnostic
trouble code
• Temporarily install a known good ECM and check for proper operation. If
problem is corrected replace ECM.
• Return vehicle to original condition. Clear all diagnostic trouble codes.
Verify by driving vehicle with SCAN TOOL connected and monitor for
pending codes.

Diagnostic trouble
code MIL circuit malfunction
No. P0650
[Related items] • Open or short to chassis ground between MIL and ECM
• Faulty MIL

1 Turn ignition to OFF and disconnect ECM Yes Poor terminal contact due to oxidation, bent or
connector. misplaced terminal at ECM.
Turn ignition to ON and measure voltage at ECM Repair as necessary.
MIL control terminal.
• Specifications: approximately B+ No Go to step 2.
2 Check for MIL in instrument cluster. Yes Open circuit or short circuit to chassis ground
Does MIL operate correctly? between ECM harness connector and MIL.
No Replace MIL.
3 Return vehicle to original condition. Clear all diagnostic trouble codes. vehicle with SCAN TOOL
Page 120 of 125

HO2S-Controller Adaptation Diagnosis Malfunction
No. P1166
[Related items] • Fuel system malfunction (fuel tank/pressure regulator/fuel pump/PCSV)
• Poor connection to fuel line hose/sealing/cut
• Sealing between PCSV and fuel tank
• Air leakage in exhaust system
• Ignition system malfunction (ignition coil, spark plug, cable)
• Faulty surge tank and intake port
If any codes relating front/rear HO2S, fuel system, EVAP, and ignition
system are present, do all repairs associated with them before proceeding
with this troubleshooting procedure.

1 First check for DTC relating to front/rear HO2S, Yes First repair all other malfunctions on DTCs.
fuel system, EVAP, and ignition system.
Do DTCs exist? No Go to step 2.
2 Check for correct vacuum hose connections to Yes Rectify as necessary.

engine dynamic chamber (especially PCV, ISC
hose, and brake booster) No Go to step 3.
Are connections OK?
EVAP valveIs vacuum available at purge valve procedures.
when EVAP valve is not operating?
No Go to step 4.
No Low pressure:
jumper wire.
Is fuel line pressure correct with ignition switch
- If pressure rises: replace pressure regulator
ON?
- If pressure does not rise: check the strainer at
• Fuel pressure at idle: 46~51 psi the fuel pump
(320~350kPa, 3.2~3.5kg/cm²)
High pressure:
blow through line towards tank
- If line is clear: replace fuel delivery module
- If line is blocked check for blockage in return
line and clear or replace as necessary

Page 121 of 125
5 Warm up engine to normal operating temperature Yes Go to step 6.
for more than 10 minutes. Using SCAN TOOL
monitor HO2S signal. No Temporarily install a known good front HO2S and
Does the front HO2S signal switch lean to rich check for proper operation.
and rich to lean over 6 times for 10 seconds? If problem is corrected, replace front HO2S.
6 Check front/rear HO2S for contamination, Yes If damaged or deteriorated, replace front/rear
deterioration or damage. HO2S.
Is front/rear HO2S contaminated, deteriorated or
damaged? No Go to step 7.

connectors at ECM and front/rear HO2S
connectors. No Repair as necessary.
Are connectors normal?
8 Visually check for leak from exhaust system. Yes Rectify as necessary.
No Go to step 9.
when disconnecting each injector connector is
sequence.
Measure the decreasing engine rpm of all 6 No Go to step 10.
cylinders. Is there any cylinder with no change in
rpm or only a small rpm change?
10 Using SCAN TOOL monitor MAFS voltage Yes Go to step 11.
signals.
• 0.2~0.8V @ idle No Do all repairs associated with MAFS.

Diagnostic trouble
code Idle air control valve opening coil signal low input
No. P1505
[Related items] • Open or short to chassis ground between IACV and ECM
• Faulty IACV
Page 122 of 125
connector.
and main relay. between IACV harness connector and main relay.
2 Turn ignition to OFF. Yes Thoroughly check for loose, bent or corroded
Measure resistance of IACV opening coil. terminals at all connectors in circuit.
• Opening coil: 16.5~18.5Ω at 20°C (68°F) No Temporarily install a known good IACV and
Is resistance within specification? check for proper operation. If problem is
corrected replace IACV.
3 IACV connector and ECM connector are still Yes Go to step 4.
disconnected.
circuit between IACV harness connector and No Open circuit between IACV harness connector
ECM harness connector. and ECM harness connector.
4 ECM connector and IACV connector are still Yes Go to step 5.
disconnected.
connector and chassis ground at IACV opening No Short circuit to chassis ground between IACV
coil circuit. harness connector and ECM harness connector.

Diagnostic trouble
code Idle air control valve opening coil signal high
No. P1506
[Related items] • Short to battery between IACV and ECM
• Faulty IACV
Page 123 of 125
opening coil circuit between IACV harness No Short circuit to battery between IACV harness
• Opening coil: 16.5~18.5Ω @ 20°C (68°F) No Temporarily install a known good IACV and

Diagnostic trouble
code Idle air control valve closing coil signal low
No. P1507
[Related items] • Open or short to chassis ground between IACV and ECM
• Faulty IACV

connector.
• Closing coil: 14.5~16.5Ω at 20°C (68°F) No Temporarily install a known good IACV and
connector.
Measure resistance of IACV closing coil signal
Page 124 of 125
Measure resistance of IACV closing coil signal
circuit between IACV harness connector and No Open circuit between IACV harness connector
ECM harness connector. and ECM harness connector.
4 ECM connector and IACV connector are still Yes Go to step 5.
disconnected.
connector and chassis ground at IACV closing No Short circuit to chassis ground between IACV
coil circuit. harness connector and ECM harness connector.
5 Return vehicle to original condition Clear all diagnostic trouble codes. Verify by driving vehicle with SCAN

Diagnostic trouble
code Idle air control valve closing coil signal high
No. P1508
[Related items] • Short to battery between IACV and ECM
• Faulty IACV

closing coil circuit between IACV harness No Short circuit to battery between IACV harness
• Specifications: below 0.5V Repair as necessary
Measure resistance of IACV closing coil. terminals at all connectors in circuit.
• Closing coil: 14.5~16.5Ω at 20°C (68°F) No Temporarily install a known good IACV and
3 Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by drivingvehicle with SCAN

Page 125 of 125
TCU request for MIL ON / Freeze Frame to ECM via CAN
No. P1529
[Related items] • This is only a request from TCM to turn the MIL ON. The fault code is
stored in the TCM.
The freeze frame data is stored in the ECM under the P1529 request code.
Be sure to retrieve freeze frame data before clearing code P1529 from
ECM.
• Check TCM

AT/MT encoding malfunction
No. P1586
[Related items] • Poor connection to chassis ground at ECM
• Open or short circuit between ECM AT/MT and chassis
ground
• Normal condition: AT-chassis ground, MT-open

1 Does vehicle have manual transmission? Yes Go to step 2.
No Go to step 3.
2 Turn ignition to OFF and disconnect ECM Yes Problem is intermittent or was repaired and engine
connector. control module memory was not cleared.
Measure resistance between ECM AT/MT
encoding terminal and ground chassis. No Short circuit to chassis ground at ECM AT/MT
• Specifications: infinite encoding terminal.
3 Turn ignition to OFF and disconnect ECM Yes Problem is intermittent or was repaired and engine
connector. control module memory was not cleared.
Measure resistance between ECM AT/MT
encoding terminal and ground chassis. No Open circuit between ECM AT/MT encoding
• Specifications: below 1Ω terminal and chassis ground.
Does resistance indicate continuity? Repair as necessary.
Page 1 of 27
RIO(BC) > 2005 > G 1.6 DOHC > Heating,Ventilation, Air Conditioning
Heating,Ventilation, Air Conditioning > General Information > Troubleshooting

TROUBLESHOOTING
Before replacing or repairing air conditioning components, first determine if the malfunction is due to the refrigerant
charge, air flow or compressor.
The following diagnostic charts have been developed as a quick reference for determining the cause of the
malfunction. If these charts do not satisfactorily describe the problem, refer to the appropriate section for a more
detailed explanation. After correcting the malfunction, check the complete system to ensure that performance is
satisfactory.
MALFUNCTION CAUSES AND REMEDIES (Numbers Indicate checking/inspection order.)
Page 2 of 27
Heating,Ventilation, Air Conditioning > General Information > Specifications

SPECIFICATIONS
A/CON
Page 3 of 27
ITEM Specification
COMPRESSOR TYPE HS-15
Oil type & Capacity FD46XG(PAG), 150±10cc
COMP.PULLEY TYPE 4PK-TYPE
PULLEY Dia.
ø49.212(ø125)
[in(mm)]
CONDENSER TYPE Corrugated
Dual pressure S/W High [psi(kg/cm²)] 455±28(32.0±2.0)
Low [psi(kg/cm²)] 28±2.8(2.0±0.2)
EXPANSION Valve TYPE BLOCK
Refrigerant Type R-134a
Capacity [oz(g)] 16.93±0.88(480±25)
BLOWER AND EVAPORATOR UNIT

ITEM Specification
Fresh and Operating method ACTUATOR
Recirculation
BLOWER Rotating direction Clockwise
SPEED step 1 - 4 Speed
SPEED control RESISTOR
EVAPORATOR TYPE DRAWN CUP
Temp. control type THERMISTER
A/C ON/OFF OFF:
33.8±32.54°F(1.0±0.3°C),
ON: 35.6±32.9°F
(2.0±0.5°C)
Cooling capacity 4100kcal/h±10%
AIR FILTER TYPE Particle(OPTION)
HEATER UNIT
ITEM Specification
HEATER MODE TYPE DIMPLED
Selection
HEATING capacity 3900kcal/h ± 10%
Operating method Cable
TEMP selection Operating method Cable
Heating,Ventilation, Air Conditioning > Air conditioning System > General Safety Information and
Caution
Page 4 of 27
INSTRUCTIONS
WHEN HANDLING REFRIGERANT
1. R-134a liquid refrigerant is highly volatile. A drop on the skin of your hand could result in localized frostbite.
When handling the refrigerant, be sure to wear gloves.
2. 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 R-134a container is highly pressurized. Never leave it in a hot place, and check that the storage temperature
is below 52°C (126°F).
4. A electronic leak detector should be used to check the system for refrigerant leakage. Bear in mind that the R-
134a, upon coming into contact with flame, produces phosgene, a highly toxic gas.
5. Use only recommended the lubricant for R-134a 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:
A. When removing refrigerant components from a vehicle, cap immediately the components to prevent from the
entry of moisture.
B. When installing refrigerant components to a vehicle, do not remove the cap until just before connecting the
components.
C. Complete the connection of all refrigerant tubes and hoses without delay to prevent the A/C system from
taking on moisture.
D. 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.
WHEN INSTALLING CONNECTING PARTS

FLANGE WITH GUIDE PIN
Check the new O-ring for damage (use only the specified) and lubricate it using compressor oil. Tighten the nut to
specified torque.
Page 5 of 27
Tightening torque (N·m (kg·m, lb-ft))

Size General bolt, nut
4T 7T
4 - 6 (0.4 - 0.6, 2.9 - 7 - 11 (0.7 - 1.1, 5.0 -
M6
4.3) 7.9)
9 - 14 (0.9 - 1.4, 6.5 - 17 - 26 (1.7 - 2.6, 12 -
M8
10) 18)
19 - 28 (1.9 - 2.8, 14 - 35 - 55 (3.5 - 5.5, 25 -
M10
20) 39)
Flange bolt, nut
Size
4T 7T
5 - 7 (0.5 - 0.7, 3.6 - 8 - 12 (0.8 - 1.2, 5.8 -
M6
5.0) 8.6)
10 - 15 (1.0 - 1.5, 7 - 19 - 28 (1.9 - 2.8, 14 -
M8
10) 20)
21 - 31 (2.1 - 3.1, 15 - 39 - 60 (3.9 - 6.0, 28 -
M10
22) 43)
HANDLING TUBING AND FITTINGS

The internal parts of the refrigeration system will remain in a state of chemical stability as long as pure moisture-free
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 rebend 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.
Heating,Ventilation, Air Conditioning > Air conditioning System > Description and Operation
REFRIGERATION CYCLE
Page 6 of 27
Heating,Ventilation, Air Conditioning > Air conditioning System > Components and Components
Location
COMPONENTS
Page 7 of 27
Page 8 of 27
Heating,Ventilation, Air Conditioning > Air conditioning System > Repair procedures
REFRIGERANT SYSTEM SERVICE BASICS
REFRIGERANT RECOVERY
Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove
HFC-134a(R-134a) from the air conditioning system.
Page 9 of 27
• 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 obatined from the refrigerant and lubricant manufacturers.
1. Connect a R-134a refrigerant Recovery/Recycling/Charging System to the high-pressure service port and the
low-pressure service port as shown, following the equipment 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
HFC-134a(R-134a)from the air conditioning system.
1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be
evacuated using a R-134a 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.)
low-pressure service port as shown, following the equipment manufacturer's instructions.
3. If the low-pressure does not reach more than 93.3 kPa(700 mmHg, 27.6 in.Hg) in 15 minutes, there is probably
a leak in the system. Partially charge the system, and check for leaks (see Leak Test.)
SYSTEM CHARGING
Page 10 of 27
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.
Connect a R-134a refrigerant Recovery/Recycling/Charging System to the high-pressure service port and the low-
pressure service port, as shown, following the equipment manufacturer's instructions.
Add the same amount of new refrigerant oil to system that was removed during recovery. Use only Specified
refrigerant oil.
Charge the system with 480±25g (16.93±0.88 oz)of R-134a refrigerant. Do not overcharge the system the
compressor will be damaged.
REFRIGERANT LEAK TEST
R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with
compressed air.
• Compressed air mixed with R-134a forms a combustible vapor.

• The vapor can burn or explode causing serious injury.
• Never use compressed air to pressure test r-134a service equipment or vehicle air conditioning systems.
low-pressure service port as shown in the previous column, following the equipment manufacturer's instructions.
2. Open the high-pressure valve to charge the system to the specitled capacity, then close the supply valve, and
remove the charging system couplers.
Refrigerant capacity : 480±25g (16.93±0.88 oz)

Page 11 of 27
3. Check the system for leaks using a R-134a refrigerant leak detector with an accuracy of 14g(0.5 oz)per year or
better.
4. If you find leaks that require the system to be opened(to repair or replace hoses, fittings, etc.) recover the system
according to the Recovery Procedure.
5. After checking and repairing leaks, the system must be evacuated.
PERFORMANCE TEST
1. Install the manifold gauge set.
2. Run the engine at 2,000 rpm and set the controls for maximum cooling and high blower speed.
3. Keep all windows and doors open.
4. Place a dry-bulb thermometer in the cool air outlet.
5. Place a wet-dry thermometer close to the inlet of the cooling unit.
6. Check that the reading on the high pressure gauge is 1,373-1,575 kPa (14-16 kg/cm², 199-228 psi). If the
reading is too high, pour water on the condenser. If the reading to too low, cover the front of the condenser.
7. Check that the reading on the dry-bulb thermometer at the air inlet at 25-35°C (77-95°F).
8. Calculate the relative humidity from the psychrometric graph by comparing the wet-and dry-bulb reading at the air inlet.
9. Measure the dry-bulb temperature at the cool air outlet, and calculate the difference between the inlet dry-bulb
and outlet dry-bulb temperatures.
Page 12 of 27
10. Check that the intersection of the relative humidity and temperature difference falls within the block below. If the
intersection is within the block, cooling performance is satisfactory.
PERFORMANCE TEST DIAGNOSIS USING MANIFOLD GAUGE

STANDARD VALUE
If cooling cycle is operating normally, the manifold gauge reading will be approx.1.5-2.0kg/cm²(21-28psi) for the
low pressure side and approx. 14.5-15kg/cm²(206-213psi) for the high pressure side. Inlet temperature should be
30-35°C(80-95°F), with the engine at 2,000 rpm, maximum cooling selected, and the blower on highest level.
DIAGNOSIS
PROBABLE
SYMPTOMS REMEDY MANIFOLD GAUGE READINGS
CAUSES
1. Low pressure and high • Gas leak. • Check and repair.
pressure are low. • Add refrigerant.
2. Cooler outlet air is a
little cooler.
1. Low pressure and high • Faulty cooling or • Maintain the

pressure are high. condenser proper level of
freezing. refrigerant. Clean
• Belt slip. the condenser.
• Adjust the belt.
1. Low pressure and high • Air in the system. • Clean or repair

pressure are high. the receiver drier..
2. Low pressure pipe is • Check for oil
not cold. contamination.
Page 13 of 27
1. Low pressure and high • Air in the system. • Clean or repair
pressure are high. the receiver drier..
2. Low pressure pipe is • Check for oil
not cold. contamination.
1. Low pressure side • Dust or moisture • Repair the

indicates negative frozen at receiver drier and
pressure and high expansion valve. replace the
pressure side indicates • Gas leak. expansion valve.
low pressure. • Replace the
2. Frost or dew on pipes expansion valve if
connected with receiver the receiver-drier
or expansion valve. is faulty.
1. Low pressure side • Intaken moisture • Repair and bleed
pressure sometimes is frozen at receiver drier
goes to negative expansion valve
pressure or normal. hole.
1. Low pressure and high • Expansion valve • Repair receiver

pressure are high. failure. Receiver- drier.
2. Much frost or dew on drier faulty. • Check oil
the low pressure side • Flow control contamination.
piping. faulty.
1. Low pressure side • Leak inside • Replace

pressure is high and high compressor. compressor.
pressure side pressure
is low.
CHECKING FOR REFRIGERANT LEAKS

Always conduct a leak test with an electronic leak detector whenever leakage or refrigerant is suspected and when
conducting service operations which are accompanied by disassembly or 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.
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.
Page 14 of 27
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.
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Components and
Components Location
COMPONENTS
Without Power steering With Power Steering
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Repair procedures
REMOVAL AND INSTALLATION
1. Loosen the tension pulley tightening bolt A, and then remove the drive belt after loosening the tension adjusting
bolt B.
(Without power steering)
Loosen the bolt A,B,C and then remove the drive belt after loosening the tension adjusting bolt D.
(With power steering)
2. Discharge the refrigerant.
3. Remove the discharge and suction hoses.
Page 15 of 27
4. Remove the compressor.
5. Installation is the reverse of removal.
Tightening torque
24~36 N·m (2.4~3.6 kg-m, 17~26 Ib·ft)
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor oil > Repair procedures
Oil Specification
• The HFC-134a system requires a synthetic (PAG) compressor oil whereas the R-12 system requires mineral
compressor oil. The two oils must never be mixed.
• Compressor (PAG) oil varies according to compressor model. Be sure to use oil specified for the model of
compressor.
Handling of Oil
• The oil should be free from moisture, dust, metal powder, etc.
• Do not mix with other oil.
• The water content in the oil increases when exposed to the air. After use, seal oil from air immediately.
(HFC-134a Compressor Oil absorbs moisture very easily.)
• 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 Capacity
Capacity total in system: 120cc
Compressor (Service parts) charging amount: 120cc
Checking and Adjusting Oil Quantity for Used Compressor

1. Perform oil return operation. Refer to Oil Return Operation in this section.
2. Discharge and recover refrigerant and remove the compressor.
Page 16 of 27
3. Drain the compressor oil and measure the extracted oil with a measuring cylinder.
4. If the amount of oil drained is much less than 60 cc, some refrigerant may have leaked out.
Conduct a leak tests on the connections of each system, and if necessary, repair or replace faulty parts.
5. Check the compressor oil contamination. (Refer to Contamination of Compressor Oil in this section.)
6. Adjust the oil level following the next procedure below.
Charging Amount Collected Amount
More than 60 cc Same as collected amount
Less than 60 cc 60 cc
7. Install the compressor, then evacuate, charge and perform the oil return operation.
8. Check system operation.
When it is impossible to perform oil return operation, the compressor oil should be checked in the
following order:
1. Discharge and recover refrigerant and remove the compressor.
2. Drain the compressor oil and measure the extracted oil with a measuring cylinder.
3. Check the oil for contamination.
4. If more than 60 cc of oil is extracted from the compressor, supply the same amount of oil to the compressor to
be installed.
5. If the amount of oil extracted is less than 60 cc recheck the compressor oil in the following order.
6. Supply 60 cc of oil to the compressor and install it onto the vehicle.
7. Evacuate and recharge with the proper amount of refrigerant.
8. Perform the oil return operation.
9. Remove the compressor and recheck the amount of oil.
10. Adjust the compressor oil, if necessary.
Checking and Adjusting for Compressor Replacement
150 cc of oil is charged in compressor (service parts). So it is necessary to drain the proper amount of oil from the
new compressor.
1. Perform oil return operation.
2. Discharge and recover the refrigerant and remove the compressor.
3. Drain the compressor oil and measure the extracted oil.
4. Check the compressor oil for contamination.
Page 17 of 27
5. Adjust the oil level as required.
Amount of oil drained from used
Draining amount of oil from new compressor
compressor
Less than 60 cc Same as drained amount
More than 60 cc 60 cc
6. Evacuate, charge and perform the oil return operation.

