CHERY Service Manual - A13T

CHERY A13T  CAUTION:
This manual is only for specialized

technicians. If non-specialized or uncertified
Service Manual individuals perform repairs and
maintenance privately only referring to this
2016 manual or without proper equipment and

tools, it may cause damage to customer's
vehicle and injury to you and other persons
01
nearby.
FOREWORD In order to prevent dangerous operation and
damage to vehicle, be sure to follow the
This manual contains on-vehicle diagnosis instructions shown below:
and service procedures for Chery A13T.
- Contents in this manual must be read
It is very important to read and be familiar thoroughly. Have a good understanding of
with this manual thoroughly for proper repair all the contents written in "PRECAUTION"
and maintenance. This manual should be of "INTRODUCTION" section.
kept in a handy place for quick and easy
reference. - Before performing repair procedures, be
sure to put on protective tools properly to
The contents in this manual, including all avoid personal injury.
illustrations and specifications, are current
at the time of printing. As modifications - When performing repair procedures, be
affecting repair and maintenance occur, sure to use specified and recommended
relevant information supplementary to this tools to prevent damage to customer's
volume will be made available at Chery vehicle. Before operating, be sure to
dealers. confirm the safety of technicians to avoid
personal injury.
Chery Automobile Co., Ltd. reserves all
rights. Specifications and contents in this - If a part needs to be replaced, use Chery
manual are subject to change without genuine part with the same part number.
notification, and Chery Automobile Co., Ltd. Do not use any inferior quality part.
takes no legal obligations and - Observe WARNING and CAUTION in this
responsibilities. manual carefully, in order to effectively
All rights reserved. Any unit or individual avoid the risk of personal injury and
shall not reproduce or copy this manual in vehicle damage due to improper
any form or by any means, or transmit it on operation during service and
network by any form for any purpose without maintenance.
written permission of Chery Automobile Co.,
Ltd.
This manual only applies to models listed
below:
A13T 1.5 L MT
A13T 1.5 L AT
All Rights Reserved © 2016

Chery Automobile Co., Ltd.
FOREWORD 01
INTRODUCTION 02
PREPARATION 03
SERVICE SPECIFICATIONS 04
MAINTENANCE 05
SQRD4G15B ENGINE MANAGEMENT SYSTEM 06
SQRD4G15B ENGINE MECHANICAL 07
SQRD4G15B FUEL SUPPLY SYSTEM 08
SQRD4G15B EMISSION CONTROL SYSTEM 09
SQRD4G15B INTAKE SYSTEM 10
SQRD4G15B EXHAUST SYSTEM 11
SQRD4G15B COOLING SYSTEM 12
SQRD4G15B LUBRICATION SYSTEM 13
SQRD4G15B IGNITION SYSTEM 14
SQRD4G15B STARTING SYSTEM 15
SQRD4G15B CHARGING SYSTEM 16
QR515MHF TRANSMISSION 17
QR416AHA 18
CLUTCH 19
DRIVE SHAFT 20
DIFFERENTIAL 21
AXLE 22
SUSPENSION 23
TIRE AND WHEEL 24
BRAKE CONTROL SYSTEM 25
BRAKE 26
PARKING BRAKE 27
STEERING COLUMN 28
HYDRAULIC ASSIST STEERING 29
AIR CONDITIONING 30
SUPPLEMENTAL RESTRAINT SYSTEM 31
SEAT BELT 32
ENGINE IMMOBILIZER 33
CONSTANT SPEED CRUISE SYSTEM 34
LIGHTING SYSTEM 35
WIPER AND WASHER 36
DOOR LOCK 37
INSTRUMENT CLUSTER 38
AUDIO SYSTEM 39
REVERSING RADAR SYSTEM 40
TIRE PRESSURE MONITORING SYSTEM 41
HORN 42
OTHER SYSTEM 43
WINDSHIELD/WINDOW GLASS 44
REAR VIEW MIRROR 45
INSTRUMENT PANEL 46
SEAT 47
ENGINE HOOD/DOOR 48
EXTERIOR 49
INTERIOR 50
SLIDING ROOF 51
BODY DIMENSIONS 52
CAN COMMUNICATION 53
MATCHING 54
WIRE HARNESS 55
INTRODUCTION
SERVICE INFORMATION 02-3 Diagnosis and Troubleshooting 02-14
How to Use This Manual 02-3 Circuit Simulation Test 02-15
Preparation 02-4 Precautions for Control Module and 
Service Operation 02-7 Electrical Components Inspection 02-18
VEHICLE INFORMATION 02-10

How to Check Connector 02-19 02
Vehicle Identification Information 02-10 CIRCUIT INFORMATION 02-21
Symbols 02-13 How to Read Circuit Diagram 02-21
Circuit Diagram Index 02-25
CIRCUIT DIAGNOSIS 
INFORMATION 02-14 ABBREVIATION TABLE 02-27
How to Use Tester 02-14 Abbreviation Table 02-27
ECM Control System 
Troubleshooting 02-14
Chery Automobile Co., Ltd. 02–1

02
02–2 Chery Automobile Co., Ltd.

02 - INTRODUCTION
SERVICE INFORMATION
INTRODUCTION
How to Use This Manual

1. General information
This manual includes all the necessary procedures for service operations.
These procedures can be divided into three categories:
 Diagnosis 02
 Removal and installation, replacement, disassembly and assembly, inspection and adjustment
 Inspection
The following procedures are omitted from this manual. However, they must be performed.
 Use a transmission carrier or lifter to perform the operations.
 Clean all the removed parts.
 Perform a visual check.
This manual includes the following prompt information:
WARNING This indicates that injuries to you or other people may happen.
This indicates that damage to the repairing components may
CAUTION
happen.
ENVIRONMENTAL PROTECTION Dispose of the waste materials according to local regulations.
Provide additional information to help you with the service
HINT
operations.
2. Service procedure
Illustrations attached with the service procedure are used to identify components, show the assembling
relevance of parts, and explain the visual check for parts. Removal and installation procedures are
explained in words.
Service procedures include:
 Detailed removal and installation instruction
 Illustration
 Torque specifications
 Specifications
Sometimes, the illustrations of similar models are used. In this case, minor details may be different from
the actual vehicle.
3. Diagnosis procedure
Diagnosis procedures are divided as below:
 Diagnostic Trouble Code (DTC)
DTC is an important hint when troubleshooting is difficult to simulate. The malfunction can be
diagnosed quickly and accurately by performing the specified DTC diagnosis and check.
 Problem symptoms table
The malfunction locations can be determined quickly by troubleshooting in accordance with the
symptom type.
4. Specifications
This manual categorizes specifications as below:
 Torque specifications
 Clearance specifications
 Capacity specifications

02 - INTRODUCTION
Preparation
1. Preparation for vehicle service
02
6 3
RA13T020010

02 - INTRODUCTION
 Always wear a clean uniform.

1 Attire
 A hat and safety shoes must be worn.
Before starting work, prepare a radiator grille cover, fender cover, seat
2 Vehicle Protection
cover and floor mat.
 When working with two or more persons, be sure to check the safety
each other.
 When working with the engine running, make sure to provide 02
ventilation for exhaust gas in the workshop.
 If working on high temperature, high pressure, rotating, moving, or
3 Safety Operation
vibrating parts, be sure to wear appropriate safety equipment and take
extra care not to injure yourself or others.
 When jacking up the vehicle, be sure to support the specified locations
with safety stands.
 When lifting up the vehicle, use appropriate safety equipment.
Preparation for Tools and Before starting work, prepare a tool stand, special tools, gauge, oil and
4
Measuring Gauge parts for replacement.
 Diagnose after thoroughly understanding the proper service
procedures and reported problem.
 Before removing the parts, inspect the general condition of the
assembly to check for any deformation or damage.
Removal and Installation,  Take notes for the complicated assembly. For example, note the total
5 Disassembly and number of electrical connections, bolts, or hoses that are removed.
Assembly Operations  Add matchmarks to ensure that each component is assembled to its
original position. Temporarily mark the hoses and their joints as
necessary.
 Clean and wash the removed parts if necessary and assemble them
after a thorough inspection.
 Place the removed parts in a separate box to avoid mixing them up
with the new parts or contaminating the new parts.
6 Removed Parts  For non-reusable parts such as gaskets, O-rings, and self-locking
nuts, replace them with new ones as instructed in this manual.
 Retain the removed parts for customer inspection, if requested.

02 - INTRODUCTION
2. Jacking up and supporting vehicle

Care must be taken when jacking up and supporting the vehicle. Be sure to jack up and support the vehicle
at proper locations.
a. Precautions for using a swing arm type lifter
 Follow the safety procedures described in the operation manual.
 Keep the vehicle stable when using a lifter to prevent the vehicle from tilting during operation.
Stabilize the vehicle by adjusting the length of lifter arm and vehicle position.
02
Lifter Center
Front
RA13T020020

02 - INTRODUCTION
b. Precautions for using a plate type lifter

 Follow the safety procedures described in the operation manual.
 Use plate type lifter attachments (rubber lifting blocks) on the plate surface.
02
Attachment
RA13T020030
Service Operation
1. How to use fasteners
WARNING
 Using incorrect fasteners may cause damage to the components. Injury and death may occur without
observing the instructions below.
 The reference values of fasteners and torque specifications in this service manual use metric unit.
 Recycling all the fasteners (nuts and bolts, etc.) during maintenance and service operation is important
for assembly.
If it's impossible to recycle fasteners, be sure to use other fasteners with the same specifications.

02 - INTRODUCTION
2. Remove parts
When repairing the malfunction, try to determine the
cause. Before starting work, parts or sub-assemblies that
have to be removed and replaced should be confirmed
first. After removing the parts, block all the holes and
ports to prevent foreign objects from entering.
02
RA13T020040
3. Disassemble components
If the disassembly procedures are complicated and multiple parts need to be disassembled, make sure
that the disassembly methods won't affect the performance or appearance of parts. Identify each part for
assembly.
4. Check parts
After removal, check each part for deformation, damage or other problems.
5. Arrange parts
Carefully arrange all the disassembled parts to make the assembly easier.
Always separately arrange the replaced parts and reusable parts, and make marks on them.
6. Clean parts
Make a thorough and careful cleaning for reusable parts.
WARNING
 Blowing out the dirt or other particles with compressed air may hurt your eyes, and be sure to wear
goggles during operation.
7. Assemble components
When assembling the parts, always strictly use the standard values (tightening torque and clearance
value, etc.).
If the following parts need to be replaced, replace them
with new ones.
- Oil seal Oil Seal Cotter Pin
- Gasket
- O-ring
Gasket Nylon Nut
- Lock washer
- Cotter Pin
- Nylon nut O-ring Lock Washer
RA13T020050
8. Lubrication and seal

Use seal gum and gasket based on the position.
If seal gum is applied, install the components before the seal gum dries to prevent leakage.
Apply lubricant to movable area and friction area of the components.
During assembly, apply permitted lubricant or grease to the specified area (such as oil seal).
9. Adjustment
Use proper meter and tester for adjustment.

02 - INTRODUCTION
10.Pre-coated parts
Pre-coated parts are bolts and nuts that are coated with
seal lock adhesive in the factory.
If a pre-coated part is retightened, loosened, or moved in
any way, be sure to reapply the specified adhesive.
Seal Lock Adhesive 02

RA13T020060
11. Rubber parts and rubber hoses

Avoid gasoline or oil dripping on the rubber parts or rubber hoses.
12.Hose clamp
Before removing a hose, observe the position of the Elastic Clamp
clamp so as to reinstall it to the same position.
Replace the deformed or dented clamps with new ones.
When reusing a hose, fix the clamp on the clamp track
portion of hose.
For elastic clamp, push tabs in the direction of arrow as
shown in the illustration after installation to widen the tabs
slightly. Clamp Track
RA13T020070
13.Vise
When using vise, install protective plates on the jaws of
vise to prevent the parts from being damaged.
RA13T020080
14.Dynamometer
When testing vehicle on the dynamometer, pay attention to the following:
- Place a fan in front of the vehicle. It's best to use a fan of which the power changes in proportion to the
vehicle speed.
- Connect an exhaust gas ventilator.
WARNING
 Exhaust gas may cause injury and death. There is odorless, colorless Carbon Oxide (CO) in the exhaust
gas. People will faint and get poisoned after inhaling it.
- Cool the exhaust pipe with a fan.

- Keep the area around vehicle clean and tidy.
- Monitor the engine coolant thermometer.

02 - INTRODUCTION
VEHICLE INFORMATION
Vehicle Identification Information
1. VIN is located on upper left of driver's side instrument
panel and can be seen from outside through the * *
windshield. LVVDBXXXXXXXXXXXX
02
RA13T020090
VIN is also located on right drip channel of engine

compartment. * *
LVVDBXXXXXXXXXXXX
RA13T020100
Vehicle Identification Number (VIN)

The Vehicle Identification Number (VIN) consists of World Manufacturer Identifier (WMI), Vehicle
Descriptor Section (VDS) and Vehicle Indicator Section (VIS), with a total of 17-digit characters. The
specifications are as follows:
WMI VDS VIS
ƶƶƶ ƶƶƶƶƶƶ ƶƶƻƻƻƻƻƻ
1 2 3 4 5 6
RA13T020110
□: represents a letter or a number (letters I, O and Q cannot be used); ○: represents a number.

02 - INTRODUCTION
No. Definition
1 World Manufacturer Identifier
2 Vehicle Features
3 Accuracy Check Digit
4 Model Year
5 Production Plant 02
6 Sequential Number
 The first three digits of VIN represent world manufacturer identifier.
No. WMI Code Vehicle Category

1 LVV Category M1 (for vehicle type number started with 7)
 The fourth digit of VIN represents vehicle type.

- Letter "D" means all vehicles in the category M1.
 The fifth digit of VIN represents vehicle body type and drive type.
- Letter "C" means 4-door sedan 4 × 2 type.
 The sixth digit of VIN represents transmission type.
- "1" means manual transmission.
- "2" means automatic transmission.
 The seventh digit of VIN represents dynamic characteristics.
- "1" means the gasoline engine that is 1.5 L - 2.0 L (2.0 L excluded).
 The eighth digit of VIN represents restraints system.
- "B" means seat belt and airbag.
 The ninth digit of VIN represents check digit.
- It is used to check the accuracy of VIN record, and made out through computation after confirming
the other sixteen digits of the VIN.
 The tenth digit of VIN represents model year:
- "G" represents 2016.
 The eleventh digit of VIN represents assembly plant code.
- "D" represents "Chery Automobile Co., Ltd.".
 The last six digits of VIN represent production sequence number.
- The number means the real production serial number of this model.
2. Vehicle data plate
The vehicle data plate is located on the upper part of right
shock absorber seat in the engine compartment, and it is
marked with chassis number and engine number.
RA13T020111

02 - INTRODUCTION
3. Engine number
The engine number is stamped on the engine block
under the exhaust manifold.
* * *
SQRD4G15B XXXXXXXXX
02
RA13T020130
4. Transmission number
The transmission number (for MT model) is stamped on
the transmission case.
QR515MHF
XXXXXXXXX
RA13T020140
5. The transmission number (for AT model) is stamped on

the transmission case.
QR416AHA
XXXXXXXXX
RA13T020143

02 - INTRODUCTION
Symbols
The symbols below are instrument cluster display symbols and some international standard symbols.
+ -
1 2 3 4 5 6
EPC 02
7 8 9 10 11 12
13 14 15 16 17 18
OFF
19 20 21 22 23 24
25 26 27 28 29 30
SRS
31 32 33 34 35 36
1 - Seat Belt Reminder Light 2 - ABS Warning Light

3 - Door Open Warning Light 4 - Brake System Warning Light
5 - High Coolant Temperature Warning Light 6 - Turn Signal Indicator
7 - Low Fuel Level Warning Light 8 - SRS Warning Light (if equipped)
9 - Low Beam Indicator 10 - Position Light Indicator
11 - Rear Fog Indicator 12 - Engine Malfunction Warning Light
13 - Low Engine Oil Pressure Warning Light 14 - Charging System Warning Light
15 - Maintenance Indicator 16 - Daytime Running Light Indicator
17 - High Beam Indicator 18 - Automatic Cruise
19 - Front Fog Indicator 20 - Transmission Malfunction Warning Light
21 - Courtesy Dome Light 22 - To turn on rear windshield defroster
23 - ESP Warning Light 24 - ESP OFF Indicator
25 - EPC Warning Light 26 - Parking Brake Warning Light
27 - Front Seat Belt Reminder Light 28 - Immobilizer System Warning Light
29 - Tire Pressure Warning Light 30 - Hazard Flasher Warning light
31 - Horn 32 - Cigarette Lighter
33 - Hood Open 34 - Rear Windshield Heater Indicator
35 - Airbag 36 - Windshield Washer

02 - INTRODUCTION
CIRCUIT DIAGNOSIS INFORMATION

How to Use Tester
Connect the tester cable to DLC, turn the ignition switch to
ON and try to use the tester. If communication malfunction
appears on the display, it indicates that the vehicle or tester
is defective.
02  If the communication is normal when the tester is
ཽ⪔⊳䖜
connected to another vehicle, inspect the DLC on the
original vehicle.
 If the communication is still not possible when the tester
is connected to another vehicle, the tester itself is
probably defective. RA13T020150
ECM Control System Troubleshooting

This model uses the ECM control system. Most malfunction inspection procedures only involve in checking
the circuits of ECM control system one by one. An adequate understanding of the system and a basic
knowledge of electricity are enough to perform effective troubleshooting, accurate diagnosis and necessary
repairs.
Diagnosis and Troubleshooting

1. Diagnosis basis and troubleshooting methods
Procedure Types Details Troubleshooting Methods

Use eliminating methods to
determine malfunctioning parts in
accordance with DTC detection
Diagnosis procedure is based on conditions.
Diagnosis based on DTC
stored DTC.
Inspect relevant parts with the
tester and eliminate possible
malfunctions one by one.
Use eliminating methods to
determine malfunctioning parts in
Diagnosis based on symptoms (no Diagnosis procedure is based on accordance with symptoms.
DTCs stored) problem symptoms. Inspect relevant parts with the
tester and eliminate possible
malfunctions one by one.
2. Detailed troubleshooting steps
Step Description
1 Obtain detailed information when electrical malfunction occurs.
Operate affected system, and perform a road test as necessary.
2 Confirm malfunction parameter.
If it is impossible to duplicate malfunction, refer to "Electrical Malfunction Simulation Test".

02 - INTRODUCTION
Step Description
Collect proper diagnosis materials, which includes:
 Circuit Diagram
 System Schematic Diagram
3  Relevant Chapter in the Service Manual
 Service Bulletin
Perform diagnosis according to the mastered system operation knowledge and customer's 02
feedback.
Check if there is any bonding, loose connector or damaged wire harness in the system.
4 Determine related circuits and components, and diagnose according to the circuit diagram and
wire harness layout diagram.
5 Repair circuit and replace component as necessary.
Operate system in all modes. Confirm that the system can operate normally in all conditions.
6 Confirm that you have not inadvertently created new malfunctions during your diagnosis or
repair steps.
Circuit Simulation Test

The non-regular malfunctions and other malfunctions that cannot be detected through a road test can be
detected by circuit simulation test. The possible vehicle malfunction can be determined efficiently by
simulating the condition/environment when the malfunction occurs.
Simulation test can be classified into the following 7 types:
 Vehicle vibration test
 Thermosensitive test
 Freezing test
 Leakage test
 Load test
 Cold/hot start test
 Voltage drop test
HINT:
It is extremely important to listen carefully to customer's description about the malfunction for simulating the
conditions when the symptoms occur.
1. Vehicle vibration test
When the vehicle is running on an uneven road or the engine is vibrating (A/C is on and engine is idling),
malfunctions may occur. In this case, check the conditions related to the vibration. Check the following
areas on the vehicle:
a. Connector and wire harness
Slightly Vibrate
Determine the connectors and wire harnesses that
may affect the electrical system being inspected.
When monitoring whether the system has
malfunctions that are being simulated, vibrate or
wiggle each connector and wire harness slightly. This
test may show loose or poor electrical connections.
Slightly Vibrate
Slightly Wiggle
RA13T020160

02 - INTRODUCTION
HINT:
When the connector is exposed to humid environment, a layer of corrosive film may be formed on its
terminals. With the connector connected, this condition may not be found by visual check. If an
intermittent malfunction occurs, it may be caused by corrosion. It is recommended that the terminals of
the relevant connectors in the system should be checked and cleaned after disconnecting the
connectors.
b. Sensors and relays
Vibrate the sensors and relays in the system being checked slightly. The sensors or relays that are
02 loose or poorly installed may be found through this test.
c. Engine compartment
 There are many reasons for the electrical malfunction that occurred due to vehicle vibration, and it is
necessary to check the following conditions:
- Connectors are not installed correctly.
- Wire harness is not long enough, so it is extended when the engine is vibrating or shaking.
- Wire harness hangs over the bracket or movable components.
- Ground wire is loose, dirty or corrosive.
- Wire harness is too close to the high temperature components.
 To inspect the components under the engine hood, first confirm that the ground connection is in
perfect condition (refer to the grounding inspection described below). First confirm that the system is
correctly grounded. Then slightly vibrate the wire harness or components as previously instructed to
check if the connection is loose. Refer to the circuit diagram to check the continuity of wire harness.
d. Backside of instrument panel
 Improper wire clamping will cause the wire harnesses to twist together when installing the
accessories. The vibration of vehicle will cause the wire harnesses near the bracket or mounting
screw to wind excessively.
 When the vehicle vibrates, unclamped or loose wire harness will be stuck in the seat components
(such as slide guide). If the wire harness passes through the underside of the mounting area, check
if the wire harness is damaged or stuck.
2. Thermosensitive test
In hot weather or after the vehicle is parked for a short time, the user may worry about the vehicle
condition. At this time, it is necessary to perform thermosensitive test.
Perform the test by heating the components with a heat gun or equivalent.
CAUTION
 DO NOT heat the components to a temperature higher than 60°C (140°F).

 If malfunction occurs when performing heating test on the components, replace or properly insulate the
components as necessary.
3. Freezing test
If the malfunction disappears after warming up the vehicle in winter, it may be caused by freezing of some
parts in the wire harness/electrical system. Use the following two methods to check this condition:
Method 1: Put the vehicle outdoors overnight. Make sure that the temperature is low enough to duplicate
the malfunction. Perform a quick and thorough diagnosis on the component that may be affected in the
morning.
Method 2: Put the suspected part in the refrigerating room and wait until it is frozen. Reinstall the
component to the vehicle and check if the malfunction reoccurs. If the malfunction occurs, repair or replace
the component.

02 - INTRODUCTION
4. Leakage test
The malfunction may occur only during high humidity or
in rainy or snowy weather. In this case, the malfunction
may occur due to water entering the electrical parts. The
leakage can be checked by spraying water to the vehicle
(similar to car wash).
02
RA13T020170
5. Load test
The malfunction occurs only when the electrical device is
turned on. Turn on the electrical equipment (including A/
C, rear window defogger, radio and fog light, etc.) one by
one and determine the relationship between electrical
equipment and malfunction. Confirm the malfunction by a
MODE SET
load test. 1 2
0 3
A/C
1 3 5
2 4 R
RA13T020180
6. Cold/hot start test

Some malfunctions occur in cold start and disappear when the engine warms up. In this case, park the
vehicle without operation for a whole night and restart it the next day, perform the test and determine the
cause quickly.
7. Voltage drop test
Generally the voltage drop test is used to find out the possible causes that affect the normal function of the
electrical components or circuits.
Check the circuit with a digital multimeter.
If the resistance of single wire harness measured by a digital multimeter is very low (0 Ω or close to 0 Ω),
the wire harness or circuit is normal.
The unnecessary resistance in the circuit may be caused by poor, loose grounding, corrosive switch
contact and loose wire connector or adapter.

02 - INTRODUCTION
Precautions for Control Module and Electrical Components Inspection

 Before performing electrical operations, turn the ignition
switch to LOCK and disconnect the negative battery
cable, then wait for 2 minutes until the backup power
supply of the airbag module is depleted (w/ airbag
system).
02
RA13T020190
 Disconnecting the battery cable will delete the clock, audio and DTC records. Therefore, it is necessary to
confirm these records before disconnecting the cable.
 Never connect the electrodes of the battery terminals reversely.
 Only install components that meet the vehicle specifications.
1. Inspect input and output conditions of components and their functions before replacing control module
 When disconnecting the components:
- Do not use excessive force when disconnecting the connector.
- If the connector is installed by tightening the bolt, loosen the mounting bolt and then disconnect the
connector by hand.
 When connecting the components:
- Before installing the connector, make sure that the terminals are not bent or damaged, and then
connect it correctly.
- When installing the connector by tightening the bolt, tighten the mounting bolt until the painted area
of the connector is flush with the surface.
 Never drop or hit the control module to prevent excessive impact.
 Note that the condensation is not formed on the control module due to extreme change of temperature
and keep it free from water drop or rain. If water is found on the control module, dry it thoroughly and
then install it to the vehicle.
 Be careful not to allow the fluid to adhere to the control module connector.
 Avoid cleaning the control module with volatile fluid.
 When using the digital multimeter, be careful not to
get the testing probes to contact with each other to
result in a short circuit. Avoid damaging the battery
due to short circuit in the power transistor inside the
control module.
RA13T020200
 Use the specified test adapter to check the input and output signals of the control module.

02 - INTRODUCTION
2. Check fuse
 Check that the fuse wire is connected.
Good Blown
02
RA13T020210
 If the fuse wire is blown, confirm that there is no short in the circuit.
 A fuse with the same rated amperage must be used for replacing.
How to Check Connector

Many electrical malfunctions are caused by electrical
connections or wire malfunctions, and also may be caused Crimping Looseness
by the bonding of components or relays. Before determining

Cord Wire
if the malfunction is caused by components or wire harness
assembly, check if the connection of the connectors is good.
Terminal
Deformation
Slightly Pull
RA13T020220
1. Check connector with a digital multimeter

 Damaged connectors and poor connections are caused by incorrect connector detection during the
circuit inspection.
 The probe of digital multimeter may be connected incorrectly with the socket of connector. To detect the
connector correctly, use a "T" shaped needle and follow the procedures below. To obtain the optimal
connection, clamp the "T" shaped needle with a spring clamp.
a. Detect from wire harness side
- If there is a back cover for the connector, remove the back cover before detecting the terminal.
- Do not detect the water-proof connector from the wire harness side. Failure to do this may
damage the seal between wire harness and connector.
b. Detect from terminal side
- Female terminal
Do not insert any object that is bigger than the male terminal into the female connector.
- Male terminal
Carefully detect the contact surfaces of each terminal with a "T" shaped needle. Do not bend the
terminal.
2. Check for proper tension of terminal contact spring
 The contact spring on the terminal may produce intermittent signals in the circuit.
 If intermittent open circuit occurs, follow the procedures below to check the open wire harness and
contact spring on the female terminal.
- Use a male terminal matched with the female terminal.
- Disconnect the suspected defective connector and secure the terminal side upward.

02 - INTRODUCTION
- When securing the wire harness of male terminal, try to insert the male terminal into the female
terminal.
- Move the connector and check if the male terminal can be inserted easily.
HINT:
If the male terminal can be inserted into the female terminal easily, replace the female terminal.
02

02 - INTRODUCTION
CIRCUIT INFORMATION
How to Read Circuit Diagram
1. Connector symbols
 Most of connector symbols in circuit diagrams indicate
the terminal side.
02
Terminal Side
Harness Side
RA13T020230
 The terminal side view in the circuit diagram is shown

at the bottom of the circuit diagram.
Female
Connector Symbol Connector

RA13T020240
2. Option splices
MANUAL TRANSMISSION AUTO TRANSMISSION

CONTROL CONTROL
UNIT UNIT
E-106 E-106
E-106 E-106
16 15 8 4
E-106 E-106
SENSOR SENSOR
E-106 E-106
RA13T020250
Option splice is indicated by diamonds (solid line), and marked with pin number inside.

02 - INTRODUCTION
3. Circuit diagram example
EXAMPLE
[1] BATTERY
IGNITION SWITCH
ON OR START [14]
ENGINE COMPARTMENT [15]

02 [2] EF05
30A
FUSE AND RELAY BOX (D)
E-049
D3
[3] A
A11 A13
2 (86) 3 (30) INSTRUMENT

PANEL FUSE
[4] MAIN
RF14 AND RELAY [16]
RELAY
10A BOX (A)
1 (85) 5 (87) I-004
RF19
15A
A4 A3 A5 A1 A2 [13]
VR
RW
RW
VR
SENSOR
I-003
MT AT [12]
VR
1 2
G
B
I-013
BW
[5] [6] 2 3 E-010

[17]
RW
RW
VR
[8]
10 13 11 3 4
1 CONTROL
MODULE
I-001
MOTOR 7 8 9
[7] M E-011
GR
ILLUMINATION [18]
V
Y
L
2 1 6
SWITCH
[9]
B
I-009
[11] [19] TO CAN
[10] SYSTEM
E-014 3 5
B
[20]
B
I-006
D1 D2 D3 D4 D5
1 2 3 4 5 6 7 8 9 10 11 12 13 A16 A15 A14 A9 A8 A7
14 15 16 17 18 19 20 21 22 23 24 25 26
A6 A5 A4
A13 A12 A11 A10
A3 A2 A1
[20] D6 D7 D8 D9 D10 D11D12
E-049
I-001 I-004 [21] W
W W
2 1
1 2 3 4 5 6 7 8 4 5 6 1 2 B+
8 7 6 5 4 3 2 1 1 2 1 2 3 6 5 4 3
9 10 11 12 13 14 15 16
16 15 14 13 12 11 10 9
E-014
I-009 I-003
B-008 I-013 B-003
E-011 W W
W W W
Gr
EA13T490000
* The circuit diagram shown here is an example only. It is different to the actual circuit shown in each
section.

02 - INTRODUCTION
The following is a list of the symbols defined in circuit diagram.
No. Definition Description

It indicates the power supply from battery positive to electrical
[1] Battery
equipment.
This symbol indicates a fuse; "EF05" indicates the fuse
[2] Fuse
number; "30A" indicates the rated amperage of this fuse.
[3] Splice Point

The solid circle indicates that each intersecting wire is 02
interconnected.
This symbol indicates a relay; "MAIN RELAY" indicates the
[4] Relay relay name; "1", "2", "3" and "5", or "85", "86", "30" and "87"
indicate the terminal numbers of relay.
It indicates the color of this wire. The color codes are as
follows:
B = Black;
W = White;
R = Red;
G = Green;
L = Blue;
Y = Yellow;
[5] Color
Br = Brown;
O = Orange;
Gr = Gray;
P = Pink;
V = Violet;
Lg = Light Green.
For example: "BrR" indicates the main color is brown in wire
color and the second color is red.
It indicates junction connectors. "Λ" is female connector and 
"I-013" is applicable code; "◊" is male connector and "E-010" is
[6] Connector applicable code. The number "2" and "3" inside male connector
indicates terminal number. "----" indicates different terminals
come from the same junction connectors.
[7] Motor This symbol indicates a motor.
[8] Component Name It indicates the name of a component.

02 - INTRODUCTION

"E-011" indicates the connector code of this component and
letter "E" indicates the wire harness code in which the
connector is located. Connector codes are as follows:
E = Engine Wire Harness and Engine Compartment Wire
Harness;
P = Battery Positive Wire Harness;
02 N = Battery Negative Wire Harness;
I = Instrument Panel Wire Harness;
[9] Connector Code B = Body Wire Harness;
F = Front Left Door Wire Harness;
H = Front Right Door Wire Harness;
L = Rear Left Door Wire Harness;
R = Rear Right Door Wire Harness;
T = Back Door Wire Harness;
C = Roof Wire Harness;
K = A/C Wire Harness.
[10] Ground Point It indicates ground connection.
[11] Switch This symbol indicates a switch.
"AT" indicates it is for AT model; "MT" indicates it is for MT
[12] Vehicle Model
model.
It indicates the terminal number in the connector of this
[13] Terminal No.
component.
It indicates the power supply from ignition switch to electrical
[14] Ignition Switch
equipment.
It indicates the wire harness is connected to the circuit
[15] Connected to… diagram on next page. The letter "A" is connected with "A" in
the circuit diagram on next page.
Fuse and Relay Box
[16] It indicates the name of fuse and relay box.
Name
[17] Twisted-pair It indicates the two wires are twisted.
It indicates the illumination power supply outputs from BCM
[18] Backlight Power Supply
(front position light power supply).
It is used for indicators, warning lights or illuminations in
[19] LED
switches or instrument cluster.
It indicates CAN wire in the electrical schematics. It is
[20] CAN
connected to CAN system.
It indicates the reference page showing parts locations and
positions of ground points on vehicle.
[21] Parts Location
Example:
Connector "E-014" is on page 08-3 of this manual.

02 - INTRODUCTION
Circuit Diagram Index

Use the table below to find the location of components or vehicle systems in the circuit diagram. It is easy to
find the circuit diagrams throughout the service manual based on components or vehicle systems.
It has been marked under "If There Is Any Circuit Diagram" column to tell you that if there is any circuit
diagram in the components or vehicle systems.
Service Manual Chapter If There Is Any Circuit Diagram

Foreword - 02
Introduction -
Preparation -
Service Specifications -
Maintenance -
SQR477F Engine Management System Yes
SQR477F Engine Mechanical -
SQR477F Fuel Supply System Yes
SQR477F Emission Control System Yes
SQR477F Intake System Yes
SQR477F Exhaust System -
SQR477F Cooling System Yes
SQR477F Lubrication System -
SQR477F Ignition System Yes
SQR477F Starting System Yes
SQR477F Charging System Yes
QR515MHA Transmission -
Clutch -
Drive Shaft -
Differential -
Axle -
Suspension -
Tire and Wheel -
Brake Control System Yes
Brake Yes
Parking Brake Yes
Steering Column -
Hydraulic Assist Steering -
Air Conditioning Yes
Supplemental Restraint System Yes
Seat Belt Yes
Engine Immobilizer Yes
Lighting System Yes

02 - INTRODUCTION
Service Manual Chapter If There Is Any Circuit Diagram

Wiper and Washer Yes
Door Lock Yes
Instrument Cluster Yes
Audio System Yes
Reversing Radar System Yes
02
Horn Yes
Other System Yes
Windshield/Window Glass Yes
Rear View Mirror Yes
Instrument Panel -
Seat -
Engine Hood/Door -
Exterior -
Interior -
Body Dimensions -
Wire Harness Yes

02 - INTRODUCTION
ABBREVIATION TABLE
Abbreviation Table
Term Abbreviation
Anti-lock Brake System ABS
Acceleration Sensor AES 02
Accelerator Pedal Position Sensor APS
Automatic Temperature Control ATC
Automatic Transmission Fluid ATF
Body Control Module BCM
Brake Pressure Sensor BPS
Camshaft Position Sensor CMP
Clutch Pedal Position Switch CPP Switch
Crankshaft Position Sensor CKP
Data Link Connector DLC
Diagnostic Trouble Code DTC
Engine Control Module ECM
Engine Coolant Temperature ECT
Engine Speed RPM
Evaporative Emission EVAP
Evaporative Emission Canister EVAP Canister
Evaporative Emission System EVAP System
Exhaust Gas Recirculation Valve EGR Valve
Front Left Wheel Speed Sensor FLS
Front Right Wheel Speed Sensor FRS
Rear Left Wheel Speed Sensor RLS
Rear Right Wheel Speed Sensor RRS
Ground GND
Heated Oxygen Sensor O2S
Idle Air Control IAC
Intake Temperature IAT
Ignition IGN
Ignition Control IC
Immobilizer Control Module ICM
Injector INJ
Input Shaft Speed Sensor ISS Sensor
Knock Sensor KS
Manifold Absolute Pressure MAP

02 - INTRODUCTION
Term Abbreviation
Mass Air Flow MAF
Malfunction Indicator Light MIL
Oil Pressure Switch OPS
Output Shaft Speed Sensor OSS Sensor
Positive Crankcase Ventilation Valve PCV Valve
02
Power Supply PWR
Supplemental Restraint System SRS
Throttle Position Sensor TPS
Transaxle Control Module TCM
Turbine Speed Sensor TSS
Vehicle Identification Number VIN
Vehicle Speed Sensor VSS

PREPARATION
SQRD4G15B ENGINE  BRAKE CONTROL SYSTEM 03-29
MANAGEMENT SYSTEM 03-3 Tools 03-29
Tools 03-3
BRAKE 03-30
SQRD4G15B ENGINE  Tools 03-30
MECHANICAL 03-5
PARKING BRAKE 03-31
Tools 03-5
Tools 03-31 03
SQRD4G15B FUEL SUPPLY 
SYSTEM 03-11 STEERING COLUMN 03-32
Tools 03-11 Tools 03-32
SQRD4G15B EMISSION  HYDRAULIC ASSIST STEERING 03-33

CONTROL SYSTEM 03-12 Tool 03-33
Tool 03-12 AIR CONDITIONING 03-34
SQRD4G15B INTAKE SYSTEM 03-13 Tools 03-34
Tools 03-13 SUPPLEMENTAL RESTRAINT 
SQRD4G15B EXHAUST SYSTEM 03-14 SYSTEM 03-35
SQRD4G15B COOLING SYSTEM 03-15 SEAT BELT 03-36

Tools 03-15 Tool 03-36
SQRD4G15B LUBRICATION  ENGINE IMMOBILIZER 03-37

SYSTEM 03-16 Tools 03-37
Tools 03-16 CONSTANT SPEED CRUISE 
SQRD4G15B IGNITION SYSTEM 03-17 SYSTEM 03-38
Tool 03-17 Tools 03-38
SQRD4G15B STARTING SYSTEM 03-18 LIGHTING SYSTEM 03-39

Tool 03-18 Tools 03-39
SQRD4G15B CHARGING SYSTEM 03-19 WIPER AND WASHER 03-40

Tool 03-19 Tool 03-40
QR515MHF TRANSMISSION 03-20 DOOR LOCK 03-41

QR416AHA 03-22 INSTRUMENT CLUSTER 03-42

CLUTCH 03-24 AUDIO SYSTEM 03-43

DIFFERENTIAL 03-25 REVERSING RADAR SYSTEM 03-44

AXLE 03-26 TIRE PRESSURE MONITORING 

SYSTEM 03-45
Tools 03-26
Tools 03-45
SUSPENSION 03-28
Tools 03-28

HORN 03-46 EXTERIOR 03-51
Tool 03-46 Tool 03-51
WINDSHIELD/WINDOW GLASS 03-47 INTERIOR 03-52

REAR VIEW MIRROR 03-48 SLIDING ROOF 03-53

Tool 03-48 Tool 03-53
INSTRUMENT PANEL 03-49 CAN COMMUNICATION 03-54

03 Tool 03-49 Tools 03-54
ENGINE HOOD/DOOR 03-50

Tool 03-50

03 - PREPARATION
SQRD4G15B ENGINE MANAGEMENT SYSTEM

PREPARATION
Tools
Special Tool
03
ཽ⪔⊳䖜
X-431 3G Diagnostic Tester
RCH0000001
General Tools
X-431 3G Fuel Injector Cleaning Analyzer
RCH0000062
Ignition Timing Light
RCH0000016
Digital Multimeter
RCH0000002

03 - PREPARATION
Cylinder Pressure Gauge
RCH0000044
03
Fuel Pressure Gauge
RCH0000048
Oscilloscope YES ENTER
ESC
NO
1 2 3 4 5
6 7 8 9 0
RCH0000061

03 - PREPARATION
SQRD4G15B ENGINE MECHANICAL

Tools
Special Tools
03
Crankshaft Front Oil Seal Guide Tool
RCH0000049
Crankshaft Front Oil Seal Installer
RCH0000067
Camshaft Oil Seal Installer
RCH0000017
Valve Spring Compression Adapter
RCH0000050
Valve Spring Compressor
RCH0000028

03 - PREPARATION
Crankshaft Rear Oil Seal Installer
RCH0000031
03
Valve Oil Seal Installer
RCH0000034
Valve Oil Seal Guide Sleeve
RCH0000035
Driven Disc Assembly, Clutch Cover Assembly,

Guide Special Tool
RCH0000018
Valve Oil Seal Remover
RCH0000037
Valve Cotter Installer
RCH0000029

03 - PREPARATION
Flywheel Holding Tool
RCH0000040
03
Oil Filter Remover
RCH0000054
General Tools
Piston Installer
RCH0000039
20
10
30
0
40
90
50
Dial Indicator and Magnetic Holder

80
60
70
RCH0000023
1.5
50
1.0
5
0
Outer Diameter Micrometer

0.01mm
50 75mm
RCH0000064

03 - PREPARATION
Vernier Caliper
RCH0000019
03
Caliper Gauge
RCH0000069
Precision Straightedge
RCH0000063
Feeler Gauge
RCH0000060
Cylinder Gauge
RCH0000065
Piston Ring Remover
RCH0000066

03 - PREPARATION
Digital Multimeter
RCH0000002
03
Flexional Magnetic Rod
RCH0000042
Engine Hoist
RCH0000043
Engine Equalizer
RCH0000026
Transmission Carrier
RCH0000005
Fuel System Pressure Tester
RCH0000048

03 - PREPARATION
RCH0000044
03
Engine Service Platform
RCH0000057

03 - PREPARATION
SQRD4G15B FUEL SUPPLY SYSTEM

Tools
Special Tool
03
Fuel Tank Pressure Cap Remover
RCH0000004
General Tools
Digital Multimeter
RCH0000002
RCH0000048
RCH0000005

03 - PREPARATION
SQRD4G15B EMISSION CONTROL SYSTEM

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
SQRD4G15B INTAKE SYSTEM

Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tools
Digital Multimeter
RCH0000002
RCH0000063
Feeler Gauge
RCH0000060

03 - PREPARATION
SQRD4G15B EXHAUST SYSTEM

Tools
General Tools
03
RCH0000063
Feeler Gauge
RCH0000060

03 - PREPARATION
SQRD4G15B COOLING SYSTEM

Tools
General Tools
03
Digital Multimeter
RCH0000002
Cooling System Pressure Tester
RCH0000055
Freezing Point Tester
RCH0000007
Engine Equalizer
RCH0000026

03 - PREPARATION
SQRD4G15B LUBRICATION SYSTEM

Tools
Special Tools
03
Oil Pan Remover and Scraper
RCH0000056
Oil Filter Remover
RCH0000054
General Tool
Oil Pressure Tester
RCH0000006

03 - PREPARATION
SQRD4G15B IGNITION SYSTEM

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
SQRD4G15B STARTING SYSTEM

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
SQRD4G15B CHARGING SYSTEM

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
QR515MHF TRANSMISSION
Tools
Special Tools
03
Input Shaft Oil Seal Installer
RCH0000008
Differential Oil Seal Installer
RCH0000009
Installer Joint
RCH0000010
Bearing Remover
RCH0000011
Punch
RCH0000015

03 - PREPARATION
Puller
RCH0000059
General Tools 03
RCH0000005
Engine Equalizer
RCH0000026
Hydraulic Press
RCH0000012

03 - PREPARATION
QR416AHA
Tools
Special Tools
03
ཽ⪔⊳䖜
RCH0000001
Puller
RCH0000059
RCH0000009
General Tools
Engine Equalizer
RCH0000026

03 - PREPARATION
RCH0000005
03
Digital Multimeter
RCH0000002

03 - PREPARATION
CLUTCH
Tools
Special Tool
03
Clutch Pressure Plate Installer
RCH0000018
General Tools
Vernier Caliper
RCH0000019
Digital Multimeter
RCH0000002

03 - PREPARATION
DIFFERENTIAL
Tools
Special Tools
03
Bearing Remover
RCH0000011
Punch
RCH0000015
General Tools
20
10
30
0
40
90
50

80
60
70
RCH0000023
Hydraulic Press
RCH0000012

03 - PREPARATION
AXLE
Tools
Special Tool
03
Ball Pin Separator
RCH0000024
General Tools
20
10
30
0
40
90
50
80
60
70
RCH0000023
RCH0000005
Hydraulic Press
RCH0000012

03 - PREPARATION
Bearing Remover
RCH0000011
03
Engine Equalizer
RCH0000026

03 - PREPARATION
SUSPENSION
Tools
Special Tools
03
Spring Compressor
RCH0000021
Shock Absorber Nut Remover
RCH0000022
General Tools
RCH0000005
Engine Equalizer
RCH0000026

03 - PREPARATION
BRAKE CONTROL SYSTEM

PREPARATION
Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
BRAKE
Tools
Special Tool
03
Brake Caliper Piston Pressing Tool
RCH0000053
General Tools
20
10
30
0
40
90
50
80
60
70
RCH0000023
Vernier Caliper
RCH0000019
Digital Multimeter
RCH0000002

03 - PREPARATION
PARKING BRAKE
Tools
General Tools
03
Digital Multimeter
RCH0000002
Vernier Caliper
RCH0000019

03 - PREPARATION
STEERING COLUMN
Tools
Special Tool
03
Steering Wheel Remover
RCH0000014
General Tool
Electric Drill
RCH0000013

03 - PREPARATION
HYDRAULIC ASSIST STEERING

Tool
Special Tool
03
Ball Pin Separator
RCH0000024

03 - PREPARATION
AIR CONDITIONING
Tools
Special Tool
03
Refrigerant Recycling Machine
RCH0000046
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
SUPPLEMENTAL RESTRAINT SYSTEM

Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
SEAT BELT
Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
ENGINE IMMOBILIZER
Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tools
Digital Multimeter
RCH0000002

03 - PREPARATION
CONSTANT SPEED CRUISE SYSTEM

Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
LIGHTING SYSTEM
Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
WIPER AND WASHER

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
DOOR LOCK
Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
INSTRUMENT CLUSTER
Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
AUDIO SYSTEM
Tool
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
REVERSING RADAR SYSTEM

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
TIRE PRESSURE MONITORING SYSTEM

Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
HORN
Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
WINDSHIELD/WINDOW GLASS
Tools
Special Tool
03
Interior Crow Plate
RCH0000025
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
REAR VIEW MIRROR

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
INSTRUMENT PANEL
Tool
Special Tool
03
RCH0000014

03 - PREPARATION
ENGINE HOOD/DOOR
Tool
General Tool
03
Interior Crow Plate
RCH0000025

03 - PREPARATION
EXTERIOR
Tool
General Tool
03
Interior Crow Plate
RCH0000025

03 - PREPARATION
INTERIOR
Tools
Special Tool
03
Interior Crow Plate
RCH0000025

03 - PREPARATION
SLIDING ROOF
Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
CAN COMMUNICATION
Tools
Special Tools
03
ཽ⪔⊳䖜
RCH0000001
ESC
NO
1 2 3 4 5
6 7 8 9 0
RCH0000061
General Tool
Digital Multimeter
RCH0000002

SERVICE SPECIFICATIONS
SQRD4G15B ENGINE MANAGEMENT SUSPENSION 04-26
SYSTEM 04-3 Specifications 04-26
Specifications 04-3
TIRE AND WHEEL 04-28
SQRD4G15B ENGINE MECHANICAL 04-4 Specifications 04-28
Specifications 04-4
BRAKE CONTROL SYSTEM 04-29
SQRD4G15B FUEL SUPPLY  Specifications 04-29
SYSTEM 04-10
Specifications 04-10
BRAKE 04-30 04
SQRD4G15B EMISSION CONTROL 
SYSTEM 04-11 PARKING BRAKE 04-32
Specifications 04-11 Specifications 04-32
SQRD4G15B INTAKE SYSTEM 04-12 STEERING COLUMN 04-33

SQRD4G15B EXHAUST SYSTEM 04-13 HYDRAULIC ASSIST STEERING 04-34

SQRD4G15B COOLING SYSTEM 04-14 AIR CONDITIONING 04-35

SQRD4G15B LUBRICATION  SUPPLEMENTAL RESTRAINT 

SYSTEM 04-15 SYSTEM 04-36
SQRD4G15B IGNITION SYSTEM 04-16 SEAT BELT 04-37

SQRD4G15B STARTING SYSTEM 04-17 ENGINE IMMOBILIZER 04-38

SQRD4G15B CHARGING SYSTEM 04-18 CONSTANT SPEED CRUISE 

SYSTEM 04-39
QR515MHF TRANSMISSION 04-19
LIGHTING SYSTEM 04-40
QR416AHA 04-20
WIPER AND WASHER 04-41
CLUTCH 04-21
DOOR LOCK 04-42
DRIVE SHAFT 04-22
INSTRUMENT CLUSTER 04-43
Specification 04-43
DIFFERENTIAL 04-23
AUDIO SYSTEM 04-44
AXLE 04-24
REVERSING RADAR SYSTEM 04-45
Specification 04-45

Tire Pressure Monitoring System 04-46 SEAT 04-51
HORN 04-47 ENGINE HOOD/DOOR 04-52

Specification 04-47 Specifications 04-52
WINDSHIELD/WINDOW GLASS 04-48 EXTERIOR 04-53

REAR VIEW MIRROR 04-49 Interior 04-54

Specification 04-49 Specifications 04-54
INSTRUMENT PANEL 04-50 SLIDING ROOF 04-55

04 Specifications 04-50 Specifications 04-55

04 - SERVICE SPECIFICATIONS

Specifications
Torque Specifications
Description Torque (N·m)

Coolant Temperature Sensor 14 ± 1
Intake Pressure/Temperature Sensor Fixing Bolt 6±1
Knock Sensor Fixing Bolt 20 ± 5 04
Engine Speed Sensor Fixing Bolt 8±2
Camshaft Position Sensor Fixing Bolt 8±1
VVT Control Valve Fixing Bolt 8±2
ECM Fixing Bolt 7±1


Specifications
SQRD4G15B Engine Specifications
Item Specification
Engine Type VVT,Vertical, in-line 4-cylinder, water-cooled, 4-stroke, SOHC
Engine Model SQRD4G15B
04 Valve Number Per Cylinder 4

Cylinder Diameter (mm) 77.40
Piston Stroke (mm) 79.52
Displacement (ml) 1497
Compression Ratio 11.4:1
Combustion Chamber Type Pentroof type
Ignition Type Individual
Ignition Sequence 1-3-4-2
Idle Speed (r/min) 650 ± 50
Rated Power (kW) 78
Max. Torque (N·m) 135
Max. Torque Speed (r/min) 2750
Max. Permissible Speed (r/min) 6000
Min. Fuel Consumption Rate
260
(g/kW·h)
Max. Intake Valve Lift (mm) 8
Max. Exhaust Valve Lift (mm) 8
Exhaust Valve Closing Angle
338°
(1 mm)
Intake Valve Closing Angle (1 mm) 571°
Exhaust Valve Opening Angle
143°
(1 mm)
Fuel Octane Number (Not Less
Unleaded gasoline, octane number 93
Than)
In summer SAE 10W-40 (SL grade or higher)
Oil Octane Number
In winter SSAE 5W-40 (SL grade or higher)
Oil Capacity (L) 3.9 ± 0.5
Crankshaft Rotation Direction Counterclockwise (viewed from end surface of engine flywheel)
Starting Type Electrical starting
Cooling Type Forced circulation type antifreeze cooling
Lubrication Type Compound type (pressure, splash lubrication)

Item Specification
Cylinder Compression Pressure
10 - 13.5
(bar) (180 - 250) r/min
Idling Speed (650 ± 50 r/min) More than 1.5
Oil Pressure (bar)
High Speed (4000 ± 50 r/min) More than 3.5
With atmospheric temperature at -30°C, engine can start smoothly
within 8 seconds without taking special measures. Starting test shows
Starting Performance
that starting can be performed 3 times consecutively. If it fails to start
once, perform starting again after 2 minutes.
Engine Mechanical Specifications 04

Item Specification
Rocker Arm Shaft Bore Diameter of Intake Left +0.035
Rocker Arm Assembly (mm) Φ19 +0.017
Rocker Arm Shaft Bore Diameter of Intake Right +0.035

Rocker Arm Shaft Intake Rocker Arm Shaft Diameter (mm) -0.002
Φ19 -0.015
Rocker Arm Shaft Bore Diameter of Exhaust Rocker +0.035
Arm Assembly (mm) Φ19 +0.017
-0.002
Exhaust Rocker Arm Shaft Diameter (mm) Φ19 -0.015
Intake Cam Lift (mm) 8
Exhaust Cam Lift (mm) 8
Camshaft
-0.02
Camshaft Journal Diameter (mm) Φ26 -0.033
Camshaft Axial Clearance (mm) 0.095 - 0.153
Lower Surface Flatness (mm) 0.055
Cylinder Head
Overall Height (mm) 97
Valve Stem Diameter Intake Valve Φ5.972 - Φ5.988

(mm) Exhaust Valve Φ5.952 - Φ5.968
Valve Head Margin Intake Valve 0.7

Thickness (mm) Exhaust Valve 0.5
Valve
Clearance Between Intake Valve 0.020 - 0.043
Valve Stem and Guide
(mm) Exhaust Valve 0.040 - 0.063
Intake Valve 107.998

Valve Height (mm)
Exhaust Valve 117.410
Free Height (mm) 47.7
Valve Spring
Preload (N) 249 - 271
Piston Piston Diameter (mm) Φ77.325 - Φ77.365

Item Specification
First Ring 0.06 - 0.10
Piston Ring Side
Second Ring 0.05 - 0.10
Clearance (mm)
Oil Ring 0.03 - 0.16
Piston Ring
First Ring 0.28 - 0.355
Piston Ring End
Clearance (mm)
Oil Ring 0.2 - 0.6
Diameter (mm) Φ48.99 ± 0.01
04 Main Bearing Shell +0.007
Thickness (mm) Φ2.131 0
Radial Clearance (mm) 0.011 - 0.058

Crankshaft Main Journal
Axial Clearance (mm) 0.09 - 0.313
Crankshaft
Runout (mm) 0.05
Cylindricity (mm) 0.008
Roundness (mm) 0.005
Crankshaft Connecting
Rod Journal
Cylinder Bore Roundness (mm) 0.008
Cylinder Block Upper Surface Flatness (mm) 0.05
Cylinder Diameter (mm) Φ77.36 - Φ77.40
Big End Axial Clearance (mm) 0.333 - 0.387
Connecting Rod Connecting Rod Bearing Shell Radial Clearance
0.006 - 0.06
(mm)
Engine Torque Specifications

Power Steering Pulley Fixing Bolt 25 ± 3
Coupling Bolt Between Steering Pump and Fixing
25 ± 3
Bracket
Idler Pulley Assembly Torx Flange Fixing Bolt 45 ± 5
Tensioner Inner Torx Round Fixing Bolt 25 ± 3
Timing Belt Upper Cover Fixing Bolt 8+3
Crankshaft Pulley Fixing Bolt 105 - 115
Timing Belt Lower Cover Fixing Bolt 8+3
Timing Belt Tensioner Fixing Bolt 20 + 5
Idler Pulley Assembly Fixing Bolt 25 ± 3
Camshaft Phaser Cover 30 ± 5
Camshaft Phaser Cover Fixing Bolt 120 ± 6
Worm Clamp 3.5 ± 0.5
Camshaft Position Sensor Fixing Bolt 10 ± 2


Fixing Bolt Between Cooling Pipe Assembly and
40 ± 4
Cylinder Block
1st step: 5 ± 1
Cylinder Head Cover Fixing Bolt
2nd step: 10 ± 1
1st step: 15 ± 1.5
Rocker Arm Shaft Fixing Bolt
2nd step: 30 ± 1.5
1st Bearing Cap Fixing Bolt 9.5 ± 1
Coupling Bolt Between Discharge Pipe and Cylinder
9±1
Head 04
1st step: 25 ± 1.5
2nd step: 40 ± 3
Cylinder Head Fixing Bolt
3rd step: clockwise rotate by 60 ± 5°
4th step: clockwise rotate by 60 ± 5°
1st step: 30 ± 2
Flywheel Fixing Bolt
2nd step: 45 ± 5°
Coupling Bolt Between Left Mounting Bracket and
65 ± 5
Transmission Case
65 ± 5
Left Mounting Cushion Assembly
Coupling Bolt Between Left Mounting Cushion
30 ± 3
Assembly and Sub Frame
Locking Nut of Through Bolt Between Front
Mounting Bracket and Front Mounting Cushion 65 ± 5
Assembly
Coupling Bolt Between Front Mounting Cushion
25 ± 3
Assembly and Front Mounting Bracket Assembly
65 ± 5
Coupling Bolt Between Right Mounting Bracket and
25 ± 3
Mounting Cushion Assembly
Coupling Bolt Between Right Mounting Cushion
65 ± 5
65 ± 5
Engine Cylinder Block
Expansion Tank Fixing Nut 5±1
Coupling Nut Between Main Catalytic Converter
45 ± 5
Assembly and Precatalytic Converter Assembly
Clutch Release Cylinder Pipe Coupling Plug 18 ± 2
Positive Wire Harness Fixing Nut 7±1
Fixing Bolt Between Negative Battery Wire Harness
20 ± 3
and Transmission Case
Fixing Bolt Between Cylinder Head Cover and
7±1
Ground Wire


A/C Compressor Bracket Fixing Bolt 45 ± 5
Knock Sensor Fixing Bolt 17 - 23
Oil Pressure Switch 20 ± 2
Exhaust Manifold Fixing Bolt 45 ± 5
1st step: 20 ± 1
Connecting Rod Bearing Cap Fixing Bolt
2nd step: 30 ± 3
Crankshaft Main Bearing Cap Fixing Bolt 90 - 100
04 Crankshaft Main Bearing Cap Stud 90 - 100

Piston Cooling Nozzle Fixing Bolt 20 + 5
Lubrication Areas during Engine Assembly
Lubrication Area Note

Piston Pin SL10W-40
Piston Ring SL10W-40
Piston SL10W-40
Cylinder Bore SL10W-40
Main Bearing Shell and Crankshaft Main Journal SL10W-40
Crankshaft Thrust Washer (Oil Groove Side) SL10W-40
Connecting Rod Bearing Cap Bolt Head and Thread SL10W-40
Connecting Rod Bearing Shell and Crankshaft
SL10W-40
Connecting Rod Journal
Main Bearing Cap Bolt Head SL10W-40
Crankshaft Front Oil Seal Lip and Crankshaft Oil
SL10W-40
Seal Journal
Crankshaft Rear Oil Seal Lip and Crankshaft Oil Seal
SL10W-40
Journal
Valve Guide Hole SL10W-40
Valve Stem SL10W-40
Camshaft Cam and Journal SL10W-40
Valve Rocker Arm Head SL10W-40
Valve Small End, Valve Rocker Arm Head SL10W-40
Valve Seat Hole (Cylinder Head Assembly) SL10W-40
Valve Guide or Guide Bottom Hole (Cylinder Head) SL10W-40
Camshaft Oil Seal Lip and Camshaft Journal SL10W-40
Oil Filter Gasket Surface SL10W-40
All engine lubricants should be 5W-40 (for winter)/10W-40 (for summer) SL grade or higher.

Areas with Seal Gum Applied during Engine Assembly
Area with Seal Gum Applied Seal Gum Type

Cylinder Block Bowl Plug Loctite 648
Semicircle Contact Surface Between Oil Pan Gasket
Loctite 5910
and Oil Pump
Loctite 5910
and Rear Oil Seal Bracket
Area Between Oil Pan Bottom Surface and Cylinder
Loctite 5910
Block Bottom Plane
Area Between Rear Oil Seal Bracket Bottom Surface
04
Loctite 5910
and Cylinder Block Bottom Plane
Loctite 5910
and Oil Pan
Cylinder Head Bowl Plug Loctite 648
1st Camshaft Bearing Cap Loctite 574
Spark Plug Socket Loctite 243
Coolant Temperature Sensor Loctite 243
Oil Pressure Switch Loctite 243
Intake/Exhaust Manifold Stud Loctite 271
Flywheel Bolt Thread Locker
Cylinder Head Cover Gasket and Bolt Loctite 5910


Specifications

Fuel Filter Bracket Fixing Screw 7 ± 1.5
Fuel Tank Pressure Cap 75 ± 5
04 Filler Tube Assembly Lower Bracket Fixing Bolt 8+3

Filler Tube Assembly Fixing Nut 8+3
Fuel Tank Fixing Bolt 23 ± 2.5
Fuel Tank Fixing Nut 23 ± 2.5
Fuel Rail Fixing Bolt 8 - 11
Fuel Pressure Specifications
SQR477F Pressure (kPa)

Fuel Rail Fuel Pressure - Key (ON) 400
Fuel Rail Fuel Pressure - Engine Idling 400
Fuel Rail Fuel Pressure - Key (OFF) 400


Specifications

Charcoal Canister Solenoid Valve Bracket Fixing Bolt 10 ± 3
Coupling Bolt Between Activated Charcoal Canister
8+3
and Body
04
Exhaust Manifold Heat Insulator Fixing Bolt 8+3
Upstream Oxygen Sensor 45 ± 5
Downstream Oxygen Sensor 45 ± 5
EGR Fixing Bolt 20 + 5


Specifications

Coupling Screw Between Air Filter Upper Housing
3±1
and Lower Housing
Air Filter Assembly Fixing Bolt 10 ± 1
04
Air Direct Pipe Fixing Bolt 10 ± 1
Electronic Throttle Assembly Fixing Bolt 8 - 11
Intake Manifold Fixing Nut 20 + 5
Charcoal Canister Solenoid Valve Bracket Fixing
20 + 5
Bolt
Intake Manifold Upper Bracket Fixing Bolt 20 + 5
Electronic Accelerator Pedal Fixing Bolt 10 ± 2


Specifications

Exhaust Manifold Fixing Nut 20 + 5
Coupling Nut Between Exhaust Manifold and Front
45 ± 5 04
Pipe Assembly
Coupling Nut Between Front Pipe Assembly and
45 ± 5
Main Catalytic Converter Assembly
45 ± 5
Assembly and Front Muffler Assembly
Coupling Nut Between Front Muffler Assembly and
45 ± 5
Rear Muffler Assembly


Specifications

Thermostat Housing Fixing Bolt 9.5 ± 1.5
04 Thermostat Seat Fixing Bolt 9.5 ± 1.5

Coolant Temperature Sensor 11 - 16
Cooling Fan Assembly Fixing Bolt 7 ± 1.5
Radiator Upper Crossmember Fixing Bolt 9±1
Water Pump Fixing Bolt 25 ± 3
Coolant Capacity
Item Capacity (L)

Cooling System 6.5 ± 0.4
Coolant Concentration
G11 Additive Soft Water

50% 50%
Coolant Freezing Point
Item Freezing Point Value (°C)

Coolant -35
Cooling System Pressure
Item System Pressure (bar)

Cooling System (Test Pressure) 1.3 ± 0.2


Specifications
System Pressures
Condition Pressure (bar)

Idling (650 ± 50 r/min, oil temperature 90°C) More than 1.5
High Idling (4000 ± 50 r/min, oil temperature 100°C) More than 3.5
Oil Specifications 04
Engine Type SQRD4G15B
Summer: SAE 10W-40 (SL grade or higher)
Oil Specifications
Winter: SAE 5W-40 (SL grade or higher)

Drain Plug 35 ± 3
Oil Filter 22 ~ 25
Coupling Bolt Between Oil Pan and Transmission
45 ± 5
Case
Fixing Bolt of Baffle Plate Between Oil Pan and
45 ± 5
Transmission Case
Oil Pan Fixing Bolt 11 ± 1
Oil Pan Baffle Plate Fixing Bolt 8+3
Oil Strainer Bracket Fixing Nut 17 - 23
Coupling Bolt Between Oil Strainer and Oil Pump 8 ~ 11
Oil Pump Fixing Bolt 8+3


Specifications

Spark Plug 20 ± 3
Ignition Coil Fixing Bolt 8±2
04 Spark Plug Specifications

Spark Plug Type K7RT1
Spark Plug Gap (mm) 0.8 - 0.9


Specifications

Starter Power Cable Nut 18 ± 2
Starter Fixing Bolt 40 ± 5
Ignition Starting Switch Fixing Screw 1.5 04


Specifications

Battery Pressure Plate Fixing Bolt 7 ± 1.5
Coupling Bolt Between Battery Tray and Air Filter
10 ± 1
Assembly
04
Battery Tray Fixing Bolt 25 ± 4
Alternator Output Cable Fixing Nut 18 - 22
Alternator Fixing Bolt 25 ± 3
Alternator Bracket Fixing Nut 45 ± 5
Alternator Bracket Fixing Bolt 45 ± 5
Battery Specification
Item Type Specification

SQRD4G15B L2 400 12 V, 60 Ah, 480 A

Specifications

Coupling Bolt Between Clutch Case and Transmission
25 ± 2
Case
Reverse Idler Gear Shaft Locating Bolt 40 ± 4
04
Coupling Bolt Between Gear Shift Mechanism and
25 ± 2
Transmission Case
Gear Shift Mechanism Locating Bolt 35 ± 5.25
Back-up Light Switch Assembly 20 ± 2
Gear Locking Bolt 35 ± 5.25
Gear Shift Control Mechanism Fixing Bolt 23 ± 2
Drain/Retaining Plug 40 ± 6
Gear Shift Arm Bracket Bolt 25 ± 2
Reverse Gear Lock Mechanism Fixing Bolt 18 ± 2
Reverse Gear Fork Fixing Bolt 25 ± 2
Transmission Lower Coupling Bolt 50 ± 5
Transmission Upper Coupling Bolt 60 ± 5
Engine Side Coupling Bolt 60 ± 5
QR515MHF Transmission Gear Ratio
Type QR515MHF
1st 3.545
2nd 2.050
3rd 1.346
Gear 4th 0.969
5th 0.725
Reverse 3.364
Final Drive Ratio 4.500

QR416AHA
Specifications

Coupling Bolt Between Transmission and Engine 50 ± 5
Coupling Bolt Between Drive Plate and Hydraulic 55 ± 5
Torque Converter
04
Transmission Control Flexible Shaft Bracket Set Bolt 22 ± 3.5
Drain plug 44 ± 4
Turbine Speed Sensor Fixing Bolt 5.4 ± 0.5
Gear Switch Assembly Fixing Bolt 5.4 ± 0.5
Oil Outlet Pipe Set Hollow Bolt 30 ± 3
Transmission Oil Dipstick Sleeve Set Bolt 11 ± 1
Oil Pressure Detection Port Plug 7.8 ± 1
TCU Fixing Bolt 9 ± 1.5
Gear Switch Lock Nut 6.9 ± 2
Gear Shift Arm Fixing Bolt 13 ± 0.6
Basic Parameters
Item Parameter
Model QR416HA
Type Hydraulic automatic torque converter (AT)
Arrangement Type Transverse FWD
Clutch Type at Driving Hydraulic torque converter
Central Distance (mm) 185
Maximum Input Torque (N·m) 160
1st 2.848
2nd 1.553
Speed Ratio at Gears 3rd 1.000
4th 0.701
Rev 2.344
Primary Reduction Ratio 1.019
Fluid Type C6AT-15 (referred to as ATF)
Transmission Oil Capacity (L) 6.35 ~ 6.81 L

CLUTCH
Specifications

Clutch Pedal Fixing Nut 25 ± 3
Clutch Pressure Plate 23 ± 2
Release Fork Fixing Bolt 32 ± 3 04
Clutch Master Cylinder Fixing Nut 25 ± 3
Hose Assembly II Bracket 10 ± 2
Clutch Pipe I 18 ± 2
Clutch Pipe Assembly II 18 ± 2
Clutch Release Cylinder Assembly 25 ± 3
Clutch Driven Disc Specifications
Measurement Item Specification (mm)

Clutch Driven Disc Standard Thickness 7.6 ± 0.3
Minimum rivet depth 0.8

DRIVE SHAFT
Specifications

Drive Shaft Fixing Nut 240 ± 20
Coupling Nut Between Steering Knuckle and Control
120 ± 10
Arm Ball Pin
04

DIFFERENTIAL
Specifications
Torque Specification

Final Drive Driven Gear Bolt 137 ± 3
Clearance Specification
04
Description Acceptable Range (mm)
Clearance Between Differential Case and Planetary
0.025 - 0.150
Gear

AXLE
Specifications

Wheel Mounting Bolt 110 ± 10
Front Drive Shaft Assembly Locking Nut 330 ± 20
04 Fixing Bolt Between Front Dust Guard and Front

9 ± 11
Steering Knuckle Assembly
Coupling Bolt Between Front Wheel Speed Sensor
10 ± 1
and Front Steering Knuckle Assembly
Self-locking Nut Between Steering Tie Rod
Assembly Ball Pin and Front Steering Knuckle 35 ± 3
Assembly
Coupling Nut Between Front Control Arm Assembly
100 ± 10
Ball Pin and Front Steering Knuckle Assembly
Coupling Bolt Between Front Shock Absorber
110 ± 10
Assembly and Front Steering Knuckle Assembly
Coupling Nut Between Front Shock Absorber
110 ± 10
Coupling Bolt Between Front Stabilizer Bar
20 ±2
Assembly and Front Sub Frame Welding Assembly
Coupling Bolt Between Front Sub Frame Welding
100 ± 10
Assembly and Steering Gear Assembly
Coupling Bolt Between Upper Part of Front Sub
180 ± 10
Frame Welding Assembly and Body
Coupling Bolt Between Rear Part of Front Sub
180 ± 10
Coupling Bolt Between Rear Mounting Cushion
Assembly Upper Body and Rear Mounting Cushion 80 ± 5
Assembly Lower Body
Coupling Nut Between Rear Mounting Cushion
Assembly Lower Body
Assembly Lower Body and Front Sub Frame 105 ± 5
Welding Assembly
Rear Shaft Assembly Locking Nut 240 ± 20
Coupling Bolt Between Rear Wheel Speed Sensor
10 ± 1
and Rear Steering Knuckle Assembly
Coupling Bolt Between Rear Brake Line Fixing
18 ± 2
Bracket and Rear Steering Knuckle Assembly


Coupling Bolt Between Parking Brake Cable
Assembly Fixing Bracket and Rear Steering Knuckle 10 ± 1.5
Assembly
Coupling Bolt Between Lower Part of Rear Shock
Absorber Assembly and Rear Steering Knuckle 160 ± 10
Assembly
Coupling Nut Between Rear Brake Plate Assembly
90 ± 5
Rear Hub Shaft and Rear Shaft Assembly
160 ± 10
Rear Hub Shaft and Rear Shaft Assembly 04
160 ± 10
160 ± 10
Coupling Bolt Between Rear Shaft Welding
135 ± 10
Assembly and Body
Clearance Specifications
Description Specified Condition (mm)

Front Hub Bearing Looseness 0.032-0.057
Front Hub Bearing Runout 0.02
Rear Hub Bearing Looseness 0.035-0.055
Rear Hub Bearing Runout 0.05

SUSPENSION
Specifications

Coupling Nut Between Front Stabilizer Link
50 ± 5
Assembly and Front Shock Absorber Assembly
04 Assembly and Front Steering Knuckle Assembly
110 ± 10

110 ± 10
50 ± 5
Assembly and Body
100 ± 10
Coupling Bolt Between Front Part of Front Control
Arm Assembly and Front Sub Frame Welding 135 ± 10
Assembly
Coupling Nut Between Front Part of Front Control
Assembly
Coupling Bolt Between Rear Part of Front Control
Assembly
Coupling Nut Between Rear Part of Front Control
Assembly
Coupling Nut Between Front Control Arm Ball Pin
50 ± 5
Assembly and Front Control Arm Assembly
Coupling Bolt Between Front Control Arm Ball Pin
50 ± 5
Coupling Nut Between Front Stabilizer Bar Assembly
50 ± 5
and Front Stabilizer Link Assembly
100 ± 10
180 ± 10
180 ± 10
Coupling Bolt Between Rear Shock Absorber
50 ± 5
Assembly and Vehicle Body
160 ± 10
Assembly and Rear Shaft Assembly
Coupling Bolt Between Rear Shaft Assembly and
90 ± 5
Rear Mounting Assembly


Steering Tie Rod Locking Nut 50 ~ 60
Steering Wheel Locking Nut 35 ± 3
04

TIRE AND WHEEL

Specifications

Tire Type
04
Description Parameter
Tire Type 205 /55 R16 91V
Rim Type
Wheel Mounting Bolt 16 × 6.5J
Cold Tire Pressure Specifications
Description Pressure (kPa)

Front Tire (Unloaded) 230
Rear Tire (Unloaded) 220
Spare Tire 420


Specifications

Brake Pipe Coupling Plug 12 - 16
Coupling Bolt Between ABS/ESC Control Module 10 ± 3
Assembly and Mounting Bracket
04
Coupling Nut Between ABS/ESC Control Module 10 ± 1
Assembly Mounting Bracket and Body
Front Wheel Speed Sensor Fixing Bolt 10 ± 1
Rear Wheel Speed Sensor Fixing Bolt 10 ± 1

BRAKE
Specifications

Coupling Plug Between Brake Master Cylinder
16 ± 1
Assembly and Brake Pipe
04
Coupling Nut Between Brake Master Cylinder
23 ± 2
Assembly and Vacuum Booster Assembly
Coupling Nut Between Vacuum Booster Assembly
23 ± 2
and Brake Pedal Assembly
Coupling Bolt Between Brake Pedal Assembly and
23 ± 2
Body
Coupling Plug Between Front Brake Caliper
16 ± 1
Assembly and Front Brake Hose Assembly
Coupling Bolt Between Front Brake Caliper
70 ± 5
Front Brake Disc Locating Screw 4.5 ± 0.5
Front Brake Caliper Bleeder Plug 9 - 11
Guide Bolt Between Front Brake Caliper Fixing
22 - 32
Bracket and Front Brake Cylinder Assembly
Coupling Plug Between Front Brake Hose Assembly
16 ± 1
and Front Brake Pipe
Coupling Bolt Between Rear Brake Caliper
16 ± 1
Assembly and Rear Brake Hose Assembly
Assembly and Brake Caliper Mounting Board 70 ± 5
Assembly
Rear Brake Disc Locating Screw 4.5 ± 0.5
Rear Brake Caliper Bleeder Plug 9 - 11
Guide Bolt Between Rear Brake Caliper Fixing
23 ± 2
Bracket and Rear Brake Cylinder Assembly
Coupling Plug Between Rear Brake Hose Assembly
16 ± 1
and Brake Pipe
Rear Hub Shaft Locking Nut 300 ± 20
Rear Left and Right Hub Shaft Fixing Bolt 70 ± 5

Front Disc Brake
Standard Thickness Minimum Thickness

Description Maximum Runout (mm)
(mm) (mm)
Front Brake Disc 25 20 0.06
Front Brake Lining 11.2 2.2 -
Rear Disc Brake

(mm) (mm) 04
Rear Brake Disc 9 7 0.06
Rear Brake Lining 9.5 2 -

PARKING BRAKE
Specifications

Locking Nut Between Parking Brake Cable and Rear
7±1
Cable
04
Coupling Nut Between Parking Brake Control
22 ± 2
Mechanism Assembly and Body
Coupling Bolt Between Parking Brake Rear Cable
6±1
Assembly Fixing Bracket and Body
Rear Disc Brake
Description Standard Thickness (mm) Minimum Thickness (mm)

Rear Brake Disc 9 7

Rear Brake Disc 9.5 2

STEERING COLUMN
Specifications
Description Tightening Torque (N·m)

Steering Wheel Assembly Fixing Nut 35 ± 3
Combination Switch Cover Fixing Screw 1.5 ± 0.5
Steering Column Assembly Upper Bracket Fixing
25 + 3 04
Bolt
Steering Column Assembly Lower Bracket Fixing
25 + 3
Bolt
Coupling Bolt Between Steering Column with
Intermediate Shaft Assembly and Steering Gear 25 ± 3
Input Shaft
Ignition Starting Switch Fixing Screw 13 ± 2
Data Specifications
Description Standard Value

Steering Wheel Free Play (Rotation Angle) ≤ 15°
Steering Wheel Centering/Returnability (Rotation
＞ 70°
Angle)


Specifications

Coupling Bolt Between Steering Column Lower Yoke
25 ± 3
and Steering Gear
Tie Rod Assembly Locking Nut 55 ± 5
04
Fixing Bolt Between Steering Gear and Sub Frame 30 ± 3
Locking Nut Between Ball Pin Assembly and
10 ± 1
Assembly
Steering Gear Heat Insulator Fixing Nut 9±1
Steering Gear Heat Insulator Fixing Bolt 25 ± 3
Power Steering Pump Pulley Fixing Bolt 25 ± 3
Power Steering Pump Fixing Bolt 25 ± 3
Fixing Clamp Between Steering Fluid Reservoir and
5±1
Bracket
Fluid Reservoir Bracket Fixing Bolt 7±1
High Pressure Fluid Pipe Clamping Bolt 30 ± 3
Hollow Bolt 45 ± 3
Fixing Bolt Between High/Low Pressure Line and
25 ± 3
Intake Manifold
Fluid Return Pipe Clamping Bolt 30 ± 3
Fluid Suction Pipe Fixing Bolt 9 ± 1.5

AIR CONDITIONING
Specifications

A/C Line l Fixing Bolt at HVAC 9±1
Hose Clamp Fixing Bolt 9±1
Connecting Pressure Plate Fixing Nut 9±1 04
Compressor Fixing Bolt 25 ± 3
Compressor Intake and Exhaust Line Fixing Bolt 25 ± 3
Condenser Fixing Nut 5±1
A/C Line Fixing Bolt 9±1
Refrigerant Charging Specification
Description Charging Capacity (g)

R134a Refrigerant 350 ± 10g
Refrigerant Oil Charging Specifications
Description Charging Capacity (ml)

Evaporator Replacement 10
Compressor Assembly Replacement 108-135
Condenser Replacement 10
A/C Line Replacement 5


Specifications

Coupling Bolt Between Front Passenger Airbag
Assembly and Instrument Panel Crossmember 10 ± 2
Assembly
04 Coupling Bolt Between Curtain Shield Airbag
10 ± 1.5
Assembly and Body
Coupling Bolt Between Side Collision Sensor and
10 ± 2
Body
Coupling Bolt Between SRS Control Module
10 ± 1.5
Assembly and Body

SEAT BELT
Specifications

Front Seat Belt Assembly Fixing Bolt 50 ± 5
Front Seat Belt Assembly Fixing Screw 7±1
Seat Belt Buckle Assembly Fixing Nut 50 ± 5 04
Height Adjuster Assembly Fixing Bolt 23 ± 3.5
Rear Seat Belt Assembly Fixing Bolt 50 ± 5
Rear Seat Belt Assembly Fixing Screw 7±1
Center Seat Belt Assembly Fixing Bolt 50 ± 5
Center Seat Belt Assembly Fixing Screw 7±1
Double Buckle Assembly Fixing Bolt 50 ± 5

ENGINE IMMOBILIZER
Specifications

Instrument Panel Relay Box Fixing Bolt 0.7 ± 0.2
BCM Fixing Bolt 0.7 ± 0.2
04 Wireless Key Coupling Screw 0.7 ± 0.2


Specifications

Ground Wire Harness Fixing Screw 0.7 ± 0.2
"Steering Wheel Quick Button Trim Cover Fixing
0.7 ± 0.2
Screw"
04

LIGHTING SYSTEM
Specifications
Bulb Specifications
Bulb Name Nominal Light Source (Model/Type)

Headlight (Low Beam) H7
Headlight (High Beam) H1
04 Front Position Light Light Guide

Front Turn Signal Light PY21W
Stop Light P21W
Rear Fog Light P21W
License Plate Light LED
High Mounted Stop Light LED
Rear Position Light LED
Rear Turn Signal Light PY21W
Back-up Light W16W
Side Turn Signal Light LED
Daytime Running Light LED

Headlight Assembly Fixing Bolt 5.0 ± 0.5
Rear Combination Light Assembly Fixing Nut 3.5 ± 0.5
Front Dome Light Assembly Fixing Screw 2.5 ± 0.5
High Mounted Stop Light Fixing Nut 2.5 ± 0.5
Daytime Running Light 1.5 ± 0.5
Rear Fog Light and Retro-reflector 1.5 ± 0.5

WIPER AND WASHER

Specifications

Front Wiper Arm Assembly Fixing Nut 18 ± 1
Wiper Motor and Link Rod Assembly Fixing Bolt 9±1
Front Wiper Motor Assembly Fixing Nut 18 ± 1 04
Rear Wiper Arm Assembly Fixing Nut 10 ± 1
Rear Wiper Motor Assembly Fixing Bolt 10 ± 1
Washer Fluid Reservoir Assembly Fixing Bolt 10 ± 1

DOOR LOCK
Specifications

Engine Hood Lock Assembly Fixing Nut 9±1
Front Door Lock Assembly Fixing Screw 5±1
04 Front Door Key Cylinder Assembly Fixing Screw 7±1

Front Door Lock Striker Assembly Fixing Screw 23 ± 1
Rear Door Lock Assembly Fixing Screw 5±1
Rear Door Lock Striker Assembly Fixing Screw 23 ± 1
Back Door Lock Assembly Fixing Screw 9±1
Back Door Lock Striker Assembly Fixing Screw 23 ± 1
Front Door Outside Handle Fixing Screw 1.5

INSTRUMENT CLUSTER
Specification

Instrument Cluster Fixing Screw 1.5 ± 0.5
04

AUDIO SYSTEM
Specifications

No Disc CD Fixing Screw 3 ± 0.5
Front Speaker Fixing Screw 2.0 ± 0.5
04 Rear Speaker Fixing Bolt 2.0 ± 0.5

Rear Left Speaker Cover Assembly Fixing Bolt 2.5 ± 0.5


Specification

Fixing Bolt Between Reversing Radar Control
5±1
Module Assembly and Body
04

Tire Pressure Monitoring System

Specifications

Body Control Module Fixing Nut 5±1
Tire Pressure Sensor Fixing Nut 8±1
04

HORN
Specification

Horn Bracket Fixing Nut 16 ± 2
04

Specifications

Front Door Cover Plate Fixing Screw 1.5 ± 0.5
Front Door Glass Rear Guide Rail Assembly Fixing
7±1
Bolt
04
Front Door Power Glass Regulator Fixing Bolt 7±1
Front Door Power Glass Regulator Fixing Nut 7±1
Rear Door Cover Plate Fixing Screw 1.5 ± 0.5
Rear Door Glass Front Guide Rail Assembly Fixing
7±1
Bolt
Rear Door Glass Rear Guide Rail Assembly Fixing
7±1
Bolt
Rear Door Power Glass Regulator Fixing Bolt 7±1
Rear Door Power Glass Regulator Fixing Nut 7±1
Center Control Integration Panel Assembly 1.5 ± 0.5

REAR VIEW MIRROR

Specification

Outside Rear View Mirror Assembly Fixing Bolt 6±1
04

INSTRUMENT PANEL
Specifications

1.3 ± 0.2
and Lower Housing
Air Filter Assembly Fixing Bolt 8 ± 1.5
04
Air Filter Assembly Fixing Nut 8 ± 1.5
Air Direct Pipe Assembly Fixing Bolt 5±1
Air Filter Bracket Fixing Bolt 5±1
Resonant Cavity Fixing Bolt 8 ± 1.5/5 ± 1
Electronic Throttle Assembly Fixing Bolt 8+3
Engine Trim Cover Bracket 8±3
Intake Manifold Assembly Fixing Nut 20 + 5
Vacuum Actuator Fixing Bolt 8+3
Rotary Valve Fixing Bolt 8+3
Variable Intake Air Control Valve Fixing Bolt 8+3
Electronic Accelerator Pedal Fixing Bolt 8±1
Worm Clamp 3 ± 0.5

SEAT
Specifications

Front Seat Assembly Fixing Bolt 25 ± 4
Seat Track Unlock Handle Fixing Screw 4.8 ± 0.5
Seat Outer Shield Assembly Fixing Screw 4.8 ± 0.5 04
Seat Belt Buckle Assembly Fixing Bolt 50 ± 5
Seat Inner Shield Assembly Fixing Screw 4.8 ± 0.5
Rear Seatback Hook Assembly Fixing Bolt 25 ± 4
Rear Seatback Rear End Webbing Short-plate Fixing
25 ± 4
Bolt
Rear Seat Protector Assembly Fixing Nut 3 ± 0.5

ENGINE HOOD/DOOR
Specifications

Fixing Bolt Between Hood Assembly and Hood
25 ± 2
Hinge Assembly
Fixing Bolt Between Hood Hinge Assembly and
04 Body
25 ± 2
Hood Lock Assembly Fixing Bolt 9±1

10 ± 1
Wing Assembly
Front Door Inner Protector Assembly Fixing Screw 1.5 ± 0.5
Front Door Inner Protector Assembly Fixing Bolt
Front Door Inside Handle Fixing Screw 1.5 ± 0.5
Front Door Outside Handle Base Assembly Fixing
7±1
Screw
Fixing Bolt Between Front Door Hinge Assembly and
24 ± 2
Front Door Assembly
24 ± 2
Body
Fixing Nut Between Door Check and Front Door
10 ± 2
Assembly
Fixing Bolt Between Door Check and Body 22 ± 3.5
Front Door Lock Striker Fixing Screw 23 ± 2
Rear Door Inner Protector Assembly Fixing Screw 1.5 ± 0.5
Rear Door Inside Handle Fixing Screw 1.5 ± 0.5
Rear Door Metal Bracket Fixing Bolt 5±1
Rear Door Outside Handle Cover Fixing Screw 7±1
Rear Door Outside Handle Base Assembly Fixing
7±1
Screw
Fixing Bolt Between Rear Door Hinge Assembly and
55 ± 5
Rear Door Assembly
55 ± 5
Body
Rear Door Lock Striker Fixing Screw 23 ± 1
Fixing Bolt Between Back Door Hinge Assembly and
25 ± 2
Back Door Assembly
25 ± 2
Body

EXTERIOR
Specifications

Front Bumper Assembly Fixing Screw 1.5 ± 0.5
Front Bumper Assembly Fixing Bolt 5±1
Name Plate "CAC" Bracket Fixing Screw 1.5 ± 0.5 04
Front Daytime Running Light Assembly Fixing Screw 1.5 ± 0.5
Front Bumper Mounting Bracket Fixing Bolt 4.5 ± 1
Front Bumper Center Bracket Fixing Bolt 4.5 ± 1
Front Bumper Crossmember Assembly Fixing Bolt 47 ± 3
Front Wheel House Wind Deflector Fixing Screw 3±1
Front Wheel House Protector Fixing Screw 3±1
Wing Cover Plate Fixing Screw 3±1
Wing Assembly Fixing Bolt 10 ± 1
Front Bumper Lower Protector Fixing Screw 1.5 ± 0.5
Rear Bumper Assembly Fixing Screw 1.5 ± 0.5
Rear Bumper Assembly Fixing Bolt 5±1
Fixing Screw Between Rear Bumper Assembly and
3±1
Rear Wheel House
Rear Bumper Mounting Bracket Fixing Screw 1.5 ± 0.5
Rear Bumper Crossmember Assembly Fixing Nut 25 ± 2
Rear Wheel House Protector Fixing Screw 3±1
Front Windshield Lower Support Assembly Fixing
3.0 ± 0.5
Screw
Fuel Filler Cap Assembly Fixing Bolt 10 ± 1

Interior
Specifications

Rear Doorsill Pressure Plate Assembly Fixing Screw 1.5 ± 0.5
Rear Doorsill Pressure Plate Assembly Fixing Nut 1.5 ± 0.5
04 Luggage Compartment Doorsill Pressure Plate

1.5 ± 0.5
Assembly Fixing Screw
A-pillar Upper Protector Assembly Fixing Screw 3 ± 0.5
Hood Grip Fixing Screw 1.5 ± 1
A-pillar Lower Protector Assembly Fixing Screw 1.5 ± 0.5
B-pillar Lower Protector Assembly Fixing Screw 1.5 ± 0.5
Front Seat Belt Assembly Lower Fixing Bolt 50 ± 5
B-pillar Upper Protector Assembly Fixing Screw 1.5 ± 0.5
C-pillar Upper Protector Assembly Fixing Screw 3 ± 0.5
Sun Visor Assembly Fixing Screw 9±1
Sun Visor Holder B Fixing Screw 5±1
Passenger Grip Assembly Fixing Screw 4±1
Interior Front Dome Light Assembly Fixing Screw 2.5 ± 0.5
Front Floor Carpet Assembly Fixing Nut 5±1
Driver Side Foot Rest Bracket Fixing Nut 5±1
High Mounted Stop Light Assembly Fixing Screw 1.5 ± 0.5
Fuel Tank Cap Opener Assembly Fixing Screw 4±1

SLIDING ROOF
Specifications

Sliding Roof Switch Assembly Fixing Screw 1.5 ± 0.5
Sliding Roof Glass Fixing Bolt 5±1
Sliding Roof Bracket Fixing Bolt 14 ± 0.5 04

- MEMO -

MAINTENANCE
MAINTENANCE ITEMS 05-3 INSPECTION ITEMS 05-8
Maintenance Schedule Table 05-3 Off-vehicle Inspection 05-8
On-vehicle Inspection 05-8
REPLACEMENT INSTRUCTION 05-6
Engine Compartment Inspection 05-10
Repalcement Instruction Chart 05-6
Brake System Inspection 05-10
ADJUSTMENT ITEM 05-7 Power Steering System Inspection 05-11
Adjustment Item Chart 05-7 Chassis Inspection 05-12
Final Inspection 05-13
05

05

05 - MAINTENANCE
MAINTENANCE ITEMS
MAINTENANCE
Maintenance Schedule Table

The maintenance schedule table lists the vehicle maintenance items that need to be performed. Please take
your vehicle to Chery authorized service station for maintenance service according to the mileages specified
in maintenance schedule table.
Maintenance Schedule Table (Note: I = Inspect, adjust and replace as necessary; R = Replace; C = Clean L =
Lubricate);
Mileages
Maintenance Items
Every 10000 km Every 20000 km Every 30000 km
Lights, hazard lights, horn: Check operation. I I I
05
Windshield wiper and washer system: Check
I I
operation. Add washer fluid if necessary.
Check clutch free travel (for MT model): Adjust if
I I
necessary.
Cooling system: Check coolant level and lines.
I I I
Add coolant if necessary.
Engine oil: Replace R R R
Engine oil filter: Replace R R R
Engine: Check for fluid leakage (engine oil,
I I I
coolant, fuel, etc.).
A/C system: Check A/C line for leakage and
check contaminated filter element. Add I I I
refrigerant and replace filter element if necessary.
Hood hinges and lock: Lubricate L L L
Door hinges and door locks: Lubricate L L L
Window glass regulator: Check that regulator
I I I
works properly. Adjust or replace if necessary.
Sunroof: Check operation of sunroof. I I I
Air filter: Clean cover and filter element. Replace
C or R C or R C or R
if necessary.
Spark plugs: Check spark plugs. Replace if
I I
necessary.
Fuel filter: Replace R R
Exhaust system: Check for air leakage and
I I
damage.
Drive belt: Check tension. Adjust or replace if
I I
necessary.
Transmission: Check for fluid leakage and
I I
damage.
Constant velocity universal joint boot: Check for
I I
boot damage.

05 - MAINTENANCE
Mileages
Maintenance Items
Every 10000 km Every 20000 km Every 30000 km
Steering tie rod end: Check for proper clearance
I I I
and boot damage.
Steering universal joint assembly boot: Check for
I I
misalignment or damage.
Power steering system: Check power steering
fluid level and check if clearance between I I
steering gear and rack is proper.
Brake system: Check brake fluid level and check
I I I
brake system for leakage and damage.
05 Parking brake: Check the stroke. Adjust if
I I I
necessary.
Brake lining: Check thickness of brake lining.
I I I
Replace if necessary.
Underbody protection layer: Visually check
I
protection layer for damage.
Seat belt: Check seat belt for damage. I I
Toe-in and camber: Check and adjust if
I I
necessary.
Ball pin: Check clearance of ball pin. I I
Rear axle rubber bush: Check for damage. I I
Engine oil pan retaining bolts: Check bolts for
looseness. Tighten bolts to specified torque if I
necessary.
Control arm rubber boot: Check for damage. I I
Brake hoses: Check for aging or damage. I I
Brake pipes: Check for damage, corrosion and
I I
check connections for leakage.
Fuel system connections: Check connections for
I
aging, damage, abnormal looseness or abrasion.
Tires (including spare tire): Check tire tread depth
and torque of wheel bolts. Adjust tire inflation I I I
pressure if necessary.
Coupling bolts between chassis and vehicle body:
Check torque of bolts. Tighten bolts to specified I I
torque if necessary.
Wheels: Check torque. I I I
Inspection under engine idling: Check if engine
working condition, electronic injection parameter I I I
and emission are proper while idling.
Test driving: Check if mechanisms function
I I I
properly.

05 - MAINTENANCE
HINT:
 For AT model, transmission oil must be replaced after first driving 40000 km and it is unnecessary to
replace since then.
 For MT model, it is recommended to replace transmission oil every year or every 30000 km (whichever
comes first).
 It is recommended to replace brake fluid every 2 years or every 40000 km (whichever comes first).
 It is recommended to check power steering fluid every 10000 km and replace it every 2 years or every
30000 km (whichever comes first).
 It is recommended to check coolant every 10000 km. Add or replace if necessary.
 It is recommended to rotate tires every 10000 km.
 It is recommended to check four-wheel alignment every 20000 km and adjust if necessary.
 It is recommended to clean throttle valve body every 15000 km.
 It is recommended to check air filter every 10000 km. Clean or replace filter element if necessary. 05
 It is recommended to replace timing belt every 40000 km.
 The battery is maintenance-free.
CAUTION
 Depending on different surroundings and road conditions, replacing intervals may be shortened.

05 - MAINTENANCE
REPLACEMENT INSTRUCTION
Repalcement Instruction Chart
Repalcement Item See page
Wiper Blade Replacement 36-29
Air Filter Element Replacement 10-9
Fuel Filter Replacement 08-12
Engine Oil Replacement 13-10
Oil Filter Element Replacement
05 13-12
Transmission Oil Replacement 17-13
Automatic Transmission Oil Replacement 18-74
Power Steering Fluid Replacement 29-8
Coolant Replacement 12-12
Brake Fluid Replacement 26-15
Electronic Throttle Replacement 10-12
Electronic Throttle Cleaning 10-13
Spark Plug Replacement 14-10
A/C Element Replacement 30-31

05 - MAINTENANCE
ADJUSTMENT ITEM
Adjustment Item Chart
Adjustment Item See page
Front Combination Light Adjustment 35-91
05

05 - MAINTENANCE
INSPECTION ITEMS
Off-vehicle Inspection
1. Check the wheel nut.
a. Check wheel nuts for looseness or missing. Tighten if necessary.
2. Check wheel and tire (spare tire included) (See page 24-9).
3. Rotate the tires.
a. Chery recommends that you should rotate the tires every 10000 km. However, the best suitable time for
tire rotation differs depending on driver's driving habits and road conditions.
Tire rotation method (See page 24-12).
05 4. Check the wiper blade (See page 36-29).
5. Check hood and door.
a. Check the hood (See page 48-13).
b. Check the front doors (See page 48-22).
c. Check the rear doors (See page 48-29).
d. Check the luggage compartment door (See page 48-36).
On-vehicle Inspection
1. Check the seat belt.
a. Check seat belt buckle and retractor.
 Pull out seat belt quickly and repeatedly when seat belt is static. If seat belt retractor cannot lock
seat belt in one step during inspection, replace seat belt assembly.
 Engage tab on seat belt buckle, and pull seat belt by hand repeatedly to check tab engagement. If
buckle cannot lock seat belt in one step, replace seat belt assembly.
WARNING
 When checking the impacted vehicle, be sure to check seat belt system. If there is any damage or
malfunction in seat belt system, replace it.
b. Pull out seat belt and check belt for oil stains or damage. Clean or replace if necessary.
c. Replace seat belt as soon as possible if any of followings occurs.
 Seat belt is broken, torn or worn.
RA13T050010

05 - MAINTENANCE
 There is a burnt mark of cigarette butt on seat belt.
RA13T050030
 Seat belt webbing is broken.
05
RA13T050020
2. Check the horn.

a. Check that the horn operates.
3. Check the vehicle lights.
a. Check that headlights, stop lights, tail lights, turn signal lights and other vehicle lights illuminate or blink.
Furthermore, check brightness of these lights.
4. Check the windshield.
a. Check for scratches, dents or wear.
5. Check windshield wiper and washer.
a. Check that washers are aligned properly. Also, check that washer fluid sprays center of operating range
of each wiper on windshield.
b. Check wiper blades for damage. Replace wiper blades if necessary (See page 36-29).
6. Check the windshield defroster.
a. Turn on A/C defroster mode switch, and check that air outlet condition of front defroster.
b. Press rear defroster switch for a period of time, then check rear windshield heat condition.
WARNING
 DO NOT touch the heated rear windshield for a long time to prevent burns.
7. Check the rear view mirror.

a. Check that rear view mirrors are securely installed.
8. Check the sun visor.
a. Check that sun visors are securely installed and move freely.
9. Check the seat.
a. Check the front seat assembly (See page 47-7).
b. Check the rear seat assembly (See page 47-15).
10.Check the clutch pedal (See page 19-16).

05 - MAINTENANCE
11. Check the accelerator pedal.

a. Check that accelerator pedal operates smoothly. That is, check that pedal does not have uneven
resistance or does not get stuck in certain position.
Engine Compartment Inspection

1. Check the engine oil level (See page 13-7).
2. Check the engine drive belt (See page 07-20).
3. Check engine for oil leakage.
a. Turn off all electrical equipment and the ignition switch, and remove key.
b. Support and raise the vehicle.
c. Check crankshaft pulley for oil stains. If there are oil stains, check crankshaft front oil seal for leakage.
05 If leakage exists, replace front oil seal.
d. Check oil pan and drain plug for oil stains. Repair or replace related components if necessary.
e. Check transmission filler plug, drain plug and case for oil stains. Repair or replace related components
if necessary.
f. If leakage occurs on crankshaft front oil seal after repair, it may be caused by 3 reasons as follows:
 Crankshaft thrust washer wear
 Crankcase ventilation system blockage
 Excessive engine oil
4. Check the battery.
a. Check battery and battery voltage (See page 16-6).
b. Check charging voltage of charging system (See page 16-6).
5. Check the cooling system hose.
a. Check that there are no cracks, kinks, corrosion or loose connections on cooling system hose.
Brake System Inspection

1. Check the brake fluid level.
WARNING
Generally, brake fluid level will change slightly because of the wear of brake pad, but it must be kept
between "MIN" and "MAX" lines.
a. Park vehicle on a level ground.

b. Make sure there is no air in brake system and
depressing feel of brake pedal is good. Perform brake
bleeding procedures if necessary (See page 26-12).
c. Check if brake fluid level is between "MAX" and "MIN"
lines.
d. If brake fluid level drops to "MIN" line or below, add
brake fluid and check brake system for leakage.
RA13T050050
HINT:
 When brake fluid level drops near "MIN" line, it indicates that wear of brake pad may reach limit.
 After brake pad is replaced, brake fluid level should be at the upper limit between "MAX" and MIN lines.

05 - MAINTENANCE
2. Check the brake pedal (See page 26-20).

3. Check brake lines and hoses.
HINT:
Work in a well-lighted area. Turn front wheels to the rightmost or leftmost position before inspection.
a. As shown in illustration, check the entire circumferential surface of brake lines and hoses with a mirror.
Check for the following conditions:
 Damage
 Wear
 Deformation
 Cracks
 Corrosion
 Leakage 05
 Bending
 Kinks
RA13T050040
b. Check all clamps for tightness and connections for leakage.

c. Check that hoses and lines are far from sharp edges, moving parts or exhaust system.
4. Check the parking brake.
a. Check that vehicle can stop steadily on a slight grade by using parking brake.
5. Check the front disc brake assembly (See page 26-27).
6. Check the rear disc brake assembly (See page 26-37).
Power Steering System Inspection

1. Check the steering wheel free play (See page 28-7).
2. Check the steering wheel centering/returnability (See page 28-7).
3. Check the power steering fluid level (equipped with hydraulic assist steering).
a. Park vehicle on a level ground.
b. Start engine. With engine running, turn steering wheel
left or right to maximum stroke and repeat operation
several times.
c. Check if fluid in steering fluid reservoir assembly is
foamed or emulsified. Perform bleeding procedure or
replace steering fluid if necessary.
d. If fluid is normal, check if steering fluid level is
between "MIN" and "MAX" lines.
RA13T050060
e. If fluid level is above "MAX" line, drain excessive
steering fluid. If fluid level is below "MIN" line, add
steering fluid to correct level, and check power
steering system for leakage.
4. Check the ball pin assembly (See page 29-17).
5. Check steering tie rod assembly and tie rod boot (See page 29-19).

05 - MAINTENANCE
6. Check power steering system for leakage.
WARNING
Generally, leakage of hydraulic assist steering system commonly occurs on the high pressure line.
a. Turn off all electrical equipment and the ignition switch, and remove key.
b. Support and raise the vehicle.
c. Check the power steering system.
If power steering fluid is found on steering system lines or other components, check steering system for
leakage. Replace related components if necessary. Components to be checked mainly include:
05  Power steering pump assembly
 Steering fluid reservoir assembly
 Steering gear assembly
 Steering gear high pressure line
 Steering gear return line
 Steering gear suction line
Chassis Inspection
1. Check the front axle hub (See page 22-14).
2. Check control arm and control arm ball pin (See page 23-17).
3. Check the rear axle hub (See page 22-21).
4. Check stabilizer bar assembly and stabilizer bar assembly rubber support and rubber bushing (See page
23-23).
5. Check the rear coil spring assembly (See page 23-30).
6. Check the exhaust pipe.
Visually check pipes, hanger blocks and connections for serious corrosion, leakage or damage.

05 - MAINTENANCE
Final Inspection
1. Check operation of body parts.
a. Hood
 Hood support rod is normal.
 Hood locks securely when it is closed.
b. Front and rear doors
 Door locks operate properly.
 Doors close properly.
c. Luggage compartment
 Luggage compartment door lock operates properly.
 Luggage compartment door closes properly.
d. Seat
05
 Seats are adjusted easily and locked securely in any position.
 Front seatback can be locked securely in any position.
 Rear seatbacks can be locked securely after folded down.
2. Be sure to deliver a clean vehicle. Focus on the following items:
 Steering wheel
 Shift lever
 All switch knobs
 Door handles
 Seats

- MEMO -

SQRD4G15B ENGINE MANAGEMENT
SYSTEM
GENERAL INFORMATION 06-3 P0121-14 06-74
Description 06-3 P0221-12 06-74
System Function 06-4 P0221-14 06-74
Precautions 06-5 P0130-23 06-81
Specifications 06-6 P0130-24 06-81
Tools 06-6 P0133-62 06-81
ECM Terminal Definition 06-8 P0136-23 06-87
Circuit Diagram 06-10 P0136-24 06-87
P0139-62 06-87
DIAGNOSIS & TESTING 06-19
P1654-62 06-93 06
Diagnostic Help 06-19
P1655-94 06-93
Intermittent DTC Troubleshooting 06-19
P1656-94 06-93
Ground Inspection 06-19
P1657-77 06-93
Throttle Self-learning 06-20
P1658-77 06-93
Flywheel Self-learning 06-20
P1659-92 06-93
Operations for Replacing New ECM 06-20
P1660-77 06-93
Diagnostic Trouble Code (DTC) Chart 06-21
P0120-12 06-99
ECM Power Supply Circuit & Ground 
P0120-14 06-99
Circuit Testing 06-26
P0220-12 06-99
P0135-12 06-34
P0220-14 06-99
P0135-14 06-34
P0351-12 06-105
P0132-12 06-34
P0351-14 06-105
P0053-1E 06-34
P0335-62 06-111
P0138-12 06-41
P0325-12 06-116
P0141-12 06-41
P1652-12 06-116
P0141-14 06-41
P1652-11 06-116
P0054-1E 06-41
P1652-49 06-116
P0201-11 06-48
P1652-64 06-116
P0201-12 06-48
P0340-11 06-121
P0201-13 06-48
P0340-15 06-121
P0105-12 06-54
P0340-62 06-121
P0105-14 06-54
P0016-76 06-121
P0106-26 06-54
P0420-62 06-128
P0106-27 06-54
P0443-11 06-130
P0101-62 06-54
P0443-12 06-130
P1663-62 06-54
P0443-13 06-130
P0110-11 06-61
P0481-13 06-136
P0110-15 06-61
P0480-13 06-136
P0110-3A 06-61
P0480-11 06-136
P0111-62 06-61
P0480-12 06-136
P0115-11 06-67
P0481-11 06-136
P0115-15 06-67
P0481-12 06-136
P0115-3A 06-67
P0560-16 06-144
P0116-62 06-67
P0560-17 06-144
P0121-12 06-74
P0645-13 06-150

P0645-11 06-150 Installation 06-235
P0645-12 06-150 Oxygen Sensor 06-236
P0504-13 06-156 Description 06-236
P0504-62 06-156 Operation 06-236
P0504-67 06-156 Upstream Oxygen Sensor 06-236
P0504-86 06-156 Downstream Oxygen Sensor 06-236
P0604-62 06-163 Removal & Installation - 
P0605-41 06-163 Upstream Oxygen Sensor 06-236
P0605-49 06-163 Removal & Installation - 
P1610-51 06-165 Downstream Oxygen Sensor 06-236
P1616-81 06-165 Camshaft Position Sensor 06-237
P1617-87 06-165 Description 06-237
P1618-87 06-165 Operation 06-237
P1614-86 06-165 Removal 06-237
06 U0129-87 06-170 Installation 06-237
U0101-87 06-173 Engine Speed Sensor 06-238
P0403-11 06-176 Description 06-238
P0403-12 06-176 Operation 06-238
P0403-13 06-176 Removal 06-238
P0403-61 06-176 Installation 06-238
P0409-12 06-183 Intake Pressure/Temperature Sensor 06-239
P0409-14 06-183 Description 06-239
P1600-11 06-189 Operation 06-239
P1600-12 06-189 Removal 06-239
P1600-13 06-189 Installation 06-239
P0010-11 06-195 Ignition Coil 06-240
P0010-12 06-195 Description 06-240
P0010-13 06-195 Operation 06-240
P0010-14 06-195 Removal & Installation 06-240
P0704-23 06-201 Electronic Accelerator Pedal Sensor 06-241
P0704-24 06-201 Description 06-241
Engine Problem Symptom Diagnosis 06-206 Operation 06-241
Diagnostic Help 06-206 Removal & Installation 06-241
Problem Symptoms Table 06-206 Electric Fuel Pump 06-242
Description 06-242
ON-VEHICLE SERVICE 06-233 Operation 06-242
VVT Control Valve 06-233 Removal & Installation 06-242
Description 06-233 Fuel Injector 06-243
Operation 06-233 Description 06-243
Removal 06-233 Operation 06-243
Installation 06-233 Removal & Installation 06-243
Coolant Temperature Sensor 06-234 Canister Solenoid Valve 06-244
Description 06-234 Description 06-244
Operation 06-234 Operation 06-244
Removal 06-234 Removal & Installation 06-244
Installation 06-234 Engine Control Module (ECM) 06-245
Knock Sensor 06-235 Description 06-245
Description 06-235 Operation 06-245
Operation 06-235 Removal 06-245
Removal 06-235 Installation 06-245

06 - SQRD4G15B ENGINE MANAGEMENT SYSTEM
GENERAL INFORMATION
Description
Engine of A13T model adopts Marelli engine management system. This system mainly consists of Engine
Control Module (ECM), sensors and actuators, which controls intake air amount, injection volume and ignition
timing, etc. when engine is operating.
In the engine management system, sensors are used as the input part to measure various physical signals
(temperature and pressure, etc.), and converts them into corresponding electrical signals; the function of ECM
is to receive the input signals from sensors and perform calculation according to set procedure, producing
corresponding control signals and outputting them to power drive circuit. The power drive circuit drives each
actuator to perform various actions, thus making the engine run according to the preset program.
Also, the trouble diagnosis system of ECM monitors each component and control function in this system.
Once detecting and confirming a fault, it will store the trouble code and recall "Limp Home" function. When
detecting that fault has been eliminated, it will return to use normal value. 06
Basic Components of Engine Management System
11
4 11
80
60 100
40
34
120
20 140
0
160
3
9
29 30 31
24 35
37
6
19 13
22
8
36 7
25 26
5 12
20
14 27
2 17
10 15
22 18
16
RA13T060000

1 - Engine Control Unit 2 - Speed Sensor

3 - Intake Pressure/Temperature Sensor 4 - Electronic Throttle Body
5 - Injector 6 - Ignition Coil
7 - Coolant Temperature Sensor 8 - Camshaft Position Sensor
9 - Throttle Position Sensor 10 - Electronic Accelerator Pedal
11 - Oil Rail 12 - Knock Sensor
13 - Canister Solenoid Valve 14 - Canister
15 - Fuel Tank Cap 16 - Fuel Tank
17 - Fuel Seal Cover 18 - Fuel Pump
19 - Upstream Oxygen Sensor 20 - Precatalytic Converter
21 - Downstream Oxygen Sensor 22 - Air Filter
06
23 - EGR Valve 24 - OBD Diagnostic Interface
25 - Brake Switch 26 - A/C Compressor Relay
27 - A/C Compressor 28 - Battery
29 - Instrument Cluster Fuel Level Indictor 30 - Warning Light
31 - Engine Tachometer 32 - Fuse
33 - VVT Driver 34 - Ignition Switch
System Function
 Calculate air flow
ECM calculates air flow entering the cylinder by signals from intake pressure/temperature sensor, and then
adjusts injection volume to make air-fuel ratio meet the requirements of various operating conditions.
 Measure crankshaft position and engine speed
ECM determines the crankshaft position and engine speed according to signals from crankshaft position
sensor, and accurately controls the engine ignition and injection timing.
 Determine operating sequence of cylinders
ECM recognizes the top dead center of No.1 cylinder by camshaft position sensor, so as to determine the
operating sequence of cylinders.
 Fuel control
There are two modes of fuel control: closed-loop fuel control and open-loop fuel control. Closed-loop fuel
control can accurately regulate the air-fuel ratio of engine, thus effectively controlling emissions. Open-
loop fuel control is applied when engine is starting or warming up and when oxygen sensor is
malfunctioning.
 Ignition control
Ignition control system of this engine adopts group control.
 Knock control
When a knocking is detected by knock sensor, system will calculate the ignition advance angle that needs
to be delayed or advanced according to current operating conditions and knock intensity and adjust the
ignition angle, thus avoiding or reducing knocking.
 Emission control
Three-way catalytic converter can convert engine exhaust gas into harmless gas and discharge it into
atmosphere. When engine temperature becomes normal after warming up, ECM will activate closed-loop
fuel control to correct the air-fuel ratio, thus realizing the optimum conversion efficiency of three-way
catalytic converter.

 Three-way catalytic converter protection

Engine management system has the function to protect three-way catalytic converter. ECM estimates the
three-way catalytic converter temperature according to engine operating conditions. When it is estimated
that exhaust temperature will exceed the converter's maximum permissible temperature for a long time,
ECM will automatically activate the protection function of three-way catalytic converter to keep the
temperature normal.
 System voltage protection
When system voltage becomes extremely high due to charging system malfunction, engine management
system will activate the protection program to limit engine speed, thus avoiding damage to ECM and
battery.
Precautions
General service requirements
 Only digital multimeter can be used to perform inspection for engine management system.
 Use genuine components to perform service work, otherwise appropriate engine management system
06
operation cannot be guaranteed.
 Only use unleaded gasoline during servicing.
 Please observe normative service and diagnostic flowchart to perform service work.
 Never disassemble components of engine management system during servicing.
 When holding electronic elements (ECM and sensor etc.) during servicing, take extra care not to drop
them on the ground.
 Set up a consciousness of environmental protection and dispose of the waste effectively that is produced
during servicing.
Precautions during servicing

1. Do not causally remove any engine management system component or its connector from its installation
position to prevent damaging accidentally, or foreign matter, such as moisture, oil from entering
connectors, which will affect the normal operation of engine management system.
2. Be sure to turn ignition switch off when disconnecting and connecting connectors. Otherwise electronic
elements may be damaged.
3. When simulating hot operating condition of malfunction and performing other service work that may cause
temperature to rise, never allow ECM temperature to exceed 80°C.
4. As the supplying pressure of fuel system is high (approximately 400 kPa), all fuel pipes are high pressure
resistant pipe. Fuel pressure in fuel lines is still high even when engine is not running. Therefore, be careful
not to casually remove fuel pipes during servicing; when it is necessary to service fuel system, discharge
pressure in the fuel system before removing fuel pipes. The way to discharge pressure is as follows:
 Remove fuel pump relay, start engine and idle it until the engine stops running by itself. Then try to start
engine 2 - 3 times to ensure fuel pressure is discharged completely. Removal of fuel pipes and
replacement of fuel filter should be performed in a well-ventilated area by professional service men.
5. Do not energize electric fuel pump when removing it from fuel tank to prevent electric sparks, which will
cause a fire.
6. Running test for fuel pump is prohibited when it is empty or in water; otherwise it will shorten the service
life. Never connect the positive and negative of fuel pump in reverse.
7. When checking ignition system, only perform spark jump test when it is necessary and duration should be
shortened as much as possible. Do not open throttle during test; otherwise a large amount of unburned
gasoline will enter the exhaust pipe, causing damage to the three-way catalytic converter.
8. Do not connect battery with its polarity reversed to prevent damage to electronic elements. This system
adopts negative ground.
9. Never remove battery cable when engine is running.
10.The positive, negative battery cables and ECM must be removed before performing welding on vehicle.