7. Check the system operation.
Contamination of Compressor Oil
Unlike engine oil, no cleaning agent is added to the compressor oil. Even if the compressor runs for a long period of
time (approximately one season), the oil never becomes contaminated as long as there is nothing wrong with the
compressor or its method of use.
Inspect the extracted oil for any of the following conditions:
• The capacity of the oil has increased.
• The oil has changed to red.
• Foreign substances, metal powder and etc. are present in the oil.
If any of these conditions exists, the compressor oil is contaminated. Whenever contaminated compressor oil is
discovered, the receiver/drier must be replaced.
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
Amount of Oil
be installed
Evaporator 40 cc
Condenser 20 cc
Receiver/dryer 20 cc
Refrigerant line
10 cc
(One piece)
Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser fan & relay > Repair
procedures
CHECKING
CONDENSER
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 a pliers.
Page 18 of 27
2. Check the condenser connections for leakage, and repair or replace it, if required.
CONDENSER FAN
1. Check the condenser fan for proper operation.
2. Check the harness connector.
3. Check the condenser fan motor using battery voltage as shown below.
Heating,Ventilation, Air Conditioning > Air conditioning System > Receiver-Drier > Repair procedures
CHECK
1. Check the fusible plug and the fittings for leakage, using a leak detector.
2. Run the engine at fast idle with the air conditioning "ON", and check both the inlet and outlet temperatures. If the
difference in temperatures between the inlet and outlet is large, replace the receiver-drier.
1. Plug the all open fittings immediately to keep moisture out of the system.
2. Do not remove plugs until ready for connection.
3. If the receiver-drier is replaced with a new unit, add 40cc of compressor oil to the compressor.
4. Evacuate, charge and test the refrigeration system.
Heating,Ventilation, Air Conditioning > Air conditioning System > Dual pressure switch > Repair
procedures
DESCRIPTION
Page 19 of 27
The dual swith is composed a low pressure and high pressure switches. The low pressure switch will be turned off to
stop compressor operation if refrigerant pressure is low. The high pressure switch will be turned off to stop
compressor operation if refrigerant pressure is too high.
OPERATING CHARACTERISTIC
Heating,Ventilation, Air Conditioning > Air conditioning System > Thermistor > Repair procedures
SENSOR CHECKING
The thermistor will detect the core temperature and interrupt compressor relay power, in order to prevent
evaporator freezing by excessive cooling.
The thermistor is an NTC device.
Page 20 of 27
Thermistor check
1. Remove the glove box.
3. Turn on the air conditioner.
4. Using the multi-tester, check the output voltage between terminals 2 and 3 in the thermistor.
Operating
Thermistor Output voltage
temperature
ON 35.6±32.9°F(2.0±0.5°C) 12V
OFF 33.8±32.54°F(1.0±0.3°C) 0V
Heating,Ventilation, Air Conditioning > Air conditioning System > Magnetic Clutch > Repair
procedures
CHECKING THE CLUTCH AIR GAP
1. Check the air gap between the clutch hub and pulley contact surface using a filler gauge.
Clutch air gap : 0.35 - 0.65mm
2. Check the gap around the pulley at 3 points.

3. If the clutch air gap is outside the normal range, correct it using a shim of proper size.
MAGNETIC CLUTCH OPERATION

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Connect the compressor terminal to battery(+) and the battery(-) terminal to the compressor body. Verify magnetic
clutch operation by a clicking noise.
Heating,Ventilation, Air Conditioning > Air conditioning System > Evaporator Air Filter > Description
and Operation
DESCRIPTION
The combination filter eliminates foreign materials and odor. The combination filter includes an odor filter as well as
conventional dust filter to ensure comfortable interior environment.
REMOVAL
1. Remove the glove box.
2. Remove the air filter cover and the air filter.
When driving in an air-polluted area or rugged terrain, check and replace the air filter as frequently as
possible.
Heating,Ventilation, Air Conditioning > Blower > Blower Motor > Repair procedures
CHECK
Page 22 of 27
1. Connect the battery voltage and check the blower motor rotation
Heating,Ventilation, Air Conditioning > Blower > Blower Speed Controller > Repair procedures
CHECK (MAMUAL CONTROL)
1. Check for continuity and resistance between terminals.

Terminal Resistance (Ω)
3-1 0.35
3-2 0.80
3-4 1.48
Heating,Ventilation, Air Conditioning > Blower > Control Panel > Schematic Diagrams
SCHEMATIC DIAGRAM (MANUAL)
BLOWER AND A/C CONTROLS (MANUAL)
Page 23 of 27
Heating,Ventilation, Air Conditioning > Blower > Control Panel > Components and Components
Location
CONTROL PANEL
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Page 24 of 27
Connector pin description

Page 25 of 27
PIN PIN
Connector PIN Name Connector PIN Name
NO. NO.
Main 1 INTAKE Blower GROUND
1
Connector (RECIRCULATION) Connector
2 INTAKE (FRESH) 2 COMMON
3 IG2 3 Middle HIGH
4 Ground 4 LOW
5 ILL(-) 5 Middle LOW
6 ILL(+) 6 HIGH
7 B+
8 REAR defroster
indicator
9 REAR defroster select
10 A/C SELECT
11 A/C THERMO LOW
12 BLOWER
COMMON
Heating,Ventilation, Air Conditioning > Blower > Control Panel > Repair procedures
DEFROST LOGIC
1. IG ON/OFF logic
Condition Mode A/C Intake
IG OFF - - Fresh
Face, Face - floor, Floor Memory Memory
IG ON
Defrost, Floor - defrost ON Fresh
Memory function
• When moving blower switch off to on, A/C and intake are changed to previous
status.
• At initial the battery on, the A/C is off and the intake is changed to fresh status.
• At blower switch off, the intake is changed to fresh status.
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Page 26 of 27
2. Defrost, Floor - defrost logic
Mode A/C Intake
ON ON Fresh
Defrost, Floor - defrost
OFF Previous Previous
The intake button enables to change the intake status at defrost and floor - defrost mode.
The A/C button enables to change the A/C ON/OFF at defrost and floor - defrost mode.
Be impossible to enter defrost and floor - defrost logic again as defrost ↔ floor - defrost
changing.
3. Dissolution & Reinstatement of logic
(1) Turn off the blower switch.
(2) Move to defrost mode
(3) Press the intake button more than 5 times within 3 seconds.
(4) Indicator of intake button is flashed 3 times.
(5) Dissolution & reinstatement of logic is completed.
(6) A/C and intake status are initialized to "A/C off" and "fresh status"
When the battery happens to be disconnected or discharged, the logic is

reinstated.
Heating,Ventilation, Air Conditioning > Blower > Air Intake Switch > Description and Operation
Intake actuator
The intake selection switch is located on the control panel. Pressing the switch will shift between recirculation and
fresh air modes.
CHECK
Input Output
Fresh/recirculation
2 1
shifting
+ - Recirculation
- + Fresh
Page 27 of 27
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Page 1 of 66
RIO(BC) > 2005 > G 1.6 DOHC > Manual Transaxle System
Manual Transaxle System > General Information > Special Service Tools (STC)
Tool
Illustration Use
(Number and Name)
0K201 170 AA0A Used to support engine.
Support, engine
0K130 990 007 Used to disassemble and assemble transaxle.

Engine stand
0K201 323 021 Used to hold primary shaft.

Holder, primary shaft
0K201 170 AA1 Used to install oil seal.

Installer, oil seal
0K670 990 AA0 Used to remove bearing.

Puller set, bearing
0K201 172 008 Used to remove gears.

Removing plate
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0K130 171 013 Used to remove bearing.
Puller, bearing
0K670 321 019 Used to remove tie-rod end.

Puller, socket
0K130 175 011A Used to disassemble and assemble transaxle.

Hanger, transaxle
0K130 170 012 Used to remove bearing.

Remover, bearing
0K130 175 008 Used to remove gears.

Puller, fan pulley boss
0K900 175 AA1 Used to install bearing.

Install set, bearing
0K130 175 AA0 Used to adjust bearing preload.

Shim selector set
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0K130 322 020 Used to measure preload.
Attachment
0K201 270 014 Used to hold differential side gears.

Holder, differential side
gear
0K930 175 AA0 Used to remove bearing.

Bearing remover set
Manual Transaxle System > General Information > Troubleshooting (STC)

Diagnostic chart
Shift lever does not Seized shift lever ball seat Replace
shift smoothly or is Seized control rod joint Replace
hard to shift Bent control rod Replace
Too much play in Worn control rod bushing Replace
shift lever Weak shift lever ball spring Replace
Worn shift lever ball bushing Replace
Difficult to shift Replace
Bent control rod
Lubricate with grease
No grease in shifter
Add oil
Insufficient oil
Replace with oil of specified
Deterioration of oil quality
quality
Wear or play of shift fork or shift rod
Replace
Worn synchronizer ring
Replace
Worn synchronizer cone area of gear
Replace
Bad contact of synchronizer ring and cone area of gear
Replace
Excessive gear side clearance
Replace
Worn bearing
Replace
Worn synchronizer key spring
Replace
Excessive primary shaft bearing preload
Adjust
Improperly adjusted change guide plate
Adjust
Does not stay in gear Bent control rod Replace
Worn control rod bushing Replace
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Weak shift lever ball spring Replace
Improperly installed extension bar Tighten
Worn shift fork Replace
Worn clutch hub Replace
Worn clutch hub sleeve Replace
Worn sliding surface of shaft gears Replace
Worn sliding surface of gear Replace
Worn sliding groove of control rod end Replace
Weak detent spring Replace
Excessive thrust clearance Replace
Worn bearing Replace
Improperly installed or loose engine mount Tighten
Abnormal noise Add oil
Insufficient oil
Replace with oil of specified
Deterioration of oil quality
quality
Worn bearing
Replace
Worn sliding surfaces of gears or shafts
eplace
Excessive gear backlash
Replace
Damaged gear teeth
Replace
Foreign material in gears
Replace
Damaged differential gear or excessive backlash
Replace
Manual Transaxle System > General Information > Specifications (STC)

Specifications
Manual Transaxle System > Manual Transaxle System > Description and Operation (STC)
Structural view
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Manual Transaxle System > Manual Transaxle System > Components and Components Location
(STC)
5th/Reverse gear and housing parts
Component
Page 6 of 66
• Clean transaxle exterior thoroughly with steam cleaner or cleaning solvent before disassembly.
• Clean removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with
compressed air.
• Clean out all holes and passages with compressed air and verify that there are no obstructions.
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Using compressed air can cause dirt and other particles to fly out, causing injury to eyes. Wear protective eye
wear whenever using compressed air.
Manual Transaxle System > Manual Transaxle System > Troubleshooting (STC)
Service adjustment procedures
Oil inspection
2. Remove the speedometer driven gear.
Keep vehicle level when checking oil level.
3. Verify that oil level is within the specification.

4. If oil level is low, fill specified amount and type of oil through the speedometer driven gear.
5. Reinstall the speedometer driven gear in case.

6. Lower vehicle.
Oil change
Keep vehicle level when checking oil

level.
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2. Remove drain plug at bottom of transaxle case and drain fluid into suitable container.
Tightening torque :
29~43 lb·ft (40~58 N·m, 4.0~6.0 kg·m)
3. Install new washer on drain plug and reinstall plug in case.

4. Add specified amount and type of oil into the speedo driven gear.
Specified oil :
Grade : API Service GL-4
Viscosity : SAE 75W-90 (Fill-for-life)
Capacity : 2.96 US qt (2.8ℓ, 2.46lmp qt)
5. Warm up vehicle until transaxle oil reaches its normal temperature, then check for leakage of transaxle oil.
6. Lower vehicle.
Oil seal change
1. Jack up vehicle and support it with safety stands.
2. Remove drain plug at bottom of transaxle case and drain fluid into a container.
3. Remove front wheel.

4. Remove splash shield.
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5. Separate the tension rod from lower arm.
Do not damage dust boots.

6. Remove the ball joint clamp bolt and pull lower arm downward to separate knuckle from lower control arm ball
joint.
7. Loosen nut and disconnect tie-rod end with SST(0K670 321 019).
Do not subject cv joint to shock when removing driveshaft.

8. Insert pry bar between outer ring and transaxle and pry driveshaft from transaxle.
gradually. (If the shaft is pulled out too quickly, the oil seal may be damaged.)
9. Suspend driveshaft with rope.
Suspend the driveshaft with a rope to protect bearing and boot from
damage.
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10. Remove oil seal with screwdriver.
• Tap in until oil seal is flush with case.

• Coat oil seal lip with transaxle oil.
11. Tap new oil seal into transaxle case with SST(0K201 170 AA1).
12. Replace driveshaft end clip and Install driveshaft into transaxle with end-gap of clip facing upward.
Manual Transaxle System > Manual Transaxle System > Manual Transaxle > Components and
Components Location (STC)
EXPLODED VIEW
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Page 11 of 66
Clutch housing and transaxle case

components
Do not remove an oil seal if not necessary.

• Disassemble in order on figure.
• Assembly will be in reversa order of disassembly.
Page 12 of 66
Manual Transaxle System > Manual Transaxle System > Manual Transaxle > Repair procedures
(STC)
Removal
1. Disconnect negative battery cable (first) and positive battery cable (second).
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Page 13 of 66
2. Put aside the coolant reserve tank to remove the battery bracket.
3. Remove the battery, battery tray and battery fixing holder.

4. Remove the fresh air duct and air cleaner assembly.
5. Disconnect back-up switch connector from connector bracket in case.
6. Disconnect vehicle speed sensor connector from right side of transaxle.
7. Disconnect ground strap (one bolt).
8. Disconnect the crankshaft position sensor connector.
9. After removing the release lever, put the release lever and the clutch pipe aside.
10. Remove one starter upper bolt.
11. Remove three clutch housing bolts.

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12. Support engine with engine support bar SST (0K201 170 AA0A).
13. Raise and properly support vehicle.

14. Remove the front wheels and tires.
15. Remove both splash shields.
16. Remove the engine mounting member (two bolts, four nuts).
17. Place drain pan under the transaxle drain plug.
18. Remove transaxle drain plug and drain transaxle oil.
19. Remove the extention bar and shift control rod.
20. Remove two engine mounting bolt No. 1.

21. Remove three engine mounting bolt No. 2.
22. Remove the tension rod mounting nuts.
23. Remove the stabilizer bar and control link(Refer to section SS Gr. - suspension system)
24. Remove the cotter pin and loosen the nuts.
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25. Disconnect the tie-rod end from the knuckle arm by using SST.
26. Remove the ball joint clamp bolt and nut from the lower arm.
27. Pry down the lower arm and disconnect the ball-joint.
Be careful not to damage the ball-joint dust boot.
28. Separate the driveshaft from the transaxle.
graduall.
Page 16 of 66
Suspend the driveshaft with a rope to protect a bearing and a boot from damage.
29. Remove one starter lower bolt and set aside starter.
30. Remove three lower clutch housing bolts and support transaxle with jack or suitable floor jack and then remove
remaining two bolts.
31. Gently separate transaxle assembly from engine and lower.
Installation
1. Raise the transaxle into the position and seat it against the back of the engine.
2. Connect the transaxle to the engine using five mounting bolt through clutch housing.
Tightening torque :
Upper bolt (4EA) : . . .
17~66 lb·ft (64~89 N·m, 6.5~9.1 kg·m)
Lower bolt (5EA) : . . . .
28~38 lb·ft (37~52 N·m, 3.8~5.3 kg·m)
3. Remove floor jack from the transaxle.

4. Remove the SST (0K201 270 014).
5. Install starter using lower starter bolt.
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6. Install new clip onto driveshaft.
7. Push the driveshaft into the transaxle with opening of clip pointing upward.
8. Install the lower arm ball joint into the steering knuckle then installthe ball joint clamp bolt and nut.
Tightening torque :
43~50 lb·ft (54~68 N·m, 5.5~6.9 kg·m)
9. Connect the tie-rod end to the steering knuckle then install the tie-rod end nut.
Tightening torque :
22~33 lb·ft (30~44 N·m, 3.0~4.5 kg·m)
10. Insert cotter pin.

11. Install the stabilizer bar and control link (Refer to section SS-Supension system).
Tightening torque :
32~45 lb·ft (43~60.8 Nm, 4.4~6.2 kg·m)
12. Install the tension rod mounting nut.
Tightening torque :
87~108 lb·ft (118~147 N·m, 12~15 kg·m)
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13. Install the engine mounting No.2.
Tightening torque :
Bolt : 32~40 lb·ft (43~54 N·m, 4.4~5.5 kg·m)
Nut : 49~69 lb·ft (67~93 N·m, 6.8~9.5 kg·m)
14. Install the engine mounting No.1.
Tightening torque :
43~54 N·m (4.4~5.5 kg·m, 32~40 lb·ft)
15. Install the extention bar and shift control rod.

16. Install the drain plug.
17. Install the engine mounting member-to-chassis bolts and nuts. (bolt two, four nuts)
After tightening the No. 1 & 2 engine mount-to-mounting member nuts.
Tightening torque :
Engine mounting member bolt and nuts :
47~66 lb·ft (64~89N·m, 6.5~9.1 kg·m)
No.1 and 2 engine mounting nut :
27~38 lb·ft (37~52 N·m, 3.8~5.3 kg·m)
18. Install the splash shields.

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19. Install the wheels and tires.
Tightening torque :
88~118 N·m (9~12 kg·m, 65~98 lb·ft)
20. Lower vehicle.

21. Remove the engine support bar SST (0K201 170 AA0A).
22. Install three clutch housing bolts.
Tightening torque :
66~86 lb·ft (89~116 N·m, 9.1~11.9 kg·m)
23. Install two starter upper bolts.
Tightening torque :
27~38 lb·ft (37~52 N·m, 3.8~5.3 kg·m)
24. Install the release lever.

25. Reconnect the crankshaft position sensor connector.
26. Reconnect the ground strap with one bolt.
27. Reconnect the speed sensor connector.
28. Reconnect the back-up switch connector.
29. Reinstall the air cleaner assembly.
30. Reconnect the air temperature sensor connector.
31. Reconnect the MAF sensor connector.
32. Reinstall the fresh air duct.
33. Reconnect positive (first) then negative (last) battery cables.
34. Add gear oil, refer to oil inspection.
35. Test vehicle and check fluid levels.
Disassembly
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1. Mount the transaxle on the SST(0K130 990 007/0K130 175 011A).
2. Remove the release bearing and the release fork.