11. Do not puncture wire outer coat to detect electric signals input and output by components.
Specifications

Coolant Temperature Sensor 14 ± 1
Knock Sensor Fixing Bolt 20 ± 5
Engine Speed Sensor Fixing Bolt 8±2
Camshaft Position Sensor Fixing Bolt 8±1
06 VVT Control Valve Fixing Bolt 8±2

ECM Fixing Bolt 7±1
Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tools
X-431 3G Fuel Injector Cleaning Analyzer
RCH0000062
Ignition Timing Light
RCH0000016

Digital Multimeter
RCH0000002
06
RCH0000044
Fuel Pressure Gauge
RCH0000048
ESC
NO
1 2 3 4 5
6 7 8 9 0
RCH0000061

ECM Terminal Definition

ECM Connector A
Terminal No. Definition Terminal No. Definition

Electronic Accelerator Pedal 2
A1 A29 Cruise Switch Ground
Sensor
A2 - A30
Power
A3 Cruise Switch Signal A31 -
A4 A/C Middle Pressure Switch A32 -
A5 Brake Switch 2 A33 -
A6 A/C Switch A34 Thermostat
06
A7 Starter Relay Control A35 -
A8 - A36 -
A9 - A37 -
A10 - A38 Sensor Ground
A11 CAN1-H A39 Sensor Ground
A12 - A40
Ground
A13 A41 -
Sensor
A14 - A42 Main Relay Coil
A15 - A43 Low-speed Fan
A16 Clutch Pedal Switch A44 A/C Compressor Relay
A17 Brake Switch 1 A45 Fuel Pump Relay
A18 - A46 High-speed Fan
A19 - A47 -
A20 - A48 -
A21 Ground A49 Upstream Oxygen Sensor Heating
Downstream Oxygen Sensor
A22 Ignition Switch (ON) A50
Heating
A23 CAN1-L A51 -
A24 - A52 Ground 1
A25 Ignition Switch (Start) A53 Ground 2
A26 Upstream Oxygen Sensor A54 Battery Power Supply
A27 Downstream Oxygen Sensor A55 Noncontinuous Power Supply
A28 A56 Noncontinuous Power Supply
Ground

ECM Connector B

B1 - B29 EGR Sensor Power
B2 - B30 Throttle Position Sensor (+)
B3 Power Steering Pump B31 Throttle Position Sensor (-)
Coolant Temperature Sensor
B4 B32 EGR Sensor Ground
Ground
B5 Knock Sensor (+) B33 Sensor Ground
B6 Throttle Position Sensor 2 B34 -
B7 Intake Temperature Sensor Signal B35 Injector 3
B8 EGR Sensor Signal B36 Injector 1
06
B9 - B37 -
B10 - B38 Variable Camshaft Timing
B11 - B39 Ignition Coil Drive
B12 Engine Speed Sensor B40 Engine Speed Sensor (+)
B13 Camshaft Position Sensor B41 Camshaft Position Sensor (+)
B14 - B42 -
B15 A/C High/Low Pressure Switch B43 -
B16 Camshaft Position Sensor (-) B44 -
B17 Knock Sensor (-) B45 -
B18 Throttle Position Sensor 1 B46 -
B19 Intake Pressure Sensor Signal B47 Injector 4
B20 - B48 Injector 2
B21 Coolant Temperature Sensor Signal B49 -
B22 - B50 Alternator
B23 - B51 Throttle Actuator (-)
B24 Engine Speed Sensor (-) B52 Throttle Actuator (+)
B25 - B53 Ignition Coil 4
B26 EGR Valve Control B54 Ignition Coil 3
B27 - B55 Ignition Coil 2
B28 Intake Pressure Sensor Power B56 Ignition Coil 1

Circuit Diagram
Engine Management System (Page 1 of 9)
BATTERY
86 30
ECM
MAIN
RELAY
EF26 EF22 85 87
06 10A 10A B
ENGINE
COMPARTMENT
FUSE AND
EF37 EF13 RELAY BOX
10A 15A E-067
75 20 115 45
R
RG
R
1 4 DOWN- 1 4
UPSTREAM
RG
RG
STREAM
R
OXYGEN OXYGEN
SENSOR SENSOR
E-037
2 3 E-038 2 3
RW
RG
BR
YB
BY
BY
A54 A42 A55 A56 A39 A27 A50 A38 A26 A49
ECM(A)
E-041
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25 E-037
B
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13 4 3 2 1
E-038
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B
E-041
B
EA13T060010

A A
B B
ENGINE
EF14 COMPARTMENT
15A FUSE AND
RELAY BOX
E-067
46
RB
E-035
7
E-007
06
RB
RB
RB
RB
1 1 1 1
CYL 1 CYL 2 CYL 3 CYL 4
IGNITION IGNITION IGNITION IGNITION

COIL 1 COIL 2 COIL 3 COIL 4
E-023 E-014 E-013 E-012
2 3 2 3 2 3 2 3
RG
RY
Gr
B
Br
B
E-022
B56 B54 B55 B53
ECM(B)
E-001
1 2 3 4 5 6
7 8 9 10 11 12
B56 B55 B54 B53 B52 B51 B50 B49
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37 E-007
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25 B
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
1 2 3
E-023 E-014
B B
E-001 E-013 E-012
B B B
EA13T060020

A A
B B
ENGINE
EF35 COMPARTMENT
FUSE AND
15A
RELAY BOX
E-067
93
RB
06 6
E-035
E-007
RB
RB
RB
RB
1 1 1 4
VARIABLE CANISTER EXHAUST GAS
THERMOSTAT CAMSHAFT SOLENOID + + - RECIRCULATION
E-036 TIMING VALVE VALVE
E-020 E-015 - E-002
2 2 2
6 1 3 2
WG
WG
RG
BG
BL
BL
G
A34 B38 B50 B26 B29 B08 B32
ECM(A)
E-041
ECM(B)
E-001
A56 A55 A54 A53 A52 A51 A50 A49 B56 B55 B54 B53 B52 B51 B50 B49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37 B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25 B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13 B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
E-041 E-001
B B
1 2 3 4 5 6 E-007 E-002
1 2 3 2 1 1 2
7 8 9 10 11 12 B B
2 1
4 5 6
E-036
E-020 E-015 Gr
B B
EA13T060030

A A
B B
EF30
10A
86 30
A/C EF38 ENGINE
CLUTCH COMPARTMENT
15A
RELAY FUSE AND
RELAY BOX
85 87 E-067
98 99 RG 116
06
R
E-035
8 12
E-007
R
1
RG
RG
RG
RG
RG
A/C
COMPRESSOR
1 1 1 1
CLUTCH
E-018 INJEC- INJEC- INJEC- INJEC-
2 TOR 1 TOR 2 TOR 3 TOR 4
B
E-024 E-011 E-010 E-009

2 2 2 2
GW
E-005
GY
GB
GL
A44 B36 B48 B35 B47

ECM(A)
E-041
ECM(B)
E-001
E-041 E-001
B B
1 2 3 4 5 6
E-007 E-018 E-024 E-011 E-010 E-009
7 8 9 10 11 12 B 2 1 B 1 2 B B B B
EA13T060040

A A
MF02 MF03 EF31

40A 50A 15A
86 30 86 30 86 30
FAN FAN FUEL ENGINE
LOW HIGH PUMP COMPARTMENT
RELAY 2 RELAY 1 RELAY FUSE AND
RELAY BOX
85 87 85 87 85 87 E-067
E-064
E-065
06 138 135 121 120 102 103
RY
Br
R
P
E-026
5 B-015
2
RY
3
M COOLING WL
FAN MOTOR 3
E-045
FUEL PUMP MOTOR &
1 M FUEL LEVEL SENSOR
B-008
B
4
B
E-066 B-009
A43 A46 A45
ECM(A)
E-041
E-045
3 2 1 B
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13 1 2 3 4 5 6 7 8 B-015
9 10 11 12 13 14 15 16 W
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
B-008
1 2 3 4 B
E-041
B
EA13T060050

IGNITION SWITCH
ON OR START
A
ENGINE
EF24 EF07 EF08 COMPARTMENT
15A 15A 10A FUSE AND
RELAY BOX
E-067
73 RW 39 40
RB
R
E-030 11 6 E-029
I-036 I-035
RW
RW
06
RW
R
RB
1 4 3 1
TO IGNITION
BRAKE
SWITCH (START)
SWITCH PRESSURE
TO TCU SWITCH
RW
I-013
E-055 TO STARTER
RELAY
3 2 4 2
TO A/C SWITCH
BR
L
I-018 I-036 E-035

2
E-054 1 12 E-030 E-007
BW
GR
LR
LR
BR
L
A17 A5 A22 A4 B15 A6 A7 A25

ECM(A)
E-041
ECM(B)
E-001
E-041 E-001 1
B B 4 3 E-055
2
Gr
1 2 3 4 5 6
7 8 9 10 11 12 1
9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 1 2 3 4 4 2
18 17 16 15 14 13 12 11 10 3
9 10 11 12 13 14 15 16 5 6 7 8 9 10
I-013
B
E-007 I-036 I-035 I-018
B B W W EA13T060060

ECM(A)
E-041
CAN L1 CAN H1
A16 A32 A13 A40 A30 A1 A28 A21 A3 A29 A52 A53 A23 A11
LY
LY
G
Y
WR
GY
LW
YR
RB
RY
LY
B
Br
L
06 10 9 3 10 6 4 5 7 16 E-030
I-036
TO CAN
WR
GY
LW
YR
RB
RY
LY
Br
SYSTEM
L
B
1 6 4 5 3 1 2 3 4
CLOCK E-043
Cruise SW ground1
Cruise SW input
CLUTCH SPRING
ON SWITCH I-031
I-009
OFF
2000
680
ELECTRONIC
2 ACCELERATOR
PEDAL
ON/OFF
B
I-012
SET/+
SET/-
I-005
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
1 2
A56 A55 A54 A53 A52 A51 A50 A49 I-009 I-036
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37 B B
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
8 7 6 5 4 3 2 1
1 2 3 4 5 6 16 15 14 13 12 11 10 9
I-012 I-031
B W
E-041
B
EA13T060070

ENGINE
SPEED
KNOCK SENSOR
SENSOR ELECTRONIC THROTTLE E-008 E-039
E-021
N
M S
2 3
3 5 2 1 6 4 1 2 3
06
RGr
RBr
YW
RG
YR
RB
YR
RY
YB
YB
RL
E-007
1 3 4 E-035
YW
YR
YB
B17 B5 B52 B51 B30 B18 B31 B6 B12 B24 B40
ECM(B)
E-001
1 2 3 4 5 6
7 8 9 10 11 12
B56 B55 B54 B53 B52 B51 B50 B49
1 2 3
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25

E-021 E-007
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13 B B
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
2 4 6
1 3 5
3 2 1
E-001
B E-039 E-008
B B
EA13T060080

ECM(B)
E-001
B3 B4 B21 B41 B16 B13 B28 B19 B7 B33
BW
BW
LW
LW
LG
LR
LB
Gr
Gr
Br
06
1 2 1 3 2 1 3 4 2 1
POWER
STEERING
ON PUMP
E-019 COOLANT
OFF
TEMPERATURE
SENSOR CAMSHAFT
E-006 POSITION
B
SENSOR INTAKE PRESSURE/

E-003
TEMPERATURE SENSOR
E-025
1 2
B56 B55 B54 B53 B52 B51 B50 B49
3 2 1
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25

E-006 E-003
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13 B B
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
1 1 2 3 4
E-019 E-025
B B
E-001
B
EA13T060090

DIAGNOSIS & TESTING

Diagnostic Help
1. Connect X-431 3G Diagnostic tester (the latest software) to Data Link Connector (DLC), and make it
communicate with vehicle electronic module through data network.
2. Confirm that malfunction is current, and carry out diagnostic test and repair procedures.
3. If DTC cannot be deleted, the malfunction is current.
4. Only use a digital multimeter to measure voltage of electronic system.
5. Refer to any Technical Bulletin that may apply to the malfunction.
6. Visually check the related wire harness.
7. Check and clean all Engine Control Module (ECM) ground points related to current DTC.
8. If multiple trouble codes were set, refer to circuit diagrams to look for any common ground circuit or power
supply circuit applied to DTC. 06
Intermittent DTC Troubleshooting
If malfunction is intermittent, perform the following:
 Check if connectors are loose.
 Check if wire harnesses are worn, pierced, pinched or partially broken.
 Monitor X-431 3G diagnostic tester (the latest software) data that is related to this circuit.
 Wiggle related wire harnesses and connectors and observe if related circuit signal is interrupted.
 If possible, try to duplicate the conditions under which DTC was set.
 Look for data that has changed or DTC to reset during wiggle test.
 Look for broken, bent, protruded or corroded terminals.
 Inspect sensors and mounting areas for damage, foreign matter, etc. that will cause incorrect signals.
 Use data recorder and/or oscilloscope to help diagnose intermittent malfunctions.
 Remove the Engine Control Module (ECM) from malfunctioning vehicle and install it to a new vehicle to
perform a test. If DTC cannot be cleared, ECM is malfunctioning. If DTC can be cleared, reinstall ECM to
original vehicle.
Ground Inspection
Ground points are very important to the proper operation of circuits. Ground points are often exposed to
moisture, dirt or other corrosive areas. Corrosion (rust) can increase resistance which will change the way in
which a circuit works.
Electrical control circuits are very sensitive to proper grounding. A loose or corroded ground point can
seriously affect control circuit. Check ground points as follows:
1. Remove ground bolt or nut.
2. Check all contact surfaces for tarnish, dirt and rust, etc.
3. Clean as necessary to ensure that contacting is in good condition.
4. Reinstall ground bolt or nut securely.
5. Check if add-on accessories interfere with ground circuit.
6. If several wire harnesses are crimped into one ground terminal, check if they are installed correctly. Make
sure that all wires are clean, securely fastened and good contacted without crimping any excessive
insulation coat.

Throttle Self-learning
Perform throttle self-learning in the following conditions:
 Battery is removed and negative battery cable is disconnected.
 ECM is replaced.
 ECM is disconnected and reconnected.
 Throttle is replaced or cleaned.
Throttle self-learning conditions:
 100.5°C > coolant temperature > 80°C
 Engine speed not more than 250 rpm
 Vehicle speed = 0 km/h
 Battery voltage 9 V ~ 15.2 V
Throttle self-learning procedures:
Start engine for 3 times to finish self-learning. Then start vehicle and observe if it operates normally.
06
Flywheel Self-learning
Flywheel self-learning conditions:
Flywheel self-learning procedure:
Depress accelerator pedal continuously and rapidly to 4500 rpm for 3 times.
Operations for Replacing New ECM

1. Engine immobilizer match (if equipped).
2. Clutch switch position learning for MT model (unlearning starter not opearte).
Method: Fully depress clutch pedal, then release it, which can allow ECM receive a complete clutch switch
signal.
3. Brake switch position learning for AT model (unlearning starter not opearte).
Method: Fully depress brake pedal, then release it, which can allow ECU receive a complete brake switch
signal.
4. Throttle self-learning.
5. Flywheel self-learning.

Diagnostic Trouble Code (DTC) Chart

P0009-62 VVT Parking Position Signal Compare Failure
P0010-11 VVT Driver Circuit Short to Ground
P0010-12 VVT Driver Circuit Short to Battery
P0010-13 VVT Driver Circuit Open
P0010-14 VVT Driver Circuit Short to Ground or Open
P0011-61 VVT Error Position Signal Calculation Failure
P0012-65 EVELVVT - Variator Speed Diagnosis Signal Has Too Few Transitions/Events
P0012-66 EVELVVT - Variator Speed Diagnosis Signal Has Too Many Transitions/Events
P0016-76 Crankshaft Position - Camshaft Position Correlation Bank 1 Sensor A
P0053-1E
Upstream Lambda Sonde Resistor (Functional Test) Circuit Resistance Out of 06
Range
Downstream Lambda Sonde Resistor (Functional Test) Circuit Resistance Out of
P0054-1E
Range
P0101-62 Air Intake Manifold Signal Compare Failure
P0105-12 Intake Manifold Pressure Sensor (Electric) Circuit Short to Battery
P0105-14 Intake Manifold Pressure Sensor (Electric) Circuit Short to Ground or Open
P0106-26 Air Pressure Sensor (Functional) Signal Rate of Change Below Threshold
P0106-27 Air Pressure Sensor (Functional) Signal Rate of Change Above Threshold
P0110-11 Air Temperature Sensor Circuit Short to Ground
P0110-15 Air Temperature Sensor Circuit Short to Battery or Open
P0110-3A Air Temperature Sensor Signal Has Too Many Pulses
P0111-62 Air Temperature Sensor (Functional) Signal Compare Failure
P0115-11 Water temperature sensor Circuit Short to Ground
P0115-15 Water Temperature Sensor Circuit Short to Battery or Open
P0115-3A Water Temperature Sensor Signal Has Too Many Pulses
P0116-62 Water Temperature Sensor (Functional) Signal Compare Failure
P0120-12 Pedal Ootentiometer 1 Circuit Short to Battery
P0120-14 Pedal Potentiometer 1 Circuit Short to Ground or Open
P0121-12 Throttle Potentiometer 1 Circuit Short to Battery
P0121-14 Throttle Potentiometer 1 Circuit Short to Ground or Open
P0130-24 Functional Test Lambda Sensor 1 Signal Stuck High
P0132-12 Electric Test Lambda Sensor 1 Circuit Short to Battery
P0133-62 First Probe Diagnosis Signal Compare Failure
P0135-12 Lambda Sensor1 Heater Driver Circuit Short to Battery
P0135-14 Lambda Sensor1 Heater Driver Circuit Short to Ground or Open
P0136-23 Functional Test Lambda Sensor 2 Signal Stuck Low
P0136-24 Functional Test Lambda Sensor 2 Signal Stuck High

P0139-62 DO2V Signal Compare Failure

P0141-12 Lambda Sensor2 Heater Driver Circuit Short to Battery
P0141-14 Lambda Sensor2 Heater Driver Circuit Short to Ground or Open
P0170-25 Frequency Diagnosis Signal Shape/Waveform Failure
P0171-62 DFSL - Lean Diagnosis Signal Compare Failure
P0171-64 DFSL - Lean Diagnosis Signal Plausibility Failure
P0171-67 DFSL - Lean Diagnosis Signal Incorrect After Event
P0172-62 Rich Diagnosis Signal Compare Failure
P0172-64 Rich Diagnosis Signal Plausibility Failure
P0172-67 Rich Diagnosis Signal Incorrect After Event
P0201-11 Injector 1 Driver Circuit Short to Ground
06
P0201-12 Injector 1 Driver Circuit Short to Battery
P0201-13 Injector 1 Driver Circuit Open
P0219-68 OSP-Engine Over Speed Event Information
P0220-12 Pedal Ootentiometer 2 Circuit Short to Battery
P0220-14 Pedal Potentiometer 2 Circuit Short to Ground or Open
P0230-11 Relay High Side Circuit Short to Ground
P0230-15 Relay High Side Circuit Short to Battery or Open
P0230-12 Relay High Side Circuit Short to Battery
P0230-13 Relay High Side Circuit Open
P023D-26 AIRC-Aircomponent Signal Rate of Change Below Threshold
P023D-27 AIRC-Aircomponent Signal Rate of Change Above Threshold
P0300-92 DM10 - 1000 Turn Misfire Diagnosis Performance or Incorrect Operation
P0300-98 DM20 - 200 Turn Misfire Diagnosis Component or System Over Temperature

P0325-12 Knock Sensor (Engine-Run) Circuit Short to Battery
P0335-62 Engine Speed Sensor Signal Compare Failure
P0340-11 Cam-shaft Sensor Circuit Short to Ground
P0340-15 Cam-shaft Sensor Circuit Short to Battery or Open
P0340-62 Cam-shaft Sensor Signal Compare Failure
P0351-12 Ignition 1 Driver Circuit Short to Battery
P0351-14 Ignition 1 Driver Circuit Short to Ground or Open
06
P0403-11 EGR Control Circuit Short to Ground
P0403-12 EGR Control Circuit Short to Battery
P0403-13 EGR Control Circuit Open
P0403-61 EGR Control Circuit Signal Calculation Failure
P0409-12 EGR Sensor Circuit Short to Battery
P0409-14 EGR Sensor Circuit Short to Ground or Open
P0420-62 Catalizer Diagnosis Signal Compare Failure
P0441-72 DNPG Actuator Stuck Open
P0443-11 Canister Purge Driver Circuit Short to Ground
P0443-12 Canister Purge Driver Circuit Short to Battery
P0443-13 Canister Purge Driver Circuit Open
P0480-11 Cooling Fan Driver 1 (Low) Circuit Short to Ground
P0480-12 Cooling Fan Driver 1 (Low) Circuit Short to Battery
P0480-13 Cooling Fan Driver 1 (Low) Circuit Open
P0481-11 Cooling Fan Driver 2 (High) Circuit Short to Ground
P0481-12 Cooling Fan Driver 2 (High) Circuit Short to Battery
P0481-13 Cooling Fan Driver 2 (High) Circuit Open
P0500-64 VEV-Vehicle Speed Sensor Signal Plausibility Failure
P0500-68 VEV-Vehicle Speed Sensor Event Information
P0504-13 Brake Signal Circuit Open
P0504-62 Brake Signal Compare Failure
P0504-67 Brake Signal Incorrect After Event

P0504-86 Brake Signal Invalid

P0560-16 ECU Power Supply Circuit Voltage Below Threshold
P0560-17 ECU Power Supply Circuit Voltage Above Threshold
P0576-62 CCANOM-Cruise Control Disabled for High Deceleration Signal Compare Failure
P0579-62 CRCAN-Cruise Control Disabled for High Acceleration Signal Compare Failure
P0601-44 EEPROM Memory Data Memory Failure
P0604-62 RAM Memory Signal Compare Failure
P0605-41 ROM (EPROM) Memory General Checksum Failure
P0605-49 ROM (EPROM) Memory Internal Electronic Failure
P0606-47 E.C.U. (Microprocessor) Watchdog/Safety uC Failure
P0606-92 E.C.U. (Microprocessor) Performance or Incorrect Operation
06
P060B-49 A/D Converter Internal Electronic Failure
P060C-62 SAFSE-Stop Engine for Safety Signal Compare Failure
P0615-11 Starter Relay Circuit Short to Ground
P0615-15 Starter Relay Circuit Short to Battery or Open
P0638-11 DC Motor Command Circuit Short to Ground
P0638-12 DC Motor Command Circuit Short to Battery
P0638-13 DC Motor Command Circuit Open
P0638-61 DC Motor Command Signal Calculation Failure
P0641-49 SSPLY - Sensor Supply 1 Internal Electronic Failure
P0645-11 Air Conditioner 1 (Relay I/O) Circuit Short to Ground
P0645-12 Air Conditioner 1 (Relay I/O) Circuit Short to Battery
P0645-13 Air Conditioner 1 (Relay I/O) Circuit Open
P0651-49 SSPLY - Sensor Supply 2 Internal Electronic Failure
P0657-16 Main Relay Circuit Voltage Below Threshold
P0657-17 Main Relay Circuit Voltage Above Threshold
P0685-11 Fuel Pump Relay Driver Circuit Short to Ground
P0685-12 Fuel Pump Relay Driver Circuit Short to Battery
P0685-13 Fuel Pump Relay Driver Circuit Open
P0697-49 Sensor Supply 3 Internal Electronic Failure
P0700-62 Engine Stop Request by Selespeed Signal Compare Failure
P0704-23 Clutch Switch Signal Stuck Low
P0704-24 Clutch Switch Signal Stuck High
P1300-55 Flywheel Self Learning Not Configured
P1430-11 A/C Defrost Temperature Diagnosis Circuit Short to Ground
P1430-15 A/C Defrost Temperature Diagnosis Circuit Short to Battery or Open
P1430-3A A/C Defrost Temperature Diagnosis Signal Has Too Many Pulses
P1600-11 Thermostat Circuit Short to Ground

P1600-12 Thermostat Circuit Short to Battery

P1600-13 Thermostat Circuit Open
P1601-23 CC_BUTTON Cruise Control Button Signal Stuck Low
P1610-51 Immo Secret Key and Security Code Not Programmed Not Programmed
P1614-86 Immo Transferred Transponder Authentication is Failed Signal Invalid
P1616-81 IMMO Authentication Fail Invalid Serial Data Received
P1617-87 IMMO Authentication Message not Received Missing Message
P1618-87 Fail to Write EOL Immobilizer Data into EEProm Missing Message
P1619-51 ECM Not Programmed (Virgin State) Not Programmed
P1666-54 EGR Selflearning Mechanical Fault Missing Calibration
P1652-12 Knock Sensor; Key on Diagnosis Circuit Short to Battery
06
P1652-11 Knock Sensor; Key on Diagnosis Circuit Short to Ground
P1652-49 Knock Sensor; Key on Diagnosis Internal Electronic Failure
P1652-64 Knock Sensor; Key on Diagnosis Signal Plausibility Failure
P1653-62 Pedal Potentiometer Congruence Signal Compare Failure
P1654-62 Throttle Potentiometer Congruence Signal Compare Failure
P1655-94 Self Learning Throttle bat Unexpected Operation
P1656-94 Self Learning Throttle slc Unexpected Operation
P1657-77 Self Learning Throttle lhp Commanded Position not Reachable
P1658-77 Self Learning Throttle trc Commanded Position not Reachable
P1659-92 Self Learning Throttle mtc Performance or Incorrect Operation
P1660-77 Self Learning Throttle tro Commanded Position not Reachable
P1661-61 Throttle Control Error Position Signal Calculation Failure
P1663-62 Low Air Manifold Pressure (Functional) Signal Compare Failure
P1667-16 Puntual ECS Fdbk Current Fault Circuit Voltage Below Threshold
P1667-17 Puntual ECS Fdbk Current Fault Circuit Voltage Above Threshold
P2227-62 Plausibility MAP at Key On Signal Compare Failure
O2 Sensor Reference Voltage Performance (Bank 1 Sensor 1) Performance or
P2244-92
Incorrect Operation
P2299-62 Gas & Brake Pedal Coherence Signal Compare Failure

ECM Power Supply Circuit & Ground Circuit Testing

Power Supply Circuit
BATTERY IGNITION SWITCH

ON OR START
86 30
ECM EF07
MAIN 15A
RELAY
EF26 EF22 85 87
06 10A 10A B
ENGINE
COMPARTMENT
FUSE AND
EF37 RELAY BOX
10A E-067
75 20 115 39
RG
RW
RG
RG
R
A54 A42 A55 A56 A22

ECM(A)
E-041
A52 A53
B
B
B
E-043
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
B
EA13T060100

Ground Circuit
ECM(A)
E-041
A52 A53
B
06
E-043
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
B
EA13T060110

DTC Confirmation Procedure

Confirm that battery voltage is over 12 V before performing following procedures.
 Turn ignition switch to LOCK.
 Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC).
 Turn ignition switch to ON.
 Using diagnostic tester, select Read Datastream.
 If datastream is not detected, malfunction indicated by datastream is current. Go to diagnosis procedure -
Step 1.
 If datastream is detected, malfunction indicated by datastream is intermittent (See page 06-19).
Diagnosis Procedure
1 Check ECM power supply circuit
06 a. Turn ignition switch to LOCK.

b. Disconnect the ECM connector E-041.
c. Check voltage between terminal of ECM connector E-
041 and body ground. V
+ -
A56 A55 A54 A53 A52 A51 A50 A49
Multimeter Specified A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
Condition
Connection Condition A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
E-041 (A54) - A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1

Always 11 to 14 V
Body ground
OK Go to step 4
E-041
RA13T060010
NG
2 Check ECM fuse
a. Unplug ECM fuse EF26 (10A) from engine compartment

fuse and relay box.
b. Check resistance of fuse.
Standard resistance: less than 1 Ω
NG Replace ECM fuse
OK

3 Check wire harness and connector (ECM - engine compartment fuse and relay box)
a. Disconnect the engine compartment fuse and relay box

connector E-067.
b. Check wire harness between connector terminals on wire
harness side. A56 A55 A54 A53 A52 A51 A50 A49
+ - A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37

Check for Open A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
Specified E-041
Multimeter Connection
Condition
E-041 (A54) - E-067 (75) Continuity
Check for Short

06
Specified EF-26
Condition
EF26 10A
E-041 (A54) or E-067 (75) - Body
No continuity
ground RA13T060020
E-041 (A54) or E-067 (75) - Battery

No continuity
positive
NG Repair or replace wire harness or

connector
OK
Repair or replace engine compartment fuse and relay box or wire harness (engine compartment fuse
and relay box - battery)
4 Check main relay circuit voltage
a. Remove main relay from engine compartment fuse and

relay box.
b. Check voltage between terminals of main relay and body
ground.
+ - 87
Multimeter Specified
86
85
Condition
Connection Condition
Main relay
30
terminals 85 and
30 (engine
compartment fuse Always 11 to 14 V
and relay box
side) - Body
ground
NG Repair or replace wire harness or RA13T060030

connector (mainrelay - battery)

OK
5 Check main relay and fuse EF30
a. Check if fuse EF30 is normal.

b. Check for continuity between terminals of main relay.
87 85
Multimeter
Specified Condition + -
Connection
Terminal 30 - No continuity
30 86
Terminal 87
Terminal 30 - Continuity (battery voltage is applied
Terminal 87 between terminals 85 and 86)
06
87
86
85
NG Replace fuse or main relay
30
RA13T060040
OK
a. Check wire harness between connector terminals.

b. Disconnect the engine compartment fuse and relay box
connector E-067.
Check for Open
Specified
Condition A56 A55 A54 A53 A52 A51 A50 A49
+ - A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
E-041 (A55,A56) - E-067 (115) Continuity A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
Check for Short E-041

A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
Specified
Condition
E-041 (A55,A56) or E-067 (115) -
No continuity
Body ground
EF37 10A
E-041 (A55,A56) or E-067 (115) - EF-37

No continuity
Battery positive
RA13T060050

Check for Open
Specified
Condition A56 A55 A54 A53 A52 A51 A50 A49
+ - A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
E-041 (A42) - E-067 (20) Continuity A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
Check for Short E-041

A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
Specified
Condition
E-041 (A42) or E-067 (20) - Body
No continuity
ground
E-041 (A42) or E-067 (20) - Battery
No continuity
positive
06
RA13T060060
connector
OK
7 Check ECM power supply circuit (ignition switch voltage)
a. Turn ignition switch to ON.

b. Check voltage between terminals of ECM connector.
Multimeter Specified V
Condition
Connection Condition + -
E-041 (A22) - E-
Ignition switch ON 11 to 14 V
A56 A55 A54 A53 A52 A51 A50 A49
041 (A52,A53) A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
OK Replace ECM A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
RA13T060070
NG
8 Check ECM fuse
a. Unplug fuse FE07(15A) from instrument panel fuse box.

NG Replace ECM fuse

OK
9 Check wire harness and connector (ECM - instrument panel fuse box and body ground)

connector E-067.
b. Check wire harness between connector terminals on wire
harness side. A56 A55 A54 A53 A52 A51 A50 A49
+ - A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
Check for Open A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
Specified E-041
Condition
E-041 (A22) - E-067 (39) Continuity
06
Check for Short
Specified
Multimeter Connection EF07
Condition
EF07 15A
E-041 (A22) or E-067 (39) - Body
No continuity
ground RA13T060080
E-041 (A22) or E-067 (39) - Battery

No continuity
positive
c. Disconnect the ground point E-043.

d. Check the ECM ground point (See page 06-19).
e. Check the ECM ground wire harness.
Check for Open + -
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
Specified A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
Condition
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041 (A52, A35) - E-043 Continuity

connector E-041
RA13T060090
OK
10 Check the ignition switch assembly (See page 15-12).
NG Replace ignition switch assembly

OK
Repair or replace engine compartment fuse and relay box or wire harness
06

DTC P0135-12 Lambda Sensor1 Heater Driver Circuit Short to Battery
Lambda Sensor1 Heater Driver Circuit Short to Ground

DTC P0135-14
or Open
DTC P0132-12 Electric Test Lambda Sensor 1 Circuit Short to Battery
Upstream Lambda Sonde Resistor (Functional Test)

DTC P0053-1E
Circuit Resistance Out of Range
06

BATTERY
86 30
ECM
MAIN
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 EF13 RELAY BOX
10A 15A E-067
75 20 115 45
06
RG
R
1 4
UPSTREAM
RG
RG
R
OXYGEN
SENSOR
E-037
2 3
B
E-043
RW
BY
BY
B
A54 A42 A55 A56 A38 A26 A49 A53 A52
ECM(A)
E-041
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13 4 3 2 1 E-037
B
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
B
EA13T060160

DTC Detection
DTC DTC Definition Possible Cause
Condition
Lambda Sensor1
P0135-12 Heater Driver Circuit
Short to Battery
Lambda Sensor1
Heater Driver Circuit
P0135-14
Short to Ground or  Upstream oxygen sensor
Open
Ignition switch ON  Wire harness or connector
Electric Test Lambda Engine running  Fuse
P0132-12 Sensor 1 Circuit Short
to Battery  ECM
Upstream Lambda
Sonde Resistor
06 P0053-1E (Functional Test)
Circuit Resistance Out
of Range

 Using X-431 3G diagnostic tester, record and clear DTCs stored in ECM.
 Start engine and warm it up to normal operating temperature, and then select Read Code.
 If DTC is detected, malfunction indicated by DTC is current. Go to diagnosis procedure - Step 1.
 If DTC is not detected, malfunction indicated by DTC is intermittent (See page 06-19).
CAUTION
 When performing circuit diagnosis and test, always refer to circuit diagram for specific circuit and
component information.
Diagnosis Procedure
1 Check ECM ground point
a. Turn ignition switch to LOCK.

b. Check ECM ground point E-043 (See page 06-19).
NG Repair or replace ground wire harness or

ground point
OK

2 Check upstream oxygen sensor connector
a. Disconnect the upstream oxygen sensor connector E-

037.
b. Check the upstream oxygen sensor connector.
NG Repair or replace connector
RA13T060110
OK
06
3 Check upstream oxygen sensor heater power supply voltage

b. Check voltage between terminal 4 of upstream oxygen
sensor connector E-037 and body ground.
V
+ -
Condition
E-037 (4) - Body 4 3 2 1
Ignition switch ON 11 - 14 V
ground
OK Go to step 5 E-037
RA13T060120
NG

4 Check upstream oxygen sensor power supply circuit

b. Check fuse EF13 and main relay.
c. Disconnect the engine compartment fuse and relay box
connector E-067. + -
4 3 2 1
d. Check wire harness between upstream oxygen sensor
connector terminal and engine compartment fuse and
relay box connector terminal.
E-037
Check for Open
Condition
06 E-037 (4) - E-067
EF-13
Always Continuity
(45)
EF13 15A
Check for Short
RA13T060130
Condition
E-037 (4) or E-
067 (45) - Body Always No continuity
ground
E-037 (4) or E-
067 (45) - Battery Always No continuity
positive
NG Replace fuse, main relay, wire harness or

connector(upstream oxygen sensor -
engine compartment fuse and relay box)
OK

5 Check upstream oxygen sensor heater control circuit
a. Disconnect the ECM connector E-041.

b. Check wire harness between upstream oxygen sensor
connector terminal and ECM connector terminal.
Check for Open + -
4 3 2 1
Multimeter Specified E-037

Condition
E-037 (3) - E-041
Always Continuity
(A49) A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
Check for Short A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
06
Condition
E-037 (3) or E- E-041
041 (A49) - Body Always No continuity RA13T060140
ground
E-037 (3) or E-
041 (A49) - Always No continuity
Battery positive

connector (upstream oxygen sensor -
ECM)
OK
6 Check upstream oxygen sensor heater
a. Measure resistance of upstream oxygen sensor.

+ -
Condition
Connection Condition D C B A
Terminal C -
20°C 7 - 11 Ω
Terminal D
Terminal A -
Terminal C
Terminal A - RA13T060150
Terminal D
Always No continuity
Terminal B -
Terminal C
Terminal B -
Terminal D
NG Replace upstream oxygen sensor

OK
7 Check for DTCs
a. Using X-431 3G diagnostic tester, read ECM DTC.

b. Refer to "DTC Confirmation Procedure".
c. Check if DTC P0135-14, P0135-12, P0132-12 or P0053-
1E still exists.
NG Replace ECM
OK
06
System is operating normally. Reassemble vehicle and perform a road test to confirm that
malfunction reported by customer has been repaired.

DTC P0138-12 Electric Test Lambda sensor 2 Circuit Short to Battery
DTC P0141-12 Lambda Sensor2 Heater Driver Circuit Short to Battery
Lambda Sensor2 Heater Driver Circuit Short to Ground

DTC P0141-14
or Open
Downstream Lambda Sonde Resistor (Functional Test)

DTC P0054-1E
Circuit Resistance Out of Range
06

BATTERY
86 30
ECM
MAIN
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 EF13 RELAY BOX
10A 15A E-067
06 75 20 115 45
RG
1 4 DOWN-
RG
RG
STREAM
R
OXYGEN
SENSOR
2 3 E-038
B
E-043
RG
BR
YB
B
A54 A42 A55 A56 A39 A27 A50 A53 A52
ECM(A)
E-041
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25

E-038
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13 4 3 2 1
B
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
B
EA13T060170

DTC Detection
Condition
Electric Test Lambda
P0138-12 sensor 2 Circuit Short
to Battery
Lambda Sensor2
P0141-12 Heater Driver Circuit
Short to Battery  Downstream oxygen sensor
Lambda Sensor2 Ignition switch ON  Wire harness or connector
Heater Driver Circuit Engine running  Fuse
P0141-14
Short to Ground or
Open  ECM
Downstream Lambda
Sonde Resistor
P0054-1E (Functional Test) 06
Circuit Resistance Out
of Range

CAUTION
Diagnosis Procedure


ground point
OK

2 Check downstream oxygen sensor connector
a. Disconnect the downstream oxygen sensor connector.

b. Check the downstream oxygen sensor connector.
RA13T060160
OK
06
3 Check downstream oxygen sensor signal
a. Connect the downstream oxygen sensor connector E-

038.
b. Turn ignition switch to ON, start engine and idle it for
about 3 minutes. V
+ -
c. Use diagnostic tester to check downstream oxygen
sensor signal voltage, or use multimeter to measure
voltage between terminals 2 and 1 of connector E-038.
Multimeter Specified 4 3 2 1
Condition
E-038 (2) - E-038 Fluctuates slightly
Engine running
(1) at about 0.45 V E-038
OK Go to step 8
RA13T060170
NG

4 Check downstream oxygen sensor signal circuit

062.
b. Turn ignition switch to LOCK.
c. Disconnect the ECM connector E-041. + -
4 3 2 1
d. Check wire harness between downstream oxygen sensor

connector terminal and ECM connector terminal. E-038
Check for Open
Condition
A56 A55 A54 A53 A52 A51 A50 A49
Connection Condition A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
E-038 (1) - E-041

A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
(A39)
Always Continuity A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
06
E-038 (2) - E-041
Always Continuity
(A27)
E-041
RA13T060180
Check for Short
Condition
E-038 (1,2) or E-
041 (A39,A27) - Always No continuity
Body ground
E-038 (1,2) or E-
041 (A39,A27) - Always No continuity
Battery positive
OK Go to step 8
NG

5 Check downstream oxygen sensor heater power supply voltage

b. Check voltage between terminal 4 of downstream oxygen
V
+ -
Condition
E-038 (4) - Body 4 3 2 1
ground
NG Replace wire harness or connector

E-038
(downstream oxygen sensor - ECM)
06
RA13T060190
OK
6 Check downstream oxygen sensor heater control circuit
a. Check wire harness between downstream oxygen sensor

b. Check for Open
4 3 2 1
+ -
Condition
E-038
E-038 (3) - E-041
Always Continuity
(A50)
Check for Short A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
Condition A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-038 (3) or E-
041 (A50) - Body Always No continuity
ground E-041
RA13T060200
E-038 (3) or E-
Battery positive

connector (downstream oxygen sensor -
ECM)
OK

7 Visually check downstream oxygen sensor
a. Remove the downstream oxygen sensor.

b. Check downstream oxygen sensor for following problems.
 Moisture enters internal of sensor, temperature changes greatly or probe is broken.
 Oxygen sensor is "poisoned" (Pb, S, Br and Si etc.).
NG Replace downstream oxygen sensor
OK
8 Check for DTCs

06
c. Check if DTC P0138-12, P0141-12, P0141-14 or P0054-1E still exists.
NG Replace ECM
OK

DTC P0201-11 Injector 1 Driver Circuit Short to Ground
DTC P0201-12 Injector 1 Driver Circuit Short to Battery
DTC P0201-13 Injector 1 Driver Circuit Open
06

BATTERY
86 30
ECM
MAIN
RELAY
EF26 EF22 85 87
10A 10A B ENGINE
COMPARTMENT
EF37 FUSE AND
EF38
RELAY BOX
10A 15A E-067
75 20 115 116
RG
12
E-035 06
RG
E-007
RG
1
INJEC-
B
RG
RG
E-043
R
TOR 1
E-024
2
B
GY
A53 A52 A54 A42 A55 A56 B36

ECM(A)
E-041
ECM(B)
E-001
E-041 E-001
B B
1 2 3 4 5 6
E-007 E-024
7 8 9 10 11 12 B 1 2 B
EA13T060120

DTC Detection
Condition
Injector 1 Driver Circuit
P0201-11
Short to Ground
 Fuel injector
Injector 1 Driver Circuit Ignition switch ON
P0201-12  Wire harness or connector
Short to Battery Engine running
 ECM
Injector 1 Driver Circuit
P0201-13
Open

06  Turn ignition switch to ON.
CAUTION
Diagnosis Procedure


ground point
OK
2 Check injector connector of cylinder 1
a. Disconnect injector connector E-024 of cylinder 1.

b. Turn ignition switch to ON.
c. Check voltage between injector connector terminal of
cylinder 1 and body ground.
RA13T060210

OK
3 Check injector power supply voltage of cylinder1
a. Disconnect injector connector E-002 of cylinder 1.

c. Check voltage between injector connector terminal of
cylinder 1 and body ground. V
+ -
Multimeter Specified 1 2
Condition
E-024
E-024 (1) - Body
ground
06
OK Go to step 5
RA13T060220
NG
4 Check injector power supply circuit of cylinder1

2
1
d. Check wire harness between connector terminals. E-024
Check for Open
Condition
EF38 15A
E-024 (1) - E-067 EF-38

Always Continuity
(116)
Check for Short
Condition RA13T060230
E-024 (1) or E-
ground
E-024 (1) or E-
067 (116) - Always No continuity
Battery positive


connector (injector- engine compartment
fuse and relay box)
OK
5 Check injector control circuit of cylinder1

Check for Open
1 2
Condition + -
06
E-024
E-024 (2) - E-001

Always Continuity
(B36)
Check for Short B56 B55 B54 B53 B52 B51 B50 B49
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
Multimeter Specified B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
Condition
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
E-024 (2) or E-
001 (B36) - Body Always No continuity
ground
E-001
E-024 (2) or E- RA13T060240

ground

connector (injector- ECM)
OK
6 Check injector
a. Check resistance of injector.
NG Replace injector
OK
7 Check for DTCs

c. Check if DTC P0201-11, P0201-12 or P0201-13 still exist.
NG Replace ECM

OK
06

Intake Manifold Pressure Sensor (Electric) Circuit

DTC P0105-12
Shortto Battery
Intake Manifold Pressure Sensor (Electric) Circuit

DTC P0105-14
Shortto Ground or Open
Air Pressure Sensor (Functional) Signal Rate of Change

DTC P0106-26
BelowThreshold
Air Pressure Sensor (Functional) Signal Rate of Change

DTC P0106-27
AboveThreshold
06 DTC P0101-62 Air Intake Manifold Signal Compare Failure
Low Air Manifold Pressure (Functional) Signal Compare

DTC P1663-62
Failure


ON OR START
86 30
ECM EF07
MAIN 15A
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 RELAY BOX
10A E-067
75 20 115 39
RG 06
RW
RG
RG
R
A54 A42 A55 A56 A22
ECM(B)
E-001
E-041
A52 A53 B28 B19 B7 B33
B
LW
LG
LR
LB
3 4 2 1
B
INTAKE PRESSURE/
E-043 TEMPERATURE SENSOR
E-025
B56 B55 B54 B53 B52 B51 B50 B49 A56 A55 A54 A53 A52 A51 A50 A49
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37 A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25 A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13 A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-001 1 2 3 4 E-041
B B
E-025
B EA13T060130

DTC Detection
Condition
Intake Manifold
Pressure Sensor
P0105-12
(Electric) Circuit Short
to Battery
Intake Manifold
Pressure Sensor
P0105-14
(Electric) Circuit Short
to Ground or Open
Air Pressure Sensor
(Functional) Signal
P0106-26
Rate of Change Below  Intake pressure sensor
Threshold Ignition switch ON
 Wire harness or connector
06 Air Pressure Sensor
Engine running
 ECM
(Functional) Signal
P0106-27
Rate of Change Above
Threshold
Low Air Manifold
Pressure (Functional)
P1663-62
Signal Compare
Failure
Air Intake Manifold
P0101-62 Signal Compare
Failure

CAUTION
Diagnosis Procedure



ground point
OK
2 Check intake pressure/temperature sensor connector
a. Disconnect the intake pressure/temperature sensor

connector E-025.
b. Check the intake pressure/temperature sensor
connector.

06
RA13T060250
OK
3 Check intake pressure sensor signal voltage
a. Connect the intake pressure/temperature sensor

connector E-025.
b. Turn ignition switch to ON and start engine.
c. Using a multimeter, measure voltage between terminal 4 V
+ -
of connector E-025 and body ground.
1 2 3 4
Condition
Connection Condition E-025
Voltage is about
1.3 V (value
Idle
changes with
model)
E-025 (4) - Body
ground Maximum
instantaneous
Rapidly depress
voltage is about 4
accelerator pedal
V (value changes RA13T060260
with model)
OK Go to step 8
NG

4 Check intake pressure sensor power supply voltage

connector E-025.
b. Check voltage between connector terminal and body
ground. V
+ -
Condition 1 2 3 4
E-025
E-025 (3) - Body
Ignition switch ON 5V
ground
OK Go to step 6
06
RA13T060270
NG
5 Check intake pressure sensor power supply circuit

c. Check wire harness between connector terminals.
1 2 3 4
Check for Open + -
E-025
Condition
E-025 (3) - E-001
Always Continuity B56 B55 B54 B53 B52 B51 B50 B49
(B28) B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
Check for Short

B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
Condition
E-025 (3) or E- E-001
RA13T060280
ground
E-025 (3) or E-
001 (B28) - Always No continuity
Battery positive
NG Replace wire harness or connector (intake

pressure/temperature sensor - ECM)
OK

6 Check intake pressure sensor signal circuit
a. Check wire harness between intake pressure/

temperature sensor connector terminal and ECM
connector terminal.
Check for Open 1 2 3 4
+ -
E-025
Condition
E-025 (4) - E-001
Always Continuity
(B19) B56 B55 B54 B53 B52 B51 B50 B49
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
Check for Short

B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
06
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
Condition
E-025 (4) or E-
E-001
001 (B19) - Body Always No continuity RA13T060290
ground
E-025 (4) or E-
Battery positive

connector (intake pressure/temperature
sensor - ECM)
OK
7 Check intake pressure sensor
a. Remove the intake pressure/temperature sensor.

b. Check sensor connection part for debris or damage.
NG Clean or replace intake pressure/

temperature sensor
OK
8 Check for DTCs

c. Check if DTC P0101-62, P0105-12, P0105-14, P1663-62, P0106-26 or P0106-27 still exists.
NG Replace ECM

OK
06

DTC P0110-11 Air Temperature Sensor Circuit Short to Ground
DTC P0110-15 Air Temperature Sensor Circuit Short to Battery or Open
DTC P0110-3A Air Temperature Sensor Signal Has Too Many Pulses
Air Temperature Sensor (Functional) Signal Compare

DTC P0111-62
Failure
06


ON OR START
86 30
ECM EF07
MAIN 15A
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 RELAY BOX
10A E-067
75 20 115 39
06 RG
RW
RG
RG
R
A54 A42 A55 A56 A22
ECM(B)
E-001
E-041
A52 A53 B28 B19 B7 B33
B
LW
LG
LR
LB
3 4 2 1
B
INTAKE PRESSURE/
E-043 TEMPERATURE SENSOR
E-025
E-001 1 2 3 4 E-041
B B
E-025
B EA13T060130

DTC Detection
Condition
Air Temperature
P0110-11 Sensor Circuit Short to
Ground
Air Temperature
Battery or Open  Intake temperature sensor
Ignition switch ON
Air Temperature  Wire harness or connector
Engine running
P0110-3A Sensor Signal Has Too  ECM
Many Pulses
Air Temperature
Sensor (Functional)
P0111-62
Signal Compare 06
Failure

CAUTION
Diagnosis Procedure


ground point
OK

2 Check intake pressure/temperature sensor connector

connector E-025.
b. Check the intake pressure/temperature sensor
connector.
RA13T060250
OK
06
3 Check intake temperature sensor signal voltage
a. Connect the intake pressure/temperature sensor

connector E-025.
b. Turn ignition switch to ON and start engine.
c. Using a multimeter, measure voltage between terminal 4 V
+ -
of connector E-025 and body ground.
1 2 3 4
Condition
E-025 (4) - Body

ground
OK Go to step 5
RA13T060310
NG

4 Check intake temperature sensor signal circuit

c. Check wire harness between connector terminal and
1 2 3 4
ECM connector terminal. + -
Check for Open E-025
Condition
B56 B55 B54 B53 B52 B51 B50 B49
E-025 (2) - E-001 B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
Always Continuity
(B7) B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
06
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
Check for Short
Condition
RA13T060320
E-025 (2) or E-
ground
E-025 (2) or E-
001 (B7) - Battery Always No continuity
positive
NG Replace wire harness or connector (intake

pressure/temperature sensor - ECM)
OK
5 Check intake temperature sensor ground circuit

Check for Open
1 2 3 4
Condition + -
E-025 (1) - E-001

Always Continuity
(B33)
Check for Short B56 B55 B54 B53 B52 B51 B50 B49
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
Multimeter Specified B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
Condition
Connection Condition B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
E-025 (1) or E-
ground
E-001
E-025 (1) or E- RA13T060330

Battery positive


connector (intake pressure/temperature
sensor - ECM)
OK
6 Check intake temperature sensor
a. Remove the intake pressure/temperature sensor.

b. Check resistance of intake temperature sensor.
Check for Open
06 Connection
Condition
Condition
Terminal 1 - 2.5 kΩ ± 5%
Always
Terminal 2 (20°C)
NG Replace intake pressure/temperature

sensor
OK
7 Check for DTCs

c. Check if DTC P0110-11, P0110-15, P0110-3A or P0111-62 exists.
NG Replace ECM
OK

DTC P0115-11 Water temperature sensor Circuit Short to Ground
Water Temperature Sensor Circuit Short to Battery or

DTC P0115-15
Open
DTC P0115-3A Water Temperature Sensor Signal Has Too Many Pulses
Water Temperature Sensor (Functional) Signal Compare

DTC P0116-62
Failure
06


ON OR START
86 30
ECM EF07
MAIN 15A
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 RELAY BOX
10A E-067
75 20 115 39
06 RG
RW
RG
RG
R
A54 A42 A55 A56 A22
ECM(B)
E-001
A52 A53 B4 B21

BW
B
Gr
2 1
COOLANT
B
TEMPERATURE
SENSOR
E-006
E-043
E-001 E-041
B B
2
E-006
1
B
EA13T060140

DTC Detection
Condition
Water temperature
P0115-11 sensor Circuit Short to
Ground
Water Temperature
Battery or Open  Engine coolant temperature sensor
Ignition switch ON
Water Temperature  Wire harness or connector
Engine running
P0115-3A Sensor Signal Has Too  ECM
Many Pulses
Water Temperature
Sensor (Functional)
P0116-62
Signal Compare
Failure 06
CAUTION
Diagnosis Procedure


ground point
OK

2 Check engine coolant temperature sensor connector
a. Disconnect the engine coolant temperature sensor

connector E-006.
b. Check engine coolant temperature sensor connector
RA13T060350
OK
06
3 Check engine coolant temperature sensor power supply voltage

b. Check voltage between engine coolant temperature
sensor terminal and body ground.
V
+ -
Condition
Connection Condition 1 2
E-006 (2) - Body

ground
E-006
OK Go to step 5
RA13T060360
NG

4 Check engine coolant temperature sensor power supply circuit
a. Disconnect the engine coolant temperature sensor

connector E-025.
2
ground.
1
+ -
c. Check wire harness between engine coolant temperature
E-006
sensor connector terminal and ECM connector terminal.
Check for Open
Condition
B56 B55 B54 B53 B52 B51 B50 B49
Connection Condition B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
E-006 (2) - E-001 B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
Always Continuity
(B4)
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
06
Check for Short
E-001
Multimeter Specified RA13T060370
Condition
E-006 (2) or E-
ground
E-006 (2) or E-
001 (B4) - Battery Always No continuity
positive
NG Replace wire harness or

connector(engine coolant temperature
sensor - ECM)
OK

5 Check engine coolant temperature sensor ground circuit
a. Check wire harness between engine coolant temperature

sensor connector terminal and ECM connector terminal.
Check for Open
1 2
+ -
Condition E-006
E-006 (1) - E-001
Always Continuity
(B21)
B56 B55 B54 B53 B52 B51 B50 B49
Check for Short B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
06 Connection
Condition
Condition
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
E-006 (1) or E-
E-001
ground RA13T060380
E-006 (1) or E-
Battery positive

connector (engine coolant temperature
sensor - ECM)
OK
6 Check engine coolant temperature sensor
a. Remove the engine coolant temperature sensor.

b. Check resistance of engine coolant temperature sensor. + -
Check for Open

1 2
Multimeter
Specified Condition
Connection
Always
Terminal 1 - Resistance is 2.5 kΩ ± 5% at normal
Terminal 2 temperature (20°C) and 300 - 400 Ω in RA13T060390
boiled water (value changes with
boiled water temperature)
NG Replace engine coolant temperature

sensor
OK

7 Check for DTCs

c. Check if DTC P0115-11, P0115-15, P0115-3A or P0116-
62 still exists.
NG Replace ECM
OK
06

DTC P0121-12 Throttle Potentiometer 1 Circuit Short to Battery
DTC P0121-14 Pedal Potentiometer 1 Circuit Short to Ground or Open
DTC P0221-12 Throttle Potentiometer 2 Circuit Short to Battery
06


ON OR START
86 30
ECM EF07
MAIN 15A
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 RELAY BOX
10A E-067
75 20 115 39
ELECTRONIC THROTTLE E-008
06
M
3 5 2 1 6 4
RG
B
RGr
RBr
RG
RW
RB
RY
RL
E-043
RG
RG
R
Y
B
A53 A52 A54 A42 A55 A56 A22 B52 B51 B30 B18 B31 B6
ECM(B)
E-001
E-001 E-041
B B
2 4 6 E-008
1 3 5 B
EA13T060150

DTC Detection
Condition
Throttle Potentiometer
P0121-12 1 Circuit Short to
Battery
Pedal Potentiometer 1
P0121-14 Circuit Short to Ground  Throttle position sensor 1
or Open Ignition switch ON  Throttle position sensor 2
Throttle Potentiometer Engine running  Wire harness or connector
P0221-12 2 Circuit Short to  ECM
Battery
P0221-14 Circuit Short to Ground
or Open
06
CAUTION
Diagnosis Procedure


ground point
OK

2 Check electronic throttle connector
a. Disconnect the electronic throttle connector E-008.

b. Check the electronic throttle connector.
RA13T060400
OK
06
3 Check throttle position sensor 1 signal voltage

b. Connect the electronic throttle connector E-008.
c. Using diagnostic tester, check signal voltage of throttle
position sensor 1. + -
2 4 6
Multimeter Specified 1 3 5
Condition
E-008
Accelerator pedal
0.78 V
released
Ignition switch ON
Accelerator pedal
4.22 V
depressed
OK Go to step 8
RA13T060410
NG

4 Check throttle position sensor power supply voltage

b. Disconnect the electronic throttle connector E-008.
c. Turn ignition switch to ON and check voltage between 2
1
4
3
6
5
electronic throttle connector terminal and body ground. + -
Voltage Inspection E-008
Condition
B56 B55 B54 B53 B52 B51 B50 B49
E-008 (6) - Body
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
ground B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
06
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
OK Go to step 6
E-001
RA13T060420
NG
5 Check throttle position sensor power supply circuit

c. Check wire harness between electronic throttle connector 2
1
4
3
6
5
terminal and ECM connector terminal. + -
Condition
B56 B55 B54 B53 B52 B51 B50 B49
E-008 (6) - E-001
Always Continuity
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
(B31) B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
Check for Short
Condition
RA13T060420
E-008 (6) or E-
ground
E-008 (6) or E-
Battery positive

(electronic throttle - ECM)

OK
6 Check throttle position sensor 1 signal circuit and ground circuit
a. Check wire harness between electronic throttle connector

terminal and ECM connector terminal.
Check for Open
2 4 6 E-008
+ - 1 3 5
Condition
E-008 (4) - E-001
Always Continuity
(B6)
E-008 (2) - E-001
(B30)
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37

06
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
Check for Short

B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
Condition
E-001
E-008 (4), E-018 RA13T060430
(B6), E-008 (2) or

E-001 (B30) -
Body ground
E-008 (4), E-018
(B6), E-008 (2) or
E-001 (B30) -
Battery positive

connector (electronic throttle - ECM)
OK
7 Check electronic throttle
a. Check electronic throttle for carbon deposits and foreign

matter accumulation inside.
+ -
b. Check if electronic throttle valve body is stuck. 3 2 1
c. Check resistance of electronic throttle. 6 5 4
Throttle Inspection
Condition
Terminal 3 - Normal RA13T060440
1.067 kΩ
Terminal 2 temperature

Condition
Resistance
Terminal 6 - increases as
Throttle turned
Terminal 2 throttle valve
opens
Resistance
Terminal 6 - decreases as
Throttle turned
Terminal 3 throttle valve
opens
NG Clean or replace electronic throttle

assembly, and go to next step
06 OK
8 Check for DTCs

c. Check if DTC P0120-12, P0120-14, P0121-12 or P0121-14 still exists.
NG Replace ECM
OK

DTC P0130-23 Functional Test Lambda Sensor 1 Signal Stuck Low
DTC P0130-24 Functional Test Lambda Sensor 1 Signal Stuck High
DTC P0133-62 First Probe Diagnosis Signal Compare Failure
06

BATTERY
86 30
ECM
MAIN
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 EF13 RELAY BOX
10A 15A E-067
06 75 20 115 45
RG
R
1 4
UPSTREAM
RG
RG
R
OXYGEN
SENSOR
E-037
2 3
B
E-043
RW
BY
BY
B
A54 A42 A55 A56 A38 A26 A49 A53 A52
ECM(A)
E-041
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13 4 3 2 1 E-037
B
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
B
EA13T060160

DTC Detection
Condition
Functional Test
P0130-23 Lambda Sensor 1
Signal Stuck Low
Functional Test  Upstream oxygen sensor
Ignition switch ON
P0130-24 Lambda Sensor 1  Wire harness or connector
Engine running
Signal Stuck High  ECM
First Probe Diagnosis
Failure

06
CAUTION
Diagnosis Procedure


ground point
OK

2 Check upstream oxygen sensor connector
a. Disconnect the upstream oxygen sensor connector E-

037.
b. Check the upstream oxygen sensor connector.
RA13T060110
OK
06
3 Check upstream oxygen sensor signal
a. Connect the upstream oxygen sensor connector E-037.

about 3 minutes.
c. Using a multimeter, measure voltage between terminals V
+ -
2 and 1 of connector E-037.
Condition
Connection Condition 4 3 2 1
Fluctuates fast
between 0.1 and
E-037
E-037 (2) - E-037 0.9 V (when
Engine running
(1) operating
temperature is
350°C)
OK Go to step 8 RA13T060460
NG

4 Check upstream oxygen sensor signal circuit

c. Disconnect the upstream oxygen sensor connector E- 4 3 2 1
037. + -
d. Check wire harness between upstream oxygen sensor E-037

Check for Open
A56 A55 A54 A53 A52 A51 A50 A49
Condition A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
E-037 (2) - E-041

(A26)
Always Continuity
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
06
Check for Short
E-041
RA13T060470
Condition
E-037 (2) or E-
ground
E-037 (2) or E-
Battery positive

(upstream oxygen sensor - ECM)
OK
5 Check upstream oxygen sensor ground circuit
a. Check wire harness between upstream oxygen sensor

Check for Open
4 3 2 1
+ -
Condition
E-037 (1) - E-041

Always Continuity
(A38)
A56 A55 A54 A53 A52 A51 A50 A49
Check for Short A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
Multimeter Specified A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1

Condition
E-037 (1) or E-
ground E-041
RA13T060480

Condition
E-037 (1) or E-
Battery positive

connector (upstream oxygen sensor -
ECM)
OK
6 Check upstream oxygen sensor

06
a. Remove the upstream oxygen sensor.
b. Check upstream oxygen sensor for following problems.
 Moisture enters internal of sensor, temperature
changes greatly or probe is broken.
NG Replace upstream oxygen sensor
OK
7 Check for DTCs

c. Check if DTC P0130-23, P0130-24 or P0133-62 still exists.
NG Replace ECM
OK

DTC P0136-23 Functional Test Lambda Sensor 2 Signal Stuck Low
DTC P0136-24 Functional Test Lambda Sensor 2 Signal Stuck High
DTC P0139-62 DO2V Signal Compare Failure
06

BATTERY
86 30
ECM
MAIN
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 EF13 RELAY BOX
10A 15A E-067
06 75 20 115 45
RG
1 4 DOWN-
RG
RG
STREAM
R
OXYGEN
SENSOR
2 3 E-038
B
E-043
RG
BR
YB
B
A54 A42 A55 A56 A39 A27 A50 A53 A52
ECM(A)
E-041
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25

E-038
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13 4 3 2 1
B
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
B
EA13T060170

DTC Detection
Condition
Functional Test
P0136-23 Lambda Sensor 2
Signal Stuck Low
 Downstream oxygen sensor
Functional Test Ignition switch ON
P0136-24 Lambda Sensor 2 Engine running
Signal Stuck High  ECM
DO2V Signal Compare

P0139-62
Failure

06
CAUTION
Diagnosis Procedure


ground point
OK

2 Check downstream oxygen sensor connector
a. Disconnect the downstream oxygen sensor connector E-

038.
b. Check the downstream oxygen sensor connector.
RA13T060160
OK
06
3 Check downstream oxygen sensor signal

038.
about 3 minutes.
+ -
c. Use diagnostic tester to check downstream oxygen
sensor signal voltage, or use multimeter to measure
voltage between terminals 2 and 1 of connector E-062.
4 3 2 1
Condition
E-038 (2) - E-038 Fluctuates slightly E-038
Engine running
(1) at about 0.45 V
OK Go to step 8
RA13T060500
NG

4 Check downstream oxygen sensor signal circuit

c. Disconnect the downstream oxygen sensor connector E- 4 3 2 1
038. + -
d. Check wire harness between downstream oxygen sensor E-038

Check for Open
A56 A55 A54 A53 A52 A51 A50 A49
Condition A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
E-038 (2) - E-041

(A27)
Always Continuity
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
06
Check for Short
E-041
RA13T060510
Condition
E-038 (2) or E-
ground
E-038 (2) or E-
Battery positive

(downstream oxygen sensor - ECM)
OK
5 Check downstream oxygen sensor ground circuit
a. Check wire harness between downstream oxygen sensor

Check for Open
4 3 2 1
+ -
Condition
E-038 (1) - E-041

Always Continuity
(A39)
A56 A55 A54 A53 A52 A51 A50 A49
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13

Condition
E-038 (1) or E-
ground E-041
RA13T060520

Condition
E-038 (1) or E-
Battery positive

connector (downstream oxygen sensor -
ECM)
OK
6 Check downstream oxygen sensor

06
a. Remove the downstream oxygen sensor.
b. Check downstream oxygen sensor for following problems.
 Moisture enters internal of sensor, temperature changes greatly or probe is broken.
OK
7 Check for DTCs

NG Replace ECM
OK

Throttle Potentiometer Congruence Signal Compare

DTC P1654-62
Failure
DTC P1655-94 Self Learning Throttle bat Unexpected Operation
DTC P1656-94 Self Learning Throttle slc Unexpected Operation
Self Learning Throttle lhp Commanded Position not

DTC P1657-77
Reachable
Self Learning Throttle trc Commanded Position not

DTC P1658-77
Reachable
06
Self Learning Throttle mtc Performance or Incorrect
DTC P1659-92
Operation
Self Learning Throttle tro Commanded Position not

DTC P1660-77
Reachable


ON OR START
86 30
ECM EF07
MAIN 15A
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 RELAY BOX
10A E-067
75 20 115 39
06 ELECTRONIC THROTTLE E-008
3 5 2 1 6 4
RG
B
RGr
RBr
RG
RW
RB
RY
RL
E-043
RG
RG
R
Y
B
A53 A52 A54 A42 A55 A56 A22 B52 B51 B30 B18 B31 B6
ECM(B)
E-001
E-001 E-041
B B
2 4 6 E-008
1 3 5 B
EA13T060150

DTC Detection
Condition
Throttle Potentiometer
P1654-62 Congruence Signal
Compare Failure
Self Learning Throttle
P1655-94 bat Unexpected
Operation
P1656-94 slc Unexpected
Operation  Unsuccessful throttle self-learning
Self Learning Throttle  Insufficient battery voltage
Ignition switch ON
P1657-77 lhp Commanded  Throttle mechanical malfunction
Engine running
Position not Reachable  Wire harness or connector 06
Self Learning Throttle  ECM
P1658-77 trc Commanded
Position not Reachable
P1659-92 mtc Performance or
Incorrect Operation
P1660-77 tro Commanded
Position not Reachable

CAUTION
Diagnosis Procedure


ground point

OK
2 Check electronic throttle connector
a. Disconnect the electronic throttle connector E-008.

b. Check electronic throttle connector
06 RA13T060400
OK
3 Perform electronic throttle self-learning procedures
a. Connect the electronic throttle connector E-008.

b. Perform the electronic throttle self-learning procedures (See page 06-20).
c. Using X-431 3G diagnostic tester, read ECM DTC.
d. Check if DTC P1654-62, P1655-94, P1656-94, P1657-77, P1658-77, P1659-92 or P1660-77 still exists.
OK System is operating normally.

Reassemble vehicle and perform a road
test to confirm that malfunction reported
by customer has been repaired.
NG
4 Check battery voltage
a. Check the battery voltage (See page 16-6).
NG Detect or replace battery
OK

5 Check electronic throttle actuator circuit

b. Disconnect the electronic throttle connector E-008.
c. Disconnect the ECM connector E-001. 2
1
4
3
6
5
d. Check wire harness between connector terminals. + -
E-008
Check for Open
Condition
B56 B55 B54 B53 B52 B51 B50 B49
E-001 (B52) - E- B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
Always Continuity B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
008 (3) B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
06
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
E-001 (B51) - E-
Always Continuity
008 (5)
Check for Short

E-001
RA13T060550
Condition
E-001 (B52), E-
008 (3), E-001
(B51) or E-008 (5)
- Body ground
E-001 (B52), E-
008 (3), E-001
(B51) or E-008 (5)
- Battery positive
NG Repair or replace related wire harness
OK
6 Check electronic throttle
a. Check electronic throttle for carbon deposits and foreign

matter accumulation inside.
+ -
3 2 1
6 5 4
RA13T060440

Check for Short
Multimeter
Condition Specified Condition
Connection
Terminal 3 -
1.067 kΩ
Terminal 2
Terminal 6 - Resistance increases as
Terminal 2 throttle valve opens
Terminal 6 - Throttle Resistance decreases
Terminal 3 turned as throttle valve opens
Terminal 5 - Resistance decreases
Terminal 2 as throttle valve opens
Terminal 5 - Resistance increases as
06 Terminal 3 throttle valve opens
NG Clean or replace electronic throttle

assembly, and go to next step
OK
7 Check for DTCs

c. Check if DTC P1654-62, P1655-94, P1656-94, P1657-77, P1658-77, P1659-92 or P1660-77 still exists.
NG Replace ECM
OK

DTC P0120-12 Pedal Ootentiometer 1 Circuit Short to Battery
DTC P0220-12 Pedal Ootentiometer 2 Circuit Short to Battery
06


ON OR START
A
86 30
ECM EF07
MAIN 15A
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 RELAY BOX
10A E-067
75 20 115 39
06 RG
RW
RG
RG
R
A54 A42 A55 A56 A22
ECM(B)
E-001
A32 A13 A40 A30 A1 A28 A21 A52 A53

LY
LY
B
WR
GY
LW
YR
LY
Br
B
9 3 10 6 4 5 E-030
I-036
WR
E-043
GY
LW
YR
LY
Br
6 4 5 3 1 2
ELECTRONIC
ACCELERATOR
PEDAL
I-012
E-001 E-041
B B
I-012
1 2 3 4 5 6
B
EA13T060180

DTC Detection
Condition
Pedal Ootentiometer 1
P0120-12
Circuit Short to Battery
 Accelerator pedal position sensor 1
or Open Ignition switch ON
Pedal Ootentiometer 2 Engine running
P0220-12  ECM
or Open

06
CAUTION
Diagnosis Procedure


ground point
OK

2 Check electronic accelerator pedal connector
a. Disconnect the electronic accelerator pedal connector I-

012 (arrow).
b. Check the electronic accelerator pedal connector.
RA13T060570
OK
06
3 Check electronic accelerator pedal voltage

b. Connect the electronic accelerator pedal connector I-012.
c. Using diagnostic tester, check signal voltage of electronic
accelerator pedal. V
+ -
Condition
Connection Condition 1 2 3 4 5 6
I-012 (1,4) - Body

5V I-012
ground
Ignition switch ON
I-012 (2,5) - Body
0V
ground
RA13T060580
OK

4 Check electronic accelerator pedal circuit

b. Disconnect electronic accelerator pedal connector I-012.
c. Check wire harness between connector terminals. 1 2 3 4 5 6
Check for Open + -
I-012
Condition
I-012 (2) - E-041
A56 A55 A54 A53 A52 A51 A50 A49
(A28) A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25

I-012 (1) - E-041 A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
(A21)
Always Continuity
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
06
I-012 (5) - E-041
(A40)
I-012 (4) - E-041 E-041
RA13T060590
(A31)
Check for Short
Condition
I-012 (1, 2, 4, 5)
or E-041 (A13,
A21, A28, A40) -
Battery positive
I-012 (1, 2, 4, 5)
or E-041 (A13,
A21, A28, A40) -
Battery positive

(electronic accelerator pedal - ECM)
OK

5 Check electronic accelerator pedal sensor circuit

Check for Open
1 2 3 4 5 6
Condition + -
I-012
I-012 (3) - E-041
(A30)
Always Continuity
I-012 (6) - E-041
(A32) A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
Check for Short A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
06 A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
Condition
I-012 (3, 6) or E- E-041
041 (A30,32) - RA13T060600
Body ground
I-012 (3, 6) or E-
041 (A30, 32) -
Battery positive

(electronic throttle pedal - ECM)
OK
6 Replace electronic throttle pedal and check DTC again

c. Check if DTC P0120-12, P0120-14, P0220-12 or P0220-
14 still exists.
NG Replace ECM
OK

DTC P0351-12 Ignition 1 Driver Circuit Short to Battery
DTC P0351-14 Ignition 1 Driver Circuit Short to Ground or Open
06

A A
B B
ENGINE
EF14 COMPARTMENT
15A FUSE AND
RELAY BOX
E-067
46
RB
E-035
7
E-007
06
RB
RB
RB
RB
1 1 1 1

E-023 E-014 E-013 E-012
2 3 2 3 2 3 2 3
RG
RY
Gr
B
Br
B
E-022
B56 B54 B55 B53
ECM(B)
E-001
1 2 3 4 5 6
7 8 9 10 11 12
B56 B55 B54 B53 B52 B51 B50 B49
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37 E-007
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25 B
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
1 2 3
E-023 E-014
B B
E-001 E-013 E-012
B B B
EA13T060190

DTC Detection
Condition
Ignition 1 Driver Circuit
P0351-12
Short to Battery  Ignition coil 1
Ignition switch ON
Ignition 1 Driver Circuit  Wire harness or connector
Engine running
P0351-14 Short to Ground or  ECM
Open

 Using X-431 3G diagnostic tester, record and clear DTCs stored in ECM. 06
CAUTION
Diagnosis Procedure


ground point
OK
2 Check ignition coil connector

b. Disconnect the ignition coil 1 connector E-023 (arrow).
c. Check the ignition coil connector.
RA13T060610

OK
3 Check compression of misfiring cylinder
a. Measure compression of misfiring cylinder (See page 07-16).
NG Check engine to confirm cause of low

compression
OK
Check injectors, valve clearance, intake system and fuel pressure, etc. of misfiring cylinder
06
4 Check ignition coil
a. Check resistance of ignition coil primary winding with an

oscilloscope.
+ -
b. Inspect resistance of ignition coil secondary winding. 1 2 3
Primary Ignition Coil Inspection
Condition
Connection Condition (KΩ)
Normal
Posts of high-
temperature 9.68 - 12.32
voltage cable RA13T060620
(25°C ± 5°C)

compression
OK

5 Check ignition coil power supply voltage

b. Check voltage between ignition coil connector terminal
and body ground.
c. Using diagnostic tester, check signal voltage of ignition V
+ -
coil.
1 2 3
Condition
E-023
E-023 (1) - Body
ground
OK Go to step 7 06
RA13T060630
NG
6 Check ignition coil power supply circuit

c. Check wire harness between ignition coil connector 1 2 3
terminal and engine compartment fuse and relay box + -

connector terminal. E-023
Check for Open
Condition
E-023 (1) - E-067
Always Continuity
(46) EF-14
EF14 15A
Check for Short
Condition
Connection Condition RA13T060640
E-023 (1) or E-
067 (46) - Body
ground
E-023 (1) or E-
067 (46) - Battery
positive

(ignition coil- engine compartment fuse
and relay box)

OK
7 Check ignition coil control circuit

c. Check wire harness between ignition coil connector 1 2 3
terminal and ECM connector terminal. + -

E-023
Check for Open
Condition
B56 B55 B54 B53 B52 B51 B50 B49
06 E-023 (2) - E-001

B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
Always Continuity B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
(B54) B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
Check for Short
Condition E-001
RA13T060641
E-023 (2) or E-
001 (B54) - Body
ground
E-023 (2) or E-
001 (B54) -
Battery positive

connector (ignition coil - ECM)
OK
8 Replace ignition coil 1 and check DTC again

c. Check if DTC P0351-12 or P0351-14 still exists.
NG Replace ECM
OK

DTC P0335-62 Engine Speed Sensor Signal Compare Failure
BATTERY
86 30
ECM
MAIN
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 RELAY BOX
10A E-067
06
75 20 115
ENGINE
N
SPEED
RG
SENSOR
S
E-039
1 2 3
RG
RG
YW
YR
YB
R
E-007
1 3 4 E-035
B
E-043
YW
YR
YB
B
A54 A42 A55 A56 B12 B24 B40 A53 A52
ECM(A)
E-041
E-041 E-001
B B
1 2 3 4 5 6 E-007
B
E-039 7 8 9 10 11 12
3 2 1
B
EA13T060200

DTC Detection
Condition
Engine Speed Sensor  Speed sensor

Ignition switch ON
P0335-62 Signal Compare  Wire harness or connector
Engine running
Failure  ECM

06
CAUTION
Diagnosis Procedure


ground point
OK
2 Check engine speed sensor signal waveform
a. Turn ignition switch to ON, start engine and observe

signal waveform of engine speed sensor with an
oscilloscope.
OK Go to step 9
RA13T060660
NG

3 Check engine speed sensor connector

b. Disconnect the engine speed sensor connector E-039.
c. Check the engine speed sensor connector.
NG Repair or replace engine speed sensor

connector
RA13T060670
OK
06
4 Check installation of engine speed sensor
a. Remove the engine speed sensor.

b. Check and clean engine speed sensor and installation area, and check for damage, foreign matter or
excessive movement, etc. that cause signal incorrectness.
NG Clean or replace engine speed sensor
OK
5 Check engine speed sensor circuit

b. Check wire harness between engine speed sensor
connector terminal and ECM connector terminal. 3 2 1
Check for Open + -

E-039
Condition
E-039 (1) - E-001
(B12) B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
E-039 (2) - E-001 B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
Always Continuity B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1

(B24)
E-039 (3) - E-001
Always Continuity
(B40)
E-001
Check for Short
RA13T060680
Condition
E-039 (1,2,3) or
E-001
(B12,B40,B24) -
Body ground

Condition
E-039 (1,2,3) or
E-001
(B12,B40,B24) -
Battery positive

(engine speedsensor - ECM)
OK
Check injectors, valve clearance, intake system and fuel pressure, etc. of misfiring cylinder
06
6 Check spark of misfiring cylinder with an normally functioning spark plug
a. Install a normal engine speed sensor and observe signal

waveform.
b. Connect the engine speed sensor connector.
c. Turn ignition switch to ON, start engine and observe
signal waveform of engine speed sensor with an
oscilloscope.
OK Replace engine speed sensor
NG
7 Check flywheel ring gear
a. Turn crankshaft and check crankshaft and flywheel ring

gear for damage or foreign matter, etc. that cause signal
incorrectness.
NG Clear off debris and clean flywheel gear

ring. Replace flywheel if necessary
OK
8 Check for DTCs

c. Check if DTC P0335-62 still exists.
NG Replace ECM

OK
06

DTC P0325-12 Knock Sensor (Engine-Run) Circuit Short to Battery
DTC P1652-12 Knock Sensor; Key on Diagnosis Circuit Short to Battery
DTC P1652-11 Knock Sensor; Key on Diagnosis Circuit Short to Ground
Knock Sensor; Key on Diagnosis Internal Electronic

DTC P1652-49
Failure
Knock Sensor; Key on Diagnosis Signal Plausibility

DTC P1652-64
Failure
06

BATTERY
86 30
ECM
MAIN
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 RELAY BOX
10A E-067
75 20 115
06
RG
KNOCK
SENSOR
E-021
2 3
RG
RG
R
YR
YB
B
E-043
B
A54 A42 A55 A56 B17 B5 A53 A52
ECM(A)
E-041
E-041 E-001
B B
1 2 3
E-021
B EA13T060210

DTC Detection
Condition
Engine Speed Sensor
Ignition switch ON
Engine running
Failure
Knock Sensor; Key on
P1652-12 Diagnosis Circuit Short
to Battery
Knock Sensor; Key on  Knock sensor
P1652-11 Diagnosis Circuit Short  Wire harness or connector
to Ground  ECM
Ignition switch LOCK
P1652-49 Diagnosis Internal
Electronic Failure
06
P1652-64 Diagnosis Signal
Plausibility Failure

CAUTION
Diagnosis Procedure


ground point
OK

2 Check knock sensor connector
a. Disconnect the knock sensor connector E-021.

b. Check the knock sensor connector.
RA13T060691
3 Check knock sensor signal circuit 06

a. Disconnect the ECM wire harness connector E-001.
b. Check wire harness between terminals of connector E-
001 and connector E-021. 1 2 3
Check for Open + -

E-021
Condition
E-001 (B17) - E-
021 (2) B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
E-001 (B5) - E- B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13

021 (3)
Check for Short
E-001
Condition
E-001 (B17,B5) or
E-021 (2,3) - Body Always No continuity
ground
E-001 (B17,B5) or
E-021 (2,3) - Always No continuity
Battery positive
NG Replace wire harness or connector (knock

sensor- ECM)
OK
4 Check installation of knock sensor
a. Remove the knock sensor.

b. Check installation area of knock sensor, and check for damage, foreign matter or excessive movement,
etc. that cause signal incorrectness.

NG Clean installation area or replace knock

sensor
OK
5 Check resistance of knock sensor
a. Check resistance between terminals 1 and 2 of knock sensor.

HINT:
OK: Above 1 MΩ (at normal temperature)
NG Replace knock sensor
06
OK
6 Check knock sensor signal
a. Install the knock sensor.

b. Slightly strike around knock sensor with a rubber hammer, and measure if voltage is generated between 2
terminals of knock sensor with multimeter (mV) at the same time.
NG Replace knock sensor
OK
7 Check for DTCs

c. Check if DTC P0325-12, P1652-12, P1652-11, P1652-49 or P1652-64 still exists.
NG Replace ECM
OK

DTC P0340-11 Cam-shaft Sensor Circuit Short to Ground
DTC P0340-15 Cam-shaft Sensor Circuit Short to Battery or Open
DTC P0340-62 Cam-shaft Sensor Signal Compare Failure
DTC P0016-76 Wrong Assembly Camshaft Wrong Mounting Position
06


ON OR START
86 30
ECM EF07
MAIN 15A
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 RELAY BOX
10A E-067
75 20 115 39
06 RG
RW
RG
RG
R
A54 A42 A55 A56 A22
ECM(B)
E-001
A52 A53 B41 B16 B13

BW
LW
B
Gr
3 2 1
CAMSHAFT
B
POSITION
SENSOR
E-043 E-003
E-001 E-041
B B
3 2 1
E-003
B EA13T060220

DTC Detection
Condition
Cam-shaft Sensor
P0340-11
Circuit Short to Ground
Cam-shaft Sensor  Camshaft position sensor
P0340-15 Circuit Short to Battery
 Incorrect installation position of
or Open
Ignition switch ON camshaft position sensor
Cam-shaft Sensor Engine running  Engine mechanical malfunction
Failure
 ECM
Wrong Assembly
P0016-76 Camshaft Wrong
Mounting Position
06
CAUTION
Diagnosis Procedure


ground point
OK

2 Check camshaft position sensor signal waveform
a. Turn ignition switch to ON, start engine and observe signal waveform of camshaft position sensor with an
oscilloscope.
Normal Waveform
Oscilloscope
06 RA13T060710
OK Go to step 10
NG
3 Check camshaft position sensor connector

b. Disconnect the camshaft position sensor connector E-003.
c. Check the camshaft position sensor connector.
NG Repair or replace camshaft position

sensor connector
OK
4 Check camshaft position sensor power supply voltage

b. Check voltage between terminal 3 of camshaft position
V
+ -
Condition
Connection Condition 3 2 1
E-003 (3) - Body

ground E-003
OK Go to step 6
RA13T060720

NG
5 Check camshaft position sensor power supply circuit

c. Check wire harness between camshaft position sensor 3 2 1

+ -
Condition
B56 B55 B54 B53 B52 B51 B50 B49
E-003 (3) - E-
001(B41)
Always Continuity B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25

06
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
E-003 (3) - E-
001(B41)
Check for Short
E-001 RA13T060730
Condition
E-003 (3) or E-
ground
E-003 (3) or E-
01(B41) - Battery Always No continuity
positive

connector (camshaft position sensor -
ECM)
OK
Replace ECM

6 Check camshaft position sensor signal circuit and ground circuit
a. Check wire harness between camshaft position sensor

Check for Open 3 2 1
+ -
Condition E-003
E-001 (1) - E-003
Always Continuity
(B13)
B56 B55 B54 B53 B52 B51 B50 B49
Check for Short B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
06 Connection
Condition
Condition
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
E-001 (1) or E-
ground E-001 RA13T060740
E-001 (1) or E-
Battery positive

(camshaft position sensor - ECM)
OK
7 Check installation of camshaft position sensor
a. Remove the camshaft position sensor.

b. Check and clean camshaft position sensor and installation area, and check for damage, foreign matter or
excessive movement, etc. that cause signal incorrectness.
NG Clean installation area or replace

camshaft position sensor
OK
8 Check camshaft ring gear
a. Check camshaft ring gear for damage or foreign matter (such as debris), etc. that cause signal
incorrectness.
NG Remove debris and clean camshaft ring

gear or replace camshaft
OK

9 Install a normal camshaft position sensor and observe signal waveform
a. Install a normal camshaft position sensor.

b. Connect the camshaft position sensor connector.
c. Turn ignition switch to ON, start engine and observe signal waveform of camshaft position sensor with an
oscilloscope.
OK Replace camshaft position sensor
NG
10 Check for DTCs

06
NG Replace ECM
OK

DTC P0420-62 Catalizer Diagnosis Signal Compare Failure
DTC Detection
Condition
 Three-way catalytic converter
Catalizer Diagnosis  Leakage in exhaust system
Ignition switch ON
P0420-62 Signal Compare  Upstream oxygen sensor
Engine running
Failure  Downstream oxygen sensor
 ECM

06  Turn ignition switch to LOCK.
Diagnosis Procedure
1 Check for any other DTCs output (in addition to DTC P0420-00)
a. Connect X-431 3G diagnostic tester to Data Link Connector (DLC).

b. Turn ignition switch to ON, start engine and warm it up to normal operating temperature, and then select
Read Code.
Display (DTC Output) Proceed to

DTC P0420-00 A
DTC P0420-00 and other DTCs B
B Go to DTC chart, and perform

troubleshooting to other DTCs first
2 Read datastream
a. Using diagnostic tester, select Read Datastream.

b. Check datastreams below.
Item OK (Idling) If it is NG, proceed to

Quickly fluctuates between 0.1
Upstream Oxygen Sensor Voltage A
and 0.9 V

Item OK (Idling) If it is NG, proceed to

Fluctuates slightly at about 0.45 V B
Voltage
Average Injection Pulse Width Approximately 2.15 ms C
A Replace upstream oxygen sensor
C Check injector, fuel pressure and other

causes for abnormal injection pulse width
3 Check exhaust system

06
a. Turn ignition switch to ON and start engine.
b. Check exhaust system for leakage.
NG Repair or replace related exhaust system

components
OK
4 Check downstream oxygen sensor
OK
Replace three-way catalytic converter, and go to step 5
5 Check for DTCs

NG Replace ECM
OK

DTC P0443-11 Canister Purge Driver Circuit Short to Ground
DTC P0443-12 Canister Purge Driver Circuit Short to Battery
DTC P0443-13 Canister Purge Driver Circuit Open
06

A A
B B
ENGINE
EF35 COMPARTMENT
FUSE AND
15A
RELAY BOX
E-067
93
RB
E-035
6
E-007
06
RB
1
CANISTER
SOLENOID
B
E-043 VALVE
E-015
2
WG
B
A53 A52 B50 ECM(A)

E-041
ECM(B)
E-001
E-041 E-001
B B
1 2 3 4 5 6 E-007
7 8 9 10 11 12 B
2 1
E-015
B
EA13T060230

DTC Detection
Condition
Canister Purge Driver
P0443-11
 Canister solenoid valve
Canister Purge Driver Ignition switch ON
P0443-12  Wire harness or connector
Circuit Short to Battery Engine running
 ECM
Canister Purge Driver
P0443-13
Circuit Open

CAUTION
Diagnosis Procedure


ground point
OK
2 Check canister solenoid valve connector
a. Disconnect the canister solenoid valve connector E-015

(arrow).
b. Check the canister solenoid valve connector.
RA13T060750

OK
3 Check canister solenoid valve power supply voltage

b. Check voltage between canister solenoid valve
connector terminals and body ground.
2 1
Check for Open + -
E-015
Condition
E-015 (1) - E-067
Always Continuity
(93)
06
EF35 15A
Check for Short EF35
Condition
E-015 (1) or E-
067 (93) - Body RA13T060760
ground
E-015 (1) or E-
067 (93) - Battery
positive
OK Go to step 5
NG
4 Check canister solenoid valve power supply circuit

connector E-067. V
+ -
d. Check wire harness between canister solenoid valve 3 2 1
connector terminal and engine compartment fuse and

relay box connector terminal.
E-003
Condition
E-003 (3) - Body
ground
OK Repair or replace wire harness or

connector (canister solenoid valve -
engine compartment fuse and relay box) RA13T060770

NG
5 Check canister solenoid valve control circuit

b. Check wire harness between canister solenoid valve
connector terminal and ECM connector terminal. 2 1
Check for Open + -
E-015
Condition
E-015 (2) - E-001
(B50)
06 B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25

Check for Short B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
Condition
E-015 (2) or E-
001 (B50) - Body E-001 RA13T060780
ground
E-015 (2) or E-
001 (B50) -
Battery positive

connector (canister solenoid valve - ECM)
6 Check canister solenoid valve
a. Check resistance of canister solenoid valve.
Multimeter
Specified Condition
Connection
Terminal 1 -
26 ± 4 Ω (20°C)
Terminal 2
b. With battery voltage applied between terminals 1 and 2, valve should open when air is sucked into the
valve; with battery voltage not applied, valve should close when air is sucked into the valve.
NG Replace canister solenoid valve
OK

7 Check for DTCs

NG Replace ECM
OK
06

DTC P0481-13 Cooling Fan Driver 2 (High) Circuit Open
DTC P0480-13 Cooling Fan Driver 1 (Low) Circuit Open
DTC P0480-11 Cooling Fan Driver 1 (Low) Circuit Short to Ground
DTC P0480-12 Cooling Fan Driver 1 (Low) Circuit Short to Battery
DTC P0481-11 Cooling Fan Driver 2 (High) Circuit Short to Ground
DTC P0481-12 Cooling Fan Driver 2 (High) Circuit Short to Battery
06

A A
B B
MF02 MF03
40A 50A
86 30 86 30
FAN FAN ENGINE
LOW HIGH COMPARTMENT
RELAY 2 RELAY 1 FUSE AND
RELAY BOX
85 87 85 87 E-067
E-064
E-065
138 135 121 120
06
Br
R
P
L
2
3
M COOLING
FAN MOTOR
E-045
1
B
E-043
B
E-066
A43 A46 A53 A52
ECM(A)
E-041
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37

E-045
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25 3 2 1 B
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
B
EA13T060240

DTC Detection
Condition
Cooling Fan Driver 2
P0481-13
(High) Circuit Open
P0480-13
(Low) Circuit Open
P0480-11 (Low) Circuit Short to
Ground
Cooling Fan Driver 1 Ignition switch ON
 Cooling fan control module (relay)
P0480-12 (Low) Circuit Short to Engine running
 ECM
Battery
06 P0481-11 (High) Circuit Short to
Ground
P0481-12 (High) Circuit Short to
Battery

CAUTION
Diagnosis Procedure


ground point
OK

2 Check cooling fan control relay
a. Remove high speed fan relay and low speed fan relay
from engine compartment fuse and relay box.
b. Check the cooling fan relays.
NG Repair or replace relay + -
06
RA13T060791
OK
3 Check cooling fan control relay circuit voltage
a. Check voltage of cooling fan control relay connector

terminals.
Multimeter Specified V
Condition
Connection Condition + -
E-067 (138, 121) -

Body ground
NG Check engine compartment fuse and relay

box, repairor replace wire harness or
connector
RA13T060790
OK

4 Check cooling fan high speed control circuit

b. Check wire harness between fan control module
connector and ECM (2) connector. A56 A55 A54 A53 A52 A51 A50 A49
Check for Open + -

A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
Condition
E-041 (A46) - E-
Always Continuity
067 (121)
Check for Short

06
Condition
E-041 (A46) or
E-067 (121) - Always No continuity RA13T060800
Body ground
E-041 (A46) or
E-067 (121) - Always No continuity
Battery positive
NG Repair or replace wire harness
OK
5 Check cooling fan low speed control circuit

connector and ECM (2) connector. A56 A55 A54 A53 A52 A51 A50 A49
Check for Open + -

A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
Condition
E-041 (A43) -
Always Continuity
E-067 (138)
Check for Short
Condition
E-041 (A43) or
E-067 (138) - Always No continuity RA13T060810
Body ground
E-041 (A43) or
E-067 (138) - Always No continuity
Battery positive

OK
6 Check cooling fan high speed power supply circuit
a. Disconnect the fan control module connector E-045.

connector E-045 and engine compartment fuse and relay
box connector.
+ - 3 2 1
Check for Open
E-045
Connection
Condition
Condition
06
E-045 (3) - E-067
Always Continuity
(120)
Check for Short
Condition
E-045 (3) or E- RA13T060820
067 (120) - Body
ground
E-045 (3) or E-
067 (120) -
Battery positive
OK

7 Check cooling fan low speed power supply circuit

box connector.
+ - 3 2 1
Check for Open
E-045
Condition
E-045 (2) - E-067
Always Continuity
(135)
Check for Short

06
Condition
E-045 (2) or E- RA13T060830
067 (135) - Body
ground
E-045 (2) or E-
067 (135) -
Battery positive
OK
8 Check cooling fan ground circuit

box connector.
+ -
Ground Inspection
3 2 1
Condition
E-045 (1) - Body

Always Continuity
ground
RA13T060840
OK

9 Replace fan control module, and check for DTCs

c. Check if DTC P0480-13, P0481-13, P0480-11, P0480-12, P0481-11 or P0481-12 still exists.
NG Replace ECM
OK
06

DTC P0560-16 ECU Power Supply Circuit Voltage Below Threshold
DTC P0560-17 ECU Power Supply Circuit Voltage Above Threshold
06


ON OR START
86 30
ECM EF07
MAIN 15A
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 RELAY BOX
10A E-067
75 20 115 39
06
RG
RW
RG
RG
R
A54 A42 A55 A56 A22

ECM(A)
E-041
A52 A53
B
B
B
E-043
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
B
EA13T060100

DTC Detection
Condition
ECU Power Supply  Fuse
P0560-16 Circuit Voltage Below
Threshold Ignition switch ON
 Battery
ECU Power Supply Engine running
 Battery terminal
P0560-17 Circuit Voltage Above
Threshold  ECM

CAUTION
Diagnosis Procedure
a. Check if battery voltage is normal.
NG Recharge or replace battery
OK
2 Check battery terminal
a. Check if battery terminals are loose or corroded.
NG Tighten or replace battery terminal
OK


b. Check the ECM ground point E-043 (See page 06-19).

ground point
OK
4 Check ECM connector

b. Check the ECM connector.
06
NG Repair or replace ECM connector
OK
5 Check ECM power supply voltage (battery voltage)
a. Check voltage between terminal of ECM connector E-

041 and body ground.
Check for Open
V
+ -
Multimeter Specified A56 A55 A54 A53 A52 A51 A50 A49
Condition
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
E-041 (A54) -
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
Always 11 to 14 V A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
Body ground
OK Go to step 8
E-041
RA13T060850
NG
6 Check ECM fuse
a. Unplug ECM fuse EF26(10A) from engine compartment fuse and relay box.
b. Check resistance of fuse EF26.
NG Replace ECM fuse

OK
Check for Open
Condition
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
+ - A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
E-041 (A54) - E- A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
Always Continuity
067 (75)
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
Check for Short
06 Multimeter
Connection
Condition
Specified
Condition
E-041 (A54) or E-
EF26
067 (75) - Body
EF26 10A
ground
E-041 (A54) or E-
067 (75) - Battery RA13T060860
positive

connector
OK
8 Check ECM power supply voltage (ignition switch voltage)

b. Check voltage between terminals of ECM connector E-
041. A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
+ - A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
Condition
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
Connection Condition E-041 A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041 (A22) - E-
067 (39)
OK Go to step 12
EF07
EF07 15A
RA13T060870
NG

9 Check ECM fuse
a. Unplug fuse EF07(10A) from instrument panel fuse and relay box.
b. Check fuse EF07(10A) on instrument panel fuse and relay box.
NG Replace fuse
OK
10 Check the ignition switch assembly (See page 15-12).
NG Replace ignition switch assembly 06
OK
Repair or replace instrument panel fuse and relay box or wire harness (instrument panel fuse and
relay box - ignitionswitch)
11 Check for DTCs

NG Replace ECM
OK

DTC P0645-13 Air Conditioner 1 (Relay I/O) Circuit Open
DTC P0645-11 Air Conditioner 1 (Relay I/O) Circuit Short to Ground
DTC P0645-12 Air Conditioner 1 (Relay I/O) Circuit Short to Battery
06

A A
B B
EF30
10A
86 30
A/C ENGINE
CLUTCH COMPARTMENT
RELAY FUSE AND
RELAY BOX
85 87 E-067
98 99
R
8
E-035 06
E-007
R
1
RG
A/C
COMPRESSOR
CLUTCH
E-018
B
2 E-043
B
E-005
B
A44 A53 A52
ECM(A)
E-041
ECM(B)
E-001
E-041 E-001
B B
1 2 3 4 5 6
E-007 E-018
2 1
7 8 9 10 11 12 B B
EA13T060250

DTC Detection
Condition
ECU Power Supply
P0627-13 Circuit Voltage Below
Threshold
 A/C compressor relay
Air Conditioner 1  Wire harness or connector
Ignition switch ON
P0645-11 (Relay I/O) Circuit
Engine running  Battery
Short to Ground
 ECM
Air Conditioner 1
P0645-12 (Relay I/O) Circuit
Short to Battery

06 Confirm that battery voltage is over 12 V before performing following procedures.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check A/C compressor relay
a. Unplug A/C compressor relay connector terminal from

engine compartment fuse and relay box.
b. Check the A/C compressor relay terminal. 87 85
+ -
Condition
30 86
Terminal 30 -
Terminal 87
Continuity 87
Terminal 30 - (Battery voltage is
Always
86
85
Terminal 87 applied between
terminals 1 and 2) 06
30
NG Replace A/C compressor relay
RA13T060880
OK
3 Check A/C compressor relay control circuit

connector E-067.
b. Disconnect the ECM connector E-041. A56 A55 A54 A53 A52 A51 A50 A49
c. Check wire harness between ECM connector terminal + -

A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
and engine compartment fuse and relay box connector A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
terminal.
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
Check for Open
Condition
E-067 (98) - B-
Always Continuity 85
041 (A44)
30 87
86
Check for Short

Condition
E-067 (98) or B-
ground
E-067 (98) or B-
Battery positive


connector (ECM- engine compartment
fuse and relay box)
OK
4 Check A/C compressor relay power supply circuit

connector E-067.
b. Disconnect the A/C compressor relay connector E-018.
c. Check wire harness between engine compartment fuse + -
2 1
and relay box connector E-067 and A/C compressor relay

06 connector E-018. E-018
Check for Open
Condition
85
30 87
E-067 (99) - E- 86
Always Continuity
018 (1)
Check for Short

Condition
E-067 (99) or E-
ground
E-067 (99) or E-
positive
NG Replace wire harness between engine

compartment fuse and relay box
connector and A/C compressor relay
connector.
OK

5 Check A/C compressor ground wire harness

b. Check voltage between A/C compressor wire harness
and body ground.
+ -
Condition
2 1
E-018 (2) - Body Ignition switch

0V
ground LOCK E-018
NG Go to step 6
06
RA13T060910
OK
6 Check main relay
NG Repair or replace engine compartment

fuse and relay box or wire harness
OK
7 Check for DTCs

NG Replace ECM
OK

DTC P0504-13 Brake Signal Circuit Open
DTC P0504-62 Brake Signal Compare Failure
DTC P0504-67 Brake Signal Incorrect After Event
DTC P0504-86 Brake Signal Invalid
06

A
IGNITION SWITCH
ON OR START
ENGINE
EF24 EF07 COMPARTMENT
15A 15A FUSE AND
RELAY BOX
E-067
73 RW 39
RB
E-030 11 6 E-029
I-036 I-035
RW
RW
RW
RB
1 4
BRAKE
06
SWITCH
TO TCU
RW
I-013
3 2
B
BR
L
E-043
I-018 I-036
E-054 1 12 E-030
B
BR
L
A17 A5 A22 A53 A52

ECM(A)
E-041
ECM(B)
E-001
E-041 E-001
B B
1
9 8 7 6 5 4 3 2 1 1 2 3 4 4 2
1 2 3 4 5 6 7 8
3
18 17 16 15 14 13 12 11 10 5 6 7 8 9 10
9 10 11 12 13 14 15 16 I-013
B
I-018
I-036 I-035 W
B W EA13T060260

DTC Detection
Condition
Brake Signal Circuit
P0504-13
Open
 Fuse
Brake Signal Compare
P0504-62  Brake switch
Failure Ignition switch ON
Brake Signal Incorrect
P0504-67  ECM
After Event
P0504-86 Brake Signal Invalid

06
CAUTION
Diagnosis Procedure


ground point
OK

2 Check fuse
a. Remove fuses EF07, EF24 from engine compartment

fuse and relay box.
b. Check if fuses EF07, EF24 are normal.
NG Replace fuse + -
06
EF07 15A
RA13T060920
OK
3 Check brake switch power supply circuit
a. Disconnect the brake switch connector I-013 (arrow).

b. Check the brake switch connector.
RA13T060930
OK
4 Check brake switch
a. Remove the brake switch.

b. Check the brake switch. + - 3
Condition
Terminal 1 -
Brake pedal Continuity
Terminal 3
depressed (switch
Terminal 4 - pin released)
1
No continuity
Terminal 2 RA13T060940

Condition
Terminal 1 -
Brake pedal No continuity
Terminal 3
released (switch
Terminal 4 - pin pushed) Continuity
Terminal 2
NG Replace brake switch
OK
5 Check brake switch power supply voltage

06 a. Turn ignition switch to LOCK and check voltage between
terminal 1 of brake switch connector and body ground.
b. Turn ignition switch to ON and check voltage between
terminal 4 of brake switch connector and body ground. V
+ -
1
Condition
Connection Condition 3
I-013
I-013 (1) - Body
11 - 14 V
ground
Ignition switch ON
I-013 (4) - Body
11 - 14 V
ground
OK Go to step 6
RA13T060950
NG

6 Check brake switch power supply circuit
a. Check the fuses EF24 and EF07.

b. Disconnect the engine compartment fuse and relay box
1
connector E-067. 4 2
3
c. Check wire harness between brake switch connector + - I-013
terminals and engine compartment fuse and relay box
connector terminals.
Check for Open
Condition
EF24
I-013 (1) - E-067
EF24 10A
Always Continuity
(73) 06
I-013 (4) - E-067
Always Continuity
(39)
Check for Short RA13T060960
Condition
I-013 (1) or E-067
(73) - Body Always No continuity
ground
I-013 (1) or E-067
(73) - Battery Always No continuity
positive
I-013 (4) or E-067
positive
I-013 (4) or E-067
positive
NG Replace fues, repair or replace wire

harness orconnector (brake switch -
engine compartment fuse and relay box)
OK

7 Check brake switch control circuit

b. Check wire harness between brake switch connector
1
terminals and ECM connector terminals. 4 2
3
Check for Open + - I-013
Condition
I-013 (3) - E-041
(A17) A56 A55 A54 A53 A52 A51 A50 A49
Always Continuity
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
I-013 (2) - E-041

A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
(A5)
06
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
Check for Short
Condition E-041
I-013 (3) or E-041

(A17) - Body
ground
I-013 (3) or E-041
(A17) - Battery
positive
I-013 (2) or E-041
(A5) - Battery
positive
I-013 (2) or E-041
(A5) - Battery
positive

connector (brake switch - ECM)
OK
8 Check for DTCs

NG Replace ECM
OK

DTC P0604-62 RAM Memory Signal Compare Failure
DTC P0605-41 ROM (EPROM) Memory General Checksum Failure
DTC P0605-49 ROM (EPROM) Memory Internal Electronic Failure
DTC Detection
Condition
RAM Memory Signal
P0604-62
Compare Failure
ROM (EPROM)
P0605-41 Memory General
Checksum Failure
Ignition switch ON
 Wire harness or connector 06
ROM (EPROM)  ECM
P0605-49 Memory Internal
Electronic Failure
EEPROM Memory
P0601-44
Data Memory Failure

CAUTION
Diagnosis Procedure


ground point
OK

2 Check ECM connector
a. Disconnect the ECM connectors E-001 and E-041.

b. Check if connectors are normal.
OK
Replace ECM
06 3 Use X-431 3G diagnostic tester to match ECM, and check for DTCs again

System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction
reported by customer has been repaired.

Immo Secret Key and Security Code Not Programmed

DTC P1610-51
Not Programmed
DTC P1616-81 IMMO Authentication Fail Invalid Serial Data Received
IMMO Authentication Message not Received Missing

DTC P1617-87
Message
Fail to Write EOL Immobilizer Data into EEProm Missing

DTC P1618-87
Message
Immo Transferred Transponder Authentication is Failed

DTC P1614-86
SignalInvalid 06


ON OR START
86 30
ECM EF07
MAIN 15A
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 RELAY BOX
10A E-067
06 75 20 115 39
RG
RW
RG
RG
R
A54 A42 A55 A56 A22

ECM(A)
E-041
A52 A53
B
B
B
E-043
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
B
EA13T060100

DTC Detection
Condition
Immo Secret Key and
Security Code Not
P1610-51
Programmed Not
Programmed
IMMO Authentication
P1616-81 Fail Invalid Serial Data
Received
IMMO Authentication  Anti-theft module
P1617-87 Message not Received
Ignition switch ON  ECM
Missing Message
Fail to Write EOL
P1618-87
Immobilizer Data into 06
EEProm Missing
Message
Immo Transferred
Transponder
P1614-86
Authentication is
Failed Signal Invalid

CAUTION
Diagnosis Procedure
1 Rematch anti-theft system

b. Check if information in anti-theft module can be read.
NG Replace a new anti-theft module and

match it.
OK

2 Read SK code in ECM
NG Program ECM again
OK
3 Check if SK codes in ECM and anti-theft module are the same.
NG Program ECM again after returning ECM
OK
06
4 Check if SK codes in ECM and anti-theft module are the same again.
NG Replace ECM and program it again
OK
5 Check ECM power supply and ground
a. Check ECM power supply and ground
Condition
Connection Condition V
+ -
E-041 (A54, A22) A56 A55 A54 A53 A52 A51 A50 A49
11 to 14 V
- Body ground
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
Ignition switch ON
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
E-041 (A52, A53)

A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
0V A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
- Body ground

E-041
RA13T060980
OK

6 Use X-431 3G diagnostic tester to match ECM, and check for DTCs again

c. Check if DTC P1610-51, P1614-86, P1616-81, P1617-87 or P1618-87 still exists.
NG Replace ECM
OK
06

DTC U0129-87 Lost Communication with BSM
CAN1-L CAN1-H
CAN1-H CAN1-L
A11 G 14
ESP
ECM(A)
A23 Y 2 E-051
E-041
06
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37 E-041
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
B
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
E-051
38 37 36 35 34 33 32 31 30 29 28 27 26 25 B
EA13T060280

DTC Detection
Condition
 CAN line or connector
Lost Communication Ignition switch ON
U0129-87  ESP (ABS)
with BSM Engine running
 ECM

06
CAUTION
Diagnosis Procedure


ground point
OK
Replace ECM
2 Check ECM connector and ESP (ABS) connector.

b. Disconnect the ESP (ABS) connector B-061.
c. Check if connectors are normal.
OK

3 Check CAN line
a. Check the CAN line.

Check for Open
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
Multimeter Specified 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Condition + -
E-041 (A11) - B- E-051
Always Continuity
051 (14)
E-041 (A23) - B-
Always Continuity
061 (2) A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
06 A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
Condition
E-041 (A11) or B-
E-041
051 (14) - Body Always No continuity RA13T060981
ground
E-041 (A11) or B-
positive
E-041 (A23) or B-
ground
E-041 (A23) or B-
positive
NG Repair or replace CAN line
OK
4 Replace ECM, and check for DTCs

c. Check if DTC U0129-87 still exists.
NG Replace ESP (ABS)
OK

DTC U0101-87 Lost Communication with TCU
ECM(A) E-041
CAN1-L CAN1-H
A23 A11
G
Y
06
31 32
CAN1-L CAN1-H
TCU
E-069
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37

1 2 3 4 5 6 7 8 9 10 41 42
E-041
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
B 11 12 13 14 15 16 17 18 19 20 43 44 E-069
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13 21 22 23 24 25 26 27 28 29 30 45 46 B
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 31 32 33 34 35 36 37 38 39 40 47 48
EA13T060270

DTC Detection
Condition
 CAN line or connector
Lost Communication Ignition switch ON
U0101-87  TCU
with TCU Engine running
 ECM

06
CAUTION
Diagnosis Procedure


ground point
OK
2 Check ECM connector and TCU connector.

b. Disconnect the TCU connector E-069.
c. Check if connectors are normal.
OK

3 Check CAN line
a. Check the CAN line.

Check for Open 1 2 3 4 5 6 7 8 9 10 41 42
11 12 13 14 15 16 17 18 19 20 43 44
21 22 23 24 25 26 27 28 29 30 45 46
Condition + -
Connection Condition 31 32 33 34 35 36 37 38 39 40 47 48
E-069
E-041 (A11) - E-
Always Continuity
069 (32)
E-041 (A23) - E-
Always Continuity
069 (31) A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
06
Condition
E-041 (A11) or E-
E-041
069 (32) - Body Always No continuity RA13T060982
ground
E-041 (A11) or E-
positive
E-041 (A23) or E-
ground
E-041 (A23) or E-
positive
OK
4 Replace ECM, and check for DTCs

NG Replace TCU
OK

DTC P0403-11 EGR Control Circuit Short to Ground
DTC P0403-12 EGR Control Circuit Short to Battery
DTC P0403-13 EGR Control Circuit Open
DTC P0403-61 EGR Control Circuit Signal Calculation Failure
06

BATTERY
86 30
ECM
MAIN
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 EF35 RELAY BOX
10A 15A E-067
75 20 115 93
RG
RB
6
E-035 06
E-007
RG
RG
R
RB
4
EXHAUST GAS
+ + - RECIRCULATION
B
E-043 VALVE
- E-002
6 1 3 2
RG
BG
BL
B
A53 A52 A54 A42 A55 A56 B26 B29 G B08 B32
ECM(B)
E-001
E-001 E-041
B B
1 2 3 4 5 6 E-007
B 1 2 3 E-002
7 8 9 10 11 12
B
4 5 6
EA13T060290

DTC Detection
Condition
EGR Control Circuit
P0403-11
Short to Ground
EGR Control Circuit
P0403-12
Short to Battery  EGR valve
Ignition switch ON
EGR Control Circuit  Wire harness or connector
P0403-13 Engine running
Open  ECM
EGR Control Circuit
P0403-61 Signal Calculation
Failure

06 Confirm that battery voltage is over 12 V before performing following procedures.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check EGR valve connector
a. Disconnect the EGR valve connector E-002 (arrow).

b. Check the EGR valve connector.
RA13T060983
OK
06
3 Check EGR valve drive motor power supply voltage

ground.
c. Check wire harness between connector terminals. V
+ -
1 2 3
Condition
E-002 (4) - Body

ground
E-002
OK Go to step 5
RA13T060984
NG

4 Check EGR valve drive motor power supply circuit and fuse EF35

b. Check if fuse EF35 is normal.
connector E-067. + - 1 2 3
d. Check wire harness between connector terminals. 4 5 6
Check for Open

Condition
E-002 (4) - E-007 1 2 3 4 5 6
(6)
06 Always Continuity
7 8 9 10 11 12
E-035 (6) - E-067

(93)
E-007
Check for Short RA13T060985
Condition
E-002 (4), E-007
(6), E-035 (6) or
E-067 (93) - Body
ground
E-002 (4), E-007
(6), E-035 (6) or
E-067 (93) -
Battery positive

connector (EGR valve - engine
compartment fuse and relay box)
OK

5 Check EGR valve drive motor control circuit

b. Check wire harness between connector terminals.
Check for Open
1 2 3
+ -
Condition
E-002 (4) - E-001
Always Continuity E-002
(B26)
Check for Short

B56 B55 B54 B53 B52 B51 B50 B49
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
Multimeter
Condition
Specified B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25 E-001
06
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
E-002 (4) or E-
001 (B26) - Body
ground RA13T060986
E-002 (4) or E-
001 (B26) -
Battery positive

connector (EGR valve - ECM)
OK
6 Check EGR valve drive motor control circuit
a. Remove the EGR valve.

b. Check the EGR valve drive motor. + -
Condition
3 2 1
Terminal 4 - 6 5 4
Always 8Ω
Terminal 6
c. When battery voltage is applied between terminals 4 and

6, control valve should move quickly. RA13T060987
NG Replace EGR valve
OK

7 Check for DTCs

NG Replace ECM
OK
06

DTC P0409-12 EGR Sensor Circuit Short to Battery
DTC P0409-14 EGR Sensor Circuit Short to Ground or Open
06

BATTERY
86 30
ECM
MAIN
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 EF35 RELAY BOX
10A 15A E-067
75 20 115 93
RG
RB
06 6
E-035
E-007
RG
RG
R
RB
4
EXHAUST GAS
+ + - RECIRCULATION
B
E-043 VALVE
- E-002
6 1 3 2
RG
BG
BL
B
A53 A52 A54 A42 A55 A56 B26 B29 G B08 B32
ECM(B)
E-001
E-001 E-041
B B
1 2 3 4 5 6 E-007
B 1 2 3 E-002
7 8 9 10 11 12
B
4 5 6
EA13T060290

DTC Detection
Condition
EGR Sensor Circuit
P0409-12
Short to Battery  EGR valve
Ignition switch ON
EGR Sensor Circuit  Wire harness or connector
Engine running
Open

CAUTION
Diagnosis Procedure


ground point
OK
2 Check EGR valve connector
a. Disconnect the EGR valve connector E-002 (arrow).

b. Check the EGR valve connector.
RA13T060988

OK
3 Check EGR valve sensor power supply

b. Check voltage between sensor connector terminals.
Condition + -
E-002 (1) - E-002
(2)
1 2 3
OK Go to step 5
06 4 5 6
E-002
RA13T060989
NG
4 Check EGR valve sensor power supply circuit

c. Check wire harness between connector terminals.
1 2 3
Check for Open + - E-002
4 5 6
Condition
E-002 (1) - E-001
(B29)
Always Continuity
E-002 (2) - E-001 B56 B55 B54 B53 B52 B51 B50 B49
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
(B32) B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25 E-001
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
Check for Short

B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
E-002 (1), E-001
(B29), E-002 (2)
or E-001 (B32) -
Body ground
E-002 (1), E-001
(B29), E-002 (2)
or E-001 (B32) -
Battery positive


OK
5 Check EGR valve sensor signal circuit

Check for Open
1 2 3
+ - E-002
Condition
06
E-002 (3) - E-001
Always Continuity
(B08)
Check for Short

B56 B55 B54 B53 B52 B51 B50 B49
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
Multimeter Specified B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25 E-001
Condition B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
Connection Condition B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
E-002 (3) or E-
001 (B08) - Body
ground RA13T060991
E-002 (3) or E-
001 (B08) -
Battery positive

OK
6 Check the EGR valve sensor.
a. Remove the EGR valve.

b. Check the EGR valve drive motor. + -
Condition
3 2 1
Terminal 1 - 6 5 4
Always 2340 Ω ~ 3380 Ω
Terminal 2
c. Apply battery voltage to terminals 4 and 6, so that EGR

valve can move; check if resistance between terminals 1 RA13T060987
and 3, and between terminals 2 and 3 changes equally in

reverse direction.
NG Replace EGR valve

OK
7 Check for DTCs

NG Replace ECM
OK
06 System is operating normally. Reassemble vehicle and perform a road test to confirm that

DTC P1600-11 Thermostat Circuit Short to Ground
DTC P1600-12 Thermostat Circuit Short to Battery
DTC P1600-13 Thermostat Circuit Open
06

BATTERY
86 30
ECM
MAIN
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 EF35 RELAY BOX
10A 15A E-067
75 20 115 93
RB
06 RG
RG
RG
R
1
THERMOSTAT
E-036
B
E-043
2
BL
B
A53 A52 A34

A54 A42 A55 A56
ECM(B)
E-001
E-001 E-041
B B
1 2
E-036
Gr
EA13T060300

DTC Detection
Condition
EGR Sensor Circuit
P0409-12
Short to Battery  Electronic thermostat
Ignition switch ON
EGR Sensor Circuit  Wire harness or connector
Engine running
Open

CAUTION
Diagnosis Procedure


ground point
OK
2 Check electronic thermostat connector
a. Disconnect the electronic thermostat connector E-036

(arrow).
b. Check the electronic thermostat connector.
RA13T060993

OK
3 Check electronic thermostat power supply voltage

ground.
+ -
Condition
1 2
E-036 (1) - Body
ground E-036
06 OK Go to step 5
RA13T060994
NG
4 Check electronic thermostat power supply circuit and fuse EF35

1 2
Check for Open
Condition
E-036 (1) - E-067
EF35 15A
Always Continuity
(93) EF35
Check for Short
E-036 (1) or E-
067 (93) - Body
ground
E-036 (1) or E-
067 (93) - Battery
positive


connector (electronic thermostat - engine
OK
5 Check electronic thermostat control circuit

Check for Open 1 2
+ -
Connection
Condition
Condition
06
E-036 (2) - E-041
Always Continuity
(A34)
A56 A55 A54 A53 A52 A51 A50 A49
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
Condition
E-036 (2) or E-
041 (A34) - Body E-041
ground RA13T060450
E-036 (2) or E-
041 (A34) -
Battery positive

connector (electronic thermostat - ECM)
OK
6 Check electronic thermostat
a. Remove the electronic thermostat.

b. Check resistance of electronic thermostat.
Condition
Terminal 1 -
Always 15 Ω
Terminal 2
c. Heat thermostat in water to 100°C, then apply battery

voltage to terminals 1 and 2 of thermostat, observe if RA13T060996
opening travel is 8 mm.