3. Remove the oil level gauge.
4. Remove the speed sensor.
5. Remove the backup lamp switch.

6. Remove the rear cover.
To remove the rear cover, lightly tap the rear cover using a plastic
hammer.
Do not reuse the removed lock nut.
7. Lock the primary shaft with the SST(0K201 323 021).
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Page 21 of 66
8. Shift to 1st or 2nd gear to lock the rotation of primary shaft.
9. Uncrimp the tabs of the locknuts.
10. Remove the lock nut from the primary and secondary shaft and remove the reverse clutch cone and the reverse
synchronizer sleeve from the primary shaft.
Do not reuse the removed roll pin.

11. Remove the roll pin from the 5th shift fork with a pin punch.
12. Remove the synchronizer ring and 5th shift fork, the 5th clutch hub assembly, 5th gear synchronizer ring, 5th
gear sleeve at the same time.
13. Remove the secondary 5th gear.
14. After loosening the detent plug, remove the spring and the steel ball by using a magnetic stick.
15. Remove the reverse idle shaft lock bolt from the transaxle case assembly.
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16. Remove the transaxle assembly.
To remove the transaxle case, lightly tap the transaxle case using a plastic
hammer.
17. Remove the magnet.
18. Remove the reverse idle shaft and the reverse idle gear.
19. Remove the control case assembly after loosening 3 bolts.
20. Remove the lever spring set.

21. After putting shift lever in neutral, remove the roll pin from the 1/2 shift fork using a pin punch.
Do not reuse the removed roll pin.
22. Remove the 1/2 shift rod and the 1/2 shift fork. tomsn048@gmail.com
Page 23 of 66
23. After removing the roll pin from the 3/4 shift fork and the 3/4 shift rod end by using a pin punch, remove the 3/4
shift fork and shift rod end.
24. Remove E-Ring from the 5/R shift rod.

25. After removing the roll pin from the 5/R shift rod end by using a pin punch, remove the 5/R shift rod and 5/R
shift rod end.
26. Remove the primary shaft geartrain and secondary shaft geartrain as an assembly.
27. Remove the differential assembly.
Disassembly
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1. Remove the speedometer driven gear.
2. Remove the pin with long-nosed pliers.

3. After removing the reverse lever shaft from the reverse shift lever, remove the reverse shift lever.
4. After loosening bolt, remove the change arm and the change rod.
5. After loosening two bolts, remove the baffle plate.
Remove the secondary bearing outer race with a screwdriver if

necessary.
6. Insert a screwdriver into the secondary bearing outer race of the clutch housing shaft.
7. Lift up the bearing outer race.
8. While lifting up the funnel and the bearing outer race, lift up the bearing outer race.
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9. Remove the change rod oil seal with a screwdriver.
Do not damage the clutch housing.
10. Remove the primary oil seal with a screwdriver.
11. Remove the differential oil seal with a screwdriver.

12. Install SST(0K130 170 012) on the differential bearing outer race.
13. Remove the bearing outer race with SST.
14. After installing SST(0K130 170 012) on the bearing outer race of the differential side, remove the bearing outer
race and the adjust shim from the transaxle case.
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15. Remove the oil seal of the transaxle case of the differential side with a screw driver.
Reassembly
Apply the transaxle oil to the differential bearing outer race.

1. Install the differential assembly in the clutch housing.
• Be sure not to damage the oil seal of the clutch housing side during installing the primary
shaft.
• Apply the transaxle oil to the lips of the primary oil seal.
• Apply the transaxle oil to the secondary bearing outer race.
2. Install the primary shaft and the secondary shaft assembly in the clutch housing.
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3. Assemble the 3rd/4th shift fork to the 3rd/4th clutch hub sleeve, insert the 5th/Rev shift rod into the shift fork and
insert the 5th/Rev shift rod pin.
Use a new roll pin.

4. Align the 5th/Rev shift rod end with the 5th/Rev shift rod and insert the roll pin.
5. After inserting the 3rd/4th shift rod into the 3rd/4th shift fork, insert the 3rd/4th shift fork into the 3rd/4th shift rod
end.
Use a new roll pin.
6. Align the 3rd/4th shift rod end with the 3rd/4th shift rod and insert the roll pin.
7. Align the 3rd/4th shift rod with 3rd/4th shift fork and insert the roll pin.
8. Assemble the 1st/2nd shift fork to the 1st/2nd clutch hub sleeve, install the 1st/2nd shift rod.
Use a new roll pin.
9. Align the 1st/2nd shift rod with the 1st/2nd shift fork and insert the roll pin.
Use a new E-ring.

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10. Insert the E-Ring into 5th/Rev shift rod.
11. Align the projection of the reverse shift lever with the 5th/Reverse shift rod end groove, and set the reverse shift
lever to the clutch housing.
12. Install a new O-Ring to the reverse shift lever shaft.
Install the O-Ring so that it is on the outside.

13. Insert the reverse lever shaft into the reverse lever.
14. Insert the pin.

15. After assembling the lever spring set, tighten bolts.
Tightening torque:
5.8~8.3 lb·ft (7.8~11.3 N·m, 80~115 kg·cm)
16. After installing the control case assembly, tighten bolts.
Tightening torque:
5.8~8.3 lb·ft (7.8~11.3 N·m, 80~115 kg·cm)
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When assembling the control case assembly, make sure to use the correct length bolt.
Bolt A is longer than bolt B
17. Install the reverse idle shaft and the reverse idle gear.
18. Install the magnet.
Thoroughly clean sealants from clutch housing and the transaxle

case.
19. Apply a thin coat of sealant (Threebond#1216T or 1216TB) on the contacting surface of the clutch housing and
the transaxle case.
20. Tighten the transaxle case mounting bolts.
Tightening torque:
13.7~18.8 lb·ft (18.6~25.5 N·m, 1.9~2.6 kg·cm)
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21. Tighten the reverse idle shaft locking bolt to the transaxle case assembly.
Tightening torque:
13.7~18.8 lb·ft (18.6~25.5 N·m, 1.9~2.6 kg·m)
• Since the length of detent springs are different, be sure to select the correct spring.
• The length of detent spring: 5th/Rev is longer than 1st/2nd, 3rd/4th.
• Apply sealant to the detent plug.
22. Insert the steel ball, spring and tighten the detent plug.
Tightening torque:
10.8~15 lb·ft (15~20 N·m, 1.5~2.1 kg·m)
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23. Assemble the secondary 5th gear.
• Since the shape of synchronizer ring are different, be sure to install correctly.
• There is missing synchronizer teeth in 3 places on the synchronizer ring of the reverse clutch hub
assembly side.
Pay attention for the assembling direction of 5th gear sleeve.
24. Install the 5th gear sleeve, 5th gear and the synchronizer ring.
Assemble the oil groove of 5th clutch hub assembly to the 5th gear
side.
25. After installing the 5th shift fork to the 5th clutch hub assembly, assemble the 5th clutch hub assembly and the
5th shift fork.
26. Assemble the synchronizer ring.
27. Assemble the reverse clutch cone and the reverse synchro sleeve at first, in stall it to the primary shaft.
Use a new roll pin.

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28. Insert the roll pin to the 5th shift fork.
29. To prevent the primary shaft from rotating, shift to 1st and 2nd gear.
30. Install SST(0K201 171 010) on the primary shaft.
Use a new lock nut.
31. To prevent the lock nut from loosening after tightening it on to the primary shaft and secondary shaft, use
caulking.
Tightening torque:
94~151 lb·ft (127~206 N·m, 13~21 kg·m)
32. Measure thrust clearance of the 5th gear and the reverse clutch cone with a dial indicator.
Clearance
5th gear: 0.0029~0.0156 in (0.075~0.395 mm)
Reverse clutch cone: 0.004~0.01 in (0.1~0.25 mm)
If not within the specification, reassemble the transaxle.
Thoroughly clean sealants from the transaxle case and the rear cover.
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33. Apply a thin coat of sealant (Threebond#1216 or 1216TB) to the contacting surface of the transaxle case and
the rear cover.
34. Install the rear cover, making sure to align the stopper groove position of the reverse clutch cone. Tighten bolts.
Tightening torque:
5.8~8.3 lb·ft (7.8~11.3 N·m, 80~115 kg·cm)
35. Insert a washer onto the backup lamp switch and install the switch.
Tightening torque:
14~21.7 lb·ft (20~29.4 N·m, 2.0~3.0 kg·m)
36. Assemble the speed sensor to the speedometer driven gear.
Tightening torque:
5.8~8.3 lb·ft (7.8~11.3 N·m, 80~115 kg·cm)
37. Insert a bush to the change rod.
38. Assemble the release bearing and the release fork. (Refer to Group CH)
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39. Remove the transaxle from the SST(0K130 175 011A)
Do not damage the transaxle case.

40. Remove the secondary bearing outer race of the transaxle case with a screw driver.
Reassembly
Precaution
• Before installing the clutch housing and the transaxle case, adjust the following bearing preload and assemble the
suitable adjust shim.
• The primary shaft preload.
• The secondary shaft preload.
• The adjust shim in the differential side.
• After measuring the secondary preload use a selected shim as a adjust shim.
• Apply the transaxle oil to the adjust shim and the bearing outer race.
1. After inserting the adjust shim into the transaxle case, assemble the secondary bearing outer race.
Apply the transaxle oil to outer surface of the oil seal.
2. Assemble the differential oil seal of the transaxle case with a SST(0K201 170 AA1).
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3. Assemble the differential oil seal of the clutch housing with a SST(0K201 170 AA1).
• Use an adjust shim which is selected for adjusting the differential.

• Apply the transaxle oil on the adjust shim and the bearing outer race.
4. After inserting the adjust shim into the transaxle case, assemble the differential bearing outer race.
5. Assemble the differential bearing outer race of the clutch housing with a SST(0K201 170 AA1).
Apply the transaxle oil to outer surface of the change rod oil seal.
6. Install the oil seal.
Apply the transaxle oil to the secondary bearing outer

race.
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7. Install the funnel and the secondary bearing outer race to the clutch housing.
8. Install the baffle plate and tighten bolts.
Tightening torque:
5~7.2 lb·ft (6.8~9.8 N·m, 70~100 kg·cm)
Assemble the boot with facing air bleed downward, as shown in figure.
9. Push the boot into the change rod assembly.
10. Install the change rod assembly to the clutch housing.
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Page 37 of 66
11. After inserting the change arm into the change rod, tighten bolts.
Tightening torque:
8.7~10 lb·ft (11.7~13.7 N·m, 1.2~1.4 kg·cm)
12. Install the speedometer shaft and gear assembly to the sleeve.
13. Install a new O-ring to the speedometer sleeve.
14. After installing the speedometer driven gear to the clutch housing, tighten bolts.
Tightening torque:
5.0~7.2 lb·ft (6.8~9.8 N·m, 80~115 kg·cm)
Manual Transaxle System > Manual Transaxle System > Clutch Housing > Repair procedures
Manual Transaxle System > Manual Transaxle System > Shift Lever > Components and Components
Location (STC)
Shift lever
COMPONENTS/DISASSEMBLY
1. Disassemble in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly, refer to reassembly.
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Manual Transaxle System > Manual Transaxle System > Shift Lever > Repair procedures (STC)
Reassembly
Extension bar
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Page 39 of 66
1. Install the extension bar to the floor and then onto the transaxle. Tighten the extension bar nut at the transaxle.
Tightening torque:
3.2~4.7 kg·m (23~34 lb·ft, 31~46 N·m)
2. Tighten the shifter bracket nuts to the specified torque.
Tightening torque:
52.1~78.1 lb·in (5.8~8.8 N·m, 60~90 kg·cm)
Spring
Make sure that the hooked part of the spring is properly seated in the bracket groove, as shown in the figure.
Manual Transaxle System > Manual Transaxle Gear System > Input Shaft > Components and
Primary shaft
Disassembly and inspection
1. Measure thrust clearance of all gears before disassembly, refer to inspection.
2. Assemble in order shown in figure.
3. Assembly will be in reverse order of disassembly.
Check thrust clearance of all gears before disassembly and after

assembly.
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Manual Transaxle System > Manual Transaxle Gear System > Input Shaft > Repair procedures (STC)
Inspection
3rd gear thrust clearance
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Page 41 of 66
1. Measure the clearance between 3rd gear and 2nd gear.
Clearance : 0.0024~0.0083 in (0.06~0.21 mm)
2. If the clearance exceeds the maximum, check the contact surface of 3rd gear, 2nd gear and the clutch hub
(2nd/3rd), replace worn or damaged parts.
4th gear side clearance
1. Measure the clearance between 4th gear and the ball bearing.
Clearance : 0~0.015 in (0~0.37 mm)
2. If the clearance exceeds the maximum, check the contact surface of 4th gear, the ball bearing and the clutch hub
(3rd/4th), replace worn or damaged parts.
Inspection
Synchronizer ring
1. Inspect individual synchronizer ring teeth for damage, wear or cracks.
2. Inspect the taper surface for wear or cracks.
Set the synchronizer ring squarely in the gear then measure around the
circumference.
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3. Measure the clearance between the synchronizer ring and the flank surface of the gear.
Standard clearance : 0.0433~0.0551 in (1.1~1.4 mm)

Minimum : 0.03 in (0.8 mm)
Primary shaft
If the shaft gear is replaced, adjust the bearing preload.

1. Inspect the shaft gear runout.
Maximum runout: 0.004 in (0.10 mm)
2. Inspect the splines for damage or wear.

3. Inspect the gear teeth surface for damage, wear or cracks.
3rd gear, 4th gear, 5th gear and gear sleeve (5th gear)
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1. Measure the clearance between the shaft gears and gears.
Oil clearance [in (mm)]

Sleeve(C)
Shaft(A) Gear(B)
Items (outer
(outer diameter) (inner diameter)
diameter)
3rd 1.377~1.378
- -
gear (34.987~34.998)
4th 1.218~1.219 1.220~1.221
-
gear (30.94~30.97) (31.00~31.02)
5th 1.339~1.340 1.336~1.337
-
gear (34.00~34.02) (33.94~33.97)
2. Inspect the 5th gear sleeve for damage.

3. Inspect the gear teeth surface for damage, wear or cracks.
Bearing
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1. Inspect for damage or rough rotation.
Inspection
Measurement of thrust clearance
If installation of the primary shaft is completely done, measure the thrust clearance.
Thrust clearance of 3rd gear
1. Measure the thrust clearance between 3rd gear and 2nd gear.
Clearance: 0.0024~0.0083 in (0.06~0.21 mm)
Thrust clearance of 4th gear

1. Measure the thrust clearance between 4th gear and the ball bearing.
Clearance: 0.0039~0.146 in (0.1~0.37 mm)

If not as specified, reassemble the primary shaft assembly.
Disassembly
Hold the shaft with one hand so that it does not fall.
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1. Remove the ball bearing with a SST(0K130 175 008).
2. Remove 4th gear.

3. Remove the retaining ring.
4. Remove the clutch hub assembly (3rd/4th), the synchronizer ring (3rd) and the 3rd gear.
5. Remove the bearing with a SST(0K670 990 AA0).
Reassembly
1. Assemble 3rd gear, the synchronizer ring and the clutch hub assembly.
2. Assemble the new retaining ring.
3. Assemble 4th gear.

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4. Assemble the new ball bearing with press.
Manual Transaxle System > Manual Transaxle Gear System > Output Shaft > Components and
Secondary shaft
COMPONENTS AND DISASSEMBLY
1. Measure thrust clearance of 1st gear and 2nd gear before disassembly.
3. Assembly will be in reverse order of disassembly.
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Page 47 of 66
Manual Transaxle System > Manual Transaxle Gear System > Output Shaft > Repair procedures
(STC)
Inspection
Secondary 1st gear thrust clearance
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1. Measure clearance between secondary 1st gear and differential drive gear.
Clearance: 0.002~0.011 in (0.05~0.28 mm)
2. If clearance exceeds maximum, check contact surfaces of secondary 1st gear, differential drive gear of secondary
shaft, and 1st/2nd clutch hub assembly.
Replace worn and damaged parts.
Secondary 2nd gear thrust clearance
1. Measure clearance between secondary 2nd gear and secondary 3rd gear.
Clearance: 0.002~0.0067 in (0.05~0.17 mm)
2. If clearance exceeds maximum, check contact surfaces secondary of 2nd gear, secondary 3rd gear, and 1st/2nd
clutch hub assembly. Replace worn and damaged parts.
Inspection
Inspect all parts and repair or replace as necessary.

Gears
1. Inspect synchronizer cones for wear.
2. Inspect gear teeth for damage, wear, and cracks.
3. Inspect synchronizer ring matching teeth for damage and wear.
Synchronizer ring tomsn048@gmail.com

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1. Inspect synchronizer ring teeth for damage, wear, and cracks.
2. Inspect tapered surface for wear and cracks.
3. Set synchronizer ring squarely in gear.

4. Measure clearance between synchronizer ring and flank surface of gear.
Standard clearance: 0.055~0.067 in (1.4~1.7 mm)

Minimum: 0.031in (0.8 mm)
Clutch hub assembly

1. Inspect clutch hub sleeve and hub operation.
3. Inspect synchronizer keys for damage, wear, and cracks.
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4. Measure clearance between clutch hub sleeves and shift forks.
Clearance [in(mm)]
Standard Maximum
0.004~0.014
1st/2nd 0.029 (0.75)
(0.1~0.35)
0.011~0.02
3rd/4th 0.070 (1.80)
(0.27~0.50)
Reverse idle gear and reverse lever

2. Measure clearance between reverse idle gear bushing and reverse lever.
Standard clearance :
0.0037~0.013 in (0.095~0.33 mm)
Maximum :
0.012 in (0.31 mm)
Bearing
1. Inspect for damage and rough rotation.
Primary shaft and secondary shaft

1. Inspect gear contact surface for damage and wear.
2. Inspect splines for damage and wear.
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4. Inspect oil passage for clogging.
5. Measure primary and secondary shaft runout.
Secondary shaft runout:

0.0006 in (0.015 mm) max.
If shaft is replaced, adjust bearing preload.

Oil clearance [in (mm)]
Shaft Gear Sleeve
Clearance
(Outer dia.) (Inner dia.) (Outer dia.)
1.553~1.554 1.555~1.556 0.001
1st -
(39.445~39.47) (39.5~39.525) ~0.003
1.384~1.385 1.850~1.851 (0.03
2nd - ~0.08)
(35.145~35.17) (47.009~47.025)
Selection of shim
Adjust the preload and select the shim as follows.
Primary shaft assembly
1. Set the primary shaft assembly into the clutch housing.
2. Install the transaxle case to the clutch housing and tighten bolts to the specified torque.
Tightening torque :
14~19 lb·ft (19~26 N·m, 1.9~2.6 kg·m)
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3. Mount the dial indicator to the transaxle hanger and measure the primary shaft thrust clearance.
Clearance: 0~0.004 in (0~0.10 mm)
4. Select the closest shim on the thin side from the table.
Thickness of adjustment shim:

0.012 in (0.3 mm), 0.016 in (0.4 mm), 0.02 in (0.5mm)
Secondary shaft assembly

1. Install the funnel and bearing outer race into the clutch housing.
2. Set the secondary shaft into the clutch housing.

3. Install the secondary shaft bearing outer race into the transaxle case.
4. Install the transaxle case to the clutch housing and tighten bolts to the specified torque.
Tightening torque:
14~19 lb·ft (19~26 ·Nm, 1.9~2.6 kg·m)
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Page 53 of 66
5. Mount a dial indicator to the transaxle case and measure the secondary shaft end play.
Clearance:
0.002~0.004 in (0.05~0.10 mm)
6. Select the shim as follows.

A. Add the 0.001 in (0.03 mm) to the thrust clearance.
B. Add the 0.003 in (0.08 mm) to the thrust.
C. Select the thickest shim in the range between a and b.
Example :
0.0087 in (0.22 mm) + 0.001 in (0.03 mm)
= 0.0098 in (0.25 mm)
0.0087 in (0.22 mm) + 0.003 in (0.08 mm)
= 0.012 in (0.30 mm)
Range : 0.0098 in (0.25 mm) - 0.001 in (0.30 mm)
Select the 0.012 in (0.30 mm) one
Thickness of adjustment shim [in (mm)]

0.0079 (0.20) 0.0098 (0.25) 0.012 (0.30) 0.014 (0.35)
0.016 (0.40) 0.018 (0.45) 0.020 (0.50) 0.027 (0.70)
Differential
1. Install the bearing outer race into the clutch housing.
2. Set the differential assembly into the clutch housing.
Turn A and B until the gap shown in figure is

eliminated.
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3. Install the transaxle case side bearing outer race to a SST(0K900 175 AA0).
4. Set the SST(0K900 175 AA0) in the positions shown in figure.
5. Tighten the SST(0K900 175 AA0) to the specified torque.
Tightening torque:
14~19 lb·ft (19~26 N·m, 1.9~2.6 kg·m)
Turn the bars until SST(0K900 175 AA0) can no longer be moved.
6. To set the bearings, mount the bars on parts A and B of the selector, and turn the selector so the gap is widened.
7. Turn in the reverse direction until the gap is eliminated.
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Page 55 of 66
8. Install SST(0K900 175 AA0/0K130 322 020) tothe differential pinion gear, through the transaxle case.
9. Turn the SST(0K130 322 020) with a spring balance. Until the specified preload can be obtained, adjust the
SST (Selector) with a bar.
Preload:
10~14 lb·ft (1.4~2.0 N·m, 14~20 kg·m)
10. Remove the SST(0K130 322 020).

11. Measure the clearance around the entire circumference of the SST(0K900 175 AA0).
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12. Select the proper adjust shim(s) to be used for the differential by referring to the table and selecting the shim
which is nearest (on the thick side) to the largest measured clearance in the selector.
Thickness of adjust shim [in (mm)]

0.004 (0.10) 0.0079 (0.20) 0.0098 (0.25) 0.012 (0.30)
0.014 (0.35) 0.016 (0.40) 0.018 (0.45) 0.020 (0.50)
0.022 (0.55) 0.024 (0.60) 0.026 (0.65) 0.028 (0370)
0.030 (0.75) 0.032 (0.80) 0.034 (0.85) 0.036 (0.90)
13. Remove the SST(0K900 175 AA0).

14. Remove the transaxle case and SST(0K900 175 AA0).
15. Remove the bearing outer race from the SST(0K900 175 AA0).
16. Install the selected shim and the bearing outer race to the transaxle case).
Bearing preload (Differential)

Measure the preload as follows.
1. Set the differential assembly into the clutch housing.
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Page 57 of 66
2. Install the transaxle case onto the clutch housing.
Tightening torque:
14~19 lb·ft (19~25 N·m, 1.9~2.6 kg·m)
3. Install a SST(0K900 175 AA0) to the differential side gear, through the transaxle case.
4. Measure the bearing preload.
Preload:
104~144 lb·ft (137~196 N·m, 14~20 kg·m)
5. If not as specified, readjust the bearing preload.

6. Remove the SST(0K130 322 020).
7. Remove the transaxle case and the differential assembly.
Disassembly
Bearing and secondary 4th gear
Remove bearing and secondary 4th gear by using SST(0K201 172 008).
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Secondary 3rd gear and secondary 2nd gear

1. Shift gears to 1st gear.
2. Remove secondary 3rd gear and secondary 2nd gear by using SST(0K201 172 008).
Reassembly
Clutch hub
Synchronizer key dimensions [in (mm)]
1 2 3
0.7087 0.167 0.197
1st/2nd
(18) (4.25) (5.0)
0.167 0.197
3rd/4th 0.669 (17)
(4.25) (5.0)
0.669 0.167 0.197
5th/Rev
(17.0) (4.25) (5.0)
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Page 59 of 66
1. Install synchronizer keys and springs in clutch hub.
Bearing (differential drive gear end)

1. Install new bearing by using SST(0K900 175 AA1).
Secondary 1st gear, 1st synchronizer ring and 1st/2nd clutch hub assembly
1. Assemble secondary 1st gear, 1st synchronizer ring, and 1st/2nd clutch hub assembly, as shown in figure.
2. Align synchronizer ring grooves and synchronizer keys.
3. Press on 1st/2nd clutch hub assembly by using SST(0K900 175 AA1).
2nd synchronizer ring, 2nd gear and secondary 3rd gear

1. Install 2nd synchronizer ring and secondary 2nd gear.
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2. Install secondary 3rd gear by using SST(0K900 175 AA1).
Secondary 4th gear and bearing inner race

1. Install secondary 4th gear and bearing inner race by using SST(0K900 175 AA1).
2. Measure clearance between 1st gear and differential drive gear.
Clearance: 0.002~0.011 in (0.05~0.28 mm)
3. Measure clearance between secondary 2nd gear and secondary 3rd gear.
Clearance: 0.004~0.008 in (0.10~0.22 mm)
4. If not as specified, disassemble and reassemble secondary shaft assembly.
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Page 61 of 66
Manual Transaxle System > Manual Transaxle Gear System > Differential > Components and
Disassembly/Inspection/Ressembly
1. Before disassembly, inspect backlash of side gears and pinion gears, refer to inspection.
2. Disassemble in order shown in figure, refer to disassembly.
4. Assemble in reverse order of disassembly, refer to reassembly.
5. Measure backlash after assembly, refer to backlash of side gear and pinion gear.
Manual Transaxle System > Manual Transaxle Gear System > Differential > Repair procedures (STC)
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inspection
Measure backlash by following procedure:
1. Install left driveshaft and right joint shaft in differential assembly.
2. Support shafts on V-blocks as shown in figure.
3. Measure backlash of both pinion gears.
Backlash : 0~0.004 in (0~0.1 mm)
4. If not as specified, replace worn and damage parts.

Inspection
Ring gear and gear case assembly
1. Inspect ring gear for wear and cracks. If gear case is replaced, adjust bearing preload.
Bearing
1. Inspect for wear and rough rotation. If bearing is removed, then replace it and bearing race together, and adjust
bearing preload.
Disassembly
Bearing (side opposite ring gear)
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Page 63 of 66
Do not remove the bearing unless you are replacing it.
Remove bearing by using SST(0K130 171 013).

Side bearing inner race
Be careful not to drop differential case.

1. With using SST(0K670 990 AA0), remove side bearing inner race (opposite side of ring gear).
Bearing (ring gear side)

Remove bearing by using SST(0K670 990 AA0).
REASSEMBLY
Bearing (ring gear side)
Bearing (side opposite ring gear)

1. Install speedometer drive gear.
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Roll pin
1. Install new roll pin as shown in figure to hold pinion shaft.

Measure backlash by following procedure :
1. Install left driveshaft and right joint shaft in differential assembly.
2. Support shafts on v-blocks as shown in figure.
3. Measure backlash of both pinion gears.
Backlash : 0~0.004 in (0~0.1 mm)
4. If not as specified, replace worn and damage parts.
Manual Transaxle System > Manual Transaxle Gear System > Shift Lever > Components and
OVERHAUL
1. Disassemble in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary
3. Assemble in the reverse order of disassembly, refer to Assembly Notice.
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Page 65 of 66
Manual Transaxle System > Manual Transaxle Gear System > Shift Lever > Repair procedures (STC)
ASSEMBLY NOTE
EXTENSION BAR
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1. Install the extension bar to the floor, and then onto the transaxle.Tighten the extension bar nut at the transaxle.
Tightening torque: 3.2~4.7 kg·m (23~34 lb·ft, 31~46 N·m)
2. Tighten the shifter bracket nuts to the specified torque.
Tightening torque:
86.9~130.2 lb·in
(9.8~14.7 N·m, 100~150 kg·m)
Spring
• Make sure that the hooked part of the spring is properly seated in the bracket groove, as shown in the figure.
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Page 1 of 21
RIO(BC) > 2005 > G 1.6 DOHC > Restraint
Restraint > General Information > General Safety Information and Caution
SERVICE WARNINGS
Personal safety
Failure to follow all warnings, cautions, notices and procedures could result in personal injury or death.
Power supply deactivation
Airbag-SRS diagnostic unit contains a backup power supply. Before disconnecting airbag-SRS components, turn
ignition switch to LOCK, disconnect battery (negative terminal first), and wait 10 minutes for backup power supply
to discharge. Failure to follow this procedure could cause airbag modules to deploy during service procedures,
which may cause serious injury.
Safety equipment
• Always wear safety glasses when handling airbag modules.
• Always wear rubber gloves when handling deployed or damaged airbag modules.
Airbag surface may be contaminated with small amounts of sodium hydroxide(NaOH). Prevent contact of airbag
module with liquids, combustibles, and flammable materials. Immediately wash contaminated hands and skin areas
with mild soap and water, flush eyes with water if exposed to byproducts. Failure to follow these instructions could
result in chemical burns and personal injury.
Wiring and electrical components
Never service wiring or electrical components when any airbag and pretensioner is connected. When a procedure
directs use of a multimeter to probe pins of a connector, insert probes into back of connector where possible. If you
must probe front face(terminal side), be certain to use a probe whose tip will not damage terminals when it is
inserted.
Component disassembly
Do not disassemble any airbag-SRS components. Disassembly can render system inoperative, which may result in
serious injury or death in event of an accident. Never attempt to disassemble or repair airbag modules. Any attempt
to adapt, re-use, or install an airbag module or its components in another vehicle may result in serious injury or death
to vehicle occupants in event of an accident.
Airbag control unit (ACU)
Do not connect ACU connector unless ACU is securely installed. Shock of installation or pinching wiring harness
between module and its mounting points can cause airbags and pretensioner to deploy, which may cause serious
injury.
Airbag module inspection
Do not probe or inspect airbag modules or any of their connectors with an ohmmeter. Inspecting airbag module with
an ohmmeter, which supplies current, can cause airbags to deploy, resulting in serious injury.
Airbag module connector
Do not cut or otherwise remove the airbag module connector. Connector contains a safety shunt which, if disabled,
could cause an unintended deployment. This may cause severe personal injury or death.
Airbag module handling
A live(undeployed) airbag may accidently deploy during handling. When carrying a live airbag module, point plastic
trim cover away from your body to lessen chance of injury in case of accidental deployment. Never carry module by
its wiring or connectors.
Securing modules
Always place live airbag modules face up (plastic trim side up) to lessen motion of the module in case of accidental
deployment. Keep the area clear of parts, tools and other debris. Never place items on or above the trim cover of a
live airbag module. In case of accidental deployment, such items may cause serious injury or death.
Live airbag module storage
Live airbag modules contain solid flammable material. Store in a cool, dry, secure area. Do not expose them to open
flame or temperatures in excess of 300°F. Do not cut, drill, braze, solder or weld an airbag module or any of its
Page 2 of 21
components. Never expose the module or any of its components to electricity. Failure to comply with this warning
can lessen the integrity of the module, causing fires, chemical exposure, or unintended deployment, which may cause
serious injury or death.
Damaged live airbag module storage
Damaged live airbag modules should be stored away from all acids, halogens, heavy metals and metal salts.
Damaged units may produce hydrozoic acid if exposed to liquids. If an undeployed airbag module or inflator is
ruptured or tampered with, refer to the Material Safety Data Sheet (MSDS) for the particular module for important
information concerning the constituents of undeployed modules. Exposure to high concentrations of propellant
mixture can cause headaches, nausea, blurred vision, faintness, cyanosis, lowering of blood pressure or tachycardia.
Failure to comply with this warning can result in fire, noxious fumes, severe personal injury or death.
Out-of-vehicle deployment
Out-of-vehicle deployment should be performed in an open area, away from other personnel. Verify that there is no
loose debris or flammable liquid near the air bag assembly. All personnel should be behind protective cover (i.e.,
wall, vehicle) to shield their bodies from potential projectiles. Do not attempt to deploy a ruptured airbag module.
Failure to comply with this warning may result in severe injury or death. Refer to Airbag Deployment and Disposal
,.
Danger of fire
Airbag module components are very hot after deployment. Units should be deployed outdoors or in open areas to
prevent fires. Allow components at least twenty minutes to thoroughly cool. Cooling modules should be continuously
monitored to ensure hot components do not create fires with spilled liquids or other debris. Failure to allow the unit
to cool could result in burns, fires or personal injury.
Storage/Transportation/Disposal/Recycling
Storage, transportation, disposal and recycling of airbag module and components must be performed in accordance
with each region regulations.
Restraint > General Information > Description and Operation

AIRBAG-SUPPLEMENTAL RESTRAINT SYSTEM
The Airbag-Supplemental Restraint System (SRS) is designed to supplement driver seat belts during front-end
collisions,reducing the risk of serious injury or death. Two collision-sensitive sensors are located in the Airbag
Control Unit (ACU). These two sensors (Safing sensor and G-sensor) are electrically connected to the airbag and
the battery. In case of a frontal crash, the G-sensor receives collision deceleration information. The collision
deceleration information is converted into digital data and transmitted to the ACU (Airbag Control Unit). The ACU
calculates the digital data andcompares them with preprogrammed data to determine whether it has to send a signal
to deploy the airbag module or not.If the calculation of the ACU corresponds to the preprogrammed data, a
deployment signal is sent. At the same moment, the safing sensor, which is linked linearly on the deployment circuit,
checks whether the deceleration has occurred due to an actual collision, or by other electronic waves and
anomolies. So, the airbags will only deploy with a deployment signal from the ACU and closing of safing sensor
switch. The Driver is protected by a steering wheel mounted airbag The Airbag-Supplemental Restraint System
consists of an Airbag Module, Airbag Control Unit, and wire harness & clock-spring assembly The driver airbag
module consists of a bag cover, airbag, retainer ring, retainer housing and inflator. The passenger airbag module
consists of a deployment door, airbag assembly, inflator and retainer housing. Because of size difference, the
passenger airbag module incorporates a larger, tubular shaped inflator.
The driver airbag cover is made of TPE (Thermos Plastic Elastomer), and it splits along a tear seam in the event of a
collision. The airbag itself is made of Nylon 66, and the face contact surface is coated with silicone. A vent hole is
provided at back side of airbag to deflate airbag immediately after inflation so that it does not interfere witht the
drivers vision The inflator produces nitrogen gas by igniting solid propellant pellets inside inflator. The ignitor is
triggered by an electrical current and the ignitors ignition intensifier, which in turn ignites propellant pellets causingthe
airbag to deploy. A heat sink and filter within the unit cools and filters nitrogen gas as it enters airbag.
Airbag Control unit (ACU) consists of a ACU, memory, auxiliary power supply and G-sensor and safing sensor. An
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auxiliary power supply is installed to ensure airbag deployment if battery power is lost in a collision.
The ACU not only initiates airbag deployment but also performs the SRS self-test. ACU initiates a test sequence
every time ignition key is turned "ON" and the Airbag Indicator is illuminated for 4~6 seconds. When the self test
sequence iscompleted and no fault is found, lamp goes out. If any failure is detected, the warning lamp will stay
"ON" or flash towarn driver. Even while driving, the ACU continually monitors circuits and components of airbag
system. If a failure occurs within system while driving, the warning lamp is immediately illuminated. Details of those
detected failures are stored in memory and can be retrieved with Scan Tool.
The clock spring assembly is incorporated into the combination switch to provide a positive connection between
vehicle wire harness and driver airbag module while allowing sufficient rotation for vehicle steering. This assembly is
also replaced as a complete assembly only.
The Airbag electrical connector has a shorting bar which will short across Airbag assembly circuits when the Airbag
connector is disconnected The Airbag circuit is automatically shorted by the shorting bar in this way to help prevent
unwanted deployment of the Airbag when servicing the instrument panel, Airbags or other SRS components.
Restraint > General Information > Specifications

SPECIFICATIONS
69~104 Ib·in (8~12 N·m, 80~120
Driver airbag installation bolts
kg·cm)
155~232 Ib·in (18~27 N·m, 180~270
Passenger airbag installation bolts
kg·cm)
29~36 Ib·ft (39~49 N·m, 4.0~5.0
Steering wheel installation nut
kg·cm)
69~120 Ib·in (8~14 N·m, 80~140
ACU installation nuts
kg·cm)
Restraint > Supplemental Restraint System Control Module (SRSCM) > Schematic Diagrams
CIRCUIT DIAGRAM
Page 4 of 21
Restraint > Supplemental Restraint System Control Module (SRSCM) > Description and Operation
DIAGNOSTIC TROUBLE CODES AND ASSOCIATED PROCEDURE
AIRBAG SYSTEM
2. The Airbag indicator should illuminate. If it does not, see Airbag Indicator Service.
3. The Airbag Indicator should go out within 4~6 seconds. If it stays out, system is OK.
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4. If Airbag Indicator remains illuminated, there is a problem in Airbag-Supplemental Restraint System(SRS).
5. Turn ignition switch to LOCK.
6. Locate Data Link Connector (DLC) in engine compartment and install Hi-Scan Pro Tool.
7. Turn ignition switch to ON and record any Diagnostic Trouble Codes displayed by Hi-Scan Pro Tool.
8. Refer to Airbag Diagnostic Troubles Codes Chart, for fault description and actions.
Servicing airbag system improperly may cause it to deploy, which CAN cause serious injury or death.
Must read and follow all service warnings, before servicing.
Never service wiring or electrical components when airbag is connected.
AIRBAG DIAGNOSTIC TROUBLE CODE ERASURE
Disconnecting battery will not erase Airbag Diagnostic Trouble Codes. This procedures can only be performed
using Hi-Scan Pro Tool equipped with appropriate software.
Restraint > Supplemental Restraint System Control Module (SRSCM) > Troubleshooting
ON-VEHICLE SERVICE PROCEDURE
GENERAL PROCEDURE
Before servicing
1. Turn the ignition switch to LOCK.
2. Disconnect the battery.
3. Wait 10 minutes for the backup power to discharge completely.
After servicing
1. Reconnect the battery.
2. Turn the ignition switch to ON.
3. Verify that airbag indicator illuminates for 4-6 seconds and then goes off.
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1 Does the indicator illuminate for a period of 4-6 Yes Go to step 8.
seconds
when ignition switch is turned to ON position,
and then No Go to next step
go off?
2 Use the fuse extraction tool in passenger Yes Replace the fuse with another 10A fuse and
compartment fuse check for short
box to extract "METER (10A)" fuse. Is it open? in its associated wire harness. Repair as
necessary and then go to step 8.
No Go to next step.
3 Follow "General procedures" (see above). Yes Go to next step.
Remove
instrument cluster and check connector C-01. No Repair malfunction and then reinstall cluster.
Are pins secure and are connectors locked in Go to step 8.
place?
4 Perform a continuity check between the terminal Yes Lamp is good. Go to next step.
A3 (Y)
of C-01and terminal B11 (Y) of C-01 (NOT on No Lamp is burnt. Replace it, reinstall instrument
wiring cluster and
harness). go to step 8.
Dose continuity exist?
5 Connect battery and verify battery Yes Go to next step.
voltag(approximately 12V). No Check harness for opens or a short to ground
Turn the ignition switch to ON position. Are
between
there apporx-
"METER" fuse and instrument cluster. Repair as
imately 12V at the terminal A3 (Y) of connector necessary.
C-01? Go to step 8.
6 Connect a voltmeter between the terminal A3 Yes Go to step 8.
(Y) of C-01
and B11 (Y) of C-01. Is 12V present for No Check harness for open or a short to ground
approximately between
4~6 seconds when the ignition switch is turned instrument cluster and airbag control unit. Repair
to ON as
position? necessary and go to next step.
7 Does the indicator illuminate for a period of 4-6 Yes Go to next step.
seconds
when ignition switch is turned to ON position, No Replace airbag control unit.
and then (Refer to Airbag Control Unit.)
go out?
8 Does the indicator illuminate constantly after Yes Refer to Diagnostic Trouble Code
initial 4-6 Troubleshooting.
second period? No Airbag Indicator is OK?
AIRBAG DIAGNOSTIC TROUBLE CODE (DTC) CHART