CAUTION
Energizing time cannot be above 60 seconds ever time.
NG Replace electronic thermostat
OK
7 Check for DTCs

06 b. Refer to "DTC Confirmation Procedure".
NG Replace ECM
OK

DTC P0010-11 VVT Driver Circuit Short to Ground
DTC P0010-12 VVT Driver Circuit Short to Battery
DTC P0010-13 VVT Driver Circuit Open
DTC P0010-14 VVT Driver Circuit Short to Ground or Open
06

BATTERY
86 30
ECM
MAIN
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 EF35 RELAY BOX
10A 15A E-067
75 20 115 93
RG
RB
06
E-035
6
RG
RG
R
E-007
Y
RB
1
VARIABLE
B
CAMSHAFT
E-043
TIMING
E-020
2
B
WG
A53 A52 A54 A42 A55 A56 B38
ECM(B)
E-001
E-001 E-041
B B
1 2 3 4 5 6 E-007
2 1
7 8 9 10 11 12 B
E-020
B EA13T060310

DTC Detection
Condition
VVT Driver Circuit
P0010-11
Short to Ground
VVT Driver Circuit
P0010-12
Short to Battery  VVT control valve
Ignition switch ON
VVT Driver Circuit  Wire harness or connector
P0010-13 Engine running
Open  ECM
VVT Driver Circuit
P0010-14 Short to Ground or
Open

Confirm that battery voltage is over 12 V before performing following procedures. 06
CAUTION
Diagnosis Procedure


ground point
OK

2 Check VVT control valve
a. Disconnect the VVT control valve connector E-020

(arrow).
b. Check the VVT control valve connector.
RA13T060997
OK
06
3 Check VVT control valve power supply voltage

ground.
V
+ -
Condition
2 1
E-020 (1) - Body
ground
E-020
OK Go to step 5
RA13T060999
NG

4 Check VVT control valve power supply circuit and fuse EF35

c. Disconnect the engine compartment fuse and relay box 2 1
Check for Open
Condition
E-020 (1) - E-067
Always Continuity EF35
(75)
06
EF26 10A
Check for Short
E-036 (1) or E-
067 (93) - Body
ground
E-036 (1) or E-
067 (93) - Battery
positive

connector (VVT control valve - engine
OK
5 Check VVT control valve control circuit

Check for Open 2 1
+ -
E-020
Condition
E-020 (2) - E-041
Always Continuity
(B35)
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
RA13T061001

Check for Short
Condition
E-020 (2) or E-
041 (B35) - Body
ground
E-020 (2) or E-
041 (B35) -
Battery positive

connector (VVT control valve - ECM)
06 OK
6 Check VVT control valve
a. Remove the VVT control valve.

b. Check the VVT control valve. + -
Condition 1 2
Terminal 1 -
Always 8Ω
Terminal 2
c. When battery voltage is applied between terminals 1 and

2, control valve should move quickly. RA13T061002
NG Replace VVT control valve
OK
7 Check for DTCs

NG Replace ECM
OK

DTC P0704-23 Clutch Switch Signal Stuck Low
DTC P0704-24 Clutch Switch Signal Stuck High
06


ON OR START
A
86 30
ECM EF07
MAIN 15A
RELAY
EF26 EF22 85 87
10A 10A ENGINE
B
COMPARTMENT
FUSE AND
EF37 RELAY BOX
10A E-067
75 20 115 39
06 RG
RW
RG
RG
R
A54 A42 A55 A56 A22
ECM(B)
E-001
A16 A52 A53

L
B
10 E-030
I-036
L
1
B
CLUTCH
ON E-043
SWITCH
I-009
OFF
2
B
I-005
E-001 1 2 E-041
B B
I-009
B EA13T060320

DTC Detection
Condition
Clutch Switch Signal
P0704-23  Clutch switch
Stuck Low Ignition switch ON
Clutch Switch Signal Engine running
P0010-12  ECM
Stuck High

06
CAUTION
Diagnosis Procedure


ground point
OK
2 Check clutch switch connector
a. Disconnect the clutch switch connector I-009 (arrow).

b. Check the clutch switch connector.
RA13T061009

OK
3 Check clutch switch
a. Remove the clutch switch.

b. Check the clutch switch. + -
1 2
Condition
Terminal 1 - ON (not pushed) Continuity

Terminal 2 OFF (pushed) No continuity
06 NG Replace clutch switch RA13T061003
OK
4 Check clutch switch circuit

c. Check wire harness between clutch switch connector 1 2
terminal and ECM connector terminal. + - I-009

Check for Open
Condition
A56 A55 A54 A53 A52 A51 A50 A49
I-009 (2) - E-041
Always Continuity A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
(A6) A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
Check for Short

A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
Condition
E-041
RA13T061004
I-009 (2) or E-041
(A6) - Body
ground
I-009 (2) or E-041
(A6) - Battery
positive

connector (clutch switch - ECM)
OK

5 Check clutch switch ground circuit
a. Check the ground point I-005.

b. Check wire harness between clutch switch connector
terminal and body ground.
Check for Open + -
1 2
Condition I-009
I-009 (1) - Body
Always Continuity
ground

connector (clutch switch - body ground) 06
RA13T061005
OK
6 Check for DTCs

NG Replace ECM
OK

Engine Problem Symptom Diagnosis

Engine Problem Symptom Diagnosis
Perform primary inspection first before performing malfunction diagnosis procedures:
1. Confirm that engine malfunction indicator operates normally;
2. Using diagnostic tester, check that no error messages are recorded;
3. Confirm that malfunction complained by customer is present, and the condition under which malfunction
occurs.
Then, perform appearance inspection:
1. Check fuel line for leakage;
2. Check if vacuum line is broken or twisted or connected correctly;
3. Check intake line for blockage, air leakage, crush or damage;
4. Check if high-voltage cable of ignition system is broken or deteriorated, and if ignition sequence is correct;
06 5. Check if wire harness ground points are clean and secure;
6. Check each sensor or actuator connector for looseness or poor contact.
HINT:
If above conditions exist, repair the trouble areas first. Otherwise it will affect the repair work for following
trouble diagnosis.
Diagnostic Help
1. Confirm that there are no trouble records for engine;
2. Confirm that complained trouble symptoms are present;
3. There are no abnormal conditions after performing inspection according to above procedures;
4. During servicing, do not ignore vehicle maintenance condition, cylinder pressure, mechanical ignition
timing and fuel condition, etc. that can affect the system;
5. Replace ECM, and perform a test. If trouble symptom can be eliminated, there may be ECM problem; if
trouble symptom still exists, reuse original ECM, repeat procedures, and perform the service again.
Problem Symptoms Table
Symptom Suspected Area See page

Battery
Starter motor
Wire harness or ignition switch
Engine does not crank or cranks slowly
Starter relay 06-19
while starting
ECM, TCM
Gear switch (AT)
Engine mechanical
No fuel in tank
Fuel pump
Fuel injector
Engine cranks normally but cannot start Engine speed sensor
06-19
successfully while starting Ignition coil
Engine immobilizer
ECM
Engine mechanical


Water in fuel
Fuel pump
Coolant temperature sensor
Engine speed sensor
Difficult to start with hot engine 06-19
Ignition coil
Camshaft position sensor
Fuel injector
Engine mechanical
Engine starts normally, but idles roughly or A/C system
stalls with part load (for example, A/C is Fuel injector 06-19
ON)
Throttle valve
06
Engine starts normally, but idle speed is too Vacuum pipe
06-19
high Coolant temperature sensor
Ignition timing
Water in fuel
Intake pressure/temperature sensor
Intake pipe
Low engine speed or stalls when Exhaust pipe
06-19
accelerating Ignition timing
Throttle position sensor
Fuel injector
Spark plug
Water in fuel
Intake pressure/temperature sensor
Intake pipe
Exhaust pipe
Slow response when accelerating 06-19
Ignition timing
Throttle position sensor
Fuel injector
Spark plug

Engine does not crank or cranks slowly while starting
1 Check voltage between two battery posts when engine starts
OK: Voltage is 11.5 - 12.5 V
NG Replace battery
OK
2 Check voltage of starter motor positive post
06 a. Ignition switch remains in START position and check voltage of starter motor positive post.
OK: Voltage is 11.5 - 12.5 V
NG Repair or replace starter relay, wire

harnessor ECM
OK
3 Check operation of starter motor
a. Remove the starter motor.

b. Check if there is an open circuit or if it is stuck due to poor lubrication.
NG Repair or replace starter
OK
4 Check engine lubricant and gear oil
a. If malfunction only occurs in winter, check if starter motor resistance is too strong because of improper
engine lubricant and gear oil selection.
NG Replace lubricant with appropriate

number
OK
5 Check engine internal mechanical resistance
a. Check if engine internal mechanical resistance is too strong, causing starter motor not to run or run slowly.
NG Check and repair engine internal

resistance malfunction

OK
Go to Diagnostic Help
06

Engine cranks normally but cannot start successfully while starting
1 Check fuel pressure
a. Using a fuel pressure gauge, check the fuel pressure (See page 08-11).
Standard Fuel Pressure
Condition Fuel System Pressure (kPa)

Key ON 400
Engine Idling 400
Key Lock 400
NG Repair or replace fuel system

06
OK
2 Using diagnostic tester, observe if any speed signal is output
a. Connect diagnostic tester, start engine and select Read Datastream.

b. Observe if any speed signal is output.
NG Check and repair engine speed sensor

wire harness
OK
3 Check spark plug
a. Remove ignition coil and spark plug of one cylinder, and ground spark plug housing. Start engine, and
check if spark is generated.
OK: Spark is generated
NG Check and repair ignition system
OK
4 Check pressure of cylinder

compression
OK


b. Turn ignition switch to ON and check ECM connector
terminals.
V
+ -
Condition
A56 A55 A54 A53 A52 A51 A50 A49
Connection Condition A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
E-041 (A54, A22) 11 to 14 V A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
Ignition switch ON A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041 (A52, A53) 0V

E-041
06
RA13T060980
OK

Difficult to start with hot engine

Key ON 400
Engine Idling 400
Key Lock 400

06
OK
2 Check spark
OK
Disconnect coolant temperature sensor connector, start engine and observe if engine starts
3 successfully at this time
OK Check and repair circuit or replace sensor
NG
4 Clamp fuel pump return pipe, measure fuel pressure and observe if fuel pressure rises
NG Replace fuel pump assembly
OK
a. Observe if trouble occurs just after fuel is filled.
NG Replace fuel

OK
06

Difficult to start with cold engine

Key ON 400
Engine Idling 400
Key Lock 400

06
OK
2 Check spark
OK
NG
4 Depress accelerator pedal slightly, and observe if it is easy to start
NG Clean throttle valve
OK
5 Check injector for leakage or blockage
NG Clean or replace injector
OK

6 Check fuel condition
NG Replace fuel
OK

compression
06
OK

Engine speed is normal, but it is difficult to start at anytime
1 Check air filter for blockage, and intake pipe for air leakage
NG Check and repair intake system
OK
06 Condition Fuel System Pressure (kPa)

Key ON 400
Engine Idling 400
Key Lock 400
OK
3 Check spark plug
a. Check spark plug of each cylinder, and observe if type and gap are as specified.
NG Spark Plug Replacement
OK
4 Check spark
OK

NG
OK 06
OK
NG Replace fuel
OK

compression
10 Check engine ignition sequence and ignition timing
a. Check if engine ignition sequence and ignition timing are as specified.
NG Check and repair ignition timing
OK

Engine starts normally, but idles roughly at anytime
OK
2 Check if throttle is sticking
NG Repair or replace throttle
06 OK
3 Check spark plug
OK
4 Check throttle for carbon deposits
OK
OK
NG Replace fuel
OK


compression
OK

06
OK

Engine starts normally, but idles roughly during warming up
OK
2 Check spark plug

06
OK
OK
Unplug coolant temperature sensor connector, start engine and observe if engine idles
4 normally during warming up
NG Check and repair circuit or replace sensor
OK
OK
NG Replace fuel
OK


compression
OK
06

Engine starts normally, but idles roughly after warming up
OK
2 Check spark plug

06
OK
Unplug coolant temperature sensor connector, start engine and observe if engine idles
3 normally during warming up
OK
OK
NG Replace fuel
OK

compression

OK
06

Engine starts normally, but idles roughly or stalls with part load (for example, A/C is ON)
OK
Observe if engine output increases when A/Cis turned on. In other words, observe changes
2 of ignition advance angle, injection pulse width and intake air volume using diagnostic
tester
OK Go to step 4
06
NG
Connect ECM adapter, and disconnect cable of ECM corresponding terminal. Check if wire
3 harness side is HIGH-level signal with A/C ON
NG Check and repair A/C system
OK
Connect ECM adapter, and disconnect cableof ECM corresponding terminal. Check if wire
4 harness side is HIGH-levelsignal with A/C ON
NG Check and repair A/C system
OK
OK

Engine starts normally, but idle speed is too high
1 Check if accelerator pedal is stuck
NG Adjust or replace accelerator pedal
OK
2 Check intake system and connected vacuum pipe for air leakage
OK Check and repair intake system
NG 06
OK
Disconnect coolant temperature sensor connector, start engine and observe if engine idling
4 is normal
OK
5 Check engine ignition timing
OK

Low engine speed or stalls when accelerating
OK

Key ON 400
Engine Idling 400
Key Lock 400
OK
3 Check spark plug
OK
OK
5 Check intake pressure/temperature sensor, throttle position sensor and circuit
NG

OK
NG Replace fuel
OK 06
OK
a. Check exhaust system for leakage or blockage.

components
OK

Slow response when accelerating
OK

Key ON 400
Engine Idling 400
Key Lock 400
OK
3 Check spark plug
OK
OK
NG

OK
NG Replace fuel
OK 06
OK

components
OK

Lack of power and poor performance when accelerating
Check if malfunctions that clutch slipping, low tire inflation pressure, brake dragging,
1 incorrect tire size and incorrect four-wheel alignment are present
NG Check and repair malfunctioning

components
OK

06
OK

Key ON 400
Engine Idling 400
Key Lock 400
OK
4 Check spark plug
OK
5 Check spark

OK
OK

06
NG
OK
NG Replace fuel
OK
OK

components

OK
06

ON-VEHICLE SERVICE
VVT Control Valve
Description
There is a VVT control valve, which is located on front end of cylinder head.
Operation
ECM controls VVT control valves depending on engine conditions, changes the flowing direction of oil in
phasers to advance or retard camshaft, thus changing the timings of intake valve and exhaust valve.
Removal
1. Turn off all electrical equipment and the ignition switch.
2. Disconnect the negative battery cable. 06
3. Remove the engine trim cover.
4. Remove the VVT control valve.
a. Disconnect VVT control valve connector (arrow), and
then remove VVT control valve fixing bolt (1).
(Tightening torque: 8 ± 2 N·m)
RA13T060997
Installation
Installation is in the reverse order of removal.

Coolant Temperature Sensor

Description
Coolant temperature sensor is a negative temperature coefficient sensor, which is installed into the mounting
hole in thermostat holder.
Operation
Coolant temperature sensor provides an input signal for Engine Control Module (ECM). As temperature
increases, the resistance of sensor decreases. As coolant temperature changes, the resistance of coolant
temperature sensor varies accordingly, resulting in a change in voltage of coolant temperature sensor signal
circuit. ECM uses this input signal to control air-fuel mixture, ignition timing, A/C compressor and radiator fan
on/off timing.
Removal
06 1. Turn off all electrical equipment and the ignition switch.
2. Disconnect the negative battery cable.
WARNING
 Always make sure engine is cold before operating cooling system. Never open expansion tank cap or
remove drain cock plug, when engine is operating or cooling system overheats. The overheated engine
coolant and steam with high-pressure may flow out and cause serious personal injury.

4. Disconnect coolant temperature sensor connector and
remove coolant temperature sensor.
RA13T060350
Installation
CAUTION
 Perform sealing with anaerobic seal gum.

 Confirm that sensor is tightened fully during installation.
 After installing engine coolant temperature sensor, check coolant level.

Knock Sensor
Description
Knock sensor is installed on cylinder block, and used to detect engine vibration caused by detonation.
Operation
Sensitive element of knock sensor is a piezoelectric ceramic. Vibration of engine cylinder block is transferred
to the piezoelectric ceramic through a mass block in sensor. Due to pressure generated by vibration of mass
block, the piezoelectric ceramic generates a voltage at both electrode faces, and converts vibration signal to
an AC voltage signal to output it. As intensity of vibration increases, knock sensor output voltage increases
accordingly.
Because frequency of vibration signal caused by engine knocking is far more than that of normal engine
vibration signal, Engine Control Module (ECM) can distinguish between knock or non-knock signals by
processing these signals from knock sensor.
06
Removal
3. Disconnect coolant temperature sensor connector and
remove coolant temperature sensor.
RA13T060691
Installation
CAUTION
 Never allow any kinds of gasket and washer between sensor and engine block. Only the metal part of
sensor can contact with engine block directly.
 DO NOT apply lubricant, grease or seal gum when installing knock sensor. Keep engine block clean and
dry, and never allow any foreign matter (such as oil) on the installation area of knock sensor.
 Never tap knock sensor when installing it.

Oxygen Sensor
Description
Oxygen sensors consist of upstream oxygen sensor and downstream oxygen sensor. Oxygen sensors
continually monitor the oxygen concentration in exhaust gas.
Operation
Oxygen sensors monitor oxygen content and convert it into voltage. Sensor generates low voltage when
oxygen content is high, and high voltage when oxygen content is low. Therefore, sensor acts as controlling
injection volume by closed-loop.
Oxygen sensor is equipped with a heating element that keeps sensor at proper operating temperature under
all operating conditions.
Upstream Oxygen Sensor

06 Input signal from heated upstream oxygen sensor is used to
inform Engine Control Module (ECM) of the oxygen content
in exhaust gas. Based on this input signal, Engine Control
Module (ECM) adjusts air-fuel ratio finely by adjusting
injector pulse width.
RA13T060110

Heated downstream oxygen sensor signal is used to detect
the catalytic converter deterioration. As converter
deteriorates, signal from downstream sensor begins to
match upstream sensor signal except for a slight delay. By
comparing signal from heated upstream oxygen sensor to
signal from downstream sensor, Engine Control Module
(ECM) calculates efficiency of catalytic converter.
RA13T060160
Removal & Installation - Upstream Oxygen Sensor

(See page 09-13)
Removal & Installation - Downstream Oxygen Sensor

(See page 09-15)

Camshaft Position Sensor

Description
Camshaft position sensor is installed on cylinder head cover.
Operation
Camshaft position sensor is a Hall type sensor and a phaser is installed on camshaft. When phaser is in high
teeth, applicable circuit output is high level; when phaser is in missing teeth, applicable circuit output is low
level. As a result, crankshaft phase information is provided to Engine Control Module (ECM), so that the
compression top dead center and exhaust top dead center of crankshaft can be distinguished.
Removal
06
4. Remove the camshaft position sensor.
a. Disconnect camshaft position sensor connector
(arrow), then remove camshaft position sensor fixing
bolt (1).
RA13T062000
Installation
CAUTION
 Sensor should be pressed into mounting hole. Never use tools (such as a hammer) to strike sensor into
mounting hole forcibly.

Engine Speed Sensor

Description
Engine speed sensor is installed on clutch case, against flywheel teeth. It is used to detect the speed and
position of crankshaft.
Operation
Engine speed sensor is a Hall type sensor. When crankshaft rotates, it drives flywheel to rotate. Flywheel
teeth will cut the magnetic line of sensor, and change of magnetic flux causes sensor output signal voltage
change, which is sent to Engine Control Module (ECM). And output signal can indicate the speed and position
of crankshaft.
Removal
06 2. Disconnect the negative battery cable.
4. Remove the engine speed sensor.
a. Disconnect engine speed sensor connector (arrow),
and remove engine speed sensor fixing bolt (1).
RA13T060670
Installation
CAUTION
 Press in crankshaft position sensor rather than tap when installing it.

Intake Pressure/Temperature Sensor

Description
Intake pressure/temperature sensor integrates with the intake manifold absolute pressure sensor and intake
temperature sensor, which is installed on the intake manifold upper body assembly.
Operation
Intake manifold absolute pressure sensing element consists of a piece of silicon chip, which will deform
mechanically as the intake manifold absolute pressure changes. The piezoresistor in sensor will also deform,
thus changing the resistance. Voltage signal linearly related to the pressure is generated after processing by
signal circuit of the silicon chip.
Intake temperature sensor is a negative temperature coefficient thermostat, whose resistance
changes with the intake temperature. This sensor sends the voltage of intake temperature change to Engine
Control Module (ECM), thus monitoring the change of intake temperature.
06
Removal
4. Disconnect the intake pressure/temperature sensor
connector (arrow).
RA13T060250
5. Remove the intake pressure/temperature sensor fixing bolt.

Installation
CAUTION
 Remove foreign matter on sensor before installation.

 Apply grease to O-ring before installation to prevent it from being damaged during installation.

Ignition Coil
Description
Ignition coil converts low voltage of primary winding into high voltage of secondary winding, and discharges
spark plug electrode to produce sparks which will ignite the combustible air-fuel mixture in cylinder.
Operation
Ignition coil consists of primary winding, secondary winding,
iron core and housing etc. Primary and secondary windings
form an induced circuit. An instant induced voltage + -
generated by turning primary circuit switch on and off, and 1 2 3
an instant high voltage generated by secondary circuit will

cause spark plugs to discharge, thus igniting the
combustible air-fuel mixture. Primary winding will recharge
when its ground line is on through an Engine Control Module
06 (ECM) signal. Once Engine Control Module (ECM) cuts off
control signal to primary winding circuit, it will stop charging
and a high voltage will be induced in secondary winding. RA13T060620
Removal & Installation

(See page 14-8)

Electronic Accelerator Pedal Sensor

Description
Accelerator pedal is installed to cowl of the body, and accelerator pedal sensor is located inside the
accelerator pedal.
Operation
Accelerator pedal sensor outputs the electrical signal which
varies linearly depending on the pedal travel to ECM, in
order to detect position of the accelerator pedal.
ECM adjusts opening angle of the electronic throttle
according to this signal and other information to meet the
intake requirements under different operating conditions.
06
RA13T060570

(See page 10-17)

Electric Fuel Pump

Description
Electric fuel pump consists of DC motor, vane pump and end cover (integrated with check valve, pressure
regulator and anti-electromagnetic interference element), etc. Pump and motor are installed coaxially, and
sealed in the same housing. Fuel is filled around the pump and motor in housing and used for heat dissipation
and lubrication.
Operation
Battery supplies power to electric fuel pump via electric fuel pump relay, which can turn on electric fuel pump
circuit only when starting and engine running. When engine stops running because of an accident, fuel pump
stops running automatically. Maximum pressure at electric fuel pump outlet is adjusted by pressure regulator
to keep the whole fuel system pressure at 400 kPa.
06 Removal & Installation

(See page 08-14)

Fuel Injector
Description
Fuel injector is located on the cylinder head near to intake valve, and nozzle end is located directly above the
intake port.
Operation
Engine Control Module (ECM) sends electric pulse to injector coil, forming magnetic field force. When
magnetic field force increases enough to overcome the resultant force from return spring pressure, needle
valve gravity and friction force, the needle valve begins to rise up and the injector starts to inject fuel. Pressure
of return spring forces the needle valve to close again when injection pulse stops.

(See page 08-22)
06

Canister Solenoid Valve

Description
Electric throttle assembly is located on the intake manifold assembly.
Operation
Canister solenoid valve consists of solenoid coil, magnet
armature and valve, etc. Air volume through canister
solenoid valve is related to electric pulse duty ratio output
from ECU and pressure difference between canister
solenoid valve inlet and outlet. When there is no electric
pulse, canister solenoid valve closes.
06
RA13T060750

(See page 09-10)

Engine Control Module (ECM)

Description
Engine Control Module (ECM), mounted on the battery bracket in engine compartment, can be removed only
as a unit for replacement.
Operation
Engine Control Module (ECM) is a pre-programmed microprocessor digital computer, which is used to adjust
ignition timing, air-fuel ratio, emission control, speed control, A/C compressor and idle speed etc. Engine
Control Module (ECM) enables the program to suit ever-changing operation conditions.
Removal
06
3. Remove the Engine Control Module (ECM).
a. Disconnect the ECM connector (arrow).
b. Remove 4 ECM fixing bolts, and take off ECM.
RA13T062001
Installation
CAUTION
 Pay attention to static electricity protection when installing.

 Take care to protect connector terminals.
 To prevent water droplets from accumulating on connector joint, face it down.

- MEMO -

GENERAL INFORMATION 07-3 Installation 07-33
Description 07-3 Camshaft & Rocker Arm 07-34
Operation 07-3 Description 07-34
Specifications 07-3 Removal 07-35
Tools 07-9 Inspection 07-36
Installation 07-38
DIAGNOSIS & INSPECTION 07-15
Cylinder Head 07-41
Problem Symptoms Table 07-15
Description 07-41
Inspection 07-16
Removal 07-42
ON-VEHICLE SERVICE 07-19 Disassembly 07-43
Drive Belt 07-19 Inspection 07-44
Description 07-19 Assembly 07-47
Removal 07-20 Installation 07-48 07
Inspection 07-20 Flywheel 07-49
Installation 07-20 Removal 07-49
Idler Pulley Assembly 07-21 Inspection 07-49
Inspection 07-21 Crankshaft Rear Oil Seal 07-51
Tensioner Assembly 07-22 Installation 07-51
Removal 07-22 Engine Mounting Assembly 07-53
Inspection 07-22 Removal & Installation - Left Mounting
Installation 07-22 Assembly 07-53
Engine Timing Belt 07-23 Removal & Installation - Front 
Mounting Assembly 07-54
Description 07-23
Removal & Installation - Right 
Removal 07-24
Mounting Assembly 07-55
Inspection 07-25
Engine Assembly 07-56
Installation 07-26
Removal 07-56
Crankshaft Front Oil Seal 07-27
Removal 07-27 ENGINE BLOCK UNIT REPAIR 07-61
Installation 07-28 Engine Block 07-61
Camshaft Oil Seal 07-29 Description 07-61
Removal 07-29 Disassembly 07-63
Installation 07-30 Inspection 07-68
Cylinder Head Cover 07-31 Selection of bearing shell 07-76
Removal 07-31 Assembly 07-77

07

07 - SQRD4G15B ENGINE MECHANICAL
GENERAL INFORMATION
Description
SQRD4G15B engine has following features:
 VVT
 EGR
 Water cooled vertical
 In-line SOHC with 4 cylinders
 Four valves per cylinder
 Aluminum cylinder head
 Cast iron cylinder block
Operation
SQRD4G15B engine is vertical, in-line 4-cylinder, water-cooled, 4-stroke, four valves per cylinder, SOHC, 07
VVT and electronic controlled sequential multiport fuel injection. The engine adopts individual ignition system.
SQRD4G15B engine uses a cast iron cylinder block. Aluminum oil pan is fixed to the bottom of cylinder block
with bolts. Aluminum cylinder head is fixed to cylinder block with bolts. Camshafts are installed in the cylinder
head. The power output from crankshaft drives camshafts to rotate by crankshaft pulley and timing belt to
make camshafts interact with valve lifter to open and close valves. Piston assembly is an aluminum piston
with cast iron connecting rod. This engine has reliable structure and good performance.
Specifications
SQRD4G15B Engine Specifications
Item Specification
Engine Type VVT,Vertical, in-line 4-cylinder, water-cooled, 4-stroke, SOHC
Engine Model SQRD4G15B
Valve Number Per Cylinder 4
Cylinder Diameter (mm) 77.40
Piston Stroke (mm) 79.52
Displacement (ml) 1497
Compression Ratio 11.4:1
Combustion Chamber Type Pentroof type
Ignition Type Individual
Ignition Sequence 1-3-4-2
Idle Speed (r/min) 650 ± 50
Rated Power (kW) 78
Max. Torque (N·m) 135
Max. Torque Speed (r/min) 2750
Max. Permissible Speed (r/min) 6000
Min. Fuel Consumption Rate (g/
260
kW·h)

Item Specification
Max. Intake Valve Lift (mm) 8
Max. Exhaust Valve Lift (mm) 8
Exhaust Valve Closing Angle (1
338°
mm)
Intake Valve Closing Angle (1 mm) 571°
Exhaust Valve Opening Angle (1
143°
mm)
Fuel Octane Number (Not Less
Unleaded gasoline, octane number 93
Than)
In summer SAE 10W-40 (SL grade or higher)
Oil Octane Number
In winter SSAE 5W-40 (SL grade or higher)
07 Crankshaft Rotation Direction Counterclockwise (viewed from end surface of engine flywheel)
Starting Type Electrical starting
Cooling Type Forced circulation type antifreeze cooling
Lubrication Type Compound type (pressure, splash lubrication)
Cylinder Compression Pressure
10 - 13.5
(bar) (180 - 250) r/min
Idling Speed (650 ± 50 r/min) More than 1.5
Oil Pressure (bar)
High Speed (4000 ± 50 r/min) More than 3.5
With atmospheric temperature at -30°C, engine can start smoothly
within 8 seconds without taking special measures. Starting test shows
Starting Performance
that starting can be performed 3 times consecutively. If it fails to start
once, perform starting again after 2 minutes.
Engine Mechanical Specifications
Item Specification
Rocker Arm Shaft Bore Diameter of Intake Left +0.035
Rocker Arm Shaft Bore Diameter of Intake Right +0.035

Rocker Arm Shaft Intake Rocker Arm Shaft Diameter (mm) -0.002
Φ19 -0.015
Rocker Arm Shaft Bore Diameter of Exhaust Rocker +0.035
Arm Assembly (mm) Φ19 +0.017
Exhaust Rocker Arm Shaft Diameter (mm) -0.002

Φ19 -0.015
Intake Cam Lift (mm) 8
Exhaust Cam Lift (mm) 8
Camshaft
Camshaft Journal Diameter (mm) -0.02
Φ26 -0.033
Camshaft Axial Clearance (mm) 0.095 - 0.153

Item Specification
Lower Surface Flatness (mm) 0.055
Cylinder Head
Overall Height (mm) 97
Valve Stem Diameter Intake Valve Φ5.972 - Φ5.988

(mm) Exhaust Valve Φ5.952 - Φ5.968
Valve Head Margin Intake Valve 0.7

Thickness (mm) Exhaust Valve 0.5
Valve
Clearance Between Intake Valve 0.020 - 0.043
Valve Stem and Guide
(mm) Exhaust Valve 0.040 - 0.063
Intake Valve 107.998

Valve Height (mm)
Exhaust Valve 117.410
Free Height (mm) 47.7
Valve Spring 07
Preload (N) 249 - 271
Piston Piston Diameter (mm) Φ77.325 - Φ77.365
Piston Ring Side
Clearance (mm)
Oil Ring 0.03 - 0.16
Piston Ring
First Ring 0.28 - 0.355
Piston Ring End
Clearance (mm)
Oil Ring 0.2 - 0.6
Main Bearing Shell +0.007
Thickness (mm) Φ2.131 0
Radial Clearance (mm) 0.011 - 0.058

Axial Clearance (mm) 0.09 - 0.313
Crankshaft
Runout (mm) 0.05
Cylindricity (mm) 0.008
Roundness (mm) 0.005
Crankshaft Connecting
Rod Journal
Cylinder Bore Roundness (mm) 0.008
Cylinder Block Upper Surface Flatness (mm) 0.05
Cylinder Diameter (mm) Φ77.36 - Φ77.40
Big End Axial Clearance (mm) 0.333 - 0.387
Connecting Rod Connecting Rod Bearing Shell Radial Clearance
0.006 - 0.06
(mm)

Engine Torque Specifications

Power Steering Pulley Fixing Bolt 25 ± 3
Coupling Bolt Between Steering Pump and Fixing
25 ± 3
Bracket
Idler Pulley Assembly Torx Flange Fixing Bolt 45 ± 5
Tensioner Inner Torx Round Fixing Bolt 25 ± 3
Timing Belt Upper Cover Fixing Bolt 8+3
Crankshaft Pulley Fixing Bolt 105 - 115
Timing Belt Lower Cover Fixing Bolt 8+3
Timing Belt Tensioner Fixing Bolt 20 + 5
Idler Pulley Assembly Fixing Bolt 25 ± 3
07 Camshaft Phaser Cover 30 ± 5
Camshaft Phaser Cover Fixing Bolt 120 ± 6
Camshaft Position Sensor Fixing Bolt 10 ± 2
Fixing Bolt Between Cooling Pipe Assembly and
40 ± 4
Cylinder Block
1st step: 5 ± 1
Cylinder Head Cover Fixing Bolt
2nd step: 10 ± 1
1st step: 15 ± 1.5
Rocker Arm Shaft Fixing Bolt
2nd step: 30 ± 1.5
1st Bearing Cap Fixing Bolt 9.5 ± 1
Coupling Bolt Between Discharge Pipe and Cylinder
9±1
Head
1st step: 25 ± 1.5
2nd step: 40 ± 3
Cylinder Head Fixing Bolt
3rd step: clockwise rotate by 60 ± 5°
4th step: clockwise rotate by 60 ± 5°
1st step: 30 ± 2
Flywheel Fixing Bolt
2nd step: 45 ± 5°
65 ± 5
Transmission Case
65 ± 5
Left Mounting Cushion Assembly
Coupling Bolt Between Left Mounting Cushion
30 ± 3
Locking Nut of Through Bolt Between Front
Mounting Bracket and Front Mounting Cushion 65 ± 5
Assembly
25 ± 3


65 ± 5
25 ± 3
Mounting Cushion Assembly
Coupling Bolt Between Right Mounting Cushion
65 ± 5
65 ± 5
Engine Cylinder Block
45 ± 5
Assembly and Precatalytic Converter Assembly
Clutch Release Cylinder Pipe Coupling Plug 18 ± 2
Positive Wire Harness Fixing Nut 7±1
07
Fixing Bolt Between Negative Battery Wire Harness
20 ± 3
and Transmission Case
Fixing Bolt Between Cylinder Head Cover and
7±1
Ground Wire
A/C Compressor Bracket Fixing Bolt 45 ± 5
Knock Sensor Fixing Bolt 17 - 23
Exhaust Manifold Fixing Bolt 45 ± 5
1st step: 20 ± 1
Connecting Rod Bearing Cap Fixing Bolt
2nd step: 30 ± 3
Crankshaft Main Bearing Cap Fixing Bolt 90 - 100
Crankshaft Main Bearing Cap Stud 90 - 100
Piston Cooling Nozzle Fixing Bolt 20 + 5
Lubrication Areas during Engine Assembly

Piston Pin SL10W-40
Piston Ring SL10W-40
Piston SL10W-40
Cylinder Bore SL10W-40
Main Bearing Shell and Crankshaft Main Journal SL10W-40
Crankshaft Thrust Washer (Oil Groove Side) SL10W-40
Connecting Rod Bearing Cap Bolt Head and Thread SL10W-40
Connecting Rod Bearing Shell and Crankshaft
SL10W-40
Connecting Rod Journal
Main Bearing Cap Bolt Head SL10W-40
Crankshaft Front Oil Seal Lip and Crankshaft Oil
SL10W-40
Seal Journal


Crankshaft Rear Oil Seal Lip and Crankshaft Oil Seal
SL10W-40
Journal
Valve Guide Hole SL10W-40
Valve Stem SL10W-40
Camshaft Cam and Journal SL10W-40
Valve Rocker Arm Head SL10W-40
Valve Small End, Valve Rocker Arm Head SL10W-40
Valve Seat Hole (Cylinder Head Assembly) SL10W-40
Valve Guide or Guide Bottom Hole (Cylinder Head) SL10W-40
Camshaft Oil Seal Lip and Camshaft Journal SL10W-40
Oil Filter Gasket Surface SL10W-40
07 All engine lubricants should be 5W-40 (for winter)/10W-40 (for summer) SL grade or higher.
Areas with Seal Gum Applied during Engine Assembly
Area with Seal Gum Applied Seal Gum Type

Cylinder Block Bowl Plug Loctite 648
Loctite 5910
and Oil Pump
Loctite 5910
and Rear Oil Seal Bracket
Area Between Oil Pan Bottom Surface and Cylinder
Loctite 5910
Block Bottom Plane
Area Between Rear Oil Seal Bracket Bottom Surface
Loctite 5910
and Cylinder Block Bottom Plane
Loctite 5910
and Oil Pan
Cylinder Head Bowl Plug Loctite 648
1st Camshaft Bearing Cap Loctite 574
Spark Plug Socket Loctite 243
Coolant Temperature Sensor Loctite 243
Oil Pressure Switch Loctite 243
Intake/Exhaust Manifold Stud Loctite 271
Flywheel Bolt Thread Locker
Cylinder Head Cover Gasket and Bolt Loctite 5910

Tools
Special Tools
Crankshaft Front Oil Seal Guide Tool
RCH0000049
Crankshaft Front Oil Seal Installer 07
RCH0000067
Camshaft Oil Seal Installer
RCH0000017
Valve Spring Compression Adapter
RCH0000050
Valve Spring Compressor
RCH0000028

Crankshaft Rear Oil Seal Installer
RCH0000031
Valve Oil Seal Installer
07 RCH0000034
Valve Oil Seal Guide Sleeve
RCH0000035
Driven Disc Assembly, Clutch Cover Assembly,

Guide Special Tool
RCH0000018
Valve Oil Seal Remover
RCH0000037
Valve Cotter Installer
RCH0000029

Flywheel Holding Tool
RCH0000040
Oil Filter Remover
RCH0000054 07
General Tools
Piston Installer
RCH0000039
20
10
30
0
40
90
50

80
60
70
RCH0000023
1.5
50
1.0
5
0
Outer Diameter Micrometer

0.01mm
50 75mm
RCH0000064

Vernier Caliper
RCH0000019
Caliper Gauge
07 RCH0000069
RCH0000063
Feeler Gauge
RCH0000060
Cylinder Gauge
RCH0000065
Piston Ring Remover
RCH0000066

Digital Multimeter
RCH0000002
Flexional Magnetic Rod
RCH0000042 07
Engine Hoist
RCH0000043
Engine Equalizer
RCH0000026
RCH0000005
RCH0000048

RCH0000044
Engine Service Platform
07 RCH0000057

DIAGNOSIS & INSPECTION

Engine Problem Symptom Chart

Engine oil (oil level high or low, oil lean or
13-7
rich)
Cam 07-34
Valve mechanism noise
Valve spring seat (excessive runout) 07-41
Valve (excessive clearance between valve
07-41
and guide)
Engine oil (low pressure) 13-7
07
Engine oil (lean) 13-7
Connecting rod bearing cap (loose fixing
07-66
nut)
Connecting rod noise
Connecting rod (misaligned) 07-66
Connecting rod bearing shell (excessive
07-66
radial clearance)
Connecting rod journal (out-of roundness) 07-66
Engine oil (low pressure) 13-7
Engine oil (lean) 13-7
Main bearing shell (excessive clearance) 07-72
Main bearing noise Crankshaft axial clearance (excessive) 07-72
Crankshaft journal (out-of roundness or
07-72
worn)
Flywheel or clutch (loose) 07-49
Piston ring (worn, scratched or damaged) 07-66
Piston ring groove (carbon deposited) 07-66
Oil loss or spark plug blockage Valve oil seal (worn or damaged) 07-41
Valve (excessive clearance between valve
07-41
and guide)


Spark plug (dirty, burned or incorrect
14-10
clearance)
Electric fuel pump assembly 08-16
Ignition coil 14-8
Incorrect valve timing 07-23
Engine power loss Cylinder head (leaked) 07-41
Valve (burned, deformed or excessive
07-41
clearance)
Low cylinder pressure
Fuel system (dirty)
Exhaust system (blocked)
07
Inspection
1. Check the coolant (See page 12-11).
2. Check the engine oil (See page 13-7).
3. Check the battery (See page 16-7).
4. Check the air filter.
a. Remove the air filter element (See page 10-9).
b. Visually check that there is no dirt, blockage or damage in air filter element.
HINT:
 If there is any dirt or blockage in air filter element, clean it with compressed air.
 If any dirt or blockage remains, even after cleaning air filter element with compressed air, replace it.
5. Check the spark plugs (See page 14-10).
6. Test the cylinder compression pressure.
 Cylinder pressure is the main index to judge engine operation and also can be used to judge definitely,
whether some system of engine operates well or not. Therefore, it is necessary to perform cylinder
pressure measurement when servicing the engine.
 Ensure battery is fully charged and engine starter is in good operating condition. Otherwise, indicated
compression pressure used for diagnosis may be invalid.
CAUTION
 Recommended compression pressure is only used as a guide for diagnosing engine malfunction.
 Never determine cause of low pressure by disassembling engine unless there are some malfunctions.
Measurement Procedures

CAUTION
 Use a cylinder pressure gauge with accurate reading and reset it to zero. Otherwise, it will affect
accuracy of reading.
a. Turn off all electrical equipment and the ignition switch.

b. Remove the ignition coil.
 Disconnect ignition coil connectors (1) and (2).
 Remove 4 fixing bolts (arrow) from ignition coil. 1 2
(Tightening torque: 8 - 11 N·m)
07
RA13T140020
c. Disconnect all injector connectors.

d. Remove the spark plugs (See page 14-10).
e. Slowly screw cylinder pressure gauge connector
vertically into spark plug hole. Do not tighten it
excessively to prevent difficult removal.
RA13T070010
CAUTION
 DO NOT tighten the cylinder pressure gauge excessively to prevent difficult removal.
f. With transmission in neutral position, depress accelerator pedal fully, then start engine and keep it
racing for 3 to 5 seconds to measure and record pressure value.
g. Press bleeder button of cylinder pressure gauge to reset it to zero. Repeat this test three times and
then calculate average test value.
Standard value for cylinder pressure: 10 - 13.5 bar
CAUTION
 During measurement, do not turn ignition switch to "START" for more than 10 seconds. Otherwise,
engine may be damaged.
 Ensure battery is fully charged when cranking engine. Correct cylinder pressure can be measured only
when engine is running at 200 - 300 r/min.
 Use same method to measure pressure of other cylinders.

Cylinder Pressure Value Judgment

 Correct cylinder pressure
- Standard cylinder pressure value is between 10 and 13.5 bar and will drop slightly with usage of
engine. But lowest value cannot be below 9 bar and pressure difference between each cylinder
should not be above 3 bar.
 If cylinder pressure of engine is lower than standard value, it indicates that cylinder pressure is
insufficient. Add a small amount of engine oil through spark plug hole and perform measurement
again.
- If pressure increases after adding oil, piston ring or cylinder bore may be worn or damaged.
- If pressure remains low, a valve may be stuck or not properly installed or there is air leakage from
cylinder head gasket.
h. Install the spark plugs (See page 14-10).
i. Connect all injector connectors (See page 08-22).
j. Install the high-voltage cable.
7. Test cylinder head gasket.
07 Cylinder head gasket leakage may be present between adjacent cylinders, between cylinder and adjacent
water jacket or from an oil passage to the external of engine.
 Possible indications of cylinder head gasket leakage between adjacent cylinders are as follows:
- Engine power loss
- Engine stall
- Low fuel economy
 Possible indications of cylinder head gasket leakage between cylinder and adjacent water jacket are as
follows:
- Engine overheating
- Coolant loss
- Excessive steam (white smoke) emitted from exhaust system
- Coolant foaming

ON-VEHICLE SERVICE
Drive Belt
Description
07
2
6
3
5
8
RA13T070020
1 - Alternator 2 - V-ribbed Belt

3 - Idler Pulley 4 - A/C Compressor
5 - Power Steering Pump Pulley 6 - V-ribbed Belt Tensioner
7 - Crankshaft Pulley 8 - Power Steering Pump Belt

Removal
4. Raise vehicle to a proper position.
5. Remove the power steering pump belt (See page 29-15).
6. Remove the V-ribbed belt.
a. Rotate V-ribbed drive belt tensioner assembly in
direction of arrow as shown in illustration with a
wrench (2), while aligning lock hole of tensioner with
lock hole of bracket, and insert lock pin (1) to lock 1
tensioner. 3
b. Remove the V-ribbed belt (3).
2
07
RA13T070040
Inspection
1. Check the V-ribbed belt.
Visually check V-ribbed belt for excessive wear, frayed
cords, etc. If any defect has been found, replace V-ribbed
belt.
Right Wrong Wrong

RA13T070041
HINT:
 Cracks on the rib side of a V-ribbed belt are considered acceptable. If drive belt has chunks missing from
its ribs, it should be replaced.
 After installing V-ribbed belt, check that it fits properly in ribbed grooves. Check that belt has not slipped
out of grooves on bottom of the crankshaft pulley by hands.
Installation

Idler Pulley Assembly

Removal
3. Loosen the V-ribbed belt.
tensioner. 3
b. Move away the V-ribbed belt (3).
RA13T070040 07
4. Remove the idler pulley assembly.
a. Remove the idler pulley fixing bolt (arrow).
RA13T070050
b. Remove the idler pulley assembly.
Inspection
1. Rotate idler pulley by hands and check if rotation is smooth and if abnormal noise occurs.
2. Wiggle idler pulley in axial and radial directions to check bearing for looseness.
3. Check if there is damage on idler pulley assembly operating surface.
Installation
CAUTION
 After installation, turn crankshaft with a wrench to run V-ribbed belt several circles, and check if
crankshaft turns smoothly and belt runs well. If it does not turn smoothly, reinstall V-ribbed belt.
 Make sure to correctly install V-ribbed belt, and it does not interfere with other components.

Tensioner Assembly
Removal
3. Loosen the V-ribbed belt.
tensioner. 3
07 RA13T070040
4. Remove the tensioner assembly.

a. Remove 3 tensioner inner torx round fixing bolts
(arrow).
(Tightening torque for inner torx round bolts: 25 ± 3
N·m)
RA13T070051
b. Remove the tensioner assembly.
Inspection
1. Rotate tensioner assembly by hands and check if rotation is smooth and if abnormal noise occurs.
2. Wiggle tensioner assembly in axial and radial direction to check bearing for looseness.
3. Check if there is damage on tensioner assembly operating surface.
Installation
CAUTION
 After installation, turn crankshaft with a wrench to run V-ribbed belt several circles, and check if
crankshaft turns smoothly and belt runs well. If it does not turn smoothly, reinstall V-ribbed belt.
 Make sure to correctly install V-ribbed belt, and it does not interfere with other components.

Engine Timing Belt

Description
2 3 4
1
×2 7 ×2
07
8
×4
×4
13
10
14 11
15
12
RA13T070060
1 - Timing Belt Upper Cover 2 - Timing Belt

3 - Phaser fixing plug 4 - Phaser fixing bolt
5 - Phaser 6 - Timing Belt Tensioner
7 - Idler Pulley 8 - Water Pump Assembly
9 - Engine Assembly 10 - Crankshaft Timing Pulley Washer
11 - Crankshaft Timing Pulley 12 - Timing Belt Lower Cover
13 - Crankshaft Pulley 14 - Crankshaft Pulley Fixing Bolt Washer
15 - Crankshaft Pulley Fixing Bolt

Removal
3. Remove the drive belt (See page 07-19).
4. Remove the timing belt cover.
a. Loosen and remove 3 fixing bolts (arrow), and remove
timing belt upper cover (1).
1
(Tightening torque: 8 ＋ 3 N·m)
RA13T070070
07 b. Rotate crankshaft pulley to align mark (arrow) on
camshaft timing pulley (1) and mark (2) on cylinder
head as shown in illustration. Also, align mark (3) on
crankshaft pulley and the fifth protrusion mark (4) on 2
timing belt lower cover.
1
RA13T070080
c. Loosen and remove fixing bolt (arrow), and remove

crankshaft pulley.
RA13T070090
HINT:
Shift transmission into 5th gear when loosening crankshaft pulley fixing bolt to engage crankshaft and
propeller shaft. Another technician depresses brake pedal, which can lock the crankshaft by mechanical
gear train.

d. Loosen and remove 3 fixing bolts (arrow), and remove

timing belt lower cover (1).
RA13T070100
5. Remove the timing belt.

a. Remove fixing bolt (1) and idler pulley assembly.
b. Remove 2 fixing bolts (arrow) and timing belt
tensioner.
(Tightening torque: 20 ＋ 5 N·m) 07
2
RA13T070110
c. Remove the timing belt (2).
Inspection
1. Check the timing belt.
CAUTION
 Check timing belt carefully before installation, replace it to avoid any of following conditions.
If timing belt has following conditions, replace it.

a. Cracks on back of belt: as shown in illustration (1).
b. Cracks at cord fabric layer and bottom of belt: as 1
shown in illustrations (2), (3) and (5).
c. Belt worn: as shown in illustration (6).
2
d. Belt teeth missing and damaged: as shown in
illustrations (4) and (6). 4
3
6
5
RA13T070120

2. Check the timing belt tensioner.

a. Rotate timing belt tensioner by hands and check if
rotation is smooth and if abnormal noise occurs.
b. Wiggle timing belt tensioner in axial and radial
direction to check if there is slackness.
c. Check if there is damage on timing belt tensioner
surface.
RA13T070121
Installation
1. Install timing belt and be sure that arrow mark on
camshaft phaser is aligned with upper mark on cylinder
(upper left local figure). Also, protrusion mark on
07 crankshaft timing pulley is aligned with mark on oil pump
house (lower right local figure). 1
2. Check if timing belt is correctly installed to camshaft
phaser (1), timing belt tensioner (5), water pump pulley
(4) and crankshaft timing pulley (3). 2
5
RA13T070130
CAUTION
 Crankshaft and camshaft must be locked when installing timing belt.
3. Rotate crankshaft for one turn to check if timing mark is offset. Remove and reinstall belt if necessary.
Other procedures are in the reverse order of removal.

Crankshaft Front Oil Seal

Removal
4. Remove the engine timing belt (See page 07-23).
5. Remove crankshaft timing pulley (1) and crankshaft
timing pulley washer (2) from crankshaft.
2
1
FRONT
07
RA13T070140
6. Remove the crankshaft front oil seal.

a. Using a flat tip screwdriver with tip wrapped with tape,
pry out crankshaft front oil seal (arrow).
RA13T070141
CAUTION
 Be careful not to damage oil seal retainer and surface of crankshaft, when removing crankshaft front oil
seal.

Installation
1. Install crankshaft front oil seal guide tool (3) to crankshaft
(4).
2. Install new oil seal (2) to crankshaft front oil seal guide 4
tool, then install new oil seal fully into oil seal retainer with 3
crankshaft front oil seal installer (1). 2
1
RA13T070142
CAUTION
 Apply a coat of engine oil to the crankshaft front oil seal guide tool before installing a new oil seal.
 Remove dirt on oil seal retainer and apply a coat of engine oil to oil seal retainer and oil seal lip before
07 installation.
 Be sure to prevent the lip of crankshaft front oil seal from being scratched during installation. If it is
damaged, replace immediately.
Other installation procedures are in the reverse order of removal.

Camshaft Oil Seal

Removal
5. Remove the cylinder head cover (See page 07-31).
6. Remove the rocker arm shaft (See page 07-34).
7. Remove the camshaft timing pulley.
a. Hold hexagon position on camshaft with a tool, and
remove camshaft phaser fixing cover with a wrench in
direction of arrow as shown in illustration.
07
RA13T070150
CAUTION
 Check if cover seal ring is in good condition before installation.
b. Hold camshaft with a tool, and remove camshaft

phaser fixing bolt with a wrench in direction of arrow
as shown in illustration.
RA13T070151
c. Remove the phaser.

8. Remove the camshaft oil seal.
a. Using a flat tip screwdriver with tip wrapped with tape,
pry out camshaft oil seal (arrow).
RA13T070160

CAUTION
 Be careful not to damage oil seal retainer and surface of camshaft, when removing camshaft oil seal.
Installation
1. Using a special tool (camshaft oil seal installer) (1), install
new oil seal (2) to camshaft (3).
3
2
07 RA13T070161
CAUTION
 Remove dirt on oil seal retainer and apply a coat of engine oil to oil seal retainer and oil seal lip before
installation.
 Be sure to prevent the lip of crankshaft front oil seal from being scratched during installation. If it is
damaged, replace immediately.
2. Dowel pin on back side of phaser and positioning hole of camshaft should be fitted in place when installing
phaser.

Cylinder Head Cover

Removal
4. Blow dirt and debris away from upper surface of cylinder head cover with compressed air.
5. Remove intake hose and crankcase ventilation hose assembly.
a. Loosen elastic clamp (arrow) and disconnect
crankcase ventilation hose from cylinder head cover.
07
RA13T070170
b. Remove the crankcase ventilation hose assembly.

6. Remove the ignition coil (See page 14-8).
7. Remove the PCV valve (See page 09-11).
8. Remove the camshaft position sensor.
a. Disconnect camshaft position sensor connector (1).
b. Remove the camshaft position sensor fixing bolt
(arrow).
1
RA13T070180
c. Remove camshaft position sensor from cylinder head cover.

9. Remove the cylinder head cover.
a. Remove 2 fixing bolts (arrow), and disconnect 2
ground wires from cylinder head cover. 1
RA13T070181
b. Remove fixing bolt (1) and move away wire harness bracket.

c. Remove 4 fixing bolts (arrow) from discharge pipe

assembly, and remove 2 front bracket assembly (1). 1
RA13T070185
d. Loosen 2 fixing bolts (arrow) from timing belt upper

cover, and remove oil dipstick.
07
RA13T070186
e. Remove cylinder head cover fixing bolts in order

shown in illustration. 6 9 13 10 5
(Tightening torque: 1st step: pre-tighten to 5 ± 1 N·m,
2nd step: tighten to 10 ± 1 N·m)
2
1
3
4
7 8 12 11
RA13T070190
f. Remove cylinder head cover from cylinder head.
CAUTION
 Remove oil and seal gum on cylinder head cover with a special tool.
10.Remove the cylinder head cover gasket.

Installation
1. Replace cylinder head cover gasket and spark plug guide gasket.
2. Install cylinder head cover gasket into groove on cylinder
head cover, and apply seal gum to cylinder head cover
gasket in elliptical areas as shown in illustration.
RA13T070191
3. Hold cylinder head cover with your hands, pass spark plug guide through gasket and press it forcefully to
match head cover with bolt hole of cylinder head, and install head cover to cylinder head after aligning.
Carefully handle during assembly to avoid gasket falling out from head cover, and it should be assemblied
in place once to prevent adhesive offset.
07
4. Install head cover bolts to cylinder head cover in order shown in illustration, and pay attention to following
procedures:
a. Install bolts and tighten them in place by hands.
b. Pre-tighten them with a force of 5 ＋ 1 N·m in
sequence;
8 5 1 4 9
c. Tighten them with a force of 10 ＋ 1 N·m in sequence;
12
13
11
10
7 6 2 3
RA13T070200

Camshaft & Rocker Arm

Description
2 1
4 3
×4 ×4
×4
5
6 ×4
9 8 7
10
07 11
13 16
12
15
14
RA13T070210

1 - Intake Rocker Arm Shaft 2 - Intake Right Rocker Arm Assembly

3 - Intake Rocker Arm Bushing 4 - Intake Left Rocker Arm Assembly
5 - Exhaust Rocker Arm Shaft 6 - Exhaust Rocker Arm Assembly
7 - 5th Bearing Cap 8 - 4th Bearing Cap
9 - 3rd Bearing Cap 10 - 2nd Bearing Cap
11 - 1st Bearing Cap 12 - Phaser
13 - Phaser fixing bolt 14 - Camshaft Phaser
15 - Camshaft Oil Seal 16 - Camshaft
Removal
3. Remove the engine trim cover. 07
5. Remove the accessory drive belt (See page 07-19).
7. Remove the cylinder head cover assembly (See page 07-31).
8. Remove the camshaft oil seal (See page 07-29).
9. Remove rocker arm shaft and camshaft.
a. Remove 10 fixing bolts in order shown in illustration,
remove rocker arm shaft with rocker arm assembly
and store them carefully.
2 8 10 6 4
3 5 9 7 1
RA13T070220
b. Remove 2 fixing bolts (arrow), and remove camshaft

bearing caps (1) to (5) in order, then remove camshaft
(6).
6
(Tightening torque: 9.5 ± 1 N·m)
1 2 3 4 5
RA13T070230

c. Place removed parts on workbench in order.
RA13T070240
d. Place intake and exhaust rocker arms and rocker

shafts in an assembly relationship on workbench after
disassembling.
07
RA13T070250
Inspection
1. Check the rocker arm shaft
a. Check the rocker arm shaft diameter.
Measure intake/exhaust rocker arm shaft diameter
with an outer diameter micrometer.
Specification
Measurement Item
(mm)
Intake Rocker Arm Shaft Diameter -0.002
Φ19 -0.015
Exhaust Rocker Arm Shaft Diameter -0.002
Φ19 -0.015
RA13T070260
If intake/exhaust rocker arm shaft diameter is not
within specified range, replace intake/exhaust rocker
arm shaft.
2. Check the valve rocker arm assembly.
a. Check rocker arm retainer for damage and rocker arm
lifter head for damage or falling off. If there is damage
or if it has fallen out, replace valve rocker arm
assembly. 1
b. Check if roller rotates freely. If it cannot rotate freely or

it is too loose, replace valve rocker arm assembly.
c. Check the valve rocker arm hole. If it is damaged or
too tight, replace valve rocker arm assembly.
RA13T070270

d. Check the rocker arm shaft bore diameter of intake

rocker arm assembly.
Measure rocker arm shaft bore diameter of intake left/
right rocker arm assembly with an inner diameter
micrometer.
Specification
Measurement Item
(mm)
Rocker Arm Shaft Bore Diameter of +0.035
Intake Left Rocker Arm Assembly Φ19 +0.017 RA13T070280

Intake Right Rocker Arm Assembly Φ19 +0.017
If rocker arm shaft bore diameter of intake left/right

rocker arm assembly is not within specified range,
replace intake left/right rocker arm assembly.
e. Check the rocker arm shaft bore diameter of exhaust 07
rocker arm assembly.
Measure rocker arm shaft bore diameter of exhaust
rocker arm assembly with an inner diameter
micrometer.
Specification
Measurement Item
(mm)
Exhaust Rocker Arm Assembly Φ19 +0.017 RA13T070290
If rocker arm shaft bore diameter of exhaust rocker

arm assembly is not within specified range, replace
exhaust rocker arm assembly.
3. Check the camshaft.
a. Check the appearance.
 Check if there are scratches on camshaft bearings and cam surfaces. If there are scratches, repair
or replace camshaft.
 Check if there are leaking holes and cracks in camshaft bearing caps. If there are leaking holes or
cracks, replace camshaft.
b. Check the camshaft journal diameter.
Measure camshaft journal diameter with an outer
diameter micrometer.
Specification
Measurement Item
(mm)
Camshaft Journal Diameter -0.02
Φ26 -0.033
If camshaft journal diameter is not within specified

RA13T070300
range, replace the camshaft.

c. Check the cam lift.

Measure cam lift with an outer diameter micrometer
A
 Cam Lift Height: Measurement A - Measurement B
B B
Specification
Measurement Item
(mm)
A
Intake Cam Lift 8
Exhaust Cam Lift 8
RA13T070310
If camshaft cam lift is not within specified range,
replace the camshaft.
d. Check the camshaft axial clearance.
 Reinstall the camshaft.
 Remove rocker arm and reinstall rocker arm shaft,
install rocker arm shaft bolt and tighten it in 2
07 steps. 1st step: tighten to 15 ± 2 N·m, and 2nd
step: tighten to 30 ± 3 N·m. After pre-tightening
70
80
60
rocker arm shaft bolts, tighten bolts on both sides
90
50
0
40
10
of 1st bearing cap to 9.5 ± 1 N·m.
30
20
 Keep plunger of dial indicator in contact with front
end of camshaft. Push camshaft forward and
backward gently (do not rotate camshaft) and read RA13T070320
value from dial indicator.
Specification
Measurement Item
(mm)
Camshaft Axial Clearance 0.095 - 0.153
If camshaft axial clearance is not within specified range,

replace the camshaft.
Installation
1. Clean intake and exhaust rocker arm shafts, camshaft
and camshaft bearing caps. 1
2. Check for any residue or impurities on rocker shaft hole.
RA13T070321
CAUTION
 Distinguish intake and exhaust rocker arm shafts. There are 4 grooves on intake rocker arm shaft (1) (to
avoid spark plug pipe), but there is no groove on exhaust rocker arm shaft (2).
 Check that there should be no burr, overlap or chips on each oil hole of rocker arm shaft and chamfers on
both ends of oil guide when assembling.
 Rocker arm shaft outer surface should be clean without residue or foreign matter.

3. Check if intake and exhaust rocker arm heads and intake

rocker arm bushing are normal. Apply engine oil to rocker
shaft, and install rocker arm to rocker arm shaft.
RA13T070330
4. Apply engine oil to contact surface of camshaft (1), and

install camshaft.
07
1
RA13T070340
5. Clean the camshaft bearing cap. Apply seal gum into

sealing area (arrow) of 1st camshaft bearing cap as
shown in the illustration.
RA13T070341
6. Apply engine oil to cam and camshaft journal, and install

camshaft bearing caps (1) to (5) in order.
1 2 3 4 5
RA13T070350
CAUTION
 Dowel pin on camshaft bearing cap should match with clearance of cylinder head. When installing
camshaft bearing cap, place your hand to correct position and tap it in place with a rubber hammer.
There is resistance when rotating camshaft (6) by hands.
7. Install intake rocker arm shaft assembly (big chamfer end should face 1st camshaft bearing cap, without
being reversed.), adjust rocker arm to place it onto bearing seat bracket.

8. Install exhaust rocker arm shaft assembly (big chamfer end should face 1st camshaft bearing cap, without
being reversed.), adjust rocker arm without rotating camshaft, and make sure that all exhaust rocker arms
are not interfere with bearing race and intake rocker arm.
9. Install the rocker arm shaft bolts. Tighten rocker arm shaft
fixing bolts in sequence from (1) to (10) shown in
illustration.
2 8 10 6 4
(Tightening torque: 1st step: tighten to 15 ± 2 N·m, 2nd
step: tighten to 30 ± 3 N·m)
10.After pre-tightening rocker arm shaft bolts, tighten bolts
(arrow) on both sides of 1st bearing cap.
3 5 9 7 1
RA13T070360
11. After tightening rocker arm shaft bolts, apply a proper amount of engine oil to roller of rocker, and make
sure that there is a proper amount of engine oil on contact surface between roller and camshaft.
07

Cylinder Head
Description
1
2
4
5 ×10
8
6
×4
9 ×10
7
18 ×2
07
×8
10
17
×7
11
19
12
16 13
20
15
14
21
22
RA13T070370

1- Valve Cotter 2 - Valve Spring Upper Seat

3 - Valve Spring 4 - Valve Oil Seal
5 - Valve Spring Lower Seat 6 - Valve Guide
7 - Spark Plug Socket 8 - Cylinder Head Fixing Bolt
9 - Cylinder Head Fixing Bolt Washer 10 - Cylinder Head
11 - Stud 12 - Cylinder Head Gasket
13 - Intake Valve Seat 14 - Intake Valve
15 - Exhaust Valve 16 - Exhaust Valve Seat
17 - Bowl Plug 18 - Stud
19 - Gasket - Upper Cover Plate 20 - Upper Cover Plate - EGR
21- Gasket - Lower Cover Plate 22 - Lower Cover Plate - EGR
07 Removal
1. Release the fuel system pressure (See page 08-10).
4. Drain the coolant (See page 12-12).
6. Remove the spark plugs (See page 14-10).
7. Remove the thermostat seat (See page 12-20).
8. Remove the EGR valve (See page 09-12).
9. Remove the fuel rail injector assembly (See page 08-22).
10.Remove the electronic throttle assembly (See page 10-11).
11. Remove the intake manifold assembly (See page 10-15).
12.Remove the exhaust manifold assembly (See page 11-7).
13.Remove the alternator and alternator bracket (See page 16-10).
14.Remove the engine timing belt (See page 07-23).
15.Remove the camshaft oil seal (See page 07-29).
16.Remove the DVVT.
a. Remove the DVVT connector (1).
b. Remove the fixing bolt (arrow).
(Tightening torque: 8 + 2 N·m)
RA13T070380
17.Remove the camshaft and rocker arm shaft (See page 07-34).

18.Remove cylinder head fixing bolts (1) to (10) in order

shown in illustration. 1 5 9 7 3
2 6 10 8 4
RA13T070390
CAUTION
 Failure to follow the sequence to remove cylinder head bolts will cause cylinder head deformation.
19.Remove the cylinder head and cylinder head gasket. 07

CAUTION
 Replace washer with a new one.
Disassembly
1. Remove 4 fixing bolts (arrow), and remove EGR cover
plate.
(Tightening torque: 10 ± 1 N.m)
RA13T070395
2. Using a special tool (valve spring compressor), compress

valve spring and remove valve cotter with a flexional
magnetic rod.
RA13T070400

3. Remove the valve spring upper seat (1), valve spring (2)
and valve (3) from cylinder head. 1
2
RA13T070410
4. Using a valve oil seal remover (1), remove the valve oil
07 seal (2).
1
RA13T070420
5. Using a flexional magnetic rod, remove the valve spring lower seat.
Inspection
1. Check the cylinder head.
a. Check the appearance.
 Check if there are scratches on camshaft bearing journals.
 Remove carbon deposits and varnish inside valve guides with valve guide cleaner.
 Make sure valve cotters can move and rotate freely.
b. Check the cylinder head flatness.
Using a precision straightedge and feeler gauge, check
cylinder head flatness. Cylinder head flatness must be
within 0.04 mm.
Specification
Measurement Item
(mm)
Cylinder Head Flatness 0.04
If cylinder head flatness is not within specified range,

modify or replace it. RA13T070430

c. Check the cylinder head height.

Using a precision straightedge, measure cylinder
head height.
Specification
Measurement Item
(mm)
a
Cylinder Head Height 97
If cylinder head height is not within specified range,

replace the cylinder head.
RA13T070440
CAUTION
 During replacement, cylinder head should be fully equipped with valves, oil seals, springs, seats, cotters,
hydraulic lifters and crankshaft.
07
2. Check the valve spring.
Using a vernier caliper, measure free height of valve
spring and length of valve spring under pre-pressure of
249 - 271 N.
Specification
Measurement Item
(mm)
Valve Spring Free Length 47.70
Valve Spring Length Under Pre-
41 RA13T070450
pressure
If valve spring length is not within specified range,

replace the valve spring.
3. Check the valve.
a. Clean the valve.
 Using a scraper, remove carbon deposited on
valve head.
 Using a wire brush, clean the valve thoroughly.
RA13T070460

b. Check the valve height.