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Diagnostic Fault Possible Warning Corrective
Trouble Description Cause Light Action
Code Mode
01~03 ACU Fault Internal Fault 1 Replace Airbag Control Unit
10~15 (ACU)
18~29 ACU Fault Internal Fault 1 Replace Airbag Control Unit
31-32 (ACU)
33 Power Supply Power Supply vlotage below 8.0 5 Repair or replace battery or
Low volts harness
34 Power Supply Power Supply High voltage above 5 Repair or replace battery or
High 16 harness
volts harness
35 Warning Light Warning Light damaged, or short 5 Repair or replace warning light or
Short circuit in harness
harness
36 Warning Light Warning Light damaged, or open 5 Repair or replace warning light or
Open circuit in harness
harness
53 Driver Module Driver Module Short to ground 5 Replace module or harness
Short
to ground
54 Driver Module Driver Module damaged, or 5 Replace module or harness
Short circuit
to battery shorted to battery
55 Driver Module Driver Module damaged, or short 5 Replace module or harness
Short circuit
in harness
56 Driver Module Driver Module damaged, or open 5 Replace module or harness
Open circuit
in harness
57 Passenger Module Passenger Module damaged, or 5 Replace module or harness
Short to ground circuit
shorted to ground
Short to battery circuit
shorted to battery
Short short
circuit in harness
Open open
circuit in harness
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61 Driver Driver pretensioner damaged, or 5 Replace pretensioner or harness
pretensioner circuit
short to ground shorted to ground
pretensioner circuit
short to battery shorted to battery
pretensioner short
short circuit in harness
pretensioner open
open circuit in harness
65 Passenger Passenger pretensioner damage, 5 Replace pretensioner or harness
pretensioner or
short to ground circuit shorted to ground
66 Passenger Passenger pretensioner damaged, 5 Replace pretensioner or harness
pretensioner or
short to battery circuit shorted to battery
pretensioner or short
short circuit in harness
pretensioner or open
open circuit in harness
77~80 ACU ACU unmatching, with 5 Replace AirBag control Unit
Inconsistency(ex- cpmponents (ACU)
clusive of PAB)
Warning light operating modes:

Mode 1:
Warning Light will be illuminated for reminder of ignition ON cycle, but it will not be illuminated after next ignition
ON cycle if fault has self-corrected.
Mode 5:
Warning Light will be illuminated for reminder of ignition ON cycle, but it will go out approximately 10 seconds later
if fault has corrected at the same ignition ON cycle.
Restraint > Supplemental Restraint System Control Module (SRSCM) > Specifications
ACU TERMINAL LAYOUT
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No. Description No. Description

1 Driver pretensioner (+) 16 Short bar (harness side)
2 Driver pretensioner (-) 17 Short bar (harness side)
3 Passenger pretensioner (-) 18 Short bar (harness side)
4 Passenger pretensioner (+) 19 Short bar (harness side)
5 Supply Power (IG1) + 20 -
Ground (Airbag warning light Short bar (harness side)
6 21
LOW)
7 Airbag warning light 22 Short bar (harness side)
8 - 23 -
9 Communication (K-line) 24 -
10 Driver airbag module (+) 25 Short bar (harness side)
11 Driver airbag module (-) 26 Short bar (harness side)
12 - 27 -
13 Passenger airbag module (+) 28 Short bar (harness side)
14 Passenger airbag module (-) 29 Short bar (harness side)
15 - 30 -
Restraint > Supplemental Restraint System Control Module (SRSCM) > SRS Control Module
(SRSCM) > Repair procedures
Removal
IMPROPER HANDLING OF ACU MAY RESULT IN UNEXPECTED AIRBAG DEPLOYMENT, WHICH

CAN CAUSE SERIOUS INJURY. READ ALL SERVICE WARNINGS BEFORE PERFORMING
SERVICE.
1. Follow General Procedures.
2. Remove ashtray.
Page 10 of 21
3. Remove center panel trim.
4. Remove two console mounting screws (one each at lower front) and one console mounting screw at center.
5. Remove console box and remove two mounting bolts in console box.
6. Remove console.
7. Disconnect ACU connector.
8. Remove three mounting nuts.
9. Lift the ACU up and back and remove ACU from vehicle.
Removing ACU may require loosening of two nuts that secure automatic shift cable housing to tunnel.
• DO NOT DISASSEMBLE ANY AIRBAG-SRS COMPONENTS. DISASSEMBLY CAN

RENDER SYSTEM INOPERATIVE, WHICH MAY RESULT IN SERIOUS INJURY OR
DEATH IN EVENT OF AN ACCIDENT. NEVER ATTEMPT TO DISASSEMBLE OR REPAIR
AIRBAG MODULES.
• ANY ATTEMPT TO ADAPT, RE-USE OR INSTALL AN AIRBAG MODULE OR ITS
COMPONENTS IN ANOTHER VEHICLE MAY RESULT IN SERIOUS INJURY OR DEATH
TO VEHICLE OCCUPANTS IN EVENT OF AN ACCIDENT.
INSTALLATION
DO NOT CONNECT ACU CONNECTOR BEFORE INSTALLING ACU SECURELY. SHOCK OF

INSTALLATION OR PINCHING WIRING HARNESS BETWEEN ACU AND ITS MOUNTING POINTS
CAN CAUSE AIRBAGS TO DEPLOY, WHICH MAY CAUSE SERIOUS INJURY.
1. Install ACU on three mounting studs. Install three nuts and torque to specification.
Tightening torque:
69~120 Ib·in (8~14 N·m, 80~140 kg·cm)
2. Connect wiring harness connector(s) to ACU.

3. Install console and its five mounting screws and two bolts.
4. Install center panel trim.
5. Perform diagnosis. Refer to Diagnostic Trouble Codes and Associated Procedures.
Restraint > Airbag Module > Description and Operation

AIRBAG DEPLOYMENT AND DISPOSAL
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• FAILURE TO FOLLOW ALL WARNINGS, CAUTIONS, NOTICES AND PROCEDURES COULD

RESULT IN PERSONAL INJURY OR DEATH.
• SURFACE OF A DEPLOYED AIRBAG MAY CONTAIN SMALL AMOUNTS OF SODIUM
HYDROXIDE(NAOH). PREVENT CONTACT OF AIRBAG MODULE WITH LIQUIDS,
COMBUSTIBLES, AND FLAMMABLE MATERIALS. IMMEDIATELY WASH HANDS AND
EXPOSED SKIN AREAS WITH MILD SOAP AND WATER. FLUSH EYES WITH WATER IF
EXPOSED TO BY PRODUCTS. FAILURE TO FOLLOWING THESE INSTRUCTIONS COULD
RESULT IN CHEMICAL BURNS AND PERSONAL INJURY.
• A LIVE(UNDEPLOYED) AIRBAG MODULE MAY ACCIDENTLY DEPLOY DURING HANDLING.
WHEN CARRYING A LIVE AIRBAG MODULE, POINT TRIM COVER AWAY FROM YOUR BODY
TO LESSEN CHANCE OF INJURY IN CASE OF ACCIDENTAL DEPLOYMENT. NEVER CARRY
MODULE BY ITS WIRING OR CONNECTORS.
• ALWAYS PLACE LIVE AIRBAG MODULES FACE UP TO LESSEN MOTION OF MODULE IN
CASE OF ACCIDENTAL DEPLOYMENT. KEEP AREA CLEAR OF PARTS, TOOLS, AND DEBRIS.
• NEVER PLACE ITEMS ON OR ABOVE TRIM COVER OF A LIVE AIRBAG MODULE. IN CASE OF
ACCIDENTAL DEPLOYMENT, SUCH ITEMS MAY CAUSE SERIOUS INJURY OR DEATH.
DAMAGED AIRBAG MODULES SHOULD BE STORED AWAY FROM ALL ACIDS, HALOGENS,
HEAVY METALS, AND METAL SALTS. DAMAGED UNITS MAY PRODUCE HYDROZOIC ACID
IF EXPOSED TO LIQUIDS. IF AN UNDEPLOYED AIRBAG MODULE OR INFLATOR IS
RUPTURED OR TAMPERED WITH, REFER TO PARTICULAR MODULE? MSDS(MATERIAL
SAFETY DATA SHEET) FOR IMPORTANT INFORMATION CONCERNING CONSTITUENTS OF
UNDEPLOYED MODULES. EXPOSURE TO HIGH CONCENTRATIONS OF PROPELLANT
MIXTURE CAN CAUSE HEADACHES, NAUSEA, BLURRED VISION, FAINTNESS, CYANOSIS,
LOWERING OF BLOOD PRESSURE OR TACHYCARDIA. FAILURE TO COMPLY WITH THIS
WARNING CAN RESULT IN FIRE, NOXIOUS FUMES, SEVERE PERSONAL INJURY, OR DEATH.
• DAMAGED AIRBAG MODULES SHOULD BE STORED AWAY FROM ALL ACIDS, HALOGENS,
HEAVY METALS, AND METAL SALTS DAMAGED UNITS MAY PRODUCE HYDROZOIC ACID
IF EXPOSED TO LIQUIDS. IF AN UNDEPLOYED AIRBAG MODULE OR INFLATOR IS
RUPTURED OR TAMPERED WITH, REFER TO PARTICULAR MODULE? MSDS(MATERIAL
SAFETY DATA SHEET) FOR IMPORTANT INFORMATION CONCERNING CONSTITUENTS OF
UNDEPLOYED MODULES EXPOSURE TO HIGH CONCENTRATIONS OF PROPELLANT
MIXTURE CAN CAUSE HEADACHES, NAUSEA, BLURRED VISION, FAINTNESS, CYANOSIS,
LOWERING OF BLOOD PRESSURE OR TACHYCARDIA. FAILURE TO COMPLY WITH THIS
WARNING CAN RESULT IN FIRE, NOXIOUS FUMES, SEVERE PERSONAL INJURY, OR DEATH.
• AIR BAG MODULE COMPONENTS ARE VERY HOT AFTER DEPLOYMENT. UNITS SHOULD BE
DEPLOYED OUTDOORS OR IN AN OPEN AREA TO PREVENT FIRES. ALLOW COMPONENTS
AT LEAST TWENTY MINUTES TO THOROUGHLY COOL. COOLING MODULES SHOULD BE
CONTINUOUSLY MONITORED TO ENSURE HOT COMPONENTS DO NOT CREATE FIRES
WITH SPILLED LIQUIDS OR OTHER DEBRIS. FAILURE TO ALLOW UNIT TO COOL COULD
RESULT IN BURNS, FIRES OR PERSONAL INJURY.
• ALWAYS WEAR RUBBER GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED
AIRBAG MODULE.
Storage, transportation, disposal and recycling of airbag module and components must be performed in
accordance with all applicable state and local regulations including, but not limited to, environmental protection,
occupational health and safety, and transportation.
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FAILURE TO FOLLOW THE FOLLOWING PROCEDURES COULD RESULT IN PERSONAL INJURY

OR DEATH.
1. Remove battery.
2. Wait 10 minutes before proceeding.
3. Disconnect appropriate Airbag Module, and remove from vehicle. For Driver airbag module, refer to page RT-
17. For Passenger Airbag Module, refer to page RT-19.
4. Locate airbag in an area that will provide protection to personnel when it deploys. An example of a safe
deployment site is a stack of used tires, 6-8 high, with undeployed bag located inside column of tires.
5. Connect the Air Bag Deployment Tool (K95U-6000-BDY) to the Air Bag Module connector, and position the
deployment tool 20 feet away from the deployment site.
6. Connect the red lead to the positive terminal of the battery.
7. Connect the black lead to the negative battery terminal.
DO NOT PLACE THE AIRBAG WITH THE TRIM COVER FACING DOWN, AS THE FORCE
OF THE DEPLOYING AIRBAG CAUSE IT TO RICOCHET AND CAUSE PERSONAL INJURY.
8. Verify that green POWER indicator on deployment tool is illuminated.

9. Depress and hold READY button (button number 1).
10. Verify that yellow READY indicator is flashing.
11. Depress and hold DEPLOY button (button number 2).
12. Verify that Air Bag module has deployed. If not, verify that red DEPLOY indicator is illuminated.
13. Release both READY and DEPLOY buttons.
14. Verify that both READY and DEPLOY indicators are no longer illuminated.
15. If air bag successfully deployed, allow a minimum of twenty minutes for bag to cool before handling. Monitor
bag throughout cool-down period to ensure that hot components do not start a fire.
16. If air bag did not deploy, keep area around deployment site clear of personnel for a minimum of 30 minutes.
17. Disconnect the power leads from the battery.
18. Remove the air bag from the stack of tires carefully, wearing rubber gloves and eye/face protection to protect
yourself from possible chemical exposure. tomsn048@gmail.com
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19. Dispose of the complete air bag assembly. No part of the air bag may be reused. Place the air bag into a sturdy
plastic bag and seal securely. Dispose of the deployed air bag according to federal, state and local laws and
regulations including, but not limited to, EPA and OSHA regulations.
20. Install battery.
Restraint > Airbag Module > Components and Components Location

Driver airbag module
Handling airbag improperly may cause it to deploy, which may cause serious injury. Read all Service Warnings,
before servicing.
Never service wiring or electrical components when any airbag is connected.

Page 14 of 21
Restraint > Airbag Module > Driver Airbag (DAB) Module and Clock Spring > Repair procedures
Removal
• Turn the front wheel to the straight-ahead position when removing/installing the Driver Airbag or Clokspring.
Follow General Procedures before removal.
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Orange and blue connectors are exclusive to air bag-SRS harness. Connector half with female pins consists of two
separate shells; one for airbag-SRS, other for horn. These two shells are mechanically configured to provide blue
airbag-SRS shell with two retention latches, reducing possibility of an unwanted separation during a collision. Blue
airbag-SRS shellalso contains a safety feature that shunts its two pins together when it is disconnected This feature
helps prevent unintentional airbag deployment.
When disconnecting two shells, it is necessary to remove orange shell first. Reconnection is reverse order of
disconnection.
• Do not disassemble any of actual airbag-SRS components. Disassembly of components can render system
inoperative, which may result in serious injury or death in event of an accident. Never attempt to disassemble or
repair airbag modules.
• Any attempt to adapt, re-use, or install an airbag module or its components in another vehicle may result in
serious injury or death to vehicle occupants in event of an accident.
• Do not cut or otherwise remove airbag module connector. Connector contains a safety shunt and disabling that
shunt couldcause unplanned deployment, which may cause severe personal injury or death.
• A live(undeployed) airbag may accidently deploy during handling. When carrying a live airbag module, point
trim cover away from your body to lessen chance of injury in case of accidental deployment. Never carry
module by its wiring or connectors.
• Always place live airbag modules face up to lessen motion of module in case of accidental deployment. Keep
area clear of parts, tools and debris.
• Never place items on or above trim cover of a live airbag module.
In case of accidental deployment, such items may cause serious injury or death.
1. Remove four airbag module retaining bolts from backside of steering wheel.
2. Pull airbag module away from steering wheel.
3. Disconnect airbag module connector from clockspring assembly and remove driver airbag module from vehicle.
4. If necessary, dispose of airbag module. Refer to Airbag Deployment and Disposal.
INSTALLATION
1. Ensure that front wheels are pointing straight ahead.
2. Holding surface of airbag away from you, couple blue airbag-SRS connectors, then couple the orange horn
connectors.
Orange and blue connectors are keyed to fit only one (1) way. When properly assembled, they will slip
into place (using slight pressure) with an audible "click" .
Do not force. If undue force. is required, connectors are not aligned properly.
3. Set module into steering wheel, taking care not to pinch wiring harness.
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4. Install four retaining bolts.
Tightening torque:
69~104 Ib·in (8~12 N·m, 80~120 kg·cm)
5. Verify that no trouble codes are present. (Refer to Diagnostic Trouble Codes and Associated Procedures.)
If clockspring assembly has been removed, please refer to Clock Spring Assembly for proper
assembly.
CLOCKSPRING ASSEMBLY
Removal
Clockspring connector is part of combination switch and is not serviced as a separate part.
1. Remove driver airbag module.
2. Remove steering wheel nut. Mark steering wheel and steering shaft so that their relative positions will be known
during re-installation.
3. Using a suitable wheel puller, remove steering wheel.
4. Remove three clockspring assembly retaining screws, disconnect three connectors and remove clockspring
assembly.
INSTALLATION
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1. Temporarily install steering wheel and turn front wheel so that front wheels are pointing straight ahead.
An alignment pin is used to aid in alignment of clockspring connector when installing steering wheel onto
steering column.An alignment pin is provided with a new combination switch, but a substitute pin will be
needed when re-aligning an original clockspring. Substitute pin should be 3 mm(0.12in)in diameter and at
least 76 mm(3.0 in) long.
2. Install clockspring assembly and retain with three screws. Connect three clockspring assembly connectors.
Tightening torque:
8 Ib·in (0.92 N·m, 9.3 kg·cm)
3. Rotate center portion of clockspring connector clockwise until it stops. Proceed to rotate center
counterclockwise two and 3/4 turns and align arrow on center decal with arrow on housing.
4. While holding arrows aligned, insert alignment pin into hole on front face of center portion until it engages in hole
located on back side of housing.
5. Re-install steering wheel by lining up marks applied during removal. Alignment pin passes through oblong hole in
steering wheel that is located immediately above hole for steering shaft. Install steering wheel nut finger tight.
6. Remove alignment pin and tighten nut.
Tightening torque:
29~36 Ib·ft (39~49 N·m, 4.0~5.0 kg·m)
7. Re-install driver airbag module. Refer to Driver Airbag Module Installation.
Restraint > Airbag Module > Passenger Airbag (PAB) Module > Repair procedures
Removal
Handling airbag improperly may cause it to deploy, which may cause serious injury Read Service Warnings, before
servicing.
Never service wiring or electrical components when any airbag is connected.

Follow General Procedures guidelines.
1. Remove instrument panel (Refer to BD Group).
2. Remove two mounting bolts and four screws.
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3. Disconnect passenger airbag module connector from wiring harness.
Orange and blue connectors are exclusive to airbag-SRS harness. Connector half with female pins consists
of two separate shells; one for airbag-SRS, other for horn. These two shells are mechanically configured to
provide blue airbag -SRS shell with two retention latches, reducing possibility of and unwanted separation
during a collision.Blue airbag-SRS shell also contains a safety feature that shunts its two pins together when
it is disconnected.
This feature helps prevent unintentional airbag deployment. When disconnecting two shells, it is necessary
to remove orange shell first.
Reconnection is reverse order of disconnection.
• Do not disassemble any of actual airbag-SRS components. Disassembly of components can render
system inoperative, which may result in serious injury or death in event of an accident. Never attempt to
disassemble or repair airbag modules.
• Any attempt to adapt, re-use, or install an airbag module or its components in another vehicle may
result in serious injury or death to vehicle occupants in event of an accident.
• Do not cut or otherwise remove airbag module connector. Connector contains a safety shunt and
disabling that shunt couldcause unplanned deployment which may cause severe personal injury or
death.
• A live(undeployed) airbag may accidently deploy during handling. When carrying a live airbag module,
point trim cover away from your body to lessen chance of injury in case of accidental deployment.
Never carry module by its wiring or connectors.
• Always place live airbag modules face up to lessen motion of module in case of accidental deployment.
Keep area clear of parts, tools and debris.
• Never place items on or above trim cover of a live airbag module. In case of accidental deployment,
such items may cause serious injury or death.
4. Remove module from instrument panel.

5. If necessary, dispose of airbag module. Refer to Airbag Deployment and Disposal.
INSTALLATION
Take care not to pinch wiring harness with other vehicle parts during reassembly. Kinks in harness will fatigue
wires and may lead to intermittent circuit failure.
1. Couple airbag connector to vehicle wiring harness. (Refer to notice in Passenger Airbag Removal.)
2. Install passenger airbag module.
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3. Install two mounting bolts.
Tightening torque:155~232 Ib·in (18~27 N·m, 180~270 kg·cm)
4. Install glove box.

5. Perform diagnosis. Refer to Diagnostic Trouble Codes and Associated Procedures.
Restraint > Troubleshooting > 01-03

DIAGNOSTIC TROUBLE CODE: 01-03/ 10-15/ 18-29/ 31-32 INTERNAL FAULT
Internal fault. There is no inspection or service possible. Replace Airbag Control Unit (ACU)
1
(Refer to Airbag Control Unit (ACU)
Servicing airbag system improperly may cause it to deploy, which cause serious injury or death.
Must read and follow all service warnings, before servicing.
Never service wiring or electrical components when airbag is connected.
Restraint > Troubleshooting > 62

DIAGNOSTIC TROUBLE CODE: 62 DRIVER PRETENSIONER SHORT TO BATTERY
Is battery voltage present at the terminal 1 (LG) No Go to next step.
or/and 2 (O) of S-01?
2 Disconnect connector S-07 from driver Yes Replace harness between S-01 and S-07.
pretensioner.
Is battery voltage at the terminal 1 (LG) or/and 2 No Replace driver pretensioner.
(O) of driver pretensioner connector S-07?

DIAGNOSTIC TROUBLE CODE: 63 DRIVER PRETENSIONER SHORT
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1 Disconnect connector S-07 from driver Yes Replace harness between S-01 and S-07.
pretensioner.
Disconnect connector S-01 from airbag control
unit.
Is there short between the terminal 1 (LG) and No Replace driver pretensioner.
terminal 2 (O) of
pretensioner S-07?

DIAGNOSTIC TROUBLE CODE: 64 DRIVER PRETENSIONER OPEN
(LG) of S-01 and terminal 1 (LG) of S-07?
2 Is there an open circuit between terminal 2 (O) of Yes Replace harness between S-01 and S-07.
S-01 and 2 (O) of S-07? No Replace passenger pretensioner.

DIAGNOSTIC TROUBLE CODE: 65 PASSENGER PRETENSIONER SHORT TO GROUND
and passenger pretensioner connector S-08.
Is ground present at the terminal 3 (B) or/and 4 No Replace passenger pretensioner.
(W) of S-01?

DIAGNOSTIC TROUBLE CODE: 66 PASSENGER PRETENSIONER SHORT TO BATTERY
Is battery voltage present at the terminal 3 (B) No Replace passenger pretensioner.
or/and 4 (W) of S-01?

DIAGNOSTIC TROUBLE CODE: 67 PASSENGER PRETENSIONER SHORT
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1 Disconnect connector S-08 from passenger Yes Replace wire harness between S-01 and S-08.
pretensioner.
Is there short between the terminal 3 (B) or/and 4 No Replace passenger pretensioner.
(W) of S-01?

DIAGNOSTIC TROUBLE CODE: 68 PASSENGER PRETENSIONER OPEN
Is there an open circuit between the terminal 3 (B) No Go to next step.
of S-01 and terminal 1 (B) of S-08?
2 Is there an open circuit between the terminal 4 Yes Replace harness between S-01 and S-08.
(W) of S-01 and terminal 2 (W) of S-08? No Replace pretensioner.

DIAGNOSTIC TROUBLE CODE: 77~80 ACU INCONSISTENCY
Trouble code Contents Action
77~80 ACU inconsistency Check ACU type and
components
ACU type Components

Single Driver module only
Dual Driver and passenger module
Single + PT Driver module + driver and passenger pretensioner
Dual + PT Driver and passenger module + driver and passenger
pretensioner
1) If Driver Module only is installed with ACU configured DAB and PAB, the ACU will show "Passenger module
open" fault.
2) If pretensioner is not installed with ACU configured pretensioner, the ACU will show "Pretensioner open"
Page 1 of 36
RIO(BC) > 2005 > G 1.6 DOHC > Steering System
Steering System > General Information > Special Service Tools

Tool
Illustration Use
(Number and Name)
0K670 321 019

For removal of tie-rod end
Ball joint puller
0K130 322 020

Attachment, steering worn For measurement of pinion pre-load
bearing preload measuring
0K201 323 AA1A

Power steering pressure For measurement of power steering pressure
guage
Steering System > General Information > Troubleshooting

Manual steering
Poor lubrication, foreign material in mechanism or
Lubricate or replace
damage of steering ball joint
Inadequate gear oil, foreign material in oil Lubricate or replace
Improper steering gear preload Adjust
Steering feels heavy Damaged steering gear Replace
(vehicle raised)
Malfunction of steering shaft joint Replace
Malfunction of steering gear Replace
Cracked or worn steering gear mounting rubber Replace
Damaged suspension Repair
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Page 2 of 36
Damaged steering linkage Replace
Steering wheel pulls to one side Damaged wheel or tire Replace
Malfunction of brake system and suspension Replace
Worn or damaged steering rack Replace
Improper steering gear preload Adjust
General instability while driving Damaged steering linkage Replace
Damaged wheel or tire Repair
Malfunctioning suspension Repair
Steering feels unstable Malfunction of steering rack Replace
Malfunction of steering linkage Replace
Worn steering gear Replace
Excessive steering wheel play Worn or damaged steering linkage Replace
Loose steering gear mounting bolts Replace
Stuck or damaged steering rack Replace
Improper steering gear preload Replace gear
Poor steering wheel return
Malfunction of suspension
Damaged steering linkage Replace
Loose steering gear mounting bolts Tighten
Shimmy Stuck or damaged steering joint Replace

(steering wheel vibrates left/right) Damaged or worn front wheel bearings Replace
Malfunctioning suspension Repair
Loose steering gear mounting bolts Tighten
Abnormal noise from steering system Obstruction near steering column Replace
Loose steering column Tighten
Worn steering joints Replace
Power steering
Preblem Possible cause Action
Looseness or damage of power steering belt Adjust or replace power steering belt
Insufficient power steering fluid or air insertion Fluid fill up or air bleeding
Crushed or twisted hoses Replace hoses
Pipe damage Replace pipes
Leakage of power steering fluid Repair or replace leaking parts
Page 3 of 36
Movements of Repair or replace power steering pump
Low fluid pressure
steering feels heavy or gear
Insufficient air pressure in tire Adjust tire air pressure
Incorrect wheel alignment adjustment Adjust wheel alignment
Steering gear linkage binding Replace or repair steering gear linkage
Interference between steering column and/or parts Repair or replace steering column
Interference between steering column and parts Replace or repair
Poor returning of Incorrect wheel alignment adjustment Adjust wheel alignment
steering wheel Steering gear linkage binding Repair or replace steering gear linkage
Malfunction of steering gear Replace steering gear
Looseness of power steering belt Adjust power steering belt
Malfunction of steering column or looseness of
Irregular steering Repair or tightening of steering column
mounting bolt
power
Steering gear linkage binding Repair or replace steering linkage
Improper preload adjustment or worn of wheel
Steering wheel pulls Adjust or replace wheel bearing
bearing
to one side
Incorrect wheel alignment Adjust wheel alignment
Problem with hose coupling Repair or replace hose coupling
Clogged or damaged hoses Replace hoses
Leakage of power Damage of power steering fluid reservoir Replace reservoir

steering fluid Over flow Air bleeding or adjust fluid level
Malfunction of power steering pump Replace power steering pump
Looseness of power steering pump Tightening of power steering pump
Looseness of steering gear Tightening of steering gear
Tightening of power steering pump
Looseness of power steering pump bracket
bracket
Tightening of power steering pump
Looseness of power steering pump pulley nut
pulley nut
Excessive tightness or looseness of belt Adjust power steering pump belt
Abnormal noise
Air insertion Air bleeding
Malfunction of power steering pump Replace power steering pump
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Remove interference on steering
Interference on steering column or pressure hose
column or repair/replace hoses
Looseness or excessive tightness of steering Adjust tightness of steering linkage or
linkage replace steering linkage
Steering System > General Information > Specifications

Specification
Steering System > Steering Column & Shaft > Steering Column-Shaft > Components and Components
Location
Component
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Steering System > Steering Column & Shaft > Steering Column-Shaft > Repair procedures
Inspection
Check the deformation, damage and cracks of the steering shaft assembly and replace it if necessary.
Installation
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1. Tighten the intermediate shaft bolt.
Tightening torque :
13~19 lb·ft (17~26 N·m, 1.8~2.7 kg·m)
2. Install the intermediate shaft dust cover and set plate.
Tightening torque :
4.3~6.5 lb·ft (5.8~8.8 N·m, 0.6~0.9 kg·m)
3. Install steering joint bolt to steering column.
Tightening torque :
13~19 lb·ft (17~26 N·m, 1.8~2.7 kg·m)
4. Put the steering column joint into the intermediate shaft and tighten bolt lightly.
5. Tighten the upper column attaching bolt to the steering column.
Tightening torque :
11~17 lb·ft (16~22 N·m, 1.6~2.3 kg·m)
6. To install the steering column, push the steering column in the shaft direction. The clearance between the lower
column attaching bolt and bracket do not have to exceed to MAX 0.02in(0.5mm)
Tightening torque :
14~19 lb·ft (18~26 N·m, 1.9~2.7 kg·m)
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7. Tighten the intermediate shaft bolt.
Tightening torque :
13~19 lb·ft (17~26 N·m, 1.8~2.7 kg·m)
8. Install the Ignition switch assembly on the jacket. Install new Ignition switch bolts, and tighten them until the heads
break off.
9. Install the ignition switch connector.
10. Install the combination switch to the steering column shaft.
11. Install the combination switch connector.
12. Tighten the combination switch screw.
13. Install the bracket.
14. Tighten the steering column cover screws after installing upper and lower steering column cover.
15. Install the steering wheel.

16. Tighten the steering wheel nut.
Tightening torque :
29~36 lb·ft (39~49 N·m, 4.0~5.0 kg·m)
17. Install the horn cap.

18. Connect he battery (-) terminal.
Removal
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2. Center the front wheels to the straight ahead position.
3. Remove the horn cap bolts and remove the horn cap.
4. Disconnect the horn switch electrical connector.
5. Make an alignment mark on the steering wheel and the steering shaft for proper installation.
6. Remove the steering wheel nut
7. Install steering suitable tool and remove the steering wheel. Route the wire harness through the steering wheel as
the wheel is lifted off the shaft.
Do not attempt to remove the steering wheel by hitting the steering shaft with a hammer. The steering shaft
will collapse, causing the steering wheel to bind.
8. Remove the three lower steering column panel screws. Separate the upper and lower steering column panels.
9. Remove bracket under the steering column after loosening two bolts.
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10. Remove the three combination switch screws.
11. Disconnect the combination switch electrical connectors.

12. Slide the combination switch off the steering column shaft.
13. Remove the steering upper column after loosening attaching bolts.
14. Disconnect the ignition switch electrical connector.

15. Use a chisel to make a groove in the head of the ignition switch bolts.
16. Remove the bolts with a screwdriver, then remove the ignition switch.
Secure the shaft in a vise protected with brass pads or cloth.
17. Remove the universal joint bolt.

18. Remove the two lower column bracket nuts.
19. Remove the steering column from the vehicle.

20. Remove set plate and dust cover. tomsn048@gmail.com
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21. Remove the intermediate bolt.
Steering System > Manual Steering System > Description and Operation
Description
The manual rack-and-pinion steering gear is sealed against the entry of water or foreign material by rubber boots
enclosing the tie rod inboard ends ateach end of the housing and by a third boot surrounding the pinion shaft and
steering column intermediate shaft. The steering gear is lubricated at assembly and must be removed and
disassembled if relubrication becomes necessary. The rack is positioned and guided in the housing by a bushing at
the right end and a support yoke holding it in engagement with the pinion at the left end. The support yoke is spring-
loaded against the rack. A yoke plug and locknut keeps the rack fully engaged with the pinion under load.
Rubber insulating mounts at each end of the housing cushion the steering gear mounting points and minimize
vibration. Looseness or deterioration of the mounts can cause noise and vibration problems. These should be
checked when investigating for such concerns.
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Steering System > Manual Steering System > Repair procedures

Service adjustment procedure
With the ignition OFF and the wheels in the straight ahead position, turn the steering wheel left and right until wheel
resistance is felt. Free play should not exceed 1.18 inches (30 mm) at the wheel rim.
Excessive free play indicates wear in the steering column intermediate shaft universal joints, worn tie rod ends or ball
joints, or improper steering gear preload.
To check the steering column joints, grip or feel the lower joint at the floorboard and repeat the free play check.
Any free play between the steering wheel and the lower joint at the floorboard, which is clamped to the pinion shaft,
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is in the steering column assembly.
Check the tie rods by raising both wheels off the floor. Check each wheel for wobble. First, check the wheels
vertically to verify that front wheel bearings are correctly adjusted; then, check the wheels horizontally while an
assistant grips the steering column lower joint from inside the vehicle. If horizontal wobble is present, check the tie
rod ends for free play or loose attachment to the steering knuckles. If no free play is detected at the tie rod ends,
any horizontal wheel wobble must be the result of worn tie rods, ball joints, or excessive gear free play between
steering gear rack and pinion. In either case the steering gear must be removed, and adjusted, repaired or replaced
to correct the condition.
Steering wheel effort
1. Raise the road wheels clear of the floor and position jack stands under the lower control arms, as close to the
wheels as possible without interfering with steering travel.
2. Turn the steering wheel lock-to-lock at least five times to free up any stickiness resulting from front suspension
components being out of their normal riding positions, then place the wheels in the straight ahead position.
3. Attach spring scale to the steering wheel rim and measure the steering effort through one full turn of the wheel.
For accurate readings, always pull the scale in the direction the point of scale attachment is moving
(tangential to the wheel rim) through the full circle.
4. Steering effort should be approximately 5~20 N (0.5~2.0 kg, 1~4.5 Ib) through a full revolution in either
direction from the straight ahead position.
5. If excessive, check for binding or damage in the front suspension and the steering linkage components. Check for
excessive steering gear preload.
Steering System > Manual Steering System > Manual Steering Gear Box > Components and
Components Location
Components
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Steering System > Manual Steering System > Manual Steering Gear Box > Repair procedures
Removal
1. Raise the front of the vehicle and support it with safety stands.
2. Remove wheel and tire.
3. Pull out cotter pins, and remove nuts.
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4. Separate the tie-rod from the knuckle arm with SST(0K670 321 019).
Replace nuts temporarily so that screw threads do not become

damaged.
5. Remove the catalytic converter.

6. Disconnect the high pressure and return pipe. Then seal them with dry cloth to prevent entry of foreign materials.
7. Remove the intermediate shaft.

8. Remove the four steering gear mounting bolts and washers.
9. Slide the steering gear to the left and pull the right tie rod through the fender opening.
10. Remove the steering gear by sliding it to the right.
Steering System > Hydraulic Power Steering System > Description and Operation
Description
The power steering system consists of :
• Rack and pinion steering gear
• Power steering pump
• Fluid reservoir
• Interconnecting hydraulic lines
The power steering system uses a hydraulic pressure which is generated by the power steering pump to reduce the
effort required to turn the steering wheel.
The power steering pump is mounted on the front of the engine. The pump has a vane-type design, and is driven by
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the crankshaft through a drive belt.
The power steering fluid is drawn into the pump from the reservoir when the engine is running. The fluid is
pressurized by the rotation of the rotor and vanes, then sent to the steering gear. The fluid pressure is monitored and
regulated by a Power Steering Pressure (PSP) switch and a control valve located in the power steering pump.
Steering System > Hydraulic Power Steering System > Repair procedures
Service adjustment procedure
Power steering pressure testing
Make sure that the power steering system analyzer valve is OPEN to allow the system to function properly.
Do not hold the steering wheel against a stop for more than ten seconds at a time.
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1. Disconnect the high-pressure line and attach Power Steering System Analyzer or equivalent using the appropriate
adapters. Tighten the adapters to 29~43 Ib·ft (39~59 N·m, 4~6 kg·m).
2. Insert a thermometer into the power steering fluid reservoir.
3. Bleed the system using the following procedure :
(1) Check the fluid level in the reservoir, add fluid if necessary.
(2) Raise and support vehicle.
(3) Turn the steering wheel fully left and fully right ten times.
(4) Recheck the fluid level. If the level has dropped, add fluid to the reservior.
(5) Repeat Steps (3) and (4) until the fluid level stabilizes.
(6) Key ON and let the engine run at idle.
(7) Turn the steering wheel fully left and fully right ten times.
(8) Verify that the fluid is not foamy. If the fluid is foamy, air is still present in the system. Repeat Steps (2)
through (7).
Check the system for an air leak if foam is still present.
4. Check the power steering fluid temperature. If the temperature is not at 50~60 °C (122~140 °F), turn the
steering wheel back and forth until the specified temperature is reached.
The valve on the power steering system analyzer must be closed briefly to read the operating pressure. Do
not leave the valve closed for more than 15 seconds.
5. Measure the power steering pump output pressure by closing the power steering system analyzer valve and
increasing the engine speed to 1,000~1,500 rpm. The pressure specification is 7,358~7,848 kPa (75~80
kg/cm², 1,067~1,138 psi).
A. If the pressure is within specification, continue with the remaining test procedures.
B. If the pressure is low, repair or replace the power steering pump. If the pressure is too high, check for a
crimped pipe and repair/replace as necessary, or replace the power steering pump.
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6. With the power steering system analyzer valve open, increase the engine speed to 1,000~1,500 rpm.
Do not hold the steering wheel against a stop for more than 15 seconds at a time.
7. Turn the steering wheel all the way to the right or left and read the measured pressure. The pressure specification
is 7,358~7,848 kPa (75~80 kg/cm², 1,067~1,138 psi). If the pressure is not within the given specification, repair
or replace the steering gear.
8. Remove the power steering system analyzer and adapters. Reconnect the high-pressure line and tighten the high-
pressure line fitting to 16~24N·m(16~2.4kg·m,11.5~17.3 1b·ft).
9. Remove the thermometer and bleed the system as stated in Step 3.
Steering wheel effort
1. Insert a thermometer into the power steering fluid reservoir.
Do not hold the steering wheel against a stop for more than ten seconds at a
time.
2. Start the engine, then turn the steering wheel left and right several times until the fluid temperature reaches 50~60
°C (122~140 °F).
3. With the vehicle on a hard, level surface, turn the steering wheel until the wheels are in the straight ahead position.
4. Attach Spring Scale to the steering wheel rim and measure the steering effort through one full turn of the wheel.
The steering wheel effort should be 39 N (4 kg, 8.8 Ibs) or less.
For accurate readings, always pull the scale in the direction the point of the scale attachment is moving
(tangential to the wheel rim) through the full circle.
5. If the effort is greater than the specification, check for low fluid level, air in the system, and fluid leakage. Check
the power steering pump pressure,steering gear pressure and tire pressure.
6. Remove the thermometer.
Power steering fluid level inspection and adding power steering fluid
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1. Check the power steering fluid level. If necessary, fill the fluid reservoir until the level is between the MAX and
MIN lines.
2. Run the engine until it reaches normal operating temperature, then turn the steering wheel from lock to lock 10
times.
3. Turn the engine off with the wheels in the straight ahead position.
4. Check the fluid level. If necessary, fill the fluid reservoir until the level is between the MAX and MIN lines.
Air bleeding
1. Check the fluid level.
2. Raise and support the vehicle.
3. Turn the steering wheel fully to the left and right several times with the engine not running.
4. Recheck the fluid level. If it has dropped, add a fluid.
5. Repeat Steps 2 and 3 until the fluid level stabilizes.

6. Start the engine and let it idle.
7. Turn the steering wheel fully to the left and right several times.
8. Verify that fluid is not foamy and that the fluid level has not dropped.
9. Add a fluid if necessary and repeat Steps 7 and 8.
Steering System > Hydraulic Power Steering System > Power Steering Gear Box > Components and
Components Location
Components
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Steering System > Hydraulic Power Steering System > Power Steering Gear Box > Repair procedures
Disassembly
1. Secure the steering gear in a vice equipped with the protective jaw caps.
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2. Remove the oil pipe.
3. Place the alignment marks on the left tie rod end to aid an installation.
4. Loosen the lock nut and remove the left tie rod end.
5. Remove the boot clips.
6. Remove the boot wires.
7. Remove the boots.