Using a vernier caliper, measure the valve height.
Specification
Measurement Item
(mm) Total Height
Intake Valve Height 107.998

Exhaust Valve Height 117.410
If height is less than specified value, replace the

RA13T070470
valve.
c. Check the valve head.
Measure valve head with a vernier caliper.
Specification
Measurement Item
(mm)
b
07 Intake Valve Head Thickness 0.7
Exhaust Valve Head Thickness 0.5 a
Valve Face Width a of Intake Valve 2.83

RA13T070480
Valve Face Width b of Exhaust Valve 2.26
If not within specified range, replace the valve.

d. Check the valve stem diameter.
Using a micrometer, measure the valve stem
diameter.
Specification
Measurement Item
(mm)
Intake Valve Stem Diameter Φ5.972 - Φ5.988
Exhaust Valve Stem Diameter Φ5.952 - Φ5.968
RA13T070490
If valve stem diameter is not within specified range,
check clearance between valve stem and valve guide.
e. Check clearance between valve stem and valve
guide.
 Install a dial indicator (1) to bracket (2). Install 1
intake valve or exhaust valve to guide to be
inspected.
 Check clearance between valve stem and valve
guide with the dial indicator. Pull valve guide 2
approximately 10 mm from valve to be inspected,
and slightly wiggle valve to measure clearance
between valve and valve guide. RA13T070500
Specification
Measurement Item
(mm)
Clearance Between Intake Valve and
0.020 - 0.043
Guide
Clearance Between Exhaust Valve
0.040 - 0.063
and Guide

If clearance is not within specified range, replace

valve or valve guide.
Assembly
HINT:
Clean all components to be assembled thoroughly before assembly.
1. Install valve (1) into cylinder head.
HINT: 5
4
 Distinguish intake valves and exhaust valves during
3
installation. 2
 Apply a light coat of engine oil to valve stem end,
when assembling valve.
2. Install new valve spring lower seat (2) if necessary.
3. Install the valve oil seal.
HINT: 07
Apply a light coat of engine oil to installation surface of
valve oil seal end, when assembling valve oil seal.
1
a. Install valve oil seal guide (3) to valve stem.
b. Install valve oil seal (4) to valve oil seal guide sleeve. RA13T070510
c. Tap valve oil seal installer lightly with a rubber

hammer to install valve oil seal in place.
4. Install valve cotter (1) to valve cotter installer (2).
2
1
RA13T070520
5. Install valve spring (1) and valve spring upper seat (2).
6. Using a valve spring compressor, compress valve spring
and install valve cotter (3) in place. 3
2
RA13T070530
7. Tap valve cotter lightly with a rubber hammer to make sure cotter is installed in place after assembly.

Installation
CAUTION
 Remove residual seal gum and oil on cylinder head and cylinder block.
 Replace O-ring and cylinder head gasket.
 Check that cylinder head gasket is neat and clean without any chips and scratches. The side stamped
with part number of cylinder head gasket should face upward.
 Install cylinder head gasket to flat surface of cylinder block with a dowel pin.
 Clean joint surfaces between cylinder head and combustion chamber, together with flat surface of
cylinder block top and thread hole.
 During installation, piston should not be located at the top dead center, in order to prevent it from being
impacted by opening valve, when installing the rocker arm.
 Install the cylinder head bolt washer with chamfering surface facing upward and flat side facing cylinder
head.
07
1. Make sure to tighten cylinder head fixing bolts in sequence from (1) to (10) shown in illustration:
a. Apply a small amount of oil to bolt head and root.
b. Install bolts and tighten them in place by hands.
c. Tighten cylinder head fixing bolts in following
procedures: 10 6 2 4 8
 1st step: Tighten bolts to 25 ± 1.5 N·m in sequence
from (1) to (10) shown in illustration.
 2nd step: Tighten bolts to 45 ± 3 N·m in sequence
from (1) to (10) shown in illustration.
 3rd step: Rotate bolts clockwise by 60° ± 5° in
tightening sequence.
 4th step: Rotate bolts clockwise by 60° ± 5° again 9 5 1 3 7
in tightening sequence. RA13T070540
CAUTION
 Check cylinder head fixing bolts before installation. If they are damaged, replace immediately.
 Be sure to tighten cylinder head bolts strictly according to operating procedures above, to achieve the
technology standard for vehicle usage.
2. Other installation procedures are in the reverse order of removal.

Flywheel
Removal
3. Remove the transmission assembly (See page 17-20, 18-82).
4. Remove the clutch assembly (See page 19-17).
5. Using a special tool (flywheel holding tool (7)), lock
flywheel and remove bolts in sequence from (1) to (6)
shown in illustration, then remove flywheel (8). 5
3
7
1
8
6 2 07
4
RA13T070550
WARNING
 Pay special attention to safety during operation.

 Do not remove all fixing bolts without any auxiliary measures.
CAUTION
 Flywheel fixing bolts must be disposed after removal. Never reuse them.
Inspection
1. Check if crankshaft position signal gear is distorted or deformed. If damaged, replace flywheel. Clean
signal gear before installation.
2. Check if starter drive gear ring is worn. If excessively worn, replace flywheel.
3. Check flywheel clutch lining contact surface. If contact surface is damaged or excessively worn, replace
flywheel with a new one.
4. Measure flywheel end surface runout with a dial indicator.
If measured value exceeds the limit, replace flywheel with
a new one.
Limit for end surface runout: 0.1 mm
RA13T070560

Installation
WARNING
 Never reuse flywheel fixing bolts after removal.

 Make sure to apply seal gum to flywheel fixing bolts, before bolting on flywheel.
CAUTION
 Six bolt holes on the flywheel have asymmetrical positions. There is a matchmark hole on flywheel. The
mark hole is located right above when 1st cylinder of engine is at top dead center and flywheel fixing
bolts are aligned with bolt holes of crankshaft.
07 Installation procedures are in the reverse order of removal, and pay attention to the following:
1. Align flywheel installation hole with crankshaft positioning journal and then lightly push flywheel onto the
journal. DO not tap flywheel with a hammer.
2. Replace the flywheel fixing bolts with new ones and apply seal gum to the bolt threads.
3. Install flywheel (8), and then hold flywheel securely with
flywheel holding tool (7), then tighten flywheel fixing bolts
in sequence from (1) to (6) in 2 steps. 5
 1st step: 30 ± 2 N·m 3
 2nd step: 45 ± 5°.
7
1
8
6 2
4
RA13T070550

Crankshaft Rear Oil Seal

Removal
3. Remove the transmission assembly (See page 17-20, 18-82).
4. Remove the clutch assembly (See page 19-17).
5. Remove the flywheel (See page 07-49).
6. Remove the crankshaft rear oil seal.
a. Using a screwdriver with the tip wrapped with tape,
remove crankshaft rear oil seal (1). 1
07
RA13T070561
CAUTION
 Be careful not to damage surrounding parts and oil seal retainer, when removing oil seal.
 Be careful not to damage oil pan gasket, when removing rear oil seal bracket.
Installation
CAUTION
 Be sure to clean dirt around oil seal retainer and on inside wall before installation.
 Check oil seal for damage before installation. If there is any damaged, replace it.
 Be sure to prevent the lip of crankshaft rear oil seal from being scratched during installation.
 Be careful not to damage oil seal retainer during installation.
1. Install new gasket and rear oil seal bracket.

2. Using crankshaft rear oil seal installer (1), install oil seal
(2) with the part number side facing outward.
2
1
RA13T070570

HINT:
Apply a coat of engine oil to rear oil seal lip or crankshaft rear oil seal journal.
07

Engine Mounting Assembly

Removal & Installation - Left Mounting Assembly
3. Support the transmission with a transmission carrier.
4. Remove the engine left mounting cushion assembly.
a. Remove coupling bolt (arrow) between left mounting
bracket and left mounting cushion assembly.
07
RA13T070580
b. Remove 3 coupling bolts (arrow) between left

mounting bracket and right side of transmission case.
RA13T070590
c. Remove the left mounting bracket.

5. Remove the engine left mounting cushion assembly.
a. Remove 2 coupling bolts (arrow) between left
mounting cushion assembly and front sub frame
welding assembly.
RA13T070591
b. Remove the left mounting cushion assembly.


Removal & Installation - Front Mounting Assembly
CAUTION
 Install protector to prevent body from being scratched.

3. Use an engine equalizer to hang the engine.
5. Remove the air filter assembly (See page 10-10).
6. Remove the engine front mounting bracket.
a. Remove locking nut (1) of through bolt between front
mounting bracket and front mounting cushion
07 assembly.
(Tightening torque: 65 ± 5 N·m) 2
b. Remove 2 coupling bolts (arrow) between front

mounting bracket and transmission case.
1
RA13T070600
c. Remove coupling bolt (2) between front mounting bracket and cylinder block.
d. Remove the front mounting bracket.
7. Remove the front mounting cushion assembly.
a. Remove fixing bolt (arrow) from front mounting
cushion assembly.
b. Remove 2 fixing bolts (1) from front mounting cushion
assembly.
1
RA13T070610
c. Remove the front mounting cushion assembly.

8. Installation is in the reverse order of removal.

Removal & Installation - Right Mounting Assembly
CAUTION

5. Remove the engine right mounting cushion assembly.
a. Remove 3 coupling bolts (arrow) between right
mounting bracket and right mounting cushion
assembly.
RA13T070620
b. Remove 2 engine left mounting cushion assembly

fixing bolts (arrow) from front sub frame welding
assembly.
RA13T070630
c. When removing engine right mounting cushion assembly, support engine with a transmission carrier,
and remove right mounting cushion assembly.
6. Remove the engine right mounting bracket.
a. Remove 4 coupling bolts (arrow) between right
mounting bracket and engine block.
RA13T070640
b. Remove the engine right mounting bracket.


Engine Assembly
Removal
CAUTION
 Remove engine and transmission as an assembly.

 Block inlet of intake pipe, after removing air filter and engine trim cover, to prevent foreign matter from
entering. Otherwise foreign matter will block intake passage when starting, which may cause serious
damage to engine.

07 3. Turn off all electrical equipment and the ignition switch.
5. Drain the engine oil (See page 13-10).
6. Drain the transmission oil (See page 17-13, 18-74).
8. Drain the steering fluid (See page 29-8).
9. Recover the refrigerant (See page 30-24).
10.Remove the engine hood assembly (See page 48-9).
11. Remove the air filter (See page 10-10).
12.Remove the battery (See page 16-7).
13.Remove the battery tray (See page 16-9).
14.Remove the ECU (See page 06-245).
15.Disconnect the connection between expansion tank and coupling hose.
a. Loosen elastic clamp (arrow) and disconnect the
connection between expansion tank and discharge
hose.
RA13T070650

16.Disconnect fuel pipe and canister vacuum pipe.

a. Disconnect the fuel pipe (arrow).
b. Loosen elastic clamp (1) and disconnect the
connection between canister vacuum pipe and
1
electronic valve.
RA13T070660
17.Move away the shift cable.

a. Remove fixing nut (arrow) from gear shift cable.
(Tightening torque: 22 ± 3.5 N·m)
b. Disengage the gear shift clip (1).
1 07
RA13T070670
c. Remove fixing bolt (arrow) from shift cable bracket.

(Tightening torque: 5.4± 0.5N·m)
RA13T070680
d. Move away the shift cable.

18.Remove the front pipe (See page 29-12).
19.Disconnect electronic thermostat connector and upstream oxygen sensor connector.
a. Disconnect the electronic thermostat connector (1).
b. Disconnect the upstream oxygen sensor connector
(2).
RA13T070681

20.Disconnect accessory on AT.

a. Loosen 2 clamping rings (arrow) and disconnect the
connection between transmission oil pipe and tank. 2
b. Disconnect the starter connector (1). 1
c. Disconnect the wire harness main connector (2). 3
d. Disconnect the gear switch connector (3).
RA13T070690
e. Remove the ground wire fixing bolt (arrow).

(Tightening torque: 10± 2 N·m)
f. Disconnect the engine speed sensor connector (1).
1
g. Disconnect the engine speed sensor connector (2).
07 h. Remove the ground wire fixing bolt (3).
3
2
RA13T070700
21.Remove the front bumper crossmember (See page 49-13).

22.Remove the condenser (See page 30-58).
23.Disconnect the connection between A/C line and compressor (See page 30-56).
24.Remove the tank (See page 12-24).
25.Remove the front wheel (See page 24-9).
26.Remove the drive shafts (See page 20-5).
27.Remove the booster pipe.
a. Remove 2 fixing bolts (arrow) from booster pipe.
RA13T070701
28.Remove the power steering pump fluid pipe (See page 29-12).

29.Disconnect the vacuum pipe.

a. Loosen elastic clamp (arrow) and disconnect the
connection between brake booster vacuum pipe and
intake manifold.
RA13T070710
30.Disconnect the heater pipe.

a. Loosen elastic clamp (1) and disconnect the
connection between heater inlet pipe and thermostat
seat. 2

connection between heater outlet pipe and cooling
1 07
pipe assembly.
RA13T070720
31.Disconnect the engine wire harness.

a. Remove the left headlight (See page 35-89).
b. Open fuse and relay box cover and remove positive
wire harness fixing nut (arrow), then disconnect the
connection between positive wire harness and fuse
and relay box.
c. Disconnect the connection (1) between starter wire
harness and fuse and relay box.
1
RA13T070730
d. Disconnect the connection (arrow) between engine

wire harness and engine compartment wire harness.
RA13T070740
32.Remove the engine left mounting through bolt (See page 07-53).
33.Remove the engine front mounting through nut (See page 07-54).
34.Remove coupling bolts between engine right mounting bracket and right mounting cushion assembly (See
page 07-55).
35.Confirm that all engine components are disconnected from engine.

36.Loosen fixing bolt between front mounting bracket assembly and tank crossmember welding assembly.
a. Raise vehicle to a proper position.
b. Remove 2 fixing bolts (arrow), and move away fluid
suction pipe assembly (1).
RA13T070741
c. Loosen 6 fixing bolts (arrow) between front mounting

bracket assembly and tank crossmember welding
assembly.
07
RA13T070745
d. Lower the vehicle to a proper position.

37.Use an engine hoist to hang lifting eyes on both sides of
engine.
RA13T070750
38.Remove front mounting bracket assembly and tank

crossmember welding assembly.
RA13T070760
39.Hang out engine with transmission from engine compartment.

40.Remove engine wire harness and battery positive wire harness from engine.
41.Separate engine and transmission.
42.Remove the engine accessory.
43.Install engine on engine service platform.

ENGINE BLOCK UNIT REPAIR

Engine Block
Description
1 07
RA13T070770

1 - Crankshaft Main Bearing Cap 2 - Crankshaft Main Bearing Upper Shell

3 - Crankshaft 4 - Crankshaft Main Bearing Lower Shell
5 - Crankshaft Thrust Washer 6 - Cylinder Block
07
7
8
2
10
3 11
5 5
RA13T070780
1 - Piston 2 - Connecting Rod

3 - Connecting Rod Bearing Shell 4 - Connecting Rod Bearing Cap
5 - Connecting Rod Fixing Bolt 6 - Piston Pin (Semi-floating)
7 - First Compression Ring 8 - Second Compression Ring
9 - Upper Rail 10 - Expander
11 - Lower Rail

Disassembly
1. Remove engine assembly and install engine on engine service platform.
3. Remove the spark plugs (See page 14-10).
4. Remove the thermostat seat (See page 12-20).
5. Remove the intake manifold assembly (See page 10-15).
7. Remove engine accessory and bracket.
a. Remove the alternator bracket (See page 16-10).
b. Remove 4 fixing bolts (arrow) and A/C compressor
bracket.
07
RA13T070790
c. Remove 4 fixing bolts (arrow) and engine right

mounting bracket.
d. Remove fixing bolt (1) and knock sensor.
1
e. Remove oil pressure switch (2) from engine block.
2
RA13T070800
8. Remove discharge pipe and front bracket assembly.

a. Remove 4 fixing bolts (arrow) and discharge pipe
assembly.
RA13T070810
b. Remove discharge pipe and front bracket assembly.

9. Remove the exhaust manifold heat insulator (See page 11-7).
10.Remove the exhaust manifold assembly (See page 11-7).

11. Remove the cooling pipe assembly.

a. Remove 2 fixing bolts (arrow) between cooling pipe
and cylinder block.
connection between hose and water pump.
RA13T070820
c. Remove the cooling pipe.

12.Remove the clutch assembly (See page 19-17).
13.Hold flywheel with flywheel holding tool (arrow).
07
RA13T070830
14.Remove fixing bolt (arrow) and crankshaft pulley (1).

RA13T070840
15.Remove the oil filter (See page 13-12).

16.Remove the flywheel assembly (See page 07-49).
17.Remove the timing belt (See page 07-23).
18.Remove the water pump (See page 12-25).
19.Remove the cylinder head cover (See page 07-31).
20.Remove the camshaft and rocker arm shaft (See page 07-34).
21.Remove the cylinder head (See page 07-41).
22.Remove the oil pan (See page 13-16).
23.Remove the oil strainer (See page 13-19).
24.Remove the oil pump assembly (See page 13-20).

25.Remove 4 fixing bolts (arrow) from crankshaft rear oil

seal bracket, and remove crankshaft rear oil seal bracket
with rear oil seal assembly.
RA13T070850
26.Remove the cylinder block inner oil deflector assembly.

a. Using a screwdriver, remove oil deflector assembly as
shown in illustration.
07
RA13T070860
27.Remove the piston connecting rod assembly.

a. Using a ridge reamer or equivalent, remove all carbon deposit from top of cylinder.
b. Remove fixing bolts (arrow) and connecting rod
bearing cap.
(Tightening torque: 1st step: tighten to 20 ± 3 N·m;
2nd step: tighten to 33 ± 3 N·m)
RA13T070870
HINT:
Using 2 removed connecting rod bearing cap bolts,
remove connecting rod bearing cap with connecting
rod bearing lower shell assembly by shaking
connecting rod bearing cap from side to side as
RA13T070880

c. Using a hammer handle (1), push piston connecting

rod assembly (2) out of top of cylinder.
1
RA13T070890
28.Remove the connecting rod bearing.

a. Remove the connecting rod bearing (arrow).
HINT:
Arrange removed parts in correct order.
07
RA13T070900
CAUTION
 Be careful not to scratch cylinder wall during operation.

 Attach a label with corresponding number to each piston connecting rod assembly to prevent incorrect
installation.
29.Remove the piston rings.

a. Using a piston ring remover (1), remove 2
compression rings (2).
2
RA13T070910
CAUTION
 Check piston ring side clearance before removing piston ring. If it is necessary to be reused, be sure to
mark the piston ring position.
b. Remove oil ring rail and expander by hands.

30.Remove the piston.

Piston pin is semi-floating, it cannot be removed during servicing, because it cannot be assembled with
ordinary processing technology after removal, if abnormal noise is occurred by incorrect piston pin
clearance, replace piston connecting rod assembly.
31.Remove the crankshaft.
a. Evenly loosen and remove 8 crankshaft main bearing
cap fixing bolts and 2 studs in order shown in
illustration. 4 8 9 5 1
(Tightening torque: 90 -100 N·m)
3 7 10 6 2
RA13T070920
b. Using 2 removed main bearing cap bolts, remove 5

main bearing caps. 07
HINT:
 Store lower bearing and main bearing cap as a set.
 Arrange main bearing caps in correct order.
RA13T070930
CAUTION
 Insert bolts into bearing caps in order. Slightly pull up bearing cap and apply force to front and rear sides
of cylinder block to pull out it as shown in illustration. Be careful not to damage the contact surface
between bearing cap and cylinder block.
c. Take out the crankshaft.

32.Remove the crankshaft thrust washer.
a. Remove crankshaft thrust washer (1) from cylinder
block.
1
RA13T070940

33.Remove the crankshaft main bearing lower shell.

a. Slightly push crankshaft main bearing lower shell (1)
in direction of arrow and remove it carefully.
HINT:
 Remove other crankshaft main bearing lower 1
shells in the same way.
RA13T070950
CAUTION
 Pay attention to clearance position. Push out bearing carefully as shown illustration. It is difficult to push
out bearing and parts may be damaged if pushing in opposite direction.
07
34.Remove the piston cooling nozzles.
a. Remove piston cooling nozzle fixing bolts (arrow), and
remove piston cooling nozzles from cylinder block.
(Tightening torque: 20 +5 N·m)
RA13T070960
Inspection
1. Check the cylinder block.
 Clean engine block thoroughly and check all hole passages for leakage.
 Check engine block and cylinder bore for cracks.
 Check bottom surface of engine block for cracks.
CAUTION
 DO NOT wash cylinder at high temperature; otherwise, cylinder liner will stick out beyond engine block.
2. Check the flatness of engine block upper surface.

a. Clean the engine block upper surface.

b. Using a precision straightedge and feeler gauge,

measure flatness of engine block upper surface.
Specification
Measurement Item
(mm)
Engine Block Upper Surface Flatness 0.05
If cylinder head flatness exceeds standard value,

adjust it. If cylinder head flatness exceeds the limit,
replace the cylinder head. RA13T070970
 Maximum allowable wear thickness of engine
block is 0.15 mm.
 Maximum allowable wear thickness of cylinder
block and cylinder head is 0.20 mm.
3. Check the cylinder.
a. Standard diameter and maintenance dimension for cylinder bore.
 Cylinder diameter is divided into four groups according to tolerance of 0.04 mm under the normal 07
production condition.
 Cylinder group marks are stamped on small flat
surface on rear part of intake manifold side of
cylinder block (as shown in illustration), code
marks with Arabic numerals from left to right in turn
are "– 4 – 3 –2–1–" of cylinder bore group number.
RA13T070975
 It is allowed to increase bore for renovation under special circumstances. Cylinder bore for
production repair are divided into three groups according to tolerance of 0.03 mm. When one
cylinder bore is renovated to repair size, the other three cylinder bores should be processed to
production repair size.
Cylinder Bore
Production Condition Group No.
Diameter (mm)
1 Φ77.36 - Φ77.37
2 Φ77.37 - Φ77.38
Normal Production
3 Φ77.38 - Φ77.39
4 Φ77.39 - Φ77.40
Production of Repair A Φ77.63 - Φ77.64
B Φ77.64 - Φ77.65
C Φ77.65 - Φ77.66

b. Check the cylindricity of cylinder.

Using a cylinder gauge, measure cylinder bore at
positions A, B and C in thrust and axial directions.
Specification
Measurement Item
(mm)
Cylindricity 0.008
Cylindricity calculation method (for general

measurement):
 Cylindricity is half of difference between maximum
Thrust Direction
and minimum values of 6 measured values (6 bore
values measured at A, B and C). Front
Cylindricity = (maximum diameter - minimum
diameter)/2 Axial Direction
A 10 mm
If average value of bore values or cylindricity
B
07 measured at positions A, B and C exceeds specified
value, replace engine block. C
Center
10 mm
RA13T070980
4. Check the piston.

a. Using a scraper, remove carbon deposits on piston
top.
RA13T070990
b. Using a piston ring, remove carbon deposits from

piston ring grooves.
RA13T071000
c. Using a brush and solvent, thoroughly clean the

piston.
RA13T071010

CAUTION
 DO NOT use a wire brush to clean.
d. Measure piston diameter with a micrometer at

position, that is approximately 10 mm above piston
skirt in vertical direction of piston pin hole.
10 mm
RA13T071020
Corresponding 07
Group No. Piston Diameter (mm) Cylinder Bore
Diameter (mm)
1 Φ77.325-Φ77.335 Φ77.36 - Φ77.37
2 Φ77.335-Φ77.345 Φ77.37 - Φ77.38
3 Φ77.345-Φ77.355 Φ77.38 - Φ77.39
4 Φ77.355-Φ77.365 Φ77.39 - Φ77.40
If piston diameter is not within specified range,

replace the piston connecting rod assembly.
5. Check clearance between piston ring and ring groove
side.
Using a feeler gauge, measure clearance between new
piston ring and ring groove side.
RA13T071030

Piston Ring Side
Clearance
Oil Ring 0.03 - 0.16
If piston ring side clearance is not within specified range,

replace the piston connecting rod assembly.

6. Check the piston ring end gap.

a. Using a piston, push piston ring from top of cylinder to
a place, that is 45 mm from the top of cylinder bore.
b. Using a feeler gauge, measure the end gap.
45 mm
07
RA13T071040

First Ring 0.28 - 0.355
Piston Ring End
Clearance
Oil Ring 0.2 - 0.6
If piston ring end gap is not within specified range,

replace piston rings with a new set.
If end gap is still not within specified range after
replacement, replace the engine block.
7. Check the diameter of crankshaft main journal.
a. Measure main journal diameter with an outer diameter
micrometer, and measure again after rotating the
crankshaft 90°.
Specification
Measurement Item
(mm)
Crankshaft Main Journal Diameter Φ48.9 9 ± 0.01
If crankshaft main journal diameter is not within

specified range, replace main bearing shells with new RA13T071050
ones and check radial clearance of crankshaft (See
page 07-73).
If radial clearance of the main bearing shell is still not
within specified range after replacement, replace the
crankshaft.

b. Calculate roundness and cylindricity with measured values (measured area is shown in the illustration).
Roundness and cylindricity calculation method (for general measurement):
 Measure the diameter twice on the same cross section, and roundness is half of difference between
maximum and minimum values.
Roundness = (maximum diameter - minimum diameter)/2
 As shown in illustration, measure diameter twice in different directions on two cross sections
separately to obtain four values. Cylindricity is half of difference between maximum and minimum
values among four values.
Cylindricity = (maximum diameter - minimum diameter)/2

Cylindricity 0.008
Roundness 0.005
If roundness or cylindricity of crankshaft main journal exceeds specified value, replace the crankshaft.
8. Check the crankshaft radial clearance. 07
a. Clean crankshaft main journals and main bearing shells.
b. Install the crankshaft. Place the plastic feeler gauge
(1) on crankshaft main journal, parallel to crankshaft
center axis and as wide as distance covered by
bearing cap.
RA13T071060
c. Install all main bearing caps and tighten main bearing cap fixing bolts to 90 ~ 100 N·m in order.
d. Remove the main bearing caps. Using a feeler gauge,
measure widest part of compressed feeler gauge.
Measured value is the crankshaft radial clearance.
Specification
Measurement Item
(mm)
Crankshaft Radial Clearance 0.011 - 0.058
If crankshaft radial clearance exceeds specified

range, install new main bearing shells. Replace the RA13T071070
crankshaft if necessary.
CAUTION
 Replace bearing shells in pairs.
For selection of main bearing shell (See page 07-73).

9. Check the crankshaft axial clearance.
a. Clean crankshaft main journals and main bearing shells.
b. Install all main bearing caps and tighten main bearing cap fixing bolts to 90 - 100 N·m in order.

c. Push crankshaft forward and backward and read

value from dial indicator.
Specification
Measurement Item
(mm)
Crankshaft Axial Clearance 0.09 - 0.313
If crankshaft axial clearance is not within specified

range, replace the thrust washers as a set.
RA13T071080
10.Check the crankshaft runout.

a. Install crankshaft onto tester and keep it level as
b. Rotate crankshaft slowly and read maximum change
value from dial indicator. (Readings from dial
indicator)/2 is the coaxiality of crankshaft.
07
Specification
Measurement Item
(mm)
Crankshaft Runout 0.05
RA13T071090
If crankshaft main journal runout is not within specified
range, replace crankshaft.
11. Check diameter of crankshaft connecting rod journal.
Using an outer diameter micrometer, measure diameter
of crankshaft connecting rod journal.
Specification
Measurement Item
(mm)
Crankshaft Connecting Rod Journal
Φ44.90 ± 0.01
Diameter
RA13T071100
If connecting rod journal diameter is not within specified range, replace the connecting rod bearing shells
with new ones, and check radial clearance of connecting rod bearing shell.
If radial clearance of connecting rod bearing shell is still not within specified range after replacement,
replace the crankshaft.
For selection of connecting rod bearing shell (See page 07-73).
12.Check radial clearance of crankshaft connecting rod bearing shell.
a. Clean connecting rod journals and connecting rod bearing shells.
b. Place a feeler gauge (arrow) on connecting rod
journal as shown in illustration.
RA13T071110

c. Install connecting rod bearing caps, and tighten connecting rod bearing cap fixing bolts to 20 + 5 N·m.
CAUTION
 DO NOT turn crankshaft during installation.
d. Remove the connecting rod bearing caps (See page 07-79).

e. Using gauge scale of feeler gauge, measure widest
part of compressed feeler gauge to obtain radial
clearance of connecting rod bearing shell as shown in
illustration.
Specification
Measurement Item
(mm)
Connecting Rod Bearing Shell Radial
Clearance
0.006 – 0.06 07
RA13T071120
If radial clearance of connecting rod bearing shell is
not within specified range, replace the connecting rod
bearing shells. Replace the crankshaft if necessary.
13.Check connecting rod big end axial clearance.
a. Install connecting rod bearing caps, and tighten connecting rod bearing cap fixing bolts to 20 + 5 N·m.
b. Install a dial indicator (2) with its plunger contacting
the side of connecting rod cap (1).
c. Turn the dial of dial indicator to reset it to zero. 1
d. Push connecting rod forward and backward (do not
move crankshaft forward and backward) and read
value on dial indicator.
Specification 2
Measurement Item
(mm)
RA13T071130
Connecting Rod Big End Axial
0.333 - 0.387
Clearance
If axial clearance of connecting rod big end is not

within specified range, replace the piston connecting
rod assembly.

Selection of bearing shell

SQRD4G15B engine uses main bearing shells and connecting rod bearing shells with "standard type" in
production, there are no color codes on main bearing shell and connecting rod bearing shell, and just "STD" is
printed on the back of bearing shell.
Main bearing shell has three kinds of bearing shell for maintenance, and connecting rod bearing shell has two
kinds of bearing shell for maintenance during production repair.
1. Selection of main bearing shell
Production Condition Symptom Bearing Shell Remark

Back of bearing shell
printed with "0.4" mark,
Cylinder block main bearing hole O/S 0.4 mm
and with black mark on
bearing shell
printed with mark, and
Crankshaft journal grinding 0.25 mm
with green mark on
07 Production of Repair bearing shell
Main bearing shell for
correcting bearing
clearance, back of
Too much noise in bearing shell bearing shell printed
with "0.02" mark, and
with yellow mark on
bearing shell
2. Selection of connecting rod bearing shell
Production Condition Symptom Bearing Shell Remark

printed with "0.25"
Crankshaft journal grinding 0.25 mm
mark, and with green
mark on bearing shell
Main bearing shell for
Production of Repair correcting bearing
clearance, back of
Too much noise in bearing shell bearing shell printed
with "0.025" mark, and
with yellow mark on
bearing shell
3. Precautions for bearing shell assembly:

 There are shell groove and oil hole on the main bearing upper shell, and oil hole should be aligned with
that on the engine block, but the main bearing lower shell has no oil hole.
 Connecting rod upper and lower bearing shells without oil grooves are universal, but one of the
connecting rod bearing shells has an oil hole.
 It is necessary to use a set of connecting rod bearing shell and main bearing shell that are provided by
the same manufacturer on the same engine.
 Apply a coat of engine oil to inner surface of connecting rod bearing shell and main bearing shell before
installation. Back side of bearing shell should be clean without any oil or foreign matter during
assembly.

Assembly
1. Install the piston cooling nozzles.
a. Remove piston cooling nozzle fixing bolts (arrow), and
remove piston cooling nozzles from cylinder block.
RA13T071140
2. Install the crankshaft main bearing shells.
CAUTION
07
 Apply a coat of engine oil to inner surface of the main bearing shell before installation.
a. Carefully install crankshaft bearing (1) in direction of

arrow, and notch of each main bearing should be
aligned with cylinder block. Oil passage hole on 1
crankshaft main bearing (2) should be aligned with the
passage hole on cylinder block after installation.
RA13T071150
3. Install the crankshaft thrust washers.

a. Clean crankshaft thrust washers and cylinder block inner wall before installation.
b. Apply a coat of engine oil to crankshaft thrust washers.
c. There are 2 crankshaft thrust washers on the cylinder, which are installed on the front and rear sides of
thrust surface (both sides of 3rd bearing) respectively.
d. As shown in the illustration, the two grooves on one
side of crankshaft thrust washers (1) face outward
while the other side without groove is jointed with the
cylinder block inside wall.
1
RA13T071160
4. Install the crankshaft.

a. Place crankshaft on cylinder block carefully.

b. "1-2-3-4-5" and "arrow" are marked on crankshaft

main bearing cap. Install crankshaft main bearing cap
from timing belt side and make sure that direction of
"arrow" towards timing belt side. 1 2 3 4 5
RA13T071170
c. Install crankshaft main bearing cap fixing bolts in

place by hands, and then tighten crankshaft main 8 4 1 5 9
bearing cap fixing bolts in sequence shown in
illustration.
07
7 3 2 6 10
RA13T071180
5. Install the piston rings.

a. First compression ring is straight-flanked ring (1),
second compression ring is conical ring (2), and oil
ring is steel band combination oil ring. Apply a small
amount of engine lubricant to piston ring grooves and
1
piston. Note that the side with words for first
compression ring should face upward, and outer cut 2
of second compression ring should face downward.
b. Oil ring is steel band combination oil ring and 3
composed of upper rail (3), lower rail (5) and 4
expander (4). When installing the oil ring, first install
the expander into oil groove, then install two rails with 5
two rails opening of steel band combination oil ring Openings of Each Ring:
staggered by 90° from the expander closed gap, and Lower Rail
the upper and lower rails 180°. Then install the First Compression Second Compression
second compression ring, and install the first Ring Ring
compression ring finally with two compression rings Front Rear
staggered by 120° from the upper rail opening. The Bushing Ring
piston ring should rotate in the ring groove freely
without any stuck condition. The piston ring should Upper Rail
rotate in the ring groove freely without any stuck

condition. RA13T071190
c. Rotate the piston ring several turns after applying engine oil to piston ring groove, and note that the
position of ring notch should be the same with that described above; clean the crankshaft connecting
rod journal and cylinder bore with a non-woven fabric cloth.

6. Install the connecting rod bearing shells.
CAUTION
 Apply a coat of engine oil to inner surface of connecting rod bearing shell before installation.
 Back side of connecting rod bearing shell should be clean without any oil or foreign matter during
assembly.
a. Carefully install the connecting rod bearing upper

shell (1) in direction of arrow, and keep the groove
1
opening of each connecting rod bearing upper shell
face the piston and connecting rod assembly.
07
RA13T071200
b. Carefully install the connecting rod bearing lower shell

(1) in direction of arrow, and keep the groove opening
of each connecting rod bearing lower shell face the
connecting rod bearing cap.
1
RA13T071210
7. Install the piston connecting rod assembly.

a. Rotate the crankshaft to the top dead center of cylinders 1 and 4.
b. Apply a coat of engine oil to the piston surface and cylinder inside wall.
c. As shown in the illustration, install the piston
connecting rod assembly to the cylinder with the
piston installer (1).
RA13T071220
CAUTION
 Pay attention to front marks on piston and connecting rod during assembly, without being reversed. Face
letter "F" side printed on connecting rod and arrow direction on piston toward pulley side to install as

AD
R
RA13T071230
8. Install the connecting rod bearing cap.

HINT:
Number on connecting rod and number on connecting
rod bearing cap should be in the same direction. These
numbers represent the number of cylinder, for example,
figure 3 indicates that installation position is cylinder 3.
07
RA13T071240
a. Correctly install connecting rod bearing caps, and

screw connecting rod bearing cap fixing bolts (arrow)
by hands, then tighten connecting rod bearing cap
fixing bolts to 20 + 5 N·m with a torque wrench.
RA13T071250
CAUTION
 Apply a small amount of engine lubricant to connecting rods, connecting rod bearing caps and thread
joint surfaces.
9. Other assembly is in the reverse order of disassembly.

GENERAL INFORMATION 08-3 Electric Fuel Pump Assembly 08-14
Description 08-3 On-vehicle Inspection 08-14
Tools 08-5 Installation 08-17
Fuel Supply System Line Connection  Filler Tube Assembly 08-18
Diagram 08-6 Removal 08-18
Circuit Diagram 08-7 Installation 08-18
Fuel Tank 08-19
Removal 08-19
Fuel Tank Accessories Description 08-21
Fuel System Pressure Release 08-10
Installation 08-22
Fuel Supply System Pressure Test 08-11
Fuel Rail Injector Assembly 08-22
ON-VEHICLE SERVICE 08-12 Removal 08-22
Fuel Filter Assembly 08-12 Inspection 08-24
Removal 08-12 Installation 08-24 08
Installation 08-13

08

08 - SQRD4G15B FUEL SUPPLY SYSTEM
GENERAL INFORMATION
Description
1
4
7
×3
2
9
8
3 08
6
10
11
12
14
×2
13
RA13T080010
1 - Fuel Filler Cap 2 - Filler Tube Assembly

3 - Fuel Filler Hose 4 - Fuel Pump Pressure Cap
5 - Electric Fuel Pump Assembly 6 - Fuel Tank Seal Ring

7 - Fluid Return Pipe 8 - Inlet Pipe I

9 - Inlet and Return Pipe Assembly 10 - Fuel Filter
11 - Fuel Tank 12 - Fixing Strap I
13 - Fixing Strap II 14 - Fuel Rail Injector Assembly
Engine fuel supply system provides a certain amount and concentration of combustible air-fuel mixture and
supplies it to cylinders according to the requirements under various operating conditions of engine. Fuel
supply system consists of fuel tank assembly, electric fuel pump assembly, fuel filter assembly, delivery pipes,
fuel rail and injectors, which is used for fuel storage, filtration, delivery and injection. The function of fuel
supply system is to provide gasoline with sufficient pressure to fuel injectors by using electric fuel pump
assembly, and injector injects a certain amount of gasoline to top of intake valve in intake manifold in
accordance with control signals from ECM.
Specifications

08 Fuel Filter Bracket Fixing Screw 7 ± 1.5
Fuel Tank Pressure Cap 75 ± 5
Filler Tube Assembly Lower Bracket Fixing Bolt 8+3
Filler Tube Assembly Fixing Nut 8+3
Fuel Tank Fixing Bolt 23 ± 2.5
Fuel Tank Fixing Nut 23 ± 2.5
Fuel Rail Fixing Bolt 8 - 11


Tools
Special Tool
Fuel Tank Pressure Cap Remover
RCH0000004
General Tools
08
Digital Multimeter
RCH0000002
RCH0000048
RCH0000005

Fuel Supply System Line Connection Diagram
3 4
2 1
08
RA13T080020
1 - Electric Fuel Pump 2 - Electric Fuel Pump Assembly Pressure Regulator

3 - Fuel Filter Assembly 4 - Inlet and Return Pipe Assembly
5 - Fuel Rail Injector Assembly
When engine operates properly, electric fuel pump (1) sucks fuel from fuel tank and filters it through fuel filter
(3), and then deliveries it to inlet and return pipe assembly (4). Part of fuel enters fuel rail (5) and is supplied to
injectors. Part of fuel flows back to electric fuel pump assembly pressure regulator (2) directly. When fuel
supply system pressure is high, diaphragm spring in regulator is jacked up by pressure, then the valve opens
and fuel flows out from regulator. When pressure reaches normal value, regulator shuts off and fuel stops
flowing out. Finally, system pressure reaches a steady state.

Circuit Diagram
Fuel Supply System (Page 1 of 2)
IGNITION SWITCH
BATTERY
ON OR START
E-030 I-036
WB WB
14
IP FUSE
AND
EF31 EF15 RF10 RF01 RELAY BOX
86 30 10A 10A I-032
15A 15A
ECM E-028
MAIN
33 7
RELAY 86 30
FUEL
EF26 EF22 85 87 ENGINE
PUMP
10A 10A RELAY EF38 COMPARTMENT
15A FUSE AND
EF37 85 87 RELAY BOX
10A E-067
08
E-063
75 20 115 102 103 116
A
RY
RG
E-026 I-002
RY
R
B-015 5 8 B-019
RY
L
RG
RG
WL
R
3 1 21 11 13
FUEL PUMP
Q MOTOR & INSTRUMENT
M FUEL LEVEL CLUSTER
SENSOR I-011
4 2 B-008 5 3
WR
WR
B
B-009 7 B-019
I-002
A54 A42 A55 A56 A45
I-005
ECM(A)
E-041
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25 I-011
L
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
1 2 3 4 5 6 7 8 9 8 7 6 5 4 3 2 1
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
9 10 11 12 13 14 15 16
18 17 16 15 14 13 12 11 10
B-015 I-036
W B
1 2 3 4 5 6 7 8 9 10
B-019 B-008
11 12 13 14 15 16 17 18 19 20 W 1 2 3 4 B
E-041
B
EA13T080010

Fuel Supply System (Page 2 of 2)
A
RG
12 E-035
E-007
RG
RG
RG
RG
08 1 1 1 1
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4
E-024 E-011 E-010 E-009
2 2 2 2
GW
GY
GB
GL
B36 B48 B35 B47
ECM(B)
E-001
B56 B55 B54 B53 B52 B51 B50 B49 1 2 3 4 5 6

E-007
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37 7 8 9 10 11 12 B
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
E-024 E-011 E-010 E-009

1 2 B B B B
E-001
B
EA13T080020

DIAGNOSIS & TESTING

Fuel Supply System Problem Symptoms Table
Fuel pressure in fuel supply system is too Fuel filter (clogged) 08-12
low Electric fuel pump (strainer blocked) 08-14
Fuel pressure in fuel supply system is too Fuel injector (clogged) 08-22
high Electric fuel pump 08-14
Low fuel level 08-14
Electric fuel pump has loud noise or a
Electric fuel pump assembly relay 55-30
delay in operating
Electric fuel pump assembly 08-14
Fuel filter (clogged) 08-12 08
Fuel injector 08-22
Fuel injector is clogged or leaked
Poor fuel quality -
Excessive impurities in fuel tank -
Fuel supply system line (broken) -
Fuel injector does not work Fuel injector (short in coil) 08-22
Wire harness -

Fuel System Pressure Release

WARNING
When engine is not operating, fuel pressure in fuel supply system is still high. Before repairing or
disconnecting fuel line or fuel supply system components, it is necessary to release fuel supply system
pressure to prevent fuel from spraying out accidentally. Failure to follow these instructions may result in
serious personal injury or death.
Perform following procedures to release fuel pressure in fuel supply system:

1. Recognize and remove electric fuel pump assembly relay
from engine compartment relay box. ERLY13
Fuel
pump
relay
08
RA13T080030
2. Start and run engine until it stalls.

3. Restart engine until it does not run.
4. Turn ignition switch to LOCK.
6. Insert electric fuel pump assembly relay into original position.

Fuel Supply System Pressure Test


WARNING
 When operating fuel supply system, work area should be in good ventilation and keep fire sources or
open flames away from work area, in which fire extinguisher should be equipped.
 Before operating fuel supply system, please touch vehicle body to discharge static electricity; failure to
do so will cause a fire, even result in an explosion.
 Before removing and installing fuel pipes, release fuel supply system pressure.
08
CAUTION
 Make sure that battery voltage is 11 - 12 V.

 Service mileages of fuel filter should be within 30000 km.
 Make sure that fuel supply system lines are securely connected, preventing fuel supply system from
leaking.

2. Disconnect inlet hose connector and connect fuel supply
system pressure tester between inlet hose and fuel rail.
Fuel Hose
RA13T080040
3. Start engine and run it at idle, and then read value on pressure tester.
Start engine and read value while idling:
 Standard pressure at idle should be higher than 400 kPa.
 If measured pressure value is lower than 400 kPa, check fuel filter for blockage.
Replace fuel filter if necessary (See page 08-12).
 If measured pressure value is lower than 400 kPa and fuel filter operates properly, check electric fuel
pump assembly. Replace as necessary.
 If measured pressure value is too high, injector may be clogged or electric fuel pump assembly
pressure modulating valve may be malfunctioning.
Replace injector (See page 08-22) or electric fuel pump assembly (See page 08-14) if necessary.

ON-VEHICLE SERVICE
Fuel Filter Assembly
Removal
CAUTION
 DO NOT damage disconnected fuel system line or connectors. Cover line joints or connectors with
plastic bags or equivalent, preventing foreign matter from entering.
WARNING
08  When operating fuel supply system, work area should be in good ventilation and keep fire sources or
 After performing procedures for fuel system pressure release, there still remains some pressure in fuel
line. When disconnecting fuel line, cover the joint with a piece of cloth or equivalent to prevent fuel from
spraying out.
 If fuel leakage occurs when operating fuel supply system, please handle leaked fuel in time.
Disconnection way for all fuel pipe coupling joints in

following procedures is shown in illustration.
RA13T080050
1. Release the fuel supply system pressure (See page 08-10).

4. Remove the fuel filter assembly.
a. Disconnect coupling joints (arrow) on both ends of
fuel filter.
1
b. Loosen the fuel filter bracket fixing screw (1).
RA13T080060
c. Remove fuel filter from fuel filter bracket.

CAUTION
 Cover both ends of fuel filter with plastic bags or equivalent to prevent foreign matter from entering.
ENVIRONMENTAL PROTECTION
 Removed fuel filter should be handled by specialized department according to local laws and
regulations. Never discard it at will.
Installation
CAUTION
 Before connecting hose, check if there is any damage or foreign matter on hose or joint. 08
 During installation, push in fuel pipe connector until a click sound is heard from coupling joint, then check
that fuel pipe joint clip is on the collar of fuel pipe joint. After installing pipe joint clip, check that fuel pipe
joint cannot be pulled out. Be careful not to damage joint. If clip is damaged, replace it.
 Turn ignition switch to ON (without starting engine) to apply fuel pressure to fuel supply system, and then

Electric Fuel Pump Assembly

1. Inspect the electric fuel pump fuel level sensor.
a. Using a flat tip screwdriver, pry up electric fuel pump
assembly protective cap, and disconnect electric fuel
pump connector.
+ -
b. Using a digital multimeter, measure resistance of fuel

level sensor based on fuel volume in fuel tank.
1 2 3 4
Fuel Level Multimeter

Specification (Ω)
Indictor Connection
Terminal 3 -
E 283 ± 5 RA13T080070
Terminal 4
Terminal 3 -
137 ± 4
Terminal 4
08
Terminal 3 -
89 ± 4
Terminal 4
Terminal 3 -
62 ± 3
Terminal 4
Terminal 3 -
40 ± 2
Terminal 4
If result is not as specified, replace electric fuel pump.

2. Check the electric fuel pump operation.
a. Using a flat tip screwdriver, pry up electric fuel pump assembly protective cap, and disconnect electric
fuel pump connector.
b. Apply battery voltage to terminals 2 and 1. Check if
electric fuel pump operates within 10 seconds.
+ -
HINT:
These tests must be finished within 10 seconds to
prevent coils from being burnt. 1 2 3 4
Keep electric fuel pump as far away from battery as

possible.
Always switch voltage on and off on battery side,
rather than electric fuel pump side. RA13T080080
Multimeter Connection Specifications

Battery positive (+) - Terminal 1 Fuel pump
Battery negative (-) - Terminal 2 operates
If electric fuel pump does not operate, replace it.

Removal
WARNING
spraying out.
CAUTION
 Only use parts approved by Chery Automobile Co., Ltd. to replace electric fuel pump assembly.
 As electric fuel pump assembly radiates through fuel, low fuel level in fuel tank will directly shorten the
08
service life of electric fuel pump assembly.
 Keep electric fuel pump assembly and work area clean when replacing electric fuel pump assembly;
otherwise the electric fuel pump assembly element will be clogged.
 DO NOT operate electric fuel pump assembly when it is dry or in water. Failure to do so will damage
electric fuel pump.
 Keep fuel tank and line clean, and replace fuel filter if electric fuel pump assembly has been replaced.

RA13T080050

4. Open fuel filler cap and discharge fuel vapor in fuel tank.
5. Remove the rear seat cushion (See page 47-15).

6. Remove the electric fuel pump assembly.

a. Using a flat tip screwdriver (1), pry up electric fuel
pump assembly protective cap (2).
RA13T080090
b. Disconnect the electric fuel pump assembly connector

(arrow).
c. Disconnect coupling joint (1) between electric fuel
pump assembly and inlet pipe I assembly. 2
d. Disconnect coupling joint (2) between electric fuel
pump assembly and return pipe assembly.
08
1
RA13T080100
CAUTION
 Before disconnecting joints, remove all dirt and foreign matter from electric fuel pump assembly pressure
cap.
 DO NOT forcefully bend or twist delivery pipes.
e. As shown in illustration, use special tool (fuel tank

pressure cap remover) to remove fuel tank pressure
cap.
RA13T080110
f. Pull electric fuel pump assembly upward and pull out

fuel tank.
RA13T080120

CAUTION
 To keep fuel tank clean, cover it completely with a plastic bag or equivalent to prevent foreign matter from
entering.
 Electric fuel pump can be put into a container and taken out of cabin, thus preventing fuel in pump from
dropping into cabin.
7. Drain fuel in electric fuel pump assembly.
CAUTION
 Cover electric fuel pump completely with a plastic bag or equivalent to prevent foreign matter from
entering.
Installation
08
CAUTION
 Before connecting hose, check if there is any damage or foreign matter on hose or joint.
 During installation, push in fuel pipe connector until a click sound is heard, then check that fuel pipe joint
clip is on collar of fuel pipe joint. After installing fuel pipe joint clip, check that fuel pipe joint cannot be
pulled out. Be careful not to damage joint. If clip is damaged, replace it.

Filler Tube Assembly

Removal
WARNING

3. Remove the filler tube assembly.
a. Open fuel filler door, rotate and open fuel filler cap in
08 direction of arrow as shown in illustration.
b. Remove 3 fixing bolts (1).
1
RA13T080130
c. Loosen worm clamp (2) and disconnect connection

between fuel filler hose and filler tube assembly.
(Tightening torque: 3.5 ± 0.5 N·m)
d. Loosen worm clamp (1) and disconnect connection
between fuel breather hose and filler tube assembly. 2
1
RA13T080140
CAUTION
 Cover joints with plastic bags after disconnecting fuel filler hose and fuel breather hose, in order to
prevent foreign matter from entering fuel tank and fuel from evaporating or leaking.
e. Remove fixing bolt (arrow) from filler tube assembly lower bracket.
f. Remove the filler tube assembly.
Installation

Fuel Tank
Removal
WARNING
spraying out.
CAUTION
08

RA13T080050

4. Remove the front muffler (See page 11-14).
5. Open fuel filler cap and discharge fuel vapor in fuel tank.
6. Disconnect connection between electric fuel pump side pipe and line.
a. Turn over the rear seat cushion (See page 47-15).
b. Using a flat tip screwdriver (1), pry up electric fuel
pump assembly protective cap (2).
RA13T080090

c. Disconnect the electric fuel pump assembly connector

(arrow).
d. Disconnect inlet pipe Ⅰ assembly jonit (1) and return
pipe assembly joint (2). 2
1
RA13T080100
7. Remove the fuel filter (See page 08-12).

8. Remove the fuel tank.
a. Loosen worm clamp (1) and disconnect connection
between fuel breather hose and filler tube assembly. 1
3
b. Loosen worm clamp (2) and disconnect connection
between fuel filler hose and filler tube assembly.
08 (Tightening torque: 3.5 ± 0.5 N·m) 2
c. Disconnect coupling joint (3) between fuel vapor line
and canister line.
RA13T080150
CAUTION
 Cover joints with plastic bags after disconnecting fuel filler hose and fuel breather hose, in order to
prevent foreign matter from entering fuel tank and fuel from evaporating or leaking.
d. Disconnect coupling joint (1) between inlet and return

pipe assembly and return pipe ssembly.
1
RA13T080160
CAUTION
 Before disconnecting joints, remove any dirt and foreign matter from retainer.
 DO NOT forcefully bend or twist delivery pipes.
e. Move cnister vacuum pipe (2) away from fuel tank.

f. Support fuel tank with a transmission carrier.
RA13T080170
g. Remove 2 fixing bolts (arrow) and 2 fixing nut (1) and

fuel tank fixing strap.
08
RA13T080180
h. Slowly lower transmission carrier to remove fuel tank.

9. Remove fuel pump pressure cap (1), electric fuel pump
assembly (2) and fuel tank seal ring (3) from fuel tank.
1
RA13T080190
Fuel Tank Accessories Description

1. Fuel Vapor Valve
Function of fuel vapor valve: 2
3 1
When fuel vapor is produced in fuel tank, fuel vapor will
enter charcoal canister through fuel vapor hose (1) by
fuel vapor valve (2). When vehicle body bumps or
overturns, fuel vapor valve will automatically lock to
prevent fuel overflow.
2. Fuel Breather Pipe
Function of fuel breather pipe:
RA13T080200
When filling fuel tank through fuel filler, fuel vapor will get
out of fuel tank through fuel breather pipe (3).

3. Fuel Tank Cushion

Pay attention to installation positions of fuel tank cushions (arrow). Incorrect installation will damage fuel
tank or fuel lines due to friction between fuel tank and vehicle body.
Installation
CAUTION
 Return fuel lines and vent line on fuel tank to their original positions, or fuel lines will be damaged due to
friction generated by vehicle body shock, causing fuel leak.
 Before connecting hose, check if there is any damage or foreign matter on hose or joint.
 During installation, push in fuel pipe connector until a click sound is heard, then check that fuel pipe joint
clip is on collar of fuel pipe joint. After installing pipe joint clip, check that fuel pipe joint cannot be pulled
out. Be careful not to damage the joint. If clip is damaged, replace it.
08
Fuel Rail Injector Assembly
Removal
WARNING
spraying out.
CAUTION
 Injector is a part of high accuracy, featuring good anti-clogging, anti-pollution and atomization, so be
careful not to damage the injector during removal of fuel rail.
1. Release the fuel supply system pressure (See page 08-12).


CAUTION

6. Remove the fuel rail injector Assembly.
a. Disconnect coupling joint (arrow) between delivery
pipe and fuel rail.
08
RA13T080210
b. Move away 2 wire harness clips (arrow).

c. Disconnect 4 connectors (1) and (2) from injectors
separately.
2
1
RA13T080220
d. Remove 2 fixing bolts (arrow) from fuel rail.

RA13T080230
e. Remove fuel rail and fuel injectors.

7. Separate injector clips and remove injectors (arrow) from
fuel rail.
RA13T080231

Inspection
1. Disconnect the injector connector.
2. Measure resistance between 2 terminals (injector side) of
injector with a digital multimeter.
+ -
1 2
Measurement Specifications
Temperature (Ω)
20°C 11–16
RA13T080240
Installation
CAUTION
08
 Install a new seal to injector sealing surface.
 Before installing injector, apply clean grease or oil to O-ring sealing surface for easy installation,
preventing damage to O-ring.

GENERAL INFORMATION 09-3 Activated Charcoal Canister 
Tool 09-4 Installation 09-10
Circuit Diagram 09-5 PCV Valve 09-11
Emission Control System (Page 2of 2) 09-6 Removal 09-11
Inspection 09-11
DIAGNOSIS & TESTING 09-7 Installation 09-11
Leakage Inspection 09-7 EGR Valve 09-12
Activated Charcoal Canister  Removal 09-12
Inspection 09-7
Inspection 09-12
Fuel Filler Cap Inspection 09-7
Upstream Oxygen Sensor 09-13
Activated Charcoal Canister Solenoid  Inspection 09-14
Valve 09-8 Installation 09-14
Removal 09-8 Downstream Oxygen Sensor 09-15
Inspection 09-9 Removal 09-15 09
Installation 09-15

09

09 - SQRD4G15B EMISSION CONTROL SYSTEM
GENERAL INFORMATION
Description
2
3
09
RA13T090010
1 - Fuel Tank Assembly 2 - Activated Charcoal Canister Solenoid Valve

3 - PCV Valve 4 - Activated Charcoal Canister
Emission control system recovers and burns fuel vapor to prevent the vapor in fuel tank from being
discharged into the atmosphere. It monitors the oxygen content in exhaust gas, so as to guarantee the
maximum efficiency of catalytic converter assembly in converting the HC, CO and NOx in exhaust gas.
Activated charcoal canister plays an important role in emission control system. it is used to absorb and filter
moisture and fuel vapor. Fresh air enters bottom of activated charcoal canister while fuel vapor enters top of
activated charcoal canister through pipe. When engine stops operating, fuel vapor and fresh air will be stored
in activated charcoal canister. When canister solenoid valve opens, fuel vapor will enter intake manifold to
burn.
Oxygen sensor consists of upstream oxygen sensor and downstream oxygen sensor. Upstream oxygen
sensor is installed on exhaust manifold, and downstream oxygen sensor is installed on main catalytic
converter assembly. Oxygen sensor can detect oxygen content in exhaust gas, and determine whether
combustible air-fuel mixture is completely burnt out or not, so as to guarantee the maximum efficiency of
catalytic converter assembly in converting the HC, CO and NOx in exhaust gas.

Specifications

Charcoal Canister Solenoid Valve Bracket Fixing Bolt 10 ± 3
Coupling Bolt Between Activated Charcoal Canister
8+3
and Body
EGR Fixing Bolt 20 + 5
Tool
General Tool
09
Digital Multimeter
RCH0000002

Circuit Diagram
Emission Control System (Page 1 of 2)
BATTERY
86 30
ECM
MAIN
RELAY
EF26 EF22 85 87
10A 10A ENGINE
A
COMPARTMENT
FUSE AND
EF37 EF13 RELAY BOX
10A 15A E-067
75 20 115 45
R
09
RG
R
1 4 DOWN- 1 4
UPSTREAM
RG
RG
STREAM
R
OXYGEN OXYGEN
SENSOR SENSOR
E-037
2 3 E-038 2 3
RW
RG
BR
YB
BY
BY
A54 A42 A55 A56 A39 A27 A50 A38 A26 A49
ECM(A)
E-041
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25 E-037
B
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13 4 3 2 1
E-038
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B
E-041
B
EA13T090010

Emission Control System (Page 2of 2)
ENGINE
COMPARTMENT
A
FUSE AND
RELAY BOX
EF35 E-067
15A
93
RB
E-035
6
E-007
RB
RB
09 1
CANISTER
4
EXHAUST GAS
SOLENOID + + - RECIRCULATION
VALVE VALVE
E-015 - E-002
2
6 1 3 2
WG
RG
BG
BL
B50 B26 B29 B08 B32

ECM(B)
E-001
1 2 3 4 5 6 E-007
7 8 9 10 11 12 B
B56 B55 B54 B53 B52 B51 B50 B49
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13
E-002
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 1 2 3
B
4 5 6
E-001
B E-015
2 1 B
EA13T090020

DIAGNOSIS & TESTING

Leakage Inspection
Visually check that hoses, connections and gaskets have no cracks, leaks or damage.
CAUTION
 Removal of engine oil dipstick, filler cap, PCV hose and other components or other problems in them
may cause engine to run improperly.
Air suction caused by disconnections, looseness or cracks in intake system pipes related to throttle
assembly will result in engine failure or abnormal operation. Replace parts as necessary.
Activated Charcoal Canister Inspection

1. Close port C and blow compressed air into port A. Check
that air flows out from port B. If result is not as specified, B C
replace canister.
2. Close port C and blow compressed air into port B. Check
that air flows out from port A. If result is not as specified, A 09
replace canister.
RA13T090020
Fuel Filler Cap Inspection

1. Visually check that fuel filler cap assembly is not deformed or damaged.
2. If result is not as specified, replace fuel filler cap.

ON-VEHICLE SERVICE
Activated Charcoal Canister Solenoid Valve
Removal
CAUTION
 Before removal, mark intake and exhaust hose to avoid confusion.

4. Remove the activated charcoal canister solenoid valve.
a. Disconnect the charcoal canister solenoid valve
connector (arrow).
09
RA13T090030
b. Loosen elastic clamps (arrow), and disconnect

connection between both ends of charcoal canister
solenoid valve and hose.
RA13T090040
CAUTION
 Positioning distance from hose end to clamp is 3 to 5 mm.
c. Remove charcoal canister solenoid valve from bracket.

Inspection
Measure resistance between 2 terminals of charcoal
canister solenoid valve with a digital multimeter.
+ -
1 2
Measurement
Specification (Ω)
Temperature
20 °C 26 ± 4
RA13T090050
Installation
09

Activated Charcoal Canister Assembly

Removal
4. Remove the activated charcoal canister assembly.
a. Loosen elastic clamps (arrow), and disconnect
connection between activated charcoal canister and
hose. 1
RA13T090060
09 CAUTION
 Positioning distance from hose end to clamp is 3 to 5 mm.
b. Remove activated charcoal canister bracket fixing bolt (1) and activated charcoal canister with bracket
assembly.
 Unneeded activated charcoal canister should be handled by specialized department according to local
laws and regulations. Never discard it at will.
Installation

PCV Valve
Removal
4. Remove the PCV valve.
a. Disconnect elastic clamp (1) between PCV valve and
hose.
b. Remove PCV valve from PCV valve rubber boot (2).
1
RA13T090061
c. Remove the PCV valve rubber boot.

09
Inspection
1. Install a clean hose to PCV valve.
2. Check the PCV valve operation.
a. Blow air into cylinder head side, and check that air flows smoothly.
b. Blow air into intake manifold side, and check that air flows difficultly.
If result is not as specified, replace PCV valve.
WARNING
 DO NOT suck air through valve. Petroleum substances inside valve are hazardous to your health.
3. Remove clean hose from PCV valve.
Installation
CAUTION
 Press PCV valve rubber boot into cylinder head cover, and then press in PCV valve.
 Positioning distance from hose end to elastic clamp is 3 to 5 mm.

EGR Valve
Removal
4. Remove the intake hose.
5. Remove the EGR valve.
a. Unplug the connector (1).
1
b. Remove 2 fixing bolts (arrow), EGR valve and washer.
RA13T090070
09
Inspection
Measure resistance of EGR valve with a digital multimeter.
+ -
3 2 1
5 4
RA13T090080
Multimeter
Condition Specification (Ω)
Connection
Terminal 1 - Normal
2340 ~ 3380
Terminal 4 - Normal
7.5 ~ 8.5
If result is not as specified, replace EGR valve.

Upstream Oxygen Sensor

Removal
WARNING
 Temperature of exhaust system is very high when engine is running. Before removal, make sure that
engine has stopped running and exhaust system has cooled down sufficiently, otherwise, there is a risk
of scald injury.

4. Remove the upstream oxygen sensor.
a. Take off and disconnect upstream oxygen sensor
connector (arrow) from bracket.
09
RA13T090090
b. Remove 5 fixing bolts (arrow) and exhaust manifold

heat insulator.
RA13T090100
c. Remove upstream oxygen sensor (arrow) from

exhaust manifold.
RA13T090110

Inspection
1. Measure resistance of upstream oxygen sensor with a
digital multimeter.
+ -
Multimeter DCB A
Connection
Terminal C - 20°C 7 - 11
Terminal D
Terminal A -
Terminal B
RA13T090120
Terminal A -
Terminal C
Terminal A -
Always ∞
Terminal D
Terminal B -
Terminal C
Terminal B -
Terminal D
09 If result is not as specified, replace upstream oxygen

sensor.
Installation


Removal
WARNING
of scald injury.

4. Remove the downstream oxygen sensor.
a. Take off and disconnect downstream oxygen sensor
connector (1) from bracket.
b. Remove downstream oxygen sensor (arrow) from
front pipe assembly. 09
RA13T090130
Inspection
1. Measure resistance of downstream oxygen sensor with a
digital multimeter.
+ -
Multimeter DCB A
Connection
Terminal C -
20°C 7 - 11
Terminal D
Terminal A -
Terminal B
RA13T090120
Terminal A -
Terminal C
Terminal A -
Always ∞
Terminal D
Terminal B -
Terminal C
Terminal B -
Terminal D
If result is not as specified, replace downstream oxygen

sensor.
Installation

- MEMO -

Description 10-3 Electric Throttle Assembly 10-11
Specifications 10-4 On-vehicle Inspection 10-11
Tools 10-5 Removal 10-11
Circuit Diagram 10-6 Inspection 10-13
Cleaning 10-13
Installation 10-14
Intake Manifold Assembly 10-15
Air Filter Element 10-9 Inspection 10-16
Installation 10-9 Electronic Accelerator Pedal 10-17
Air Filter Assembly 10-10 Removal 10-17
10

10

10 - SQRD4G15B INTAKE SYSTEM
GENERAL INFORMATION
Description
6 7
10
×4
×8
10
×3
9
14 11
×2
12
×3
13
RA13T100010

1 - Charcoal Canister Solenoid Valve Bracket 2 - Intake Pressure/Temperature Sensor

3 - Intake Manifold Upper Bracket 4 - Intake Manifold Gasket
5 - Intake Manifold 6 - Electronic Throttle Assembly Gasket
7 - Electric Throttle Assembly 8 - Intake Hose
9 - Worm Clamp 10 - Crankcase Vent Hose
11 - Air Filter Upper Housing 12 - Air Filter Element
13 - Air Filter Lower Housing 14 - Air Direct Pipe
Intake system mainly consists of air direct pipe, air filter assembly, intake pressure/temperature sensor, intake
hose, electronic throttle assembly and intake manifold assembly, etc.
Intake system uses air filter to filter particulates and dust in air, and then the air filtered flows into intake
manifold assembly through electronic throttle assembly and mixes with fuel at the end of intake manifold
assembly port to form flammable gas mixture, which is transmitted to each cylinder uniformly to coordinate
with engine operation. Electronic throttle assembly is a critical part for engine intake system. Its main function
is to control intake air volume by adjusting intake passage area according to driver's driving intention to meet
intake requirements in different engine operating conditions, and send back position signals of throttle valve
plate to control unit to achieve accurate control and run the engine under optimal control state.
Specifications
10 Torque Specifications

3±1
and Lower Housing
Air Filter Assembly Fixing Bolt 10 ± 1
Air Direct Pipe Fixing Bolt 10 ± 1
Electronic Throttle Assembly Fixing Bolt 8 - 11
Intake Manifold Fixing Nut 20 + 5
Charcoal Canister Solenoid Valve Bracket Fixing
20 + 5
Bolt
Intake Manifold Upper Bracket Fixing Bolt 20 + 5
Electronic Accelerator Pedal Fixing Bolt 10 ± 2

Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tools
Digital Multimeter
10
RCH0000002
RCH0000063
Feeler Gauge
RCH0000060

Circuit Diagram
Intake System (Page 1 of 2)
BATTERY
ENGINE
COMPARTMENT
86 30 FUSE AND
RELAY BOX ELECTRONIC
ECM
E-067 ACCELERATOR
MAIN
RELAY PEDAL
EF26 EF22 85 87 I-012
10A 10A
EF37 EF35
10A 15A
6 4 5 3 1 2
75 20 115 93
RB
RG
WR
GY
LW
YR
LY
Br
6 E-035
E-007
RB
I-036
9 3 10 6 4 5
10 1 E-030
RG
RG
VARIABLE
R
WR
GY
LW
YR
CAMSHAFT
LY
Br
TIMING
E-020
2
WG
LY
LY
A54 A42 A55 A56 B38 A32 A13 A40 A30 A1 A28 A21
ECM(A)
E-041
ECM(B)
E-001
E-041 E-001
B B
1 2 3 4 5 6 E-007 9 8 7 6 5 4 3 2 1
7 8 9 10 11 12 B 2 1 1 2 3 4 5 6
18 17 16 15 14 13 12 11 10
E-020 I-012 I-036

B B B EA13T100010

Intake System (Page 2 of 2)
ELECTRONIC THROTTLE E-008
N
ENGINE
SPEED
M S SENSOR
E-039
RGr
3 5 2 1 6 4 1 2 3
RBr
YW
RG
RB
YR
RY
YB
RL
E-007
1 3 4 E-035
YW
YR
YB
B52 B51 B30 B18 B31 B6 B12 B24 B40
ECM(B)
E-001
B41 B16 B13 B28 B19 B7 B33
10
BW
LW
LW
LG
LR
LB
Gr
3 2 1 3 4 2 1
CAMSHAFT
POSITION
SENSOR INTAKE PRESSURE/
E-003
TEMPERATURE SENSOR
E-025
1 2 3 4 5 6
7 8 9 10 11 12
B56 B55 B54 B53 B52 B51 B50 B49
B48B47 B46 B45 B44 B43 B42 B41B40 B39 B38B37 1 2 3 4
B36 B35B34 B33 B32 B31B30 B29 B28B27 B26 B25

E-025 E-007
B24 B23 B22 B21 B20 B19 B18 B17B16B15 B14 B13 B B
B12 B11B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
2 4 6
1 3 5
3 2 1
E-001
B E-003 E-039 E-008
B B B
EA13T100020

DIAGNOSIS & TESTING

HINT:
Use symptoms table below to help determine cause of problem. Check each suspected area in sequence.
Repair or adjust faulty components, or replace as necessary.
Symptom Possible Cause See page

Electronic throttle assembly (dirty) 10-11
Intake manifold assembly (broken, leaked) 10-15
Activated charcoal canister solenoid valve
09-8
(remaining on)
Engine idles roughly
Intake pressure/temperature sensor 10-15
Throttle gasket (damaged) 10-13
Fuel rail injector assembly (installed
08-22
incorrectly)
10

ON-VEHICLE SERVICE
Air Filter Element
Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents when repairing.

 Try to prevent body paint surface from being scratched during removal and installation.

3. Remove the air filter element.
a. Remove 3 coupling screws (arrow) between air filter
upper housing and lower housing.
1
b. Loosen worm clamp (1), and disconnect air filter and
intake hose. 10
c. Remove the air filter upper housing.
RA13T100020
d. Remove the air filter element.
RA13T100030
Installation
1. Clean air filter upper housing and lower housing.
2. Install a new air filter element.
 Wasted air filter element should be handled by the specialized department according to local laws and

Air Filter Assembly

Removal
CAUTION


3. Remove the air direct pipe assembly.
a. Remove 2 fixing bolts (arrow) from air direct pipe, and
remove air direct pipe.
10
RA13T100040
4. Remove the air filter assembly.

a. Loosen worm clamp (1), and disconnect air filter and
intake hose.
1
b. Remove 3 fixing bolts (arrow) from air filter.
RA13T100050
c. Remove the air filter assembly.
Installation

Electric Throttle Assembly

1. Check the electronic throttle assembly.
a. Throttle valve plate should be in NLP position with power off and can rotate smoothly when flipping it by
hand. If seizing occurs, it indicates that internal components may be damaged, and replace electronic
throttle assembly.
b. Connect X-431 3G diagnostic tester to Data Link Connector (DLC).
c. Turn ignition switch to ON and turn on X-431 3G diagnostic tester.
d. Read datastream on X-431 3G diagnostic tester.
Accelerator pedal released
Datastream
Datastream Name Specification (V) Datastream name Value Unit
multiplicative correction of the mixture adaptation 1.00
Sensor voltage from throttle Lambda controller output bank 2 0.00
0.78
potentiometer 1
sensor voltage from throttle potentiometer 1 0.78 V
sensor voltage from throttle potentiometer 2 4.21 V
Sensor voltage from throttle additive correction of the mixture adaptation 0.00 %
4.21 Volage PWG potentiometer 1 0.99

potentiometer 2
V
Volage PWG potentiometer 2 0.50 V
Doubled PWG potentiometer-2 voltage 1.00 V
RA13T100060
Accelerator pedal depressed

10
Datastream
Datastream Name Specification (V) Datastream name Value Unit
multiplicative correction of the mixture adaptation 1.00
Sensor voltage from throttle Lambda controller output bank 2 0.00
4.25
potentiometer 1 sensor voltage from throttle potentiometer 1
sensor voltage from throttle potentiometer 2

4.25 V
0.75 V
Sensor voltage from throttle additive correction of the mixture adaptation 0.00 %
0.75
potentiometer 2
Doubled PWG potentiometer-2 voltage 4.29 V
If result is not as specified, check wire harness, ECM,

or replace electronic throttle assembly. RA13T100070
Removal
WARNING
 The temperature of engine compartment is very high when engine is running. Before removal, you must
make sure that engine has shut off, and engine compartment has cooled down sufficiently, otherwise,
there is a risk of scald injury.


4. Move away intake hose from electronic throttle assembly side.

a. Loosen worm clamp (arrow) between intake hose and
electronic throttle assembly.
RA13T100080
b. Disconnect intake hose and electronic throttle assembly, and move intake hose to one side.
5. Remove the electronic throttle assembly.
a. Disengage the wire harness clip (arrow).
b. Disconnect the electronic throttle assembly connector 1
(1).
10
RA13T100090
c. Remove 4 fixing bolts (arrow) from electronic throttle

assembly.
RA13T100100
d. Remove the electronic throttle assembly.

e. Remove electronic throttle assembly gasket (arrow)
from intake manifold.
RA13T100110

Inspection
1. Check the electronic throttle assembly gasket.
Check electronic throttle assembly gasket for wear or
deterioration. If there is, replace electronic throttle
assembly gasket.
RA13T100120
Cleaning
Cleaning Tool
1. Thin stick: used to support throttle valve plate for cleaning the carbon deposited on contact wall between
valve plate and throttle. Please use plastic, wooden or bamboo thin stick. Do not use metal thin stick to
avoid scratching or deforming the valve plate.
2. Clean cloth or paper towel.
Cleaning Process
1. Remove electronic throttle assembly, and face valve plate upward in free condition. Avoid cleaner flowing
into electronic element through valve plate shaft, resulting in functional failure. 10
2. Start to clean when it is as shown in illustration.
RA13T100130
WARNING
Cleaner is a kind of flammable and corrosive fluid. Follow safety cautions to prevent accidents, and avoid
skin contacting with cleaner.
3. Apply appropriate amount of cleaner to inner wall of throttle valve body, and remove the carbon with clean
cloth.
4. Support the throttle valve with a thin stick, and clean
carbon on valve plate and throttle valve body inner wall.
RA13T100131

5. Turn over the throttle 180°, and clean with the same procedures as above. Repeat several times until it is
clean.
6. Push valve plate by hand, and check if it rotates smoothly. If it is stuck, perform cleaning again according to
cleaning procedures.
7. After cleaning, wipe off cleaner in throttle valve body with absorbent paper.
Installation
CAUTION
 Clean fitting surface of electronic throttle assembly.

 Perform throttle self-learning procedures after installation (See page 06-20). After self-learning is
completed, start the vehicle and check for proper operation.
10

Intake Manifold Assembly

Removal
CAUTION
 The temperature of exhaust system is very high when engine is running. Before removal, you must make
sure that engine has shut off, and exhaust system has cooled down sufficiently, otherwise, there is a risk
of scald injury.

6. Remove the electronic throttle assembly (See page 10-11).
7. Remove the intake manifold assembly. 10
a. Disconnect intake pressure/temperature sensor
connector (1), loosen and remove fixing bolt (arrow),
then remove intake pressure/temperature sensor. 3
b. Loosen elastic clamp (1), and disconnect PCV hose 1

and intake manifold. 4
c. Loosen elastic clamp (3), and disconnect vacuum
booster hose and intake manifold.
d. Disconnect charcoal canister solenoid valve RA13T100140
connector (4), and move away charcoal canister
solenoid valve from bracket.
e. Disconnect oil pressure switch connector (1) and wire
harness clip.
f. Remove 2 fixing bolts (arrow) from booster pipe.
RA13T100150

g. Remove 8 fixing nuts (arrow) from intake manifold.

(Tightening torque:20 +5 N·m)
RA13T100160
h. Move away engine wire harness bracket, remove engine right lifting eye and intake manifold assembly.
8. Disassemble the intake manifold.
a. Remove fixing bolt (1) from charcoal canister solenoid
valve bracket, and remove charcoal canister solenoid 2
valve bracket.
1
b. Remove fixing bolt (2) from intake manifold upper
bracket, and remove intake manifold upper bracket.
c. Remove gasket (arrow) from intake manifold.
10 RA13T100170
Inspection
1. Check the intake manifold gasket.
Check the intake manifold gasket, and replace if it is
deteriorated or damaged.
RA13T100180
Installation
CAUTION
 Clean inner wall and fitting surface of intake manifold assembly.

 Replace intake manifold gasket if it is damaged during installation.

Electronic Accelerator Pedal

Removal
CAUTION

 Try to prevent interior from being scratched during removal and installation.

3. Remove the electronic accelerator pedal.
a. Disconnect the electronic accelerator pedal connector
(1).
b. Remove 3 fixing nuts (arrow) from electronic
accelerator pedal.
1
10
RA13T100190
c. Remove the electronic accelerator pedal.
Installation

- MEMO -

Description 11-3 Front Pipe Assembly 11-10
Main Catalytic Converter Assembly 11-12
Removal 11-12
Installation 11-13
Exhaust System Gas Leakage 
Front Muffler Assembly 11-14
Inspection 11-6
Removal 11-14
ON-VEHICLE SERVICE 11-7 Installation 11-15
Exhaust Manifold Assembly 11-7 Rear Muffler Assembly 11-16
Removal 11-7 Removal 11-16
Inspection 11-8 Installation 11-16
11

11

11 - SQRD4G15B EXHAUST SYSTEM
GENERAL INFORMATION
Description
×5
2
4
3
×2
5
×4
6
7
8
10 ×2
×2
12 ×2
×7
9
×2
×2 ×5
11
11
13
14
×2
×2
RA13T110010

1 - Exhaust Manifold Heat Insulator 2 - Exhaust Manifold Assembly

3 - Heat Insulator 4 - Exhaust Manifold Gasket
5 - Upstream Oxygen Sensor 6 - Downstream Oxygen Sensor
7 - Gasket 8 - Front Pipe Assembly
9 - Diamond Shaped Hanger Block 10 - Muffler Heat Insulator Ⅰ
11 - Main Catalytic Converter Assembly 12 - Front Muffler Assembly
13 - Fuel Tank Heat Insulator 14 - Rear Muffler Assembly
Exhaust system is used to control engine exhaust, reducing vehicle emissions by precatalytic converter and
main catalytic converter, and eliminating exhaust noise by muffler.
When exhaust system discharges gas, oxygen sensor monitors oxygen content in exhaust gas. Engine
control module adjusts air-fuel ratio of combustible gas mixture to control vehicle emissions and achieve
optimal fuel economy according to feedback signals of oxygen sensor and combining with other sensor
signals.
Specifications

11 Exhaust Manifold Fixing Nut 20 + 5
Coupling Nut Between Exhaust Manifold and Front
45 ± 5
Pipe Assembly
Coupling Nut Between Front Pipe Assembly and
45 ± 5
45 ± 5
Assembly and Front Muffler Assembly
Coupling Nut Between Front Muffler Assembly and
45 ± 5

Tools
General Tools
RCH0000063
Feeler Gauge
RCH0000060
11

DIAGNOSIS & TESTING

Exhaust pipe (loose connection) -
Main catalytic converter assembly
11-12
(damaged or leaked)
Front muffler assembly (damaged or
Excessive exhaust noise 11-14
leaked)
Rear muffler assembly (damaged or leaked) 11-16
Exhaust manifold assembly (damaged or
11-7
leaked)
Precatalytic converter assembly (blocked) 11-7
Main catalytic converter assembly (blocked) 11-12
Excessive exhaust temperature
Incorrect ignition timing in ignition system 07-23
Inadequate gas mixture combustion -
Exhaust pipe gasket (damaged) -
Exhaust pipe leakage
11 Exhaust pipe (damaged) -
Exhaust System Gas Leakage Inspection

Inspection method for gas leakage in exhaust system joints:
Warm up engine for a while, and check exhaust system joints for gas leakage. A certain amount of gas
leakage at exhaust pipe joint is allowed, but gas leakage at joint between exhaust manifold and cylinder head
is prohibited. Judging standard is that there is no shuddering in engine and no "poof" sound is heard from
joints.

ON-VEHICLE SERVICE
Exhaust Manifold Assembly
Removal
WARNING
of scald injury.
CAUTION

11
5. Take off and disconnect upstream oxygen sensor
connector (arrow) from bracket.
RA13T110020
6. Remove the exhaust manifold heat insulator.

a. Remove 5 fixing bolts (arrow) from exhaust manifold
heat insulator.
RA13T110030
b. Remove the exhaust manifold heat insulator.

7. Remove the exhaust manifold assembly.

a. Remove 2 coupling nuts (arrow), disconnect exhaust
manifold assembly and front pipe assembly, and
remove gasket from connecting part.
RA13T110040
b. Remove 7 fixing nuts (arrow) and fixing bolt (arrow)

from exhaust manifold assembly.
RA13T110050
c. Remove engine lifting eye and exhaust manifold assembly, and take off exhaust manifold assembly and
gasket.
11
8. Remove upstream oxygen sensor (arrow) from exhaust
manifold assembly.
RA13T110060
Inspection
1. Measure warpage on surface of exhaust manifold
assembly with a precision straightedge and a feeler
gauge. If warpage on surface is greater than 0.5 mm,
replace it.
RA13T110070

2. Measure warpage on exhaust surface of cylinder head

with a precision straightedge and a feeler gauge. If
warpage on surface is greater than 0.4 mm, replace it.
RA13T110080
3. Check the exhaust manifold gasket. There should be no

scratches or roughness. Otherwise, replace it.
RA13T110090
Installation
11
CAUTION
 After installation is completed, check that there is no exhaust gas leakage between exhaust manifold
assembly and cylinder head or front pipe assembly.
 Check that there is no exhaust gas leakage in connecting part of upstream oxygen sensor.

Front Pipe Assembly

Removal
WARNING
of scald injury.

3. Remove the front pipe assembly.
a. Take off and disconnect downstream oxygen sensor
connector (1) from bracket.
b. Remove 2 coupling nuts (2), disconnect exhaust
manifold assembly and front pipe assembly, and
remove gasket from connecting part. 2
1
11
RA13T110100
c. Remove 2 diamond shaped hanger blocks (1)

between front pipe and sub frame.
d. Remove 2 coupling nuts (arrow), disconnect front pipe
assembly and main catalytic converter assembly, and
RA13T110110
e. Remove the front pipe assembly.

4. Remove downstream oxygen sensor (arrow) from front
pipe assembly.
RA13T110111

Installation
CAUTION
 If gasket is damaged, replace it, and remove foreign matters on joints and threads.
 If there is any crack or leakage in front pipe assembly, replace it.
 Check for exhaust gas leakage. If gas leaks, tighten the malfunctioning part to prevent leakage. Replace
damaged parts as necessary.
11


Removal
WARNING
of scald injury.

3. Remove the main catalytic converter assembly.
a. Remove 2 coupling nuts (arrow), disconnect main
catalytic converter assembly and front pipe assembly,
and remove gasket from connecting part.
11
RA13T110120
b. Remove 2 coupling nuts (arrow), disconnect main

catalytic converter assembly and front muffler
assembly, and remove gasket from connecting part.
RA13T110130
c. Remove the main catalytic converter assembly.

Installation
CAUTION
 If there is any crack or leakage in main catalytic converter assembly, replace it.
 Keep sufficient space between main catalytic converter assembly and vehicle body during installation.
 Lubricate joints with lubricant firstly, which can be helpful in separating front exhaust pipe assembly and
diamond shaped hanger block.
11

Front Muffler Assembly

Removal
WARNING
of scald injury.

3. Remove the front muffler assembly.
a. Remove 2 coupling nuts (arrow), disconnect front
muffler assembly and main catalytic converter
assembly, and remove gasket from connecting part.
b. Detach diamond shaped hanger block (1) between
1
front muffler assembly and body hook.
11
RA13T110140
c. Remove 2 coupling nuts (arrow), disconnect front

muffler assembly and rear muffler assembly, and
1
d. Detach diamond shaped hanger block (1) between
front muffler assembly and body hook.
RA13T110150
e. Remove the front muffler assembly.

4. Remove the muffler heat insulator Ⅰ .
a. Remove the main catalytic converter assembly (See page 11-12).
b. Remove 7 clamping pieces (arrow) from muffler heat
insulator Ⅰ .
RA13T110151
c. Remove the muffler heat insulator Ⅰ .

5. Remove the fuel tank heat insulator.

a. Support fuel tank with a transmission carrier, and
remove fuel tank fixing straps (arrow).
RA13T110152
b. Remove 5 screws (arrow) from fuel tank heat

insulator.
RA13T110153
c. Remove the fuel tank heat insulator.
Installation 11
CAUTION
 If there is any crack or leakage, replace it.
 During installation, check that exhaust system components do not contact with muffler heat insulator Ⅰ
or vehicle underbody. Make sure that clearance between exhaust system components and muffler heat
insulator or vehicle underbody is more than 25 mm.


Removal
WARNING
of scald injury.

3. Remove the rear muffler assembly.
a. Remove 2 coupling nuts (arrow), disconnect front
muffler assembly and rear muffler assembly, and
11
RA13T110160
b. Detach 2 diamond shaped hanger blocks (arrow)

between rear muffler assembly and body hooks.
RA13T110170
c. Remove the rear muffler assembly.
Installation
CAUTION
 If there is any crack or leakage, replace it.
 During installation, make sure that clearance between rear muffler assembly tailpipe and bumper on rear
body is more than 30 mm.

Description 12-3 Electronic Thermostat 12-18
Cooling System Operation Flowchart 12-6 Installation 12-19
Circuit Diagram 12-8 Thermostat Seat 12-20
Removal 12-20
Installation 12-21
Cooling Fan Assembly 12-22
Cooling System Pressure Test 12-10
Coolant Freezing Point Test 12-11
Removal 12-22
Coolant Replacement 12-12 Radiator 12-24
Coolant Draining 12-12 Removal 12-24
Coolant Adding 12-13 Installation 12-24
Tank Upper Crossmember Assembly 12-15 Water Pump 12-25
Expansion Tank 12-17 Installation 12-26
Removal 12-17
12

12

12 - SQRD4G15B COOLING SYSTEM
GENERAL INFORMATION
Description
1
×6
25
26
2
×2
24
×4
4 15
22
23
5
×4
21 12
13 14 27
6 12
11
20
×3 16
9
18
17
19
×3
7 ×2
8
10
RA13T120010

1 - Tank Upper Crossmember 2 - Rubber Bushing

3 - Radiator 4 - Rubber Bushing
5 - Cooling Fan Assembly 6 - Engine Outlet Pipe
7 - Electronic Thermostat 8 - Electronic Thermostat Gasket
9 - Coolant Temperature Sensor 10 - Thermostat Seat
11 - Thermostat Seat Gasket 12 - Heater Inlet Pipe
13 - Engine to Expansion Tank II Water Pipe 14 - Discharge Steel Pipe
15 - Discharge Hose I 16 - Engine Inlet Pipe I
17 - Hose 18 - Cooling Pipe Assembly
19 - Heater Outlet Pipe 20 - Small Circulation Hose II
21 - Engine Inlet Pipe II 22 - Engine Inlet Pipe III
23 - Water Pump Assembly 24 - Engine Inlet Pipe IV
25 - Expansion Tank 26 - Discharge Hose III
27 - Water Pump Assembly Gasket
Engine cooling system adjusts engine operating temperature by flow of coolant and makes engine operate
normally under various operating conditions.
Engine cooling system is a forced circulation system, which supplies circulation pressure for cooling system
by water pump and forces coolant to circulate in the engine cylinder block, and distributes excessive heat to
radiator by the flow of coolant, and radiates it to the air by cooling fan. Also, engine cooling system provides
12 heat to heater core in cabin to improve driving comfort.
Specifications

Thermostat Housing Fixing Bolt 9.5 ± 1.5
Thermostat Seat Fixing Bolt 9.5 ± 1.5
Coolant Temperature Sensor 11 - 16
Cooling Fan Assembly Fixing Bolt 7 ± 1.5
Radiator Upper Crossmember Fixing Bolt 9±1
Water Pump Fixing Bolt 25 ± 3
Coolant Capacity
Item Capacity (L)


50% 50%

Coolant Freezing Point
Item Freezing Point Value (°C)

Coolant -35
Cooling System Pressure
Item System Pressure (bar)

Cooling System (Test Pressure) 1.3 ± 0.2
Tools
General Tools
Digital Multimeter
RCH0000002
12
Cooling System Pressure Tester
RCH0000055
Freezing Point Tester
RCH0000007
Engine Equalizer
RCH0000026

Cooling System Operation Flowchart
17
15
1
11
10
16
14
4
13
9
12
5
12 8
7
RA13T120020
1 - Expansion Tank Cap 2 - Expansion Tank

3 - Discharge Hose III 4 - Water Pump
5 - Engine Inlet Pipe III 6 - Engine Inlet Pipe IV
7 - Radiator 8 - Engine Inlet Pipe II
9 - Discharge Steel Pipe 10 - Cylinder Block
11 - Cooling Pipe 12 - Engine Outlet Pipe
13 - Electronic Thermostat 14 - Coolant Temperature Sensor
15 - Heater Inlet Pipe 16 - Heater Outlet Pipe
17 - Heater Core

Cooling fan operates under following conditions:

1. When coolant temperature is higher than 92°C in low temperature range (large load), cooling fan starts to
operate at low speed.
2. When coolant temperature is higher than 95°C in low temperature range (large load), cooling fan starts to
operate at high speed.
3. When coolant temperature is below 89°C in low temperature range (large load), cooling fan stops
operating at low speed.
4. When coolant temperature is below 93°C in low temperature range (large load), cooling fan stops
operating at high speed.
5. When coolant temperature is higher than 107°C in high temperature range (small load), cooling fan starts
to operate at low speed.
to operate at high speed.
to operate at low speed.
8. When coolant temperature is higher than 104°C in high temperature range (small load), cooling fan stops
operating at high speed.
12

Circuit Diagram
Cooling System
BATTERY
ENGINE
COMPARTMENT
FUSE AND
86 30 MF02 MF03 RELAY BOX
ECM 40A 50A E-067
MAIN
RELAY E-064
EF26 EF22 85 87 86 30 86 30 E-065
10A 10A FAN FAN
LOW HIGH
RELAY 2 RELAY 1
EF37 EF35
15A 85 87 85 87
10A
75 20 115 93 138 135 121 120

RG
Br
R
P
L
COOLANT
2
TEMPERATURE
3 SENSOR
RB
E-006
M COOLING 2 1
1
RG
RG
FAN MOTOR
R
THER- E-045
MOSTAT 1
BW
E-036
Gr
B
2
12
BL
E-066
A54 A42 A55 A56 A34 A43 A46 B4 B21

ECM(A)
E-041
ECM(B)
E-001
E-041 E-001
B B
1 2 E-045 E-006
3 2 1 B 2
B
1
E-036
Gr
EA13T120010

DIAGNOSIS & TESTING

Coolant pipe (deteriorated and leaked) -
Expansion tank (leaked) 12-17
Radiator (leaked) 12-24
Insufficient coolant Water pump (bearing loose and leaked) 12-25
Engine cylinder head gasket (damaged) 07-18
Engine cylinder head (water jacket leaked) 07-18
Engine cylinder block (water jacket leaked) 07-48
Low coolant level 12-13
Air resistance exists in pipe -
Expansion tank cap (damaged) -
Engine overheating Cooling fan 12-22
Radiator 12-24
Electronic Thermostat 12-18
Leakage in engine -
12
Unable to reach normal engine Cooling fan (constantly operating) 12-22
temperature Electronic Thermostat 12-18
Fuse open circuit -
Relay malfunction -
Cooling fan does not operate or abnormal
Cooling fan 12-22
air speed
Wire harness -
Engine Control Module (ECM) failure -

Cooling System Pressure Test

WARNING
 Always make sure engine is in low temperature before operating cooling system. Never open expansion
tank cap or remove drain cock plug, when engine is operating or cooling system overheats. High-
pressurized hot engine coolant and steam may flow out and cause serious personal injury.
CAUTION
 When testing cooling system, please pressurize system to specified pressure. Otherwise, it may damage
system components.
 Before testing cooling system, do not perform operation until coolant temperature drops to normal level.
Otherwise, it may cause scald.
Test Procedures
2. Check if coolant level is between "MAX" and "MIN" lines.
If coolant level is below "MIN" line, add coolant.
12 MAX
MIN
RA13T120030
3. Connect cooling system pressure tester to coolant

pressure release cap port (expansion tank cap port) and
tighten it slowly.
RA13T120040
CAUTION
 Make sure there is no leakage in connecting part of coolant system pressure tester, in order to avoid
pressure leakage during test.
4. Pressurize cooling system to 1.3 ± 0.2 bar with cooling system pressure tester, and then observe if
pressure changes. If system pressure does not drop within 2 minutes, it indicates there is no leakage in
system. If pressure changes greatly, it indicates that there is a leakage in system; find the leaking area and
perform troubleshooting.

Coolant Freezing Point Test

CAUTION
 DO NOT mix coolant with different colors and specifications.

 Please select coolant that is suitable for local climate in different areas.
 Please read measured value at the scale line. In order to distinguish scale line more clearly, drip a drop
of water on glass of freezing point tester with a pipette, then scale line can be clearly distinguished via a
"waterline".
Test Procedures
1. As shown in illustration, drip a drop of coolant on glass of
freezing point tester with a pipette, and then observe
freezing point value of coolant.
RA13T120050
2. As shown in illustration, observe scale 3 of freezing point

tester to read ethylene glycol coolant freezing point
value. Freezing point value must be kept at -35°C or PROPYLENE
GLYCOL
ETHYLENE
GLYCOL
-50
12
2
lower.
-50 1.40
1.35
-40 -40
If freezing point is beyond specified value, replace 1 GOOD

1.30 3
coolant.
-30 -30
1.25
FAIR
-20 1.20 -20

RECHARGE
HINT: -10 BATTERY

1.15
-10
ELECTROLYTE 1.10 d
Scale 1 is used to measure freezing point value of
20
20
0( C)
O
WATERLINE 0( C)
O
ANTIFREEZE
propylene glycol coolant, and scale 2 is used to measure
RA13T120060
density of battery electrolyte.

ON-VEHICLE SERVICE
Coolant Replacement
Coolant Draining
WARNING

3. Remove expansion tank cap when engine temperature and radiator temperature are low.
5. Put a coolant collector under vehicle, rotate radiator drain
cock plug (arrow), then drain coolant in radiator and
expansion tank.
HINT:
Put a drainage device or similar tool at radiator outlet, so
12 that coolant can flow into collector smoothly.
RA13T120070
6. After coolant stops flowing, retighten radiator drain cock plug.
CAUTION
 Tighten drain cock plug to prevent leakage.
 Wasted coolant should be handled by the specialized department according to local laws and

Coolant Adding
Only use coolant that meets Chery specifications.
Coolant Capacity
Item Capacity (L)


50% 50%
WARNING
 If it is necessary to add coolant when engine is hot, loosen expansion tank cap slightly first to release
internal pressure and loosen cap completely after waiting for a while, and then add coolant.
 If your body contacts coolant accidentally, clean it with water immediately. If it is serious, please go to
hospital.
CAUTION
 DO NOT use inferior coolant. 12

 DO NOT mix coolant with different colors and specifications.
 Be careful when adding coolant, avoid spilling coolant on any area of engine.
1. Open expansion tank cap and add coolant until coolant

level reaches "MAX" line.
MAX
MIN
RA13T120030
2. Tighten expansion tank cap, start and run engine. Maintain engine speed between 2000 and 2500 rpm to
warm up engine until cooling fan operates.

CAUTION
If there is no coolant in expansion tank after engine just starts, perform the followings:
 Stop engine;
 Wait until coolant cools down;
 Add coolant to "MAX" line on expansion tank.
Run the engine at 2500 rpm until coolant level becomes stable.
3. Stop engine and wait until coolant temperature drops to the ambient temperature. Check that coolant level
is between "MAX" and "MIN" lines. If coolant level is below "MIN" line, repeat all the above procedures. If
coolant level is above "MAX" line, drain coolant until level is between "MAX" and "MIN" lines.
12

Tank Upper Crossmember Assembly

Removal
WARNING
 Perform removal procedures with engine compartment at low temperature, after cooling fan stops
completely; otherwise rotating cooling fan or hot components of engine compartment may cause serious
injury.
CAUTION


3. Remove the front bumper (See page 49-7).
4. Remove the air direct pipe assembly (See page 10-10).
5. Remove the tank upper crossmember assembly.
a. Remove 6 fixing bolts (arrow) from tank upper 12
crossmember deflector.
b. Remove 2 fixing screws (1) from deflector.
RA13T120071
c. Remove 3 hood lock fixing bolts (arrow) from tank

upper crossmember, and move away cable clip (1).
1
RA13T120072

d. Turn over tank upper crossmember, and disconnect

engine compartment contact switch connector
(arrow).
RA13T120073
e. Remove the tank upper crossmember assembly.

6. Remove engine compartment contact switch (arrow) from
tank upper crossmember.
RA13T120074
Installation
12

Expansion Tank
Removal
WARNING

3. Remove the expansion tank.
a. Loosen elastic clamp (1), and disconnect expansion
tank and discharge hose.
b. Loosen elastic clamp (2), and disconnect expansion
tank and radiator discharge hose.
1
c. Remove 2 fixing bolts (arrow) from expansion tank.
2
RA13T120080
d. Pull out expansion tank upward, loosen elastic clamp

12
(arrow), and disconnect expansion tank and
expansion tank outlet hose.
RA13T120090
e. Remove the expansion tank.
Installation

Electronic Thermostat
Removal
WARNING

5. Remove the electronic thermostat.
a. Remove the electronic thermostat connector (1).
b. Loosen engine outlet hose elastic clamp (2), and
disconnect engine outlet hose and electronic
thermostat.
c. Remove 3 fixing bolts (arrow) from electronic 1
thermostat cover.
2
12
RA13T120100
d. Remove the electronic thermostat.
Inspection
1. Measured resistance is 15 Ω at normal temperature.
2. Heat thermostat in water and energized it, and check if it
can be opened.
RA13T120102
CAUTION
 Energized time should not be too long each time.

Installation
RA13T120103
CAUTION
 During installation, align protrusion of thermostat grommet with groove of thermostat as shown in the
illustration.
 Check that coolant has been added to the specified level after installation.
12

Thermostat Seat
Removal
WARNING

5. Remove the battery (See page 16-7).
6. Remove the battery tray (See page 16-9).
8. Remove the electronic thermostat (See page 12-20).
9. Remove the thermostat seat.
a. Disconnect the coolant temperature sensor connector
(1).
12 b. Remove 2 fixing bolts (arrow), move wire harness
1
bracket sideways to one side.
RA13T120110
c. Loosen elastic clamp (1), and disconnect thermostat

seat and engine discharge hose.
d. Loosen elastic clamp (2), and disconnect thermostat 1
seat and hose.
e. Loosen elastic clamp (3), and disconnect thermostat 2
seat and heater inlet pipe.
RA13T120120

f. Remove 3 fixing bolts (arrow) from thermostat seat.

RA13T120130
g. Remove thermostat seat and thermostat seat washer.

10.Remove coolant temperature sensor (arrow) from
thermostat seat.
RA13T120140
Installation
Installation is in the reverse order of removal. 12
CAUTION
 Replace thermostat seat washer with a new one during installation, and removed washer cannot be
reused.

Cooling Fan Assembly

1. Measure cooling fan resistance with a digital multimeter.
a. Cooling fan
+ -
Multimeter
Connection C B A
Terminal A - Normal
0.8 ± 0.1
Terminal B temperature
Terminal A - Normal
0.6 ± 0.1
Terminal C temperature
If inspection result is not as specified, replace cooling RA13T120150
fan assembly (See page 12-22).

2. Apply battery voltage to specified connector terminals of
cooling fan respectively according to table below, and
check that cooling fan operates smoothly when applying
battery voltage.
a. Cooling fan
+ -
Measurement Specified
Condition
Condition Condition C B A
Battery positive
12 (+) - Terminal B Operates
Always smoothly at low
Battery negative speed
(-) - Terminal A
Battery positive RA13T120152
(+) - Terminal C Operates
Always smoothly at high
Battery negative speed
(-) - Terminal A
If inspection result is not as specified, replace cooling

fan assembly (See page 12-22).
Removal
WARNING

5. Remove the tank upper crossmember assembly (See page 12-15).

7. Remove the cooling fan assembly.

a. Loosen elastic clamp (1), and disconnect engine
outlet hose and radiator assembly.
1
b. Disconnect the cooling fan assembly connector
(arrow).
RA13T120160
c. Remove 3 fixing bolts (1) from oil pipe (for AT model).

d. Remove 4 fixing bolts (arrow) from cooling fan 1
assembly.
RA13T120170
e. Remove cooling fan assembly from radiator assembly.
Installation
Installation is in the reverse order of removal. 12

Radiator
Removal
WARNING

6. Remove the front anti-collision crossmember (See page 49-13).
8. Remove the cooling fan assembly (See page 12-22).
9. Remove the radiator.
a. Loosen elastic clamp (1), and disconnect radiator
discharge hose III and radiator assembly.
12 b. Loosen elastic clamp (2), and disconnect engine inlet 1
pipe and radiator assembly.
RA13T120171
c. Remove 4 coupling bolts (arrow) between tank and

condenser.
RA13T120180
d. Remove the radiator.
Installation

Water Pump
Removal
WARNING

5. Remove alternator and alternator bracket (See page 16-10).
7. Use the engine equalizer to hang the engine.
8. Remove the right mounting bracket (See page 07-55).
9. Remove the water pump.
a. Loosen elastic clamp (arrow), and disconnect engine
inlet hose and water pump.
12
RA13T120190
b. Remove the water pump fixing bolt (arrow).

c. Loosen elastic clamp (1), and disconnect water pump 1
and hose.
RA13T120200
d. Remove water pump and gasket.

Inspection
1. Check water pump gasket for wear or bend. If wear or
bend is found, replace gasket.
RA13T120210
2. Check if water pump bearing is loose. If it is loose, replace water pump assembly.
Installation
CAUTION
 If water pump is damaged, replace rather than attempt to repair it.

12

Description 13-3 Oil Pressure Switch 13-14
Lubrication System Flowchart 13-6 Installation 13-15
Oil Pan 13-16
Removal 13-16
Installation 13-17
Engine Oil Level Inspection 13-7
Oil Strainer 13-19
Oil Pressure Inspection 13-8
Removal 13-19
Engine Oil Replacement 13-10 Oil Pump Assembly 13-20
Engine Oil Draining 13-10 Removal 13-20
Engine Oil Adding 13-11 Installation 13-21
Oil Filter 13-12
Removal 13-12
13

13

13 - SQRD4G15B LUBRICATION SYSTEM
GENERAL INFORMATION
Description
4
5
7
6
8
×2 13
×6
×6
10
11
×14
×4
RA13T130010

1 - Engine Assembly 2 - Oil Dipstick

3 - Oil Dipstick Tube 4 - Oil Pressure Switch
5 - Oil Filter 6 - Oil Pump Assembly
7 - Water Pump Assembly Gasket 8 - Oil Strainer
9 - Oil Pan Gasket 10 - Oil Deflector
11 - Oil Pan
Function of lubrication system is that when engine is operating, oil pump driven by crankshaft, sucks oil from
oil pan and pumps it through oil filter. This filtered oil then flows through oil passages, to surfaces of all engine
drive parts and forms oil films between moving surfaces to reduce friction and finally returns to oil pan, thus
reducing friction resistance between parts, power consumption and parts wear, to increase reliability and
durability of engine operation.
WARNING
Prolonged and repeated contact with engine oil will result in the removal of natural oils from skin, leading to
dryness, irritation and dermatitis. In addition, the used engine oil contains potentially harmful contaminants,
which may cause skin cancer.
Precautions should be followed when replacing engine oil to minimize the risk of your skin making contact
with used engine oil.
 Wear protective clothing and gloves.
 Wash your skin thoroughly with soap and water, or use waterless hand cleaner to remove any used
engine oil.
 Never use gasoline, thinners or solvents.
13
Specifications
System Pressures
Condition Pressure (bar)

Idling (650 ± 50 r/min, oil temperature 90°C) More than 1.5
High Idling (4000 ± 50 r/min, oil temperature 100°C) More than 3.5
Oil Specifications

Oil Specifications

Drain Plug 35 ± 3
Oil Filter 22 ~ 25
Coupling Bolt Between Oil Pan and Transmission
45 ± 5
Case


Fixing Bolt of Baffle Plate Between Oil Pan and
45 ± 5
Transmission Case
Oil Pan Fixing Bolt 11 ± 1
Oil Pan Baffle Plate Fixing Bolt 8＋3
Oil Strainer Bracket Fixing Nut 17 - 23
Coupling Bolt Between Oil Strainer and Oil Pump 8 ~ 11
Oil Pump Fixing Bolt 8＋3
Tools
Special Tools
Oil Pan Remover and Scraper
RCH0000056
13
Oil Filter Remover
RCH0000054
General Tool
Oil Pressure Tester
RCH0000006

Lubrication System Flowchart
12
13
11
6
10 9 8 7
RA13T130020
1 - Oil Filler Cap 2 - Phaser

3 - VVT Solenoid Valve 4 - Cylinder Block
5 - Oil Pump 6 - Engine Oil
7 - Drain Plug 8 - Oil Strainer
9 - Oil Pressure Switch 10 - Oil Filter
11 - Oil Pan 12 - Crankshaft
Description
1. Solid arrow: indicates flow of high-pressure lubricant.
2. Hollow arrow: indicates flow of low-pressure lubricant.
3. Dark area: indicates high-pressure lubricant.
4. Bright area: indicates low-pressure lubricant.

DIAGNOSIS & TESTING

Oil pan (dirty, leakage) 13-16
Oil strainer (mesh dirty, blocked) 13-19
Low pressure in lubrication system
Oil pump 13-20
Line (blocked) -
Engine oil (excessive oil filling capacity) 13-10
Oil filter 13-12
High oil consumption
Each engine seal surface (leakage) -
Engine oil (leakage) -
Engine oil (insufficient oil, low oil viscosity) 13-10
Oil filter (blocked) 13-12
Lubrication system (leakage) -
Oil pressure switch 13-14
Oil pressure warning light comes on Instrument cluster (oil pressure warning
38-8
light)
Cylinder block (cracks occur in water
jacket, resulting in coolant leaking into oil
13
07-68
pan, which will cause oil dilution)
Line (blocked) -
Engine oil (high oil viscosity, excessive oil
After engine cranked, engine produces 13-7
filling capacity)
clunk sound
Cylinder block (blocked oil passage) 07-68
Engine Oil Level Inspection

HINT:
Check oil level indicated by oil dipstick, when engine is stopped after it reaches operating temperature.
1. Park vehicle on level ground, stop engine after warming up and wait for 5 minutes.
2. Open hood, pull out oil dipstick and wipe it off with a clean piece of cloth.
CAUTION
 Please put a piece of cloth under oil dipstick end, to prevent oil from splashing onto engine and body.
3. Reinsert oil dipstick and check if oil level is proper.

4. Pull out oil dipstick again and check if oil level is proper.
If engine oil level is too low, check for leakage and add oil up to full level mark.

a. If oil level is at or above "MAX" mark, drain excessive

engine oil.
b. If oil level is between "MIN" mark and "MAX" mark, it
shows that oil level is proper. MAX MIN
c. If oil level is at or below "MIN" mark, it is necessary to

add engine oil.
RA13T130021
CAUTION
 When adding engine oil, oil level should not be above "MAX" mark.
Oil Pressure Inspection

Preconditions
1. Engine oil level is proper.
2. Oil filter is used within 5000 km.
3. Engine reaches the normal operating temperature.
Inspection
1. Disconnect oil pressure switch connector (1) and remove
oil pressure switch (2).
13 (Tightening torque: 20 ± 2 N·m)
2
RA13T130030
2. Screw oil pressure tester into threaded hole of oil

pressure switch as shown in illustration.
RA13T130031
3. Start the engine.When engine inspection conditions are met, read oil pressure values at idling speed and
high speed respectively. If lubrication system pressure is low, clean oil pan and oil strainer mesh, and then
test again. If lubrication system pressure is still low, it shows there is a malfunction in oil pump and the oil
pump must be replaced.
Oil pressure at idling speed (650 ± 50 r/min): more than 1.5 bar.
Oil pressure at high speed (4000 ± 50 r/min): more than 3.5 bar.

4. Install the oil pressure switch.

HINT:
Apply a small amount of seal gum to threads when installing oil pressure switch.
5. Connect oil pressure switch connector and check engine oil for leakage.
13

ON-VEHICLE SERVICE
Engine Oil Replacement
Engine Oil Draining
3. Open the oil filler cap.
RA13T130040
4. Unscrew drain plug (arrow), and drain oil into a container.
13
RA13T130050
WARNING
 Apply a certain pushing force to drain plug while loosening plug by hand, and have drain plug attached to
thread tightly to prevent oil from overflowing in advance. Move away your hand quickly to prevent burn by
oil with a certain temperature.
 Wasted engine oil should be handled by specialized department according to local laws and regulations.
Never discard it at will.
5. Wipe off and tighten drain plug.


Engine Oil Adding

Only use engine oil that meets Chery specifications.

Oil Specifications
CAUTION
 DO NOT use inferior engine oil.

 DO NOT mix different types of engine oil.
 Be careful not to spill engine oil on any part of engine, when adding engine oil.
1. Add a proper amount of oil, and check that oil level is

between "MIN" mark and "MAX" mark with oil dipstick.
MAX MIN
RA13T130021
13
2. Turn off engine after running for 1 to 2 minutes, park vehicle on a level surface and wait for approximately
5 minutes. Check if oil level is between "MIN" mark and "MAX" mark. Refill oil if necessary.
3. Check vehicle for oil leakage after replacing oil.

Oil Filter
Removal
WARNING
 DO NOT remove oil filter until engine cools down.

 Prolonged and repeated contact with engine oil will be harmful to your skin. If engine oil spills on your
skin, wash it off immediately with water. In addition, used engine oil contains potentially harmful
contaminants, which may cause skin cancer. Therefore, always take proper skin protection measures
when servicing vehicle.
CAUTION
 When repairing oil filter, use oil filter installer to prevent oil filter from deforming.

4. Remove the oil filter.
a. Using oil filter remover (1), remove oil filter (2).
13
2
RA13T130060
 Removed oil filter should be handled by specialized department according to local laws and regulations.
Installation

CAUTION
 Check oil filter bracket grommet for damage and cracks. If there is damage or cracks, replace grommet.
 Check and clean installation surface between oil filter and oil filter bracket.
 Apply a layer of clean engine oil to a new oil filter grommet.
 Slightly rotate oil filter in place by hand, and tighten oil filter until grommet contacts with oil filter bracket
base.
 Use a special tool to tighten oil filter.
 (Tightening torque: 22 - 25 N·m)
13

Oil Pressure Switch

Removal
WARNING

when servicing vehicle.

3. Remove the oil pressure switch.
a. Disconnect oil pressure switch connector (1) and
remove oil pressure switch (2).
2
13 RA13T130030
Inspection
CAUTION
 Before inspecting oil pressure switch, please make sure that oil level is correct, coolant temperature is
above 90°C, oil filter is used within 5000 km and electric fan has stopped operating.
1. Use an oil pressure tester as shown in illustration.
RA13T130070

2. Install oil pressure tester into threaded hole (4) of oil

pressure switch as shown in illustration. 1
3
3. Install oil pressure switch (2) onto tester (1) and connect
oil pressure switch connecter.
4. Connect oil pressure switch to body.
+ -
5. After engine starts and oil pressure warning light (3)
comes on, observe pressure reading on tester. If warning
light still comes on when oil pressure is higher than 75 4
kPa, replace oil pressure switch. 2
RA13T130071
Installation
1. Remove oil and impurities on oil pressure switch and its threaded hole.
2. Apply a small amount of seal gum to threads when
installing oil pressure switch as shown in illustration.
Width of a: 3 mm a
RA13T130072
13

Oil Pan
Removal
WARNING

when servicing vehicle. DO NOT remove oil filter until engine cools down.

3. Remove the front pipe assembly (See page 11-10).
5. Remove baffle plate between oil pan and transmission case.

13 a. Remove 2 coupling bolts (1) between oil pan and
transmission case.
b. Remove fixing bolt (2) of baffle plate between oil pan 2
1
and transmission case.
RA13T130079
c. Remove baffle plate between oil pan and transmission case.

6. Remove the oil pan.
a. Pre-loosen oil pan fixing bolts first, and then remove
oil pan fixing bolts in order shown in illustration. 5 9 13 18 15 11 7
4
1
2
3
8 12 16 17 14 10 6
RA13T130090

b. Pry oil pan at specific prying locations on oil pan with oil pan remover and scraper and remove it.
CAUTION
 Because seal gum is used as a seal between oil pan and cylinder block, never use hard objects, such as
a hammer, to tap it during removal, but it can be tapped slowly from left and right with a rubber hammer.
 A transmission carrier can be used to support oil pan during removal, to prevent personal injury from
sudden dropping of oil pan.
c. Remove the oil pan gasket.

d. Remove fixing bolt (arrow) from oil pan oil deflector,
and remove oil pan oil deflector.
RA13T130100
Installation
CAUTION
13
 When applying seal gum, check type and expiration date of seal gum.
 Remove impurities, iron chips and seal gum residues from oil pan.
 Remove oil stain and seal gum residues from cylinder block and threaded hole of oil pan.
 Seal gum should not be applied too thick; otherwise it will overflow into oil pan due to squeezing, which
will block oil strainer.
 DO NOT add engine oil until seal gum becomes dry after installing oil pan.
1. Apply seal gum to joint surface between oil pan gasket

and oil pump, and semicircular joint surface between rear
oil seal bracket and oil pan as shown in illustration.
Recommended seal gum: Loctite 5910
RA13T130110
2. Replace oil pan gasket with a new one.

3. Pre-tighten oil pan fixing bolts until oil pan is sufficiently

pressed, and then tighten bolts in order as shown in 14 10 6 1 4 8 12
illustration.
18
17
16
11 7 3 2 5 9 13
RA13T130120
13

Oil Strainer
Removal
WARNING


3. Remove the oil pan (See page 13-16).
4. Remove the oil strainer.
a. Remove fixing nut (arrow) from oil strainer bracket.
b. Remove coupling bolt (1) between oil strainer and oil
pump.
1
13
RA13T130130
c. Remove oil strainer and its grommet.
Installation
CAUTION
 Check oil strainer grommet for damage and cracks. If there is damage or cracks, replace grommet.

Oil Pump Assembly

Removal
WARNING


4. Remove the engine accessory drive belt (See page 07-19).
6. Remove crankshaft timing pulley (1) and crankshaft
timing pulley gasket (2) from crankshaft.
2
1
FRONT
13
RA13T130140
7. Remove the crankshaft front oil seal (See page 07-27).

8. Remove the oil pan (See page 13-16).
9. Remove the oil pump assembly.
a. Remove coupling bolt (arrow) between oil strainer and
oil pump.
RA13T130150

b. Remove 6 fixing bolts (arrow) from oil pump assembly.

RA13T130160
c. Remove oil pump assembly and its grommet.
Installation
CAUTION
 When installing crankshaft pulley, make "FRONT" side of crankshaft pulley face forward.
 Rotate oil pump until oil in oil passage overflows from outlet.
 Replace the oil pump gasket.
 Apply seal gum to flat surface between bottom of oil pump assembly and cylinder block, then install oil
13
pump assembly.
 Replace oil strainer gasket, and install oil strainer.
 Replace oil pan gasket, and install oil pan.

- MEMO -

GENERAL INFORMATION 14-3 ON-VEHICLE SERVICE 14-8
Description 14-3 Ignition Coil and High-voltage Cable 14-8
Specifications 14-4 Inspection 14-8
Circuit Diagram 14-5 Spark Plug 14-10
Removal 14-10
Inspection 14-10
Installation 14-11
Service Precautions 14-7
14

14

14 - SQRD4G15B IGNITION SYSTEM
GENERAL INFORMATION
Description
1
5
14
RA13T140010
1 - Spark Plug 2 - Cylinder 4 Ignition Coil Assembly

3 - Cylinder 3 Ignition Coil Assembly 4 - Cylinder 2 Ignition Coil Assembly
5 - Cylinder 1 Ignition Coil Assembly

Operation
Ignition system mainly consists of sensors, Engine Control Module (ECM), ignition coils, spark plugs, etc.
Ignition advance angle is controlled by Engine Control Module (ECM) directly.
As an integrated module, the ignition coil cannot be disassembled. SQRD4G15B ignition system is an
independent one, and the secondary high-voltage terminals of each ignition coil are connected to spark plugs
in each engine cylinder respectively via high-voltage posts. Primary low-voltage terminal of ignition coil
connects to Engine Control Module (ECM) via wire harness.
Engine Control Module (ECM) uses phase sensor input to decide the Top Dead Center (TDC) position of
cylinder 1 piston, and uses the speed sensor to decide which ignition coil is to be energized.
Specifications

Spark Plug 20 ± 3
Ignition Coil Fixing Bolt 8±2
Spark Plug Specifications

Spark Plug Type K7RT1
Spark Plug Gap (mm) 0.8 - 0.9
Tool
General Tool
14
Digital Multimeter
RCH0000002

Circuit Diagram
Ignition System
BATTERY
ENGINE
COMPARTMENT
86 30 FUSE AND
RELAY BOX
ECM
MAIN E-067
RELAY
EF26 EF22 85 87
10A 10A
EF37 EF14
RB
10A 15A
7 E-035
75 20 115 46 E-007
RG
RB
RB
RB
RB
1 1 1 1

RG
RG
R
E-023 E-014 E-013 E-012

2 3 2 3 RG 2 3 2 3
RY
Gr
Br
B
B
B
E-022
A54 A42 A55 A56 B56 B54 B55 B53
ECM(A)
E-041
ECM(B)
14
E-001
E-041 E-001
B B
1 2 3 4 5 6
7 8 9 10 11 12
E-007 1 2 3 E-023 E-014 E-013 E-012
B B B B B
EA13T140010

DIAGNOSIS & TESTING

HINT:

Ignition coil 14-8
Camshaft position sensor 06-237
Spark plug 14-10
Stall
VVT Control Valve 06-233
Wire harness -
ECM 06-245
Ignition coil 14-8
Knock Knock sensor 06-235
ECM 06-245
Battery 16-7
Ignition coil 14-8
Difficult to start
Spark plug 14-10
Engine speed sensor 06-238
14
Ignition coil 14-8
VVT Control Valve 06-233
Engine hesitation, power drop,
Canister Solenoid Valve 06-244
unstable performance
Spark plug 14-10
ECM 06-245
Ignition coil 14-8
Rough, unstable idling or stall
Spark plug 14-10
ECM 06-245

Service Precautions
Visual inspection can reduce unnecessary test and diagnostic time, so pay attention to following inspection
items:
1. Check lines and hoses for obvious looseness, and if they are disconnected or routed improperly.
2. Make sure that battery connections are clean and fixed firmly.
3. Check if alternator wire and belt are installed correctly and securely.
4. Confirm that ignition coils and high-voltage cables are installed securely.
5. Check if engine wire harness connectors are inserted fully.
6. Check if all electrical connectors are installed correctly and securely.
7. Check the following electrical connections:
a. Engine speed sensor;
b. Oxygen sensor;
c. Intake pressure/temperature sensor;
d. Oil pressure switch;
e. Ignition coil;
f. Canister solenoid valve;
g. Camshaft position sensor;
h. Electronic throttle;
i. VVT control valve;
j. Fuel injector.
8. Check routing of all vacuum hoses.
9. Confirm that following vacuum hoses are connected securely without any leakage:
a. Canister solenoid valve;
b. Charcoal canister; 14
c. PCV valve;
d. Brake booster.
10.Check fuel pump hose and wire connections to make sure that they are connected securely.