8. Remove the tie rods from the rack.
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9. Remove the yoke plug locknut and yoke plug.
10. Remove the spring and support yoke.
11. Remove the pinion and control valve assembly snap ring.
12. Remove the oil seal.
13. Remove the two valve housing attaching bolts.

14. Remove the valve housing and the pinion and control valve assembly.
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15. If present, remove the shim(s) from the steering gear housing.
16. Remove the O-ring.

17. Remove the lower pinion bearing from the steering gear housing.
18. Tap lightly with a rubber mallet to remove the pinion and control valve assembly from the valve housing.
19. Remove the four Teflon R seals from the pinion and control valve assembly.
20. Use the suitable tool to press the bearing out of the valve housing.
21. Use the Outer Box Torque Adapter to rotate the rack bushing until the hooked end of the retaining wire is
aligned with the slot in the steering gear housing.
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22. Rotate the bushing.
23. Remove the rack from the right side of the steering gear.
24. Remove the bushing from the rack.

25. Remove the O-ring.
26. Use the Rack Oil Seal Remover to remove the seal by bottoming it into the rack with a plastic hammer.
27. Use the impact Slide Hammer and the Rack Oil Seal Remover to pull the seal out of the rack.
28. Remove the mounting brackets and grommets.
Assembly
1. Install the grommets and mounting brackets.
Ensure the lip spring of the seal points toward the installation
tool.
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2. Use the Rack Oil Seal Replacer and install a new seal.
3. Install a new O-ring by using the Piston Seal Replacer and the Rack Piston Seal Sizer.
4. Place the Short Rack Seal Protector over the end of the rack to protect the bushing. Install the bushing on the
rack.
5. Place the Rack Oil Seal Protector over the rack as shown. Install the rack, with the rack oil seal protector, into
the steering gear housing. Remove the rack oil seal protector.
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6. Use the Pinion Bearing Replacer to install the lower pinion bearing.
7. If the valve housing, steering gear housing, or pinion and control valve assembly have been replaced, perform the
valve housing adjustment procedure outlined in this section. If none of these components have been replaced,
install any shims that were removed.
8. Use the Seal Installation Set to install a new Teflon R pinion seals on the pinion and control valve assembly.
A. Install the first seal (the seal closest to the bearing) by sliding the Mandrel over the valve assembly to the first
seal groove. Push the seal into the groove by using the Pusher.
B. Size the seal by sliding the large end of Sizer over the seal.
C. Before installing the second seal, place one Spacer, on the valve assembly as shown. Install and size the seal
by using the Mandrel and the Pusher.
D. Before installing the third seal, place two Spacers, on the valve assembly.Make sure both spacers are
positioned on the valve assembly as the one shown. Install and size the third seal.
E. To install the fourth seal, turn the second spacer around so the small ends of the spacers are facing each other
on the valve assembly.
9. Insert the pinion and control valve assembly into the valve housing making sure that it seats properly.
10. Install a new O-ring.
11. Position the valve housing and the pinion and control valve assembly, then install the valve housing bolts. Tighten
the valve housing bolts to 15~19 lb·ft (21~26 N·m, 2.1~2.6 kg·m).
12. Use the Pinion Seal Replacer / Torque Adapter to install the bearing.
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13. Use the Pinion Seal Replacer / Torque Adapter to install the seal.
14. Install the support yoke.

15. Install the spring.
16. Apply a sealant to the yoke plug threads. Install the yoke plug and tighten it to the specified torque.
Tightening torque :
14.5 lb·ft (19.6 N·m, 2 kg·m)
17. Loosen the support yoke.

18. Tighten the yoke plug with torque wrench to 43 lb·in (4.9 N·m, 50 kg·cm) three times, then return it 67.5
degrees.
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19. Measure the pinion torque with the SST and spring scale.
Standard :
Center of rack ± 90°
6.9~11.3 lb·in (0.8~1.3 N·m, 8~13 kg·cm)
Scale reading : 800~1,300 kg (28.2~45.9 oz)
20. If not within the specification, repeat steps 18 through 21.

21. Use the Yoke Locknut Wrench to install the locknut and tighten to 29~36 lb·ft (39~49 N·m, 4~5 kg·m).
22. Install the tie rods.

23. Align the washer with the rack groove, and then crimp the washer.
24. Install the boots.
25. Install the boot wires.
26. Install the boot clips.
27. Install the left tie rod end and lock nut.
28. Install the oil pipes.
Installation
1. Position the steering gear in its mounting location.
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2. Attach the intermediate shaft to the steering gear pinion and tighten the mounting bolt to 13~20Ib·ft (18~26
N·m,1.8~2.7 kg·m)
3. Connect the high pressure and return pipe and then tighten the bolts.
Tightening torque :
29~43 lb·ft (39~59 N·m, 4.0~6.0 kg·m)
4. Install the steering gear mounting and tighten mounting bolt and nut.
Tightening torque :
27~38 lb·ft (37~52 N·m, 3.8~5.3 kg·m)
5. Install the catalytic converter to the exhaust pipe.
Tightening torque :
27~38 lb·ft (37~52 N·m, 3.8~5.3 kg·m)
6. Install the tie-rod end to the steering knuckle.
Tightening torque :
27~38 lb·ft (37~52 N·m, 3.8~5.3 kg·m)
7. Install the tie rod end cotter pin.

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8. Install the wheel and tire.
Tightening torque :
65~87 lb·ft (88~118 N·m, 9~12 kg·m)

10. Add the power steering fluid and bleed air from the system.
Steering System > Hydraulic Power Steering System > Power Steering Oil Pump > Components and
Components Location
Components
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Component
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Steering System > Hydraulic Power Steering System > Power Steering Oil Pump > Repair procedures
Removal
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1. Disconnect the electrical connector from the Power Steering Pressure (PSP) switch.
2. Disconnect the suction hose.
3. Disconnect the high pressure hose.
4. Loosen the mounting bolt.

Remove the lock bolt and disconnect the drive belt.
5. Remove the mounting bolt.

6. Remove the power steering pump.
Installation
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1. Install the power steering oil pump and install the mounting bolt.
2. Connect the drive belt.

3. Connect the high pressure hose.
Tightening torque :
33~40 lb·ft (44~54 N·m, 4.5~5.5 kg·m)
4. Tighten the lock bolt.
Tightening torque :
27.5~38.4 lb·ft (37.24~51.94 N·m, 3.8~5.3 kg·m)
5. Connect the return hose.
Verify that the white mark on return hose aligned with the white mark on return
pipe.
6. Adjust the belt deflection by turning the adjusting bolt.

7. Connect the electrical connector from the Power Steering Pressure (PSP) switch.
Drive belt
Inspection
1. Check the drive belts for wear,cracks and fraying: replace if necessary.
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2. Check the drive belt deflection by applying moderate pressure (22Ib, 98 N,10kg) midway between the pulleys.
Adjust if necessary.
Torsion
3. Check the drive belt tension with the tension gauge.

Adjustment
1. Loosen the bolt A, B, and C. Turn the adjusting bolt D to adjust the belt to the specified tension.
2. Tighten the lock C, bolt A, and B to the specified torques.
Torquening torque :
Bolt
A : 27.4~38.3 lb·ft (37.2~51.9 N·m, 3.8~5.3 kg·m)
B : 27.4~38.3 lb·ft (37.2~51.9 N·m, 3.8~5.3 kg·m)
C : 27.4~38.3 lb·ft (37.2~51.9 N·m, 3.8~5.3 kg·m)
Replacement
1. Loosen the bolt A, B, and C.
2. Turn the adjusting bolt D to release the belt tension.
3. Remove the belt.
4. Install a new drive belt and adjust the tension and deflection. (Refer to above forthe adjustment).
Inspection
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Replace the pump assembly if necessary.

1. Check the front and rear pump bodies for cracking or other damage and for abnormal wear of the moving
surface of the rotor.
2. Check the moving surface of the cam ring's vanes for abnormal wear.
3. Check the moving surface of the side plate and the pump bodies for abnormal wear.
4. Check the moving surface of the vane cam ring for abnormal wear.
5. Check the clearance of the rotor and vanes.
6. Check the control valve for cracking and other damage, for clogging, and for abnormal wear of the moving part.
7. Check the spring for damage.
Assembly note
1. Install the rotor to the shaft with the rotor's identification mark facing upward.
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2. Install the cam ring so that its identification mark is facing downward.
3. Install the vanes (10 pieces) to the rotor, with the R part of the vanes facing outward.
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RIO(BC) > 2005 > G 1.6 DOHC > Suspension System
Suspension System > General Information > Special Service Tools

Tool
Illustration Use
(Number and Name)
0K130 322 020

Attachment steering worm For measurement of ball joint preload
bearing preload measuring
0K670 990 AA0

For removal of bearing
Bearing puller set
0K2A1 341 001A

For removal of front shock absober spring
Coil spring compressure
0K201 170 AA0A

Used to support engine
Support, engine
Suspension System > General Information > Troubleshooting

Suspension system
Condition Possible cause Action
CHECK the alignment. if the camber is
incorrect, and the camber change option is in
Excessive side-to-side difference in camber the right direction, CHANGE the camber
or caster setting as described in this section.INSPECT
the suspension components for looseness or
deformation.
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Wander/Pull/Drift INSPECT the tire for excessivewear.

Tire(s) have excessive wear
REPLACE as necessary.
CHECK alignment. REALIGN as
Toe setting unequal
necessary.
Vehicle attitude incorrect (high or low at CHECK for abnormal loading, spring
front or rear) damage, spring sag, or non-standard springs.
Steering gear or linkage worn or defective CHECK the steering system. If necessary.
CHECK the caster. If incorrect, CHECK
Excessive positive caster the suspension components for looseness or
damage.
Vehicle attitude incorrect (high at front or CHECK for abnormal loading, spring
Hard Steering low at rear) damage, spring sag, or non-standard springs.
Steering gear or linkage worn, damaged or
CHECK for steering system conditions.
improperly adjusted
LUBRICATE or REPLACE the lower ball
Poor lubrication or wear of lower ball joint
joint.
Excessive negative caster the suspension. components for looseness or
damage.
Brake Pull
INFLATE the tires uniformly to the
Unequal tire pressure
recommended pressure.
Brake drag or damage to brake system CHECK the brakes.
CHECK caster. If incorrect, CHECK the
Excessive positive caster or side-to-side
suspension. components for looseness or
caster difference
damage.
Shimmy Wheel/tire imbalance or runout CHECK for wheel and tire conditions.
CHECK for worn or deteriorated steering
Steering gear mounts loose gear mount bushings, or loose mounting
brackets.
Excessive side-to-side caster the suspension. components for looseness or
damage.
Dog-tracking If the caster is uniform, COMPARE the

wheelbase at right side and left side of the
Rear suspension damage vehicle. If not the same, CHECK for
looseness or damage of rear suspension
components.
REPLACE the steering gear mounting
Worn steering gear mounting bushings
bushings
Bump steer Loose or bent steering gear mounting TIGHTEN or REPLACE the steering gear
brackets mounting brackets
Steering gear not level ADJUST steering gear mounting
CHECK the camber. If incorrect, and
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camber change option is in right direction,
Excessive positive or negative camber ADJUST the camber setting. CHECK the
front suspension components for loosenessor
Outer or Inner
damage.
Shoulder Tire wear
Incorrect tire pressure ADJUST the tire pressure
CHECK the toe and ADJUST to
Excessive toe adjustment
REALIGN if necessary
SawtoothPattern or Excessive toe-in (high inboard edges) or CHECK the toe and ADJUST to
Excessive Tire Wear toe-out (high outboard edges) specification
Wheel/tire imbalance or runout CHECK for wheel and tire conditions
Cupping, Dishing or Defective struts CHECK struts and REPLACE if necessary
Excessive Tire wear
Tires should be ROTATED every 12,000
Tires not rotated properly
km
CHECK the tires REPLACE the tires if
Damaged tires or unbalanced wheels necessary. BALANCE the wheels if
necessary.
Steering Wheel Does Improper wheel alignment ADJUST the wheel alignment
Not Return properly
Steering system malfunction CHECK the steering system. If necessary
Damaged or stuck lower control arm ball
REPLACE the lower control arm ball joint
joint
CHECK the tires REPLACE the tires if
Damaged tires or unbalanced wheels necessary BALANCE the wheels if
necessary
Braking system malfunction CHECK the brakes. If necessary
CHECK the steering system. (Refer to
Steering system malfunction
section ST)
Steering Wheel Pulls
One Side Improper wheel alignment ADJUST the wheel alignment
Damaged lower control arm ball joint REPLACE the lower control arm ball joint
Weak coil spring REPLACE the coil spring
Damaged or worn lower control arm bushing REPLACE the lower control arm bushing
Damaged or worn stabilizer bushings Damaged or worn stabilizer
Damaged or worn stabilizer REPLACE the stabilizer
Poor lubrication/wear of lower control arm LUBRICATE or REPLACE the lower
ball joint control arm ball joint if necessary
Damaged or worn stabilizer REPLACE the stabilizer
Abnormal Noise
From Suspension Damaged or worn torsion beam REPLACE the torsion beam
System th Looseness of suspension connection TIGHTEN the connection
Strut malfunction REPLACE the strut if necessary
TIGHTEN/REPLACE the strut mount bolts.
Loose/broken strut mount bolts.
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Page 4 of 37
Loose/broken strut mount bolts.
REFER to Section SS.
Front/Rear TIGHTEN/REPLACE the strut mounting
Loose/missing strut mounting block
Suspension Noises block
Loose/missing strut bolt to lower control arm TIGHTEN/REPLACE the strut bolts
Dry rough brake cable holders LUBRICATE the cable and cable holders.
Weak stabilizer REPLACE the stabilizer
Damaged or worn stabilizer bushings REPLACE the stabilizer bushings
Body Rolls Damaged or worn lower control arm bushing REPLACE the stabilizer bushings
Body Leans Damaged or worn stabilizer bushings REPLACE the stabilizer bushings
Poor Riding Comfort
CHECK the tires
Damaged tires or unbalanced wheels REPLACE the tires if necessary.
BALANCE the wheels if necessary
Improper wheel alignment ADJUST the wheel alignment
Steering system malfunction CHECK the steering system. IF necessary
General Driving
Instability Damaged lower control arm ball joint REPLACE the lower control arm ball joint
Damaged or worn stabilizer bushings REPLACE the stabilizer bushings
Wheel and tire

Condition Possible cause Action Page
Excessive or irregular
Wheel and Tire
tire wear
Premature tire wear Incorrect tire pressure Adjust Section SS
Incorrect tire pressure Adjust Section SS
Tire squeal
Tire deterioration Replace -
Insufficient tire pressure Adjust Section SS
Road noise or body Unbalanced wheel(s) Adjust Section SS

vibration Deformed wheel(s) or tire(s) Repair or replace Section SS
Irregular tire wear Replace Section SS
Excessive tire and wheel runout Replace -
Page 5 of 37
"Shake" occurs Loose lug nuts Tighten Section SS

(Steering wheel Unbalanced wheel(s) Adjust Section SS
vibrates up/down)
Cracked or worn engine mount rubber Replace Section EM
Cracked or worn transaxle mount rubber Replace Section MT, AT
Excessive tire and wheel runout Replace -
Loose lug nuts Tighten Section SS
Unbalanced wheel(s) Adjust Section SS
"Shimmy" occurs Irregular tire wear - Section SS
(Steering wheel
vibrates left/right) Insufficient tire pressure Adjust Section SS
Damaged or worn front wheel bearing Replace Section DS
Malfunction of steering system - Section ST
Malfunction of suspension - Section SS
Incorrect tire pressure Adjust Section SS
Excessive or irregular tire wear - Section SS
Steering wheel pulls
to one side
Malfunction of braking system - Section BR
Unequal tire pressures Adjust Section SS
Deformed wheel(s) or tire(s) Repair or replace -
General driving
Loose lug nuts Tighten Section SS
instability
Uneven (one-sided) Unequal tire pressures Adjust Section SS
braking Malfunction of braking system - Section BR
Insufficient tire pressures Adjust Section SS
Heavy handling Malfunction of steering system - Section ST
Steering wheel Insufficient tire pressure Adjust Section SS

doesn't retrun Malfunction of steering system - Section ST
proprely Malfunction of suspension - Section SS
Irregular tire wear

Abnormal tire wear patterns, such as shown in the illustration, may occur. Refer to the chart for the possible causes
and remedies.
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Page 6 of 37
Wear condition Possible cause Remedy
SHOULDER WEAR
• Underinflation (both sides worn)

• Measure and adjust pressure
• Hard cornering
• Reduce speed
• Lack of rotation
• Rotate tires
CENTER WEAR
• Overinflation • Measure and adjust pressure

• Lack of rotation • Rotate tires
FEATHERED EDGE
• Incorrect toe adjustment • Adjust toe-in
UNEVEN WEAR
• Repair or replace axle or suspension
• Incorrect camber or caster
parts
• Malfunctioning suspension
• Repair or replace suspension
• Unbalanced wheel
• Balance or replace
• Out-of-round brake drum or disc
• Correct or replace
• Lack of rotatin
• Rotate tires
Suspension System > General Information > Specifications

Specifications
Suspenion system
Page 7 of 37
Items Specification
Suspension type Macpherson strut
Toe-in (in(mm)) Vacancy 0.16 ± 0.12 (4 ± 3)
3 passengers
0 ± 0.12 (0 ± 3)
laden
Vacancy 32′ ± 45′
Camber angle 3 passengers
0° ± 45′
Wheel laden
Front alignment Vacancy 1°55′ ± 45′
Caster angle 3 passengers
2°13′ ± 45′
laden
Vacancy 13° 05′
King pin angle 3 passengers
13° 50′
laden
Cylindrical double-
Front strut type
acting
Suspension type Torsion beam axle
Toe-in (in(mm)) Vacancy 0.20 ± 0.24 (5±6)
3 passengers
0.24 (6)
Wheel laden
Rear alignment Camber angle Vacancy -0° 53′ ± 18′
3 passengers
-1° 00′ ± 18′
laden
Cylindrical double-
Rear strut type
acting
* Front caster and camber are not adjustable.

Rear camber and toe-in are not adjustable.
Wheel and tire
Item Size
Size 5J x 13 5.5JJ x 14
Off-set (in(mm)) 1.57 ± 0.04 (40 ± 1)
Wheel
Steel /
Material Steel
Alumninum
P175/70 R13 P175/65 R14
Size
82T 81T
Tire
Air pressure Front 29 (200)
(psi(kPa)) Rear 29 (200)
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Page 8 of 37
Suspension System > Front Suspension System > Description and Operation
Description
the front suspension system on Rio is a typical MacPherson strut layout with single pivot forged control arms. The
front suspension consists of the following :
• A transverse front tension rod that limits sway and doubles as a trailing arm on each side to maintain control arm
alignment.
• The control arms include integral ball joints which allow steering and ride travel of the wheels. The wheels are
mounted on steering knuckle forgings, clamped to the control arm ball joints and bolted to the strut lower ends.
• The upper ends of the struts are seated in towers in the engine compartment. Caster and camber are not
adjustable.
• Rubber bushings at the control arm and tension rod mounting points cushion road shocks.
Page 9 of 37
Suspension System > Front Suspension System > Repair procedures

Inspection (Check and adjustment)
Coil spring
If loading is normal and vehicle attitude is not, check for spring damage, spring sag, or non-standard replacement
springs.
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Page 10 of 37
Struts
Bounce test the vehicle at each front corner and at the rear bumper to check the strut function. Damping action
should be positive and uniform all around. Inspect the struts for evidence of oil leakage. A thin film is normal. Check
the rearstrut upper bushing by shake-testing with the vehicle raised just enough to unload the struts (wheels still on
the ground). Any looseness is indicative of worn or deteriorated bushings, which must be replaced.
Lower arm
Check the following points, repair or replace if necessary.
1. Loose installation bolts and nuts.
2. Deformation or cracks in the lower arm
Tension rod
Check the following points or replace if necessary.
1. Looseness of the installation bolts and nuts.
2. Worn or deteriorated bushing.
Front wheel alignment
Pre-inspection
1. Check the tire inflation and set to the recommended pressure if necessary.
2. Inspect the front wheel bearing play and correct if necessary.
3. Inspect the wheel and tire runout.
4. Inspect the ball-joints and steering linkage for excessive looseness.
5. Place the vehicle on level ground with no luggage or passenger load.
6. The difference in height from the center of the wheel to the fender brim between the left and right sides should be
within 0.39 in (10 mm).
The caster and camber is not adjustable.

The toe-in is adjustable.
Adjustments
Steering angle-aximum turning angle to left and to right
1. Place both front wheels on a turning radius gauge.
2. Turn wheels fully to left and note angles for left (inner) and right (outer) wheels.
3. Loosen both left and right tie rod jam nuts, then turn both tie rods to achieve specified angles. Tighten jam nuts.
Page 11 of 37
4. Repeat for a full right turn; right is now inner and left is now outer.
5. Tighten tie-rod jam nuts.
Tightening torque :
25~37 lb·ft (34~50 N·m, 3.5~5.1 kg·m)
6. Inspect and adjust toe after adjusting steering angle.
Toe-in
Inspection
1. Raise the front of the vehicle until the wheels clear the ground.
2. Turn the wheels by hand and mark a line in the center of each tire tread using a scribing block.
3. Place the front wheels in the straight-ahead position and lower the vehicle.
4. Measure the distance between the marked lines at the front and rear of the wheels.
Both measurements must be taken at equal distances from the ground.
The distance between the wheels at the rear should be greater than that at the front by 0.16 ± 0.12 in (4±3mm).
Adjustment
To adjust the toe-in, loosen the left and right tie-rod lock nuts and turn the tie-rods by the same amount.
The left and right tie-rods are both right hand thread. To increase the toe-in, turn the right tie-rod toward the front
of the vehicle, and turn the lefttie-rod by the same amount toward the rear. One turn of the tie-rod (both sides)
changes the toe-in by about 0.24 in (6 mm).
Adjust the toe-in after adjusting the steering angle.
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Page 12 of 37
Tighten the tie-rod lock nuts to the specified torque.
Tightening torque :
25~36 lb·ft (34~50 N·m, 3.5~5.1 kg·m)
Suspension System > Front Suspension System > Front Strut Assembly > Components and
Components Location
Front macpherson strut and spring
Raise the front of the vehicle and support it with safety stands.
Component
Page 13 of 37
Component
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Page 14 of 37
Suspension System > Front Suspension System > Front Strut Assembly > Repair procedures
Removal
Raise the front of the vehicle and support it with safety stands.
1. Remove the clip of the strut side.
Page 15 of 37
2. Remove the flexible hose and ABS sensor cable from the strut bracket.
3. Remove the stabilizer control link from the bracket mounted to the strut.
4. Detach the knuckle from the strut.
5. Remove the attaching nut.

6. Remove the strut from suspension tower.
Installation
1. Position the strut, with adjusting plate in place into the strut tower with the raised rubber mounting facing in board.
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Page 16 of 37
2. Install the strut mounting block nuts.
Tightening torque:
34~46 lb·ft (46~63 N·m, 4.7~6.4 kg·m)
3. Install the steering knuckle in the strut lower bracket and install the two strut lower bracket nuts with attaching
nuts.
Tightening torque :
76~90.4 lb·ft (103~123 N·m, 10.5~12.5 kg·m)
4. Install the stabilizer control link to the bracket mounted to the strut.
Tightening torque :
32~45 lb·ft (43~60.8 N·m, 4.4~6.2 kg·m)
Page 17 of 37
5. Position the brake line and ABS sensor cable in the cutout on the strut lower bracket and secure it with the brake
line clip.
Disassembly
1. Secure the mounting block in a vise.
Use protective plates in the jaws of the

vise
2. Loosen the piston rod nut a few turns. Do not remove it.
Do not remove the nut.
3. Use the SST or equivalent, and compress the spring to unload the strut.
4. Remove the strut nut and lockwasher.

5. Remove the strut mounting block and plate.
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Page 18 of 37
6. Remove the bearing from the strut rod.
7. Remove the spring seat, seat rubber and spring.

8. Slide the bump stopper off the strut.
If replacing a spring, release the spring compressor progressively to prevent spring arching. Open the
compressor jaws wide enough to grip the new spring in the same position, and tighten the compressor
screws progressively, compressing the spring until the strut can be assembled without interference.
9. Before assembly, inspect the struts.
Inspection
Check the following points, repair or replace if necessary.
1. Oil leakage or abnormal noise from the MacPherson strut.
2. Deterioration or damage to the mounting block.
3. Damaged or loose bearing.
Wear or damage to bump stopper.
Assembly
1. Slide the bump stopper onto the strut rod and over the body.
2. Install the compressed spring, seat rubber, and upper spring seat, positioning the spring ends against the step in
the seats.
3. Install the bearing on the strut rod.
Page 19 of 37
4. Install the strut mounting block with the white alignment spot on the same side of the strut as the steering knuckle
mounting bracket.
5. Install the plate.
6. Temporarily tighten strut rod nut by hand.

7. Release and remove the spring compressor.
8. Secure the strut rod in the mounting block with the lockwasher and strut rod nut.
Tightening torque :
41~50 lb·ft (55~68 N·m, 5.6~6.9 kg·m)
Suspension System > Front Suspension System > Front Lower Arm > Components and Components
Location
Component
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Page 20 of 37
Suspension System > Front Suspension System > Front Lower Arm > Repair procedures
Removal
1. Jack up the front of the vehicle and support it with safety stands.
Page 21 of 37
3. Remove the tension rod attaching bolt at the frame bracket.
4. Remove the tension rod from the lower arm after loosening two nuts.
5. Pull the tension rod out of the lower arm and remove the front bushing and washer.
6. Lower the lower arm, prying the ball joint stud out of the steering knuckle, after loosening bolt and nut.
7. Remove the lower arm after loosening the lower arm attaching bolt from the frame bracket.
Installation
1. Connect the SST to the ball stud, and measure the torque with a pull scale.
Rotation torque :
7.2~25.2 lb·ft (1.0~3.5 N·m, 10~35 kg·cm)
Pull scale reading :
2.2~7.7 lb (10~35 N, 1~3.5 kg)
2. Raise the inner end of the lower arm into the pivot bracket on the frame, and loosely tighten the arm frame
bracket pivot to hold it in place.
3. Position the lower arm ball joint stud in the clamp bore of the steering knuckle and install the ball joint clamp bolt
and nut.
Tightening torque :
40~50 lb·ft (54~68 N·m, 5.5~6.9 kg·m)
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Page 22 of 37
4. Tighten the lower arm frame bracket pivot bolt.
Tightening torque :
87~108 lb·ft (118~147 N·m, 12~15 kg·m)
5. Install the tension rod to the lower arm.

Tighten two nuts.
6. Tighten tension rod front nut.
Tightening torque :
87~108 lb·ft (118~147 N·m, 12~15 kg·m)
Inspection
Check the following points, replace if necessary.
1. Deformation or cracks in lower arm.
2. Deformation or wear of bushing.
3. Rotation torque of ball-joint.
Suspension System > Front Suspension System > Front Stabilizer Bar > Components and Components
Location
Component
Page 23 of 37
Suspension System > Front Suspension System > Front Stabilizer Bar > Repair procedures
Removal
1. Support engine with SST (OK201 170 AA0A).
2. Raise and support the vehicle with safety stand.

3. Remove wheel and tire.
4. Remove the stabilizer from the stabilizer control link.
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Page 24 of 37
5. Remove the control link from the control link bracket on the strut.
6. Remove the stabilizer bar mounting bracket attaching bolt and mounting bracket.
7. Remove the engine-mounting member bolts and nuts from the front side of the engine-mounting member.
8. Lower the engine-mounting member enough to pull the stabilizer out from the engine-mounting member.
9. Remove the stabilizer bar.
Installation
1. Align the stabilizer bushing with the installation position line painted on the stabilizer bar. Locate the bushing
adjacent to the position line on stabilizerbar.
2. Position stabilizer forward of the engine-mounting member.

Page 25 of 37
3. Raise the engine-mounting member into place and tighten the engine-mounting member bolts and nuts on the front
side of the engine-mounting member.
Tightening torque :
bolt : 47~66 lb·ft (65~9 N·m, 6.5~9.1 kg·m)
Nut : 28~38 lb·ft (39~52 N·m, 3.9~5.3 kg·m)
4. Install the stabilizer bar mounting bracket attaching bolt and mounting bracket and tighten the attaching bolt.
Tightening torque :
26~42 lb·ft (36~56 N·m, 3.7~5.8 kg·m)
5. Install the stabilizer control link onto control link bracket on the strut.
Tightening torque :
32~45 lb·ft (43~60.8 N·m, 4.4~6.2 kg·m)
6. Install the stabilizer bar on the stabilizer control link.
Tightening torque :
32~45 lb·ft (43~60.8 N·m, 4.4~6.2 kg·m)
Tighten the two stabilizer control link nuts to specified torque before lowering vehicle (unload
condition).
7. Install the wheel and tire.
9. Remove the SST (201 170 AA0A) from engine.
Inspection tomsn048@gmail.com
Page 26 of 37
Check the following points and replace if necessary.
1. Worn or deteriorated rubber bushing.
2. Bent, cracked, or damaged stabilizer.
Suspension System > Rear Suspension System > Description and Operation
Description
The rear suspension system is the torsion beam axle type separated with spring and damper. The rear suspension
system works as follows :
• Suspension action is semi-independent, with the wheels carried on trailing arms, rigidly connected to each other
by a torsion beam.
• The beam provides positive control of trailing arm alignment, yet flexes in torsion to permit limited independent
wheel action, and is welded with the stabilizer bar at the beam to prevent it from rolling.
• For isolation of road vibration, heavy rubber bushings are installed at the torsion beam/trailing arm body
brackets, andrubber insulators cushion the spring seats in the strut towers.
Component
Page 27 of 37
Suspension System > Rear Suspension System > Components and Components Location
Component (Torsion beam axle)
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Page 28 of 37
Suspension System > Rear Suspension System > Repair procedures

Removal
1. Raise the rear of the vehicle and support it with safety stands after releasing the parking brake.
2. Remove the wheel and tire assemblies.
3. Install the jack under the torsion beam axle.
Page 29 of 37
4. Loosen the rear shock absorber lower bolt.
5. Remove the coil spring from the torsion beam after lowering the jack slightly.
6. Remove the flexible hose clip and remove the brake pipe from bracket.
Cover the brake pipe and flexible hose to prevent them from leaking fluid and dust
contamination.
7. Remove the flexible hose clip.

8. Remove the flexible hose from the torsion beam axle.
9. Remove the parking brake cable bracket from the torsion beam.
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Page 30 of 37
10. Release the backing plates and wheel spindle supports after removing the four brake backing plate/wheel
spindle support assembly nuts from the back of each brake assembly.
11. Remove the torsion beam trailing bracket bolt.

12. Loosen the flange nut and bolt to remove the torsion beam and trailing bracket.
13. Remove the lateral link from the body.
14. Loosen the lateral link and torsion beam axle tightening nut to remove the lateral link.
Be careful not to damage the parking brake cable.
15. Remove the torsion beam axle.

16. Remove the rear shock absorber upper bolt.
17. Remove the spring upper seat bolt.
Page 31 of 37
18. Use the SST or equivalent to press the bushing out of the torsion beam arms from the inboard side.
Installation
1. Position the bushing on the outboard sides of the torsion beam arms with the marks aligned parallel to the arm
axis and press them in with the SST or equivalent.
The arrow mark mould on the bushing face should be front side up.
The bushings may be lubricated with soapy water for easier installation. Do not use oil or grease.
2. Install the spring upper seat.
Tightening torque :
27~40 lb·ft (36~54 N·m, 3.7~5.5 kg·m)
3. Install the rear shock absorber upper bolt.
Tightening torque :
34~42 lb·ft (46~57 N·m, 4.7~5.8 kg·m)
4. Tighten the flange nut and bolt lightly to install trailing bracket to the torsion beam axle.
5. Install the torsion beam axle to the vehicle by using the mission jack.
6. Install the lateral link to the body.
Tightening torque :
58~72 lb·ft (78~98 N·m, 8~10 kg·m)
7. Install the lateral link to the torsion beam axle.
Tightening torque :
58~72 lb·ft (78~98 N·m, 8~10 kg·m)
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Page 32 of 37
8. Tighten the flange bolt and nut of the torsion beam bracket.
Tightening torque :
40~50 lb·ft (54~68 N·m, 5.5~6.9 kg·m)
9. Tighten the flange bolt and nut of the trailing bracket.
Tightening torque :
72~87 lb·ft (98~118 N·m, 10~12 kg·m)
10. Install the brake back plate and wheel support assembly.
Tightening torque :
32~45 lb·ft (43~61 N·m, 4.4~6.2 kg·m)
11. Install the parking brake cable bracket to the torsion beam axle.
Tightening torque :
14~19 lb·ft (19~26 N·m, 1.9~2.6 kg·m)
12. Install the flexible hose to the torsion beam axle.

13. Insert the flexible hose clip.
14. Connect the brake pipe to the brake hose.
Tightening torque :
9.4~17 lb·ft (13~23 N·m, 1.3~2.3 kg·m)
15. Lower the jack slightly to install the coil spring to the torsion beam axle.
Page 33 of 37
16. Tighten the rear shock absorber lower bolt.
Tightening torque :
58~72 lb·ft (78~98 N·m, 8~10 kg·m)
Inspection
Check the deformation damage, or cracks, replace if necessary.
Suspension System > Tires/Wheels > Tire > Repair procedures

Inspection/Adjustment
Air pressure
Always check tire inflation pressure using an accurate pressure gauge. Never inflate the tires to levels above or
below the recommended pressure. Tire inflation pressures are carefully calculated to give the vehicle satisfactory ride
and steering characteristics, without compromising the tire tread life.
Air pressure psi (kPa)
Item Tire size
Front Rear
P175/70 R13
29(200) 29(200)
82T
Standard
P175/65 R14
29(200) 29(200)
81T
Temporary
T105/70D14 60(415) 60(415)
spare
Air leakage
Verify that there is no air leakage from the air valve.
Tire wear tomsn048@gmail.com

Page 34 of 37
To maximize tire performance, inspect the tires for patterns of wear that may indicate improper inflation, a need for
rotation, a need for balancing orfront-end alignment, or a need for front suspension alignment. If the tires show
uneven or abnormal wear pattern.
Check the tires frequently for cuts, stone bruises, abrasions, blisters, and objects imbedded in the tread. Inspect
themmore frequently in times of rapid or extreme temperature changes, and after driving on rough road surfaces and
road surfaces that are littered with debris.
As an additional tire condition check, wear indicators are imbedded in the bottom of the tread grooves. These
indicatorsappear as 0.5inch (12.7mm) wide bands that show when the tread depth is reduced to 0.0625 inch
(1.6mm). When the wear indicators appear in two or more adjacent tread grooves, at three or more locations on the
tire, or when cord or fabric isexposed, replace the tire.
Inspection (Tire and wheel)

Check any tire for leaks if it regularly requires the addition of more air. Check for leaks at the valve stem, valve
core, tread, sidewall, and bead. Checktires visually for cracks, damage, and foreign matter such as pieces of metal,
stones, glass, and nails. Check the wheel rims regularly for damage.
Wheel and tire runout

1. Jack up the vehicle and place it on safety stands.
Page 35 of 37
2. Set the probe of a dial indicator against the wheel, and measure the runout through one full revolution.
Runout (in(mm))
Wheel 0.059 (1.5) max.
Tire 0.059 (1.5) max.
3. Replace the wheel if necessary.
Adjust wheel balance after replacement of a wheel or

tire.
Lug nut
1. Verify that the lug nuts are tightened to the specified torque.
Tightening torque :
65~87 lb·ft (88~118 N·m, 9~12 kg·m)
Tire rotation
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Page 36 of 37
1. To prolong tire life and assure uniform tire wear, rotate the tires every 4,960 miles (8,000km).
Use the best tires on the front axle.

After rotating the tires, adjust each tire to the specified air pressure.
Remove/Installation
1. The wheel-to-hub contact surfaces must be clean.
2. Tighten the lug nuts to the specified torque.
Tightening torque :
65~87 lb·ft (88~118 N·m, 9~12 kg·m)
Suspension System > Tires/Wheels > Wheel > Repair procedures

Wheel balance adjustment
If a wheel becomes unbalanced or if a tire is replaced or repaired, the wheel must be rebalanced to within
specification.
Maximum unbalance (at rim edge) : 20 g (0.71 oz)

Page 37 of 37
• Do not use more than two balance weights on the inner or outer side of the wheel.
• If the total weight exceeds 100 g (3.5 oz), rebalance after moving the tire around on the rim.
• Attach the balance weights tightly on the wheel.
• Select suitable balance weights for steel.
• Do not use an on-car balancer on automatic transaxle models; it may cause transaxle damage.
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Kia Rio 2005

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Page 1 of 15

RIO(BC) > 2005 > G 1.6 DOHC > General Information

General Information > General Information > General Information

Apply oil New engine oil, gear oil, etc. as appropriate

Apply brake fluid Only brake fluid

Apply automatic transmission fluid

Apply grease Appropriate grease

Apply sealant Appropriate sealant

Apply petroleum jelly Appropriate petroleum jelly

Whenever special oil or grease is required, it will be identified in figure.

A word about safety

Special service tools (SST's)

Cleaning parts for reuse

Rubber parts and tubing

Electrical troubleshooting tools (Test Light)

Electrical troubleshooting tools(Jumper wire)

Electrical troubleshooting tools(Voltmeter)

Electrical troubleshooting tools(Ohmmeter)

2. Connectors can be removed by pressing or pulling lock lever.

• Use a fine wire to prevent damage to the terminal.

Follow the same procedure as female-type terminal.

Terminals(Sensors, switches, and relays)

Wiring color codes

Jack and safety stand positions

Safety stand positions:

Jack and safety stand positions

Safety stand positions:

VEHICLE LIFT(2-SUPPORT TYPE) POSITIONS

With either automatic or manual transmission:

ENGINE NUMBER LOCATIONS

English/Metric conversion table

SCHEDULED MAINTENANCE SERVICES

Scheduled maintenance services

Scheduled maintenance services

0K201 190 016 Used to disassemble/assemble 3-4 clutch.

0K130 322 020 Used to measure bearing preload.

0K201 170 AA1 Used to install oil seal.

0K201 190 AA1 Used to measure line pressure.

0K130 191 034 Used to adjust bearing preload.

0K201 190 017 Used to disassemble transaxle.

0K201 190 019 Used to remove/install turbine shaft.

0K201 175 AA0 Used to adjust preload.

0K130 171 013 Used to remove differential bearing.

0K2CA 190 AA2 Used to press servo piston lifter.

0K2CA 190 AA1 Used to remove / install spring retainer

0K2CA 089 HSP Used for diagnosis trouble codes.

Automatic Transaxle System > General Information > Specifications (F4E-K)

Hydraulic circuit(R range)

Hydraulic circuit(N range)

Hydraulic circuit(D range:1ST GEAR)

Hydraulic circuit(D range:2nd GEAR)

Hydraulic circuit(D range:3rd GEAR)

Hydraulic circuit(D range:o/d gear converter off)

Hydraulic circuit(D range:o/d gear torque converter clutch on)

Hydraulic circuit(2nd gear)

Hydraulic circuit(1 range)

Power flow diagram

Component operation table: O/D OFF system

Solenoid valve operation table: O/D OFF system

Fluid passage locations

Fluid passage locations

Step Inspection Action