ON-VEHICLE SERVICE
Ignition Coil and High-voltage Cable
Removal
CAUTION

 It is prohibited to use high-voltage cable to perform ignition spark test during repair; otherwise it may
damage electronic controllers.

4. Remove the ignition coil.
a. Disconnect ignition coil connectors (1) and (2).
b. Remove 4 fixing bolts (arrow) from ignition coil. 1 2
(Tightening torque: 8 ~ 11 N·m)
14
RA13T140020
c. Remove the ignition coil.
CAUTION
 Be careful not to damage ignition coils when pulling them upward.
Inspection
1. Inspect resistance of ignition coil primary winding.
Turn digital multimeter to ohm band, and check + -
resistance between terminal 2 and terminal 3. 1 2 3
If result is not as specified, replace ignition coil.
Multimeter
Condition Specification (W)
Connection
Terminal 2 - Normal
0.6 - 0.9
RA13T140030

Installation
CAUTION
 Make sure that the connection between ignition coil high-voltage output terminal and spark plug is
reliable, or it may cause high-voltage leakage, resulting in poor ignition.
14

Spark Plug
Removal
CAUTION

 It is prohibited to use high-voltage cable to perform ignition spark test during repair; otherwise it may
damage electronic controllers.
 DO NOT remove spark plugs when engine is hot; failure to do this may cause damage to spark plug
thread holes on cylinder head.
 Before removal, remove dirt and foreign matter around spark plug holes to prevent them from dropping
into cylinders.
1. Turn off all electrical equipment and the ignition switch. Wait until engine cools down.
3. Remove the engine trim cover assembly.
5. Remove the spark plug.
a. Using a special spark plug socket wrench (1), loosen
spark plug.
b. Remove the spark plug (2). 1
14 2
RA13T140050
CAUTION
 Be careful not to damage ignition coils when pulling them upward.
Inspection
Check spark plug gap a: 0.8 - 0.9 mm.
RA13T140060

Installation
CAUTION
 Check spark plug type to confirm if it is suitable.

 Please install spark plug with a special spark plug socket wrench, and never touch the spark plug socket.
DO NOT damage the normal spark plug gap.
1. Install 4 spark plugs respectively into cylinder head mounting holes for pre-tightening, and then retighten
spark plugs with a torque wrench.
2. Other procedures are in the reverse order of removal.
14

- MEMO -

Description 15-3 Starter 15-9
Circuit Diagram 15-5 Ignition Starting Switch 15-12
Removal 15-12
Inspection 15-12
Installation 15-12
Starter Relay Inspection 15-7
Precautions for Starting System 15-8
15

15

15 - SQRD4G15B STARTING SYSTEM
GENERAL INFORMATION
Description
2
1
3
15
RA13T150010
1 - Battery 2 - Fuse and Relay Box

3 - Ignition Starting Switch 4 - Starter
Starting system consists of battery, ignition switch and starter etc. It converts electrical energy from battery
into mechanical energy by starter, allowing engine to crank initially, and disconnects power transmission
between starter and engine when engine runs normally.
Operation
Starter consists of three parts: control mechanism, drive train mechanism and DC motor.
1. Control mechanism (solenoid switch): controls engagement and disengagement between starter drive
gear and engine flywheel gear and switches on/off the DC circuit.
2. Drive train mechanism: When engine starts, it engages starter drive gear with flywheel gear ring and
transmits torque of starter to engine crankshaft. After engine starts, drive gear will automatically disengage
from the flywheel gear, so that engine cannot drive starter at high speed, avoiding damage to starter.
3. DC motor: converts electrical energy from battery into electromagnetic moment.

Specifications

Starter Power Cable Nut 18 ± 2
Starter Fixing Bolt 40 ± 5
Ignition Starting Switch Fixing Screw 1.5
Tool
General Tool
Digital Multimeter
RCH0000002
15

Circuit Diagram
Starting System (Page 1 of 2)
MT
BATTERY
R
ENGINE
COMPARTMENT
SB07 MF05 FUSE AND
30A 40A RELAY BOX
E-067
30 86
E-063
STARTER
R
RELAY
IP FUSE
R
87 85
AND RELAY BOX
RF22 RF21
I-032
10A 10A
128 129 130 E-028
51 50
RB
B
R
1 5
AM1 IG1 ACC AM2 IG2 ST
E-066
OFF
IGNITION
ACC SWITCH
I-025
ON
R
ST
4
B 1
LR
GR
STARTER
P-002
I-035
E-042 1 E-029
GR
A07 A25 15
M
ECM(A)
B
E-041
8 7 6 5 4 3 2 1
1 16 15 14 13 12 11 10 9
A56 A55 A54 A53 A52 A51 A50 A49 E-042

B E-029
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37 W
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 1 2 3
4 5 6
I-025
P-002 W
E-041
B
EA13T150010

Starting System (Page 2 of 2)
4AT
BATTERY
R
ENGINE
COMPARTMENT
SB07 MF05 FUSE AND
30A 40A RELAY BOX
E-067
30 86
E-063
STARTER
R
RELAY
IP FUSE
R
87 85
AND RELAY BOX
RF22 RF21
I-032
10A 10A
128 129 130 E-028
51 50
RB
B
R
1 5
AM1 IG1 ACC AM2 IG2 ST
E-066
OFF
IGNITION
ACC SWITCH
I-025
ON
R
ST
4
GW
B 1
LR
STARTER
P-002
I-035
E-042 1 E-029
GW
GR
A07 A25 2 1
M
15
ECM(A) GEAR RANGE SWITCH
B
E-041 E-073
E-042
B
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13 4 3 2 1
P-002
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
5 6 7 8 9 10
1 2 3
E-073
4 5 6
B
I-025
E-041 W
B
EA13T150020

DIAGNOSIS & TESTING

When ignition switch is turned to START,
Battery (weak battery, poor contact of
solenoid switch makes a "clanking" sound -
battery cable)
and engine cannot start
Battery (depleted) -
Starter 15-9
Starter does not run
Ignition switch 15-12
Starting system wire harness -
Battery (weak battery, internal fault) 16-7
Starter runs weakly
Starter 15-9
Starter (incorrect installation, internal fault) 15-9
Starter is racing
Flywheel ring gear (gear teeth broken) 07-49
Starter Relay Inspection

1. Indentify and remove starter relay from engine
compartment fuse and relay box.
ERLY16
Starter
relay
15
RA13T150020
2. Starter the relay.

a. Check the starter relay.
Using a digital multimeter, measure resistance 30 85
+ -
according to the value(s) in table below.
Standard Resistance
Multimeter 87 86
Specified Condition
Connection
30-87 10 kΩ or more
Below 1 Ω (When battery voltage is 30
30-87 applied between terminal 85 and

85
86
terminal 86)
If result is not as specified, replace starter relay. 87
RA13T150030

Precautions for Starting System

1. Before starting engine, shift transmission to N and apply parking brake while depressing clutch pedal.
2. Make sure that battery is fully charged to reduce repeat operating time of starter.
3. Do not start engine for more than 5 seconds each time, repeated starting interval should not be less than
10 -15 seconds, and consecutive starting is not allowed for more than 3 times.
4. If starter cannot stop, turn off ignition switch immediately, or remove the negative battery cable to find the
problem.
5. Check the starter circuit frequently to make sure that each wire of starting system is connected securely
and in good insulation.
6. Generally, perform maintainable service for starter when servicing the vehicle. Also, maintenance interval
can be shortened or extended depending on actual conditions.
7. Remove the negative battery cable before removing starter.
15

ON-VEHICLE SERVICE
Starter
Removal
3. Remove the starter (MT).
a. Remove the air filter assembly (See page 10-10).
b. Remove the battery (See page 16-7).
c. Remove the battery tray (See page 16-9).
d. Disconnect the starter connector (1).
e. Move away terminal cap, remove starter power cable
nut (2) and disconnect starter power cable.
f. Remove 2 fixing bolts (arrow) from starter. 2
RA13T150040
g. Remove the starter.

4. Remove the starter (AT).
a. Remove the air filter assembly (See page 10-10).
b. Disconnect the starter connector (1).
c. Remove starter power cable nut (2) and disconnect 1
starter power cable. 15
d. Remove 2 fixing bolts (arrow) from starter. 2
RA13T150041
e. Remove the starter.

Inspection
1. Check the starter solenoid switch.
a. Check the pull-in coil.
 Measure resistance between terminal 50 and
terminal C.
Terminal 50
 Standard resistance should be below 2 Ω.
Terminal C
RA13T150050
If result is not as specified, replace starter.

b. Check the hold-in coil.
 Measure resistance between terminal 50 and
starter solenoid switch body.
Switch Body
 Standard resistance should be below 2 Ω. Terminal 50
RA13T150060
If result is not as specified, replace starter.

2. Check the starter assembly.
15 CAUTION
 These measurements must be performed within 3 to 5 seconds to avoid coil burnout.

 Place the starter assembly onto a vise. The jaws of vise should be covered by aluminum sheet or brass
plate; otherwise, the starter assembly will be easily damaged when clamping it.
a. Perform the pull-in test.

 Remove nut and disconnect field coil lead from terminal C.
 As shown in illustration, connect battery to
solenoid switch, and check that starter clutch Terminal 50
pinion sticks out.
Terminal C Body
- +
RA13T150070
If starter clutch pinion does not move, replace starter assembly.

b. Perform the hold-in test.

 Keep starter clutch pinion sticking out and
connection condition of battery mentioned above, Terminal 50
and disconnect negative battery cable from
terminal C.
Check that starter clutch pinion keeps sticking out.
Terminal C Body
- +
RA13T150080
If starter clutch pinion moves inward, replace starter assembly.

c. Check if starter clutch pinion returns back.
 Disconnect negative battery cable from starter
body. Check that starter clutch pinion returns back. Terminal 50
Terminal C Body
- +
RA13T150090
If starter clutch pinion does not return back, replace starter assembly.
d. Check if starter rotates smoothly.
 Connect field coil lead to terminal C, and tighten it with a nut.
 As shown in illustration, connect battery to starter.
Check that starter rotates smoothly when starter Terminal 50
clutch pinion moves outward.
15
Terminal 30 Body
- +
RA13T150100
CAUTION
 The lead to be connected should avoid the pinion side to prevent lead stuck as pinion rotates.
If result is not as specified, replace starter assembly.
Installation

Ignition Starting Switch

Removal
3. Remove the steering column cover assembly (See page 28-11).
4. Remove the ignition starting switch.
a. Disconnect ignition switch assembly wire harnss
connector (1). 1
2
b. Move wire harness connector (2) away from ignition

switch.
c. Remove fixing screw (arrow) from ignition starting
switch.
(Tightening torque: 1.5 N·m)
RA13T100110
d. Remove the ignition starting switch.
Inspection
1. Check for continuity of ignition starting switch.
+ - ST B1 IG2
Multimeter Switch Specified
Connection Condition Condition
All terminals LOCK No continuity
Terminal B1 - ACC B2 IG1
ACC Continuity
Terminal ACC
15 Terminal B1 -
Terminal IG1 RA13T150120
Terminal B1 -
Terminal ACC
ON Continuity
Terminal IG2 -
Terminal B2
Terminal IG1 -
Terminal ACC
Terminal ST -
Terminal B2
START Continuity
Terminal IG1 -
Terminal B1
If result is not as specified, replace ignition starting

switch.
Installation

Description 16-3 Battery 16-7
Alternator Operation 16-4 On-vehicle Inspection 16-7
Circuit Diagram 16-5 Battery Tray 16-9
Removal 16-9
Installation 16-9
Alternator and Alternator Bracket 16-10
Charging System Charging Voltage 
Removal 16-10
Inspection 16-6
Installation 16-11
16

16

16 - SQRD4G15B CHARGING SYSTEM
GENERAL INFORMATION
Description
2
1
16
RA13T160010
1 - Fuse and Relay Box 2 - Battery

3 - Alternator 4 - ECM
Alternator is a key component of charging system. As one of main power sources of the vehicle,it is a device
that converts mechanical energy into electrical energy and generates DC voltage. The alternator operates as
a complete assembly. If alternator fails for any reason, the entire unit must be replaced.

Alternator Operation
Alternator is a silicon rectifying alternator, which mainly consists of rotor, stator and rectifier.
When direct current flows to rotor winding, rotor claws energize magnetic field to produce alternating induced
electromotive force. Stator is installed outside of rotor, which is secured together with front and rear end
covers of alternator. When alternator rotor is rotated by drive belt, magnetic pole lines cut stator winding,
causing a change in magnetic flux of stator winding, generating an induced electromotive force, producing
alternating current. Three-phase alternating current generated by alternator is converted to direct current from
alternating current by rectifier, and direct current is transmitted to the vehicle electrical system and battery.
Specifications

Battery Pressure Plate Fixing Bolt 7 ± 1.5
Coupling Bolt Between Battery Tray and Air Filter
10 ± 1
Assembly
Battery Tray Fixing Bolt 25 ± 4
Alternator Output Cable Fixing Nut 18 - 22
Alternator Fixing Bolt 25 ± 3
Alternator Bracket Fixing Nut 45 ± 5
Alternator Bracket Fixing Bolt 45 ± 5
Battery Specification
Item Type Specification

SQRD4G15B L2 400 12 V, 60 Ah, 480 A
16 Tool
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Charging System
IGNITION SWITCH
BATTERY
ON OR START
ENGINE
MF01 COMPARTMENT
EF09
FUSE AND
150A 7.5A RELAY BOX
E-067
41 P-005
INSTRUMENT
CLUSTER
I-011
16
WG
R
I-035
2 E-029
WG
11 10 E-035
B
E-007
WG
P
ALTERNATOR
16
P-001
E-017
1
1 2 3 4 5 6 7 8
1 2 3 4 5 6
9 10 11 12 13 14 15 16 7 8 9 10 11 12
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-035
W
E-007
B
1 2 3
I-011
L E-017
B
P-001
EA13T160010

DIAGNOSIS & TESTING

HINT:

Alternator 16-10
Charging system warning light comes on
Instrument cluster 38-13
after engine starts
Wire harness -
Fixing bolt (loose) 16-10
Noises are heard from alternator after Accessory drive belt (misaligned, loose or
07-19
engine starts fault)
Alternator 16-10
Charging System Charging Voltage Inspection

1. Leave vehicle under no load test condition and idle engine. Measure battery voltage with a digital
multimeter. Standard voltage: 13 ± 0.3 V
If result is not as specified, replace the alternator (See page 16-10).
2. Leave vehicle under load test condition and idle engine. Measure battery voltage with a digital multimeter.
Load test condition:
 Set headlight to high beam;
 Turn on blower and adjust blower speed to the highest;
 Turn on the "A/C" switch.
 Turn cold-hot switch to adjust temperature of outlet to the highest.
16 Standard voltage: 14.1 ± 0.3 V.
If result is not as specified, replace the alternator (See page 16-10).
CAUTION
 If charging system warning light comes on, charging system may have a malfunction.
 If noises are heard from alternator or generating capacity is extremely high or low, check and repair or
replace the alternator.

ON-VEHICLE SERVICE
Battery
1. Check that battery terminals are not loose or corroded. If battery terminals are corroded, clean them.
2. Check battery for damage, deformation or leakage. If serious damage, deformation or leakage is found,
replaced the battery.
3. Check the battery voltage.
Turn ignition switch to on, and turn it off 20 to 30 seconds after turning on headlight. This will eliminate the
surface charge on battery. Measure battery voltage with a digital multimeter.
Measurement Temperature Specification

20°C 12 - 13 V
Removal
CAUTION


2. Remove the battery.
a. Loosen negative battery cable locking nut, and
remove negative (-) battery cable (1).
1
b. Open positive battery terminal cover, loosen positive 3
battery cable locking nut, and remove positive (+) 16
battery cable (2).
c. Remove 2 battery pressure plate fixing bolts (3), and
take off battery pressure plate. 2
RA13T160020
CAUTION
 Please be careful to prevent metal tools from contacting both electrodes of battery at the same time or
accidentally touching the positive electrode and vehicle body.
d. Remove the battery.

Installation
CAUTION
 Replace battery with a new one which conforms to the specifications.

 Used battery contains sulfuric acid and lead, so never discard it at will. Please dispose of it at a qualified
local waste treatment station.
16

Battery Tray
Removal
CAUTION


3. Remove the battery tray.
a. Remove 2 coupling bolts (1) between battery tray and
air filter assembly.
b. Remove 2 fixing bolts (2) between battery tray and
ECU.
2
c. Remove 4 battery tray fixing bolts (arrow). 1
RA13T160030
d. Disconnect connecting clips (arrow) between wire

harness and battery tray.
e. Remove the battery tray.
16
RA13T160031
Installation

Alternator and Alternator Bracket

Removal
CAUTION


4. Move away the accessory drive belt.
a. Using a wrench (2), turn V-ribbed belt tensioner in
direction (arrow) shown in illustration, so that lock hole 1
of tensioner is aligned with lock hole of bracket, and
insert lock pin (1) at the same time to lock the
tensioner. 3

2
RA13T160040
5. Remove the alternator.

a. Move away terminal cap, remove alternator output
cable fixing nut (1) and put output cable aside.
b. Remove alternator field coil fixing nut (2), and move
16 away field coil.
2
c. Remove 2 fixing bolts (arrow) from alternator.
RA13T160050
d. Remove the alternator.

6. Remove the alternator (AT).
a. Move away terminal cap, remove alternator output
cable fixing nut (1) and put output cable aside.
3
b. Disconnect the wire harness connector (2).
c. Disengage the wire harness clips (arrow).
1
d. Remove 1 fixing bolt (3) from alternator..
(Tightening torque: 45 ± 5N·m) 2
4
RA13T160051
e. Remove 1 fixing bolt (4) from alternator.


f. Remove the alternator.

7. Remove the alternator bracket.
a. Remove the idler pulley (See page 07-21).
b. Remove the tensioner assembly (See page 07-22).
1
RA13T160060
c. Remove the water pipe bracket fixing bolt (arrow).

d. Remove fixing nut (1) and 2 fixing bolts (2) from alternator bracket.
(Tightening torque for nut: 45 ± 5 N·m)
(Tightening torque for bolt: 45 ± 5 N·m)
e. Remove the alternator bracket.
Installation
16

- MEMO -

GENERAL INFORMATION 17-3 Disassembly 17-22
Operation 17-7 Adjustment 17-32
Specifications 17-7 Installation 17-38
Tools 17-8 Shift Fork 17-39
Disassembly 17-39
Inspection 17-39
Assembly 17-39
Input Shaft 17-41
Transmission Oil Replacement 17-13 Assembly 17-45
Draining 17-13 Inspection 17-49
Differential Oil Seal 17-15 Output Shaft 17-50
Removal 17-15 Disassembly 17-50
Gear Select and Shift Cable 17-17 Inspection 17-58
Removal 17-17 Transmission External Accessory 17-59
Gear Shift Control Mechanism 17-19 Installation 17-59
Removal 17-19 Transmission Case 17-61
Installation 17-19 Disassembly 17-61
Transmission Assembly 17-20 Assembly 17-64
Removal 17-20
17

17

17 - QR515MHF TRANSMISSION
GENERAL INFORMATION
Description
Input Shaft
7 8
6
5
3
18
2
17
16
1
15
14
13
12
11 22
10
9
21
17
20
19
RA13T170010

1 - Input Shaft Rear Snap Ring 2 - Input Shaft Rear Bearing

3 - 5th Synchronizer Gear Hub 4 - 5th Synchronizer Meshing Plate
5 - 5th Synchronizer Gear Hub Outer Race 6 - 5th Synchronizer Ring
7 - 5th Drive Gear 8 - 5th Gear Shaft Bushing
9 - 5th Needle Roller Bearing 10 - 4th Drive Gear
11 - 4th Needle Roller Bearing 12 - 4th Gear Gasket
13 - 4th Synchronizer Ring 14 - Snap Ring
15 - 3rd-4th Synchronizer Gear Hub 16 - 3rd-4th Synchronizer Meshing Key and Spring
17 - 3rd-4th Synchronizer Outer Race 18 - 3rd Synchronizer Ring
19 - 3rd Drive Gear 20 - 3rd Needle Roller Bearing
21 - Input Shaft 22 - Input Shaft Front Bearing
17

Output Shaft
4 5
3
1 2
9
8
10
10
10
12 11
13
13
17
16
14
15
13
17
RA13T170020
1 - Output Shaft Rear Bearing 2 - Snap Ring

3 - 5th Driven Gear 4 - 4th Driven Gear
5 - Gear Shaft Bushing 6 - 3rd Driven Gear
7 - 2nd Driven Gear 8 - 2nd Needle Roller Bearing
9 - 1st-2nd Synchronizer Outer Race 10 - Synchronizer Ring Set
11 - Snap Ring 12 - 1st-2nd Synchronizer Gear Hub
13 - Synchronizer Ring Set 14 - 1st Driven Gear
15 - 1st Needle Roller Bearing 16 - Output Shaft
17 - Output Shaft Front Bearing

Transmission and Clutch Cases
16
15
14
13 20
12
11
10
4
5
9
6
8 3
2
19
17 7
18
RA13T170030
17
1 - Linear Bearing 2 - Differential Oil Seal
3 - Bearing Outer Race 4 - Bearing Outer Race
5 - Oil Deflector 6 - Input Shaft Oil Seal
7 - Clutch Case 8 - Oil Guide
9 - Transmission Case 10 - Washer
11 - Transmission Retaining Plug 12 - Washer
13 - Drain Plug 14 - Bearing Outer Race
15 - Adjusting Washer 16 - Differential Oil Seal
17 - Output Shaft Assembly 18 - Input Shaft Assembly
19 - Shift Fork Assembly 20 - Differential Assembly

Operation
This transmission has five forward gears and one reverse gear, which is achieved by three sets of
synchronizers and two shafts (input shaft and output shaft). All forward gears use conventional engagement,
and reverse gear uses a sliding idler gear device. 1st-2nd synchronizer is installed on output shaft and 3rd-4th
and 5th synchronizers are installed on input shaft. Transmission will engage with its corresponding gear hub
separately when it is shifted to each different gear position, thus realizing the power transmission. Drive gear
of final drive, which is on output shaft, rotates driven gear of final drive and differential assembly, thus
propeller shaft is driven to turn wheels.
Specifications

Coupling Bolt Between Clutch Case and Transmission
25 ± 2
Case
Reverse Idler Gear Shaft Locating Bolt 40 ± 4
Coupling Bolt Between Gear Shift Mechanism and
25 ± 2
Transmission Case
Gear Shift Mechanism Locating Bolt 35 ± 5.25
Gear Locking Bolt 35 ± 5.25
Gear Shift Control Mechanism Fixing Bolt 23 ± 2
Drain/Retaining Plug 40 ± 6
Gear Shift Arm Bracket Bolt 25 ± 2
Reverse Gear Fork Fixing Bolt 25 ± 2
Transmission Lower Coupling Bolt 50 ± 5
Transmission Upper Coupling Bolt 60 ± 5
Engine Side Coupling Bolt 60 ± 5 17
QR515MHF Transmission Gear Ratio
Type QR515MHF
1st 3.545
2nd 2.050
3rd 1.346
Gear 4th 0.969
5th 0.725
Reverse 3.364

Tools
Special Tools
Input Shaft Oil Seal Installer
RCH0000008
RCH0000009
Installer Joint
RCH0000010
17 Bearing Remover
RCH0000011
Punch
RCH0000015

Puller
RCH0000059
General Tools
RCH0000005
Engine Equalizer
RCH0000026
Hydraulic Press
17
RCH0000012

DIAGNOSIS & TESTING

Oil level (too low) 17-13
Oil grade (incorrect) 17-12
Noise Gear (worn or damaged) 17-41
Bearing (worn or damaged) 17-41
Gear thrust position and clearance (improper) -
Drain plug 17-13
Drain plug washer 17-13
Oil leakage Differential Oil Seal 17-15
Joint surface subjected to impact and not trimmed in
-
time
Oil level (too low) 17-13
Shift cable (stuck or damaged) -
Hard shifting or Clutch disengagement (incomplete) -

impossible to shift Gear (worn or damaged) 17-41
Synchronizer ring (worn or damaged) 17-41
Shift key spring (worn or damaged) 17-39
Detent ball spring -
Shift fork (worn) 17-39
Jumps out of gear
Gear (worn or damaged) 17-41
17 Bearing (worn or damaged) 17-41

Lubricant (with metal impurities) -
Bearing is damaged
Insufficient lubrication or lubricant not as specified -
irregularly
Bearing (irregular) -
Release fork makes a
"click" sound when Insufficient lubrication at joint surface between release
-
clutch pedal is fork and hydraulic sub cylinder or ball pin seat
depressed
Shift drive train (loose) -
No shift
Driver rocker arm (loose) -

CAUTION
 To guarantee the service quality of transmission, perform operations carefully and keep each component
clean.
 Select appropriate or special tools.
 Transmission can achieve a good operation condition only when strictly performing service according to
technical requirements of assembly or adjustment.
17

Transmission Oil
Check the transmission oil level.
1. Raise vehicle with a lift.
WARNING
 Be sure to wear necessary safety equipment to prevent accidents.

 Check if safety lock of lift is locked when repairing or inspecting the lifted vehicle.
2. Remove transmission filler plug and washer.

3. Check that oil level is at the opening of retaining plug.
Transmission Oil Type Viscosity Standard Capacity

API GL 75W-90 2.3 L ± 0.1 L
CAUTION
 An excessively large or small amount of oil may affect proper functioning of transmission.
 After filling oil, run vehicle and then check oil level.
17

ON-VEHICLE SERVICE
Transmission Oil Replacement
CAUTION
 Replace transmission oil only when engine stops and transmission cools down.
 Before installation, replace drain/retaining plug washer with a new one.
Draining
2. Raise the vehicle to a proper height.
3. Place a recovering container under transmission drain hole.
4. Using a wrench, loosen transmission oil filler plug
(arrow).
RA13T170040
5. Using a wrench, remove transmission drain plug (arrow).

Replace drain plug washer and tighten drain plug after
draining transmission oil.
17
RA13T170050
 Drained transmission oil should be collected with a recovering container.
6. Fill transmission oil.

a. Make sure that transmission drain plug has been tightened in place.
b. Using a filling tool, fill transmission oil into transmission filler until it overflows.
c. Replace filler plug washer and tighten filler plug after filling.

CAUTION
 Only use transmission oil approved by Chery Automobile Co., Ltd.
7. Make sure that transmission drain plug has been tightened in place.
8. Using a filling tool, fill transmission oil into transmission
filler until it overflows.
RA13T170060
9. Replace filler plug washer and tighten filler plug after filling.
17

Differential Oil Seal

Removal
Use same procedures for right and left sides.
Procedures listed below are for left side.
WARNING

 Check if safety lock of lift is locked when repairing or inspecting the lifted vehicle.
2. Drain transmission oil.

a. Remove retaining plug and washer.
b. Remove drain plug and washer to drain transmission oil.
c. Install a new washer and drain plug.

3. Remove the front left wheel (See page 24-7).
4. Remove the left drive shaft (See page 20-5).
5. Pull out oil seal with a puller.
17
RA13T170070

Installation
1. Apply an appropriate amount of transmission oil to lip of new oil seal.
2. Using a special tool and a hammer, tap in oil seal.
RA13T170080
CAUTION
 DO NOT damage oil seal during installation.

4. Other procedures are in the reverse order of removal.
17

Gear Select and Shift Cable

Removal
6. Disconnect gear select and shift cable from transmission.
a. Remove cotter pins (1) connecting gear select and
shift cable with transmission gear shift mechanism.
b. Remove the flexible shaft clamps (2).
2
RA13T170090
7. Remove the auxiliary fascia console (See page 46-8).

8. Remove fixing bolts (arrow) between gear select and shift
cable and body.
RA13T170091
9. Disconnect gear select and shift cable from gear shift control mechanism.
a. Remove cotter pins (arrow) connecting gear select
17
and shift cable with gear shift control mechanism.
RA13T170100

b. Remove flexible shaft clamps (arrow) connecting gear

select and shift cable with gear shift control
mechanism.
RA13T170110
10.Remove the gear select and shift cable.
Installation
CAUTION
 DO NOT install gear select and shift cable in reverse position during installation.
17

Gear Shift Control Mechanism

Removal
4. Remove the gear shift control mechanism.
RA13T170100
b. Remove flexible shaft clamps (arrow) connecting gear

select and shift cable with gear shift control
mechanism.
RA13T170110
c. Remove 4 fixing bolts (arrow) from gear shift control

mechanism, and remove gear shift control
mechanism.
17
RA13T170120
Installation

Transmission Assembly
Removal
6. Drain transmission oil (See page 17-13).
7. Remove the front wheels (See page 24-7).
8. Remove the drive shaft (See page 20-5).
9. Loosen the front exhaust pipe (See page 11-10).
10.Disconnect the back-up light switch connector (1).
RA13T170130
11. Remove flexible shaft clamps and cotter pins connecting gear select and shift cable with gear shift
mechanism (See page 17-17).
12.Remove the crankshaft position sensor.
a. Remove fixing bolt (1) from crankshaft position sensor
and remove crankshaft position sensor (2).
2
17
1
RA13T170140
13.Remove 2 fixing bolts from clutch release cylinder, so

that clutch release cylinder is separated from
transmission.
RA13T170150

14.Remove 1 fixing bolt between clutch release cylinder

hose and transmission case, so that clutch release
cylinder hose is separated from transmission.
RA13T170151
15.Use an engine equalizer to hang the engine.

16.Remove the left mounting (See page 07-53).
17.Remove the transmission negative ground wire harness.
RA13T170152
18.Remove the starter (See page 15-9).

19.Remove the front mounting (See page 07-54).
20.Remove the transmission.
a. Remove the transmission upper coupling bolts
(arrow).
17
RA13T170180
b. Raise vehicle and support transmission assembly with a transmission carrier.

c. Remove transmission lower coupling bolts (arrow)
and baffle plate.
RA13T170170

d. Remove coupling bolts (arrow) between engine rear

mounting and transmission side.
RA13T170190
e. Remove coupling bolt (arrow) between engine and

rear side of transmission.
f. Remove engine rear mounting, and pull transmission
to separate it and engine.
RA13T170181
Disassembly
1. Remove the vehicle speed sensor cover.
a. Remove vehicle speed sensor cover fixing bolt
(arrow) and vehicle speed sensor cover (1).
RA13T170200
17 2. Remove the back-up light switch.
a. Remove back-up light switch (arrow) from
transmission.
RA13T170220

3. Remove the gear shift mechanism.

a. Remove the gear shift mechanism fixing bolts (arrow).
RA13T170230
b. Remove the gear shift mechanism.

HINT:
Tap the protrusion of gear shift mechanism with a
rubber hammer if it is difficult to remove.
RA13T170240
4. Remove the reverse idler gear shaft locating bolt.

a. Remove reverse idler gear shaft locating bolt (arrow)
from transmission assembly.
RA13T170250
5. Remove the transmission case. 17

a. Remove clutch case fixing bolts (arrow) from
transmission assembly.
RA13T170260

b. Remove transmission case fixing bolts (arrow) from

RA13T170270
c. Separate transmission case and clutch case, and

remove transmission case.
HINT:
Tap the protrusion of transmission case with a rubber
hammer or equivalent for easy removal, as it may be
difficult to remove because of seal gum.
RA13T170280
6. Remove the reverse gear fork.

a. Remove reverse gear fork fixing bolts (arrow), and
remove reverse gear fork (1).
RA13T170290
7. Remove reverse gear shaft and reverse gear.

17 a. Remove reverse gear shaft (1) and reverse gear (2)
together from clutch case.
RA13T170300

8. Remove the input shaft rear washer.

a. Remove input shaft rear washer (1) from input shaft.
RA13T170310
9. Remove the magnet.

a. Remove magnet (1) from clutch case.
RA13T170320
10.Remove input shaft, output shaft and fork mechanism.

a. Remove input shaft, output shaft and fork mechanism
(1) together from clutch case.
HINT:
Gently jiggle them during removal.
17
RA13T170330
CAUTION
 Prevent input shaft spline from damaging input shaft front oil seal during removal.
 Prevent interference between output shaft bearing cage and differential big ring gear to avoid damaging
the bearing cage during removal.

11. Remove the shift fork assembly.

a. Separate shift fork assembly (2) from input shaft and
output shaft (1).
2
1
RA13T170340
12.Remove the differential assembly.

a. Remove differential assembly (1) from clutch case.
RA13T170350
Assembly
CAUTION
 Before assembling components, wash them clean.

 Remove seal gum residues from cases.
 Make sure that joint surface of cases is free of oil, and uniformly apply seal gum.
 Make sure joint surface of case and shift assembly is free of oil, and uniformly apply seal gum.
 Tighten bolts to specified torques.
17
1. Install the differential assembly.
a. Apply transmission oil to each sliding part of
differential, and install differential (1) to clutch case in
direction of arrow. 1
RA13T170360

2. Install the shift fork assembly.

a. Install shift fork assembly (1) to input shaft and output
shaft (2).
2
1
RA13T170340
3. Install input shaft, output shaft and fork mechanism.

a. Apply transmission oil to each sliding part of input
shaft and output shaft, and install input shaft, output
shaft and fork mechanism together into clutch case in
direction of arrow.
RA13T170370
CAUTION
 Prevent input shaft spline from damaging input shaft front oil seal during installation.
17
4. Install reverse idler gear and reverse gear.
a. Apply transmission oil to contact part between reverse
gear and reverse gear shaft, and install reverse idler
gear (1) and reverse gear (2) together into clutch
case. 1
RA13T170300

5. Install the reverse gear fork.

a. Install reverse gear fork (1) to clutch case, and tighten
reverse gear fork fixing bolts (arrow).
RA13T170290
6. Install the input shaft rear washer.

a. Apply an appropriate amount of transmission oil to
input shaft rear washer, and put input shaft rear
washer (1) onto input shaft rear bearing.
1
RA13T170310
CAUTION
 Evenly put the input shaft rear washer onto input shaft rear bearing with washer edge not out of input
shaft rear bearing.
7. Install the magnet.

a. Install magnet (1) to clutch case in direction of arrow.
17
RA13T170380

8. Install the transmission case.

a. Install transmission case to clutch case.
RA13T170390
CAUTION
 Install transmission case to clutch case.

b. Install and tighten transmission case fixing bolts.

RA13T170270
c. Install and tighten clutch case fixing bolts.

17
RA13T170260
9. Install the reverse idler gear shaft locating bolt.

a. Install reverse idler gear shaft locating bolt (arrow) to
transmission case.
RA13T170250

10.Install the back-up light switch.

a. Install gear shift mechanism (1) to transmission case.
RA13T170400
CAUTION
 Clean engagement portion between gear shift mechanism and transmission case, and apply seal gum
evenly.
b. Install coupling bolts between gear shift mechanism

and transmission case.
RA13T170230
11. Install the gear shift mechanism.

HINT:
Apply thread adhesive to threads before installation.
a. Install back-up light switch (arrow) to transmission.
17
RA13T170220

12.Install the vehicle speed sensor cover.

a. Install vehicle speed sensor cover (1) and its fixing
bolt (arrow).
RA13T170200
17

Adjustment
Rear Bearing Adjusting Washer Selection
Differential Rear Bearing Adjusting Washer Selection
1. Take out the assembled differential assembly.
RA13T171210
2. Take out the assembled clutch case assembly.
RA13T171220
3. Assemble differential assembly to clutch case assembly.
17 RA13T171230
4. Take out the differential rear bearing outer race (1).
RA13T171240
CAUTION
 It is recommended that differential rear bearing outer race and differential front bearing outer race should
be from the same manufacture.

5. Install differential rear bearing outer race onto differential

rear bearing (arrow).
RA13T171250
6. Place a measuring tool onto differential rear bearing

outer race.
RA13T171260
7. Using a depth gauge, measure distance A from rear end

surface of differential rear bearing outer race to joint
surface of clutch case (and transmission case).
RA13T171270
8. Place transmission case to be assembled onto

workbench.
17
RA13T171280

9. Place a measuring tool onto joint surface of transmission

case (and clutch case).
RA13T171300
CAUTION
 DO NOT hit joint surface of transmission case (and clutch case).
10.Using a depth gauge, measure distance B from locating

end surface of differential rear bearing hole to joint
surface of transmission case (and clutch case).
RA13T171310
11. Thickness of differential rear bearing adjusting washer

should be (B - A) + (0.05 ~ 0.166) mm. Select thickness
of differential rear bearing adjusting washer according to
calculated measurement value. Select adjusting washer
type according to thickness.
(B－A)+(0.05~0.166)
17
RA13T171320
Input Shaft Rear Bearing Adjusting Washer Selection

1. Take out assembled input shaft assembly and output
shaft assembly.
RA13T171330

2. Place a measuring tool onto end surface of input shaft

rear bearing outer race.
RA13T171340
3. Using a depth gauge, measure distance C from rear end

surface of input shaft rear bearing outer race to rear end
surface of clutch.
RA13T171350

workbench.
RA13T171280

17
RA13T171300
CAUTION
 DO NOT hit joint surface of transmission case (and clutch case). Be sure to measure with parallelism of
0.03 or less between input shaft rear bearing surface and joint surface of transmission case (and clutch
case).

6. Using a depth gauge, measure distance D from locating

end surface of transmission case input shaft rear bearing
hole and front end surface of transmission case.
RA13T171380
7. Thickness of input shaft rear bearing adjusting washer

should be (D - C) - (0.01 ~ 0.08) mm. Select thickness of
input shaft rear bearing adjusting washer based on
(D－C)-(0.01~0.08)
RA13T171381
Output Shaft Rear Bearing Adjusting Washer Selection

1. Take out assembled input shaft assembly and output
shaft assembly.
RA13T171330
2. Install output shaft rear bearing outer race (1) to output

17 shaft rear bearing.
1
RA13T171331
CAUTION
 It is recommended that output shaft rear bearing outer race and output shaft front bearing outer race
should be from the same manufacture.

3. Place a measuring tool onto end surface of output shaft

rear bearing outer race.
RA13T171410
CAUTION
0.03 or less between output shaft rear bearing surface and joint surface of transmission case (and clutch
case).
4. Using a depth gauge, measure distance E from rear end

surface of output shaft rear bearing outer race to rear end
surface of clutch.
RA13T171420

workbench.
17
RA13T171280


RA13T171300
CAUTION
0.03 or less between input shaft rear bearing surface and joint surface of transmission case (and clutch
case).
7. Using a depth gauge, measure distance F from locating

end surface of transmission case output shaft rear
bearing hole and front end surface of transmission case.
RA13T171440
8. Thickness of output shaft rear bearing adjusting washer

should be (F - E)+(0.05 ~ 0.15) mm. Select thickness of
output shaft rear bearing adjusting washer based on
17 (F－E)+(0.05~0.15)
RA13T171450
Installation

CAUTION
 After installation, add transmission oil and check transmission oil level.
Shift Fork
Disassembly
1. Remove the 1st gear shift fork.
a. Using a punch (1), tap out dowel pin (3) from 1st-2nd
gear shift shaft (2).
2 1
RA13T170410
2. Remove the 3rd-4th gear shift fork.

a. Using a punch (1), tap out dowel pin (3) from 3rd-4th
gear shift shaft (2).
2
RA13T170420
3. Remove the 5th and reverse gear shift fork.

a. Remove snap ring (1) and 5th and reverse gear shift
17
fork (4). 2
b. Using a punch (2), tap out dowel pin (3) from shift
shaft (5). 5 3
1
RA13T170430
Inspection
1. Check shift shaft for excessive wear or damage. Replace if damaged.
2. Check shift fork for excessive wear or damage. Replace if damaged.
Assembly
Assembly is in the reverse order of disassembly.

CAUTION
 When installing dowel pins, if there is excessive wear or damage, replace with new ones.
17

Input Shaft
Disassembly
1. Remove the input shaft (See page 17-20).
2. Remove 5th synchronizer outer race and 3rd-4th synchronizer outer race.
a. Remove 5th synchronizer outer race (1) and 3rd-4th
synchronizer outer race (2) from input shaft.
1
RA13T170440
3. Remove the rear snap ring.

a. Using snap spring calipers, remove rear snap ring.
RA13T170450
4. Remove the input shaft rear bearing.

a. Using a special tool (1), secure input shaft rear
bearing (2). 2
17
1
RA13T170460
b. Using a hydraulic press (1), press out input shaft (2)

and remove input shaft rear bearing (3).
1
RA13T170470

5. Remove 5th drive gear and 5th synchronizer gear hub.

a. Using a special tool (1), secure 5th drive gear (2).
RA13T170480
b. Using a hydraulic press (1), press out input shaft (2),

and remove 5th drive gear and 5th synchronizer gear 1
hub (3). 2
RA13T170490
6. Remove the 5th needle roller bearing.

a. Remove 5th needle roller bearing (1) from input shaft.
RA13T170500
17 7. Remove 5th drive gear needle roller bearing bushing and 4th drive gear.
a. Install a special tool.
RA13T170510


and remove 5th drive gear needle roller bearing
1
bushing and 4th drive gear (3).
2
RA13T170520
8. Remove the 4th needle roller bearing.

a. Remove 4th needle roller bearing (arrow) from input
shaft.
RA13T170530
9. Remove 3rd drive gear and 3rd-4th synchronizer gear hub.

a. Remove synchronizer ring (arrow) from 3rd-4th
synchronizer gear hub.
RA13T170540
b. Using snap spring calipers (1), remove snap ring (2). 17
RA13T170550

c. Using a special tool (1), secure 3rd drive gear (2).
2
1
RA13T170560
d. Using a hydraulic press (1), press out input shaft (2),

and remove 3rd drive gear and 3rd-4th synchronizer 1
gear hub (3).
RA13T170570
10.Remove the 3rd needle roller bearing.

a. Remove 3rd needle roller bearing (1) from input shaft.
RA13T170580
11. Remove the input shaft front bearing.

17 a. Using a special tool (1), secure input shaft front
bearing (2).
2
RA13T170590


and remove input shaft front bearing (3). 1
RA13T170600
Assembly
1. Install the input shaft front bearing.
a. Using a hydraulic press (1), press input shaft (2) into
input shaft front bearing (3). 1
RA13T170610
CAUTION
 When pressing in input shaft front bearing, make sure that pressure is applied to bearing inner race as
the bearing may be damaged due to uneven force.
2. Install the 3rd needle roller bearing.

a. Apply transmission oil to 3rd needle roller bearing (1),
and install it to input shaft.
17
RA13T170580
3. Install the 3rd drive gear.

a. Apply transmission oil to 3rd drive gear, and install it
to input shaft.
RA13T170620

4. Install the 3rd synchronizer ring.

a. Apply transmission oil to 3rd synchronizer ring, and
install it to input shaft.
RA13T170630
5. Install the 3rd-4th synchronizer gear hub.

a. Using a hydraulic press (3), press 3rd-4th
synchronizer gear hub (1) into input shaft. 3
2
1
RA13T170640
CAUTION
 When pressing in synchronizer gear hub, prevent 3rd drive gear (2) from disengaging.
b. Using snap spring calipers (1), remove snap ring (2).
17
1
RA13T170550
6. Install the 4th synchronizer ring.

a. Apply transmission oil to 4th synchronizer ring, and
install it to input shaft.
RA13T170650

7. Install the 4th gear needle roller bearing.

a. Apply transmission oil to 4th gear needle roller
bearing, and install it to input shaft.
RA13T170660
8. Install the 4th drive gear.

a. Apply transmission oil to 4th drive gear, and install it to
input shaft.
RA13T170670
9. Install the 5th drive gear needle roller bearing bushing.

a. Using a hydraulic press (1), press 5th drive gear
needle roller bearing bushing (2) into input shaft.
1
RA13T170680
17
10.Install the 5th gear needle roller bearing.
a. Apply transmission oil to 5th gear needle roller
bearing (1), and install it to input shaft.
RA13T170500

11. Install 5th drive gear and 5th synchronizer ring.

a. Apply transmission oil to 5th drive gear (1) and 5th
synchronizer ring (2), and install them to input shaft.
RA13T170690
12.Install the 5th synchronizer gear hub.

a. Using a hydraulic press (3), press 5th synchronizer
3
gear (2) and 5th synchronizer gear hub (1) together
into input shaft.
1 2
RA13T170700
CAUTION
 When pressing in synchronizer gear hub, prevent 5th drive gear (2) from disengaging.
13.Install the input shaft rear bearing.

a. Using a hydraulic press (1), press input shaft (2) into
1
input shaft rear bearing (3).
2
17
RA13T170710
14.Install 5th synchronizer outer race and 3rd-4th synchronizer outer race.
a. Apply transmission oil to 5th synchronizer outer race
and 3rd-4th synchronizer outer race, and install them
1
to input shaft.
RA13T170440

15.Install the input shaft rear bearing snap ring.

a. Using snap spring calipers, install the rear bearing
snap ring.
RA13T170450
CAUTION
 Check gears on input shaft for smooth rotation after installation.

 Check engagement of gears on input shaft for looseness or sticking.
Inspection
Check gears on input shaft for smooth rotation after installation.
1. Using a feeler gauge, measure clearance between 3rd
drive gear and synchronizer ring.
Standard value: 1.35 mm
Limit value: 1.100 - 1.600 mm
RA13T170720
2. Using a feeler gauge, measure clearance between 4th

drive gear and synchronizer ring.
Standard value: 1.35 mm 17
RA13T170730
3. Using a feeler gauge, measure clearance between 2nd

drive gear and 3rd drive gear.
RA13T170740

Output Shaft
Disassembly
1. Remove the output shaft (See page 17-20).
2. Remove the output shaft rear bearing.
a. Using a special tool (1), secure output shaft rear
bearing (2). 2
RA13T170750
b. Using a hydraulic press (1), press out output shaft (2)

1
and remove output shaft rear bearing (3).
2 3
RA13T170760
3. Remove 4th and 5th driven gears.

a. Using snap spring calipers (1), remove snap ring (2).
17
1
RA13T170770
b. Using a special tool (1), secure 4th and 5th driven

gear set (2).
2
RA13T170780

c. Using a hydraulic press (1), press out output shaft (2)

and remove 4th and 5th driven gears (3). 1
RA13T170790
4. Remove the gear shaft bushing.

a. Remove gear shaft bushing (1) from output shaft.
RA13T170800
5. Remove 2nd and 3rd driven gears.

a. Using a special tool (1), secure 2nd driven gear (2).
1 2
RA13T170810
b. Using a hydraulic press (1), press out output shaft (2) 17

and remove 2nd and 3rd driven gears (3).
1
RA13T170820

6. Remove the 2nd needle roller bearing.

a. Remove 2nd needle roller bearing (1) from output
shaft.
RA13T170830
7. Remove 1st driven gear and 1st-2nd synchronizer gear hub.

a. Remove the 1st-2nd synchronizer ring set (1).
b. Remove the 1st-2nd synchronizer outer race (2).
2
RA13T170840
c. Using snap spring calipers (1), remove snap ring (2).
RA13T170850
17 d. Secure a special tool to 1st driven gear.
RA13T170860

e. Using a hydraulic press (1), press out output shaft (2),

1
and remove 1st driven gear and 1st-2nd synchronizer
(3).
RA13T170870
8. Remove the 1st needle roller bearing.

a. Remove the 1st needle roller bearing (1).
RA13T170880
9. Remove the output shaft front bearing.

a. Using a special tool (1), secure output shaft front
bearing (2).
2
RA13T170890
b. Using a hydraulic press (1), press out output shaft (2)

1 17
and remove front bearing (3).
2
RA13T170900

Assembly
1. Install the output shaft front bearing.
a. Using a hydraulic press (1), press output shaft front
bearing (3) into output shaft (2). 1
3 RA13T170910
CAUTION
 When pressing in bearing, make sure that pressure is applied to bearing inner race as the bearing may
be damaged due to uneven force.
2. Install the 1st needle roller bearing.

a. Apply transmission oil to 1st needle roller bearing (1),
and install it to output shaft.
RA13T170920
3. Install the 1st driven gear.

a. Apply transmission oil to 1st driven gear (1), and
17 install it to output shaft.
RA13T170930

4. Install the 1st synchronizer ring set.

a. Apply transmission oil to 1st synchronizer ring set (1),
RA13T170940
5. Install 1st-2nd synchronizer gear hub and 1st driven gear.

a. Place 1st-2nd synchronizer gear hub (1) in place, and
then press 1st-2nd synchronizer gear hub (1) into
output shaft with a hydraulic press.
RA13T170950
b. Using snap spring calipers (1), install snap ring (2).
RA13T170850
6. Install the synchronizer ring set. 17

a. Apply transmission oil to synchronizer ring set, and
install it to output shaft.
RA13T170960

7. Install the synchronizer outer race.

a. Apply transmission oil to synchronizer outer race, and
RA13T170970
8. Install the 2nd needle roller bearing.

a. Apply transmission oil to 2nd needle roller bearing,
RA13T170980
9. Install the 2nd driven gear.

a. Apply transmission oil to 2nd driven gear (1), and
17 RA13T170990
10.Install the 3rd driven gear.

a. Using a hydraulic press, press 3rd driven gear (1) into
output shaft.
RA13T171000

11. Install the gear shaft bushing.

a. Apply transmission oil to gear shaft bushing (1), and
RA13T171010
12.Install 4th and 5th driven gears.

a. Using a special tool (1), secure 4th and 5th driven
gears (2).
1
RA13T171020
b. Using a hydraulic press (1), press 4th and 5th driven

1
gears (3) into output shaft (2).
2
RA13T171030
c. Using snap spring calipers (1), install snap ring. 17
RA13T171040

13.Install the output shaft rear bearing.

a. Using a hydraulic press (1), press output shaft rear
bearing (3) into output shaft (2). 1
3
RA13T171050
CAUTION
 Check gears on the output shaft for smooth rotation after installation.
 Check engagement of gears on the output shaft for looseness or sticking.
Inspection
1. Using a feeler gauge, measure clearance between 1st
driven gear and synchronizer ring.
RA13T171060

driven gear and synchronizer ring.
17 Limit value: 1.240 - 1.840 mm
RA13T171070

driven gear and 3rd driven gear.
RA13T171080

Transmission External Accessory

Removal
1. Remove the vehicle speed sensor cover.
a. Remove vehicle speed sensor cover fixing bolt
(arrow) and vehicle speed sensor cover (1) from
RA13T170200
2. Remove the back-up light switch.

transmission.
RA13T170220
3. Remove the reverse idler gear shaft locating bolt.

a. Remove reverse idler gear shaft locating bolt (arrow)
from transmission assembly.
17
RA13T170250
Installation
1. Remove the back-up light switch.
HINT:
Apply thread adhesive to threads before installation.


transmission.
RA13T170220
2. Install the vehicle speed sensor cover.

a. Install vehicle speed sensor cover (1) and its fixing
bolt (arrow).
RA13T170200
3. Install the reverse idler gear shaft locating bolt.

a. Install reverse idler gear shaft locating bolt (arrow) to
transmission case.
RA13T170250
17

Transmission Case
Disassembly
CAUTION
 Use same removal procedures for differential bearing outer races and oil seals of transmission case and
clutch case.
 Replace the oil seals if removed, as they are not reusable.
1. Remove the differential bearing outer race.

a. Secure bearing outer race puller joint (1) to bearing
outer race (2). 1
RA13T171090
b. Install puller (1) to bearing outer race remover (2), and

pull out bearing outer race (3) with a puller.
17
RA13T171100

2. Remove the drive shaft oil seal.

a. Using a flat tip screwdriver (1), pry out drive shaft oil
seal (2).
RA13T171110
3. Remove the input shaft oil seal.

a. Using a flat tip screwdriver (1), pry out input shaft oil
seal (2).
RA13T171120
4. Remove the output shaft bearing outer race.

a. Secure output shaft end bearing outer race puller joint
(1) to output shaft bearing outer race (2).
17 RA13T171130

b. Install puller (1) to bearing outer race remover (2).

c. Using a puller, pull out output shaft bearing outer race
(3).
1
RA13T171140
5. Remove the oil deflector.

a. Remove oil deflector (1) from clutch case.
RA13T171150
6. Remove the magnet.

a. Remove magnet (1) from clutch case.
17
1
RA13T171160

7. Remove the oil guide.

a. Remove oil guide (1) from transmission case.
RA13T171170
8. Remove the reverse gear lock mechanism.

a. Remove reverse gear lock mechanism fixing bolts
(arrow) and reverse gear lock mechanism (1).
RA13T171180
Assembly
1. Install the drive shaft oil seal.
CAUTION
 Apply a proper amount of transmission oil to the lip when installing the oil seal.
a. Using a drive shaft oil seal installer (1), install drive

17 shaft oil seal (2) to transmission case (3).
RA13T171190

2. Install the oil deflector.

a. Install oil deflector (1) to clutch case.
RA13T171150
3. Install the input shaft oil seal.

a. Using an input shaft oil seal installer (1), install input
shaft oil seal (2) to clutch case (3).
1
2
3
RA13T171200
4. Install the differential bearing outer race.

a. Install an installer joint (1) to bearing outer race (2),
and install bearing outer race (2) to case (3) with a
rubber hammer (4).
RA13T171210
17
5. Install the magnet.
a. Install magnet (1) to clutch case.
RA13T171160

6. Install the oil guide.

a. Install oil guide (1) to transmission case.
RA13T171170
7. Remove the reverse gear lock mechanism.

a. Remove reverse gear lock mechanism fixing bolts
(arrow) and reverse gear lock mechanism (1).
RA13T171180
17

QR416AHA
GENERAL INFORMATION 18-3 P0745-11 18-42
Description 18-3 P0745-15 18-42
Precautions 18-8 P0743-72 18-47
System Function 18-9 P0743-73 18-47
Hydraulic Torque Converter 18-9 P0743-11 18-47
Hydraulic Torque Converter 18-9 P0743-15 18-47
Transmission Control Unit (TCU) 18-9 P0710-11 18-52
Gear Shift Switch 18-10 P0710-15 18-52
Turbine Speed Sensor 18-10 P0705-29 18-57
Gear Shift Solenoid Valve 18-10 P0715-00 18-61
Sport Mode Switch 18-11 P0863-00 18-65
System Control Logic 18-11 U0100-87 18-68
Specifications 18-12 U0121-87 18-71
Tools 18-13
ON-VEHICLE SERVICE 18-74
Circuit Diagram 18-15
Automatic Transmission Fluid (ATF)
TCU Terminal Definition 18-17 Replacement 18-74
DIAGNOSIS & TESTING 18-18 Draining 18-74
Transmission Oil Level and Quality  Filling Transmission Oil 18-75
Inspection 18-18 Differential Oil Seal 18-76
Gear Shift Cable Adjustment and  Removal 18-76
Gear Switch Assembly Inspection 18-19 Transmission Oil Cooling Line Set 18-77
Transmission Oil Temperature  Removal 18-77
Sensor 18-19 Installation 18-77
Turbine Speed Sensor Inspection 18-20 Gear Select and Shift Cable 18-79
Problem Symptoms Table 18-20 Removal 18-79
Diagnostic Help 18-21 Installation 18-80
Intermittent DTC Troubleshooting 18-21 Gear Shift Control Mechanism 18-81
Ground Inspection 18-21 Removal 18-81
Stall Test 18-21 Installation 18-81
Diagnostic Trouble Code (DTC)  Transmission Assembly 18-82 18
Chart 18-22
Disassembly 18-82
TCU Power Supply Circuit & 
Assembly 18-83
Ground Circuit Testing 18-24
Transmission External Accessory 18-86
P0750-72 18-27
Removal of Turbine Speed Sensor 18-86
P0750-73 18-27
Installation 18-86
P0750-11 18-27
Removal of Gear Switch Assembly 18-86
P0750-15 18-27
Installation 18-87
P0755-72 18-32
Removal of Oil Dipstick and Oil 
P0755-73 18-32 Dipstick Sleeve Set 18-88
P0755-11 18-32
Installation 18-88
P0755-15 18-32
TCU 18-89
P0785-11 18-37 Removal 18-89
P0785-15 18-37
Installation 18-89
P0745-00 18-42

18

18 - QR416AHA
GENERAL INFORMATION
QR416AHA
Description
QR416AHA hydraulic automatic transmission can realize speed change automatically by combining hydraulic
transmission device and planetary gear. It consists of hydraulic torque converter, planetary gear mechanism,
gear shift actuator, gear shift control system and gear shift control mechanism, etc. For AT model, it is not
required to shift gears using clutch, which has less gear positions with great speed change and stable
connection.
In the transmission management system, sensors are used as input part to measure various physical signals
(temperature and speed, etc.), and converts them into corresponding electrical signals; the function of TCU is
to receive input signals from sensors and perform calculation according to set procedure, producing
corresponding control signals and outputting them to power drive circuit. The power drive circuit drives each
actuator to perform various actions, thus making the engine run according to preset program.
QR416AHA transmission mainly consists of following components:
 Hydraulic torque converter
 Oil pump
 Input shaft assembly
 Output shaft assembly
 Differential assembly
 Planetary gear mechanism
 Transmission case
QR416AHA transmission features with:
 Mature technology
 Good reliability
 Large torque output
Internal Structure Diagram
18

18 - QR416AHA
9 8 7 6 5
4
10
11 3
12 2
13
14
15
16
18
RA13T180010

18 - QR416AHA
1 - Hydraulic Torque Converter 2 - Input Shaft

3 - Oil Pump Assembly 4 - C1 Clutch
5 - Front Planetary Gear Set 6 - B3 Brake
7 - Rear Planetary Gear Set 8 - B2 Brake
9 - B1 Brake 10 - C3 Clutch
11 - C2 Clutch 12 - Intermediate Shaft
13 - F1 One-way Clutch 14 - F2 One-way Clutch
15 - Input Shaft Assembly 16 - Differential Assembly
18

18 - QR416AHA
Main Electronic Element
18
RA13T180020
1 - Speed Sensor Set 2 - Wire Harness Assembly Connector

3 - Gear Switch Assembly

18 - QR416AHA
4
3
RA13T180030
1 - Gear Shift Boot Assembly 2 - Gear Position Indicating Panel Assembly

3 - Gear Shift Control Mechanism Assembly 4 - Gear Shift Cable Assembly
18

18 - QR416AHA
Precautions
General service requirements
 Only digital multimeter can be used to perform inspection for engine management system.
 Use genuine components to perform service work, otherwise appropriate engine management system
operation cannot be guaranteed.
 Only use unleaded gasoline during servicing.
 Please observe normative service and diagnostic flowchart to perform service work.
 Never disassemble components of engine management system during servicing.
 When holding electronic elements (TCU and sensor etc.) during servicing, take extra care not to drop them
on the ground.
 Set up a consciousness of environmental protection and dispose of the waste effectively that is produced
during servicing.
Precautions during servicing

1. During removal and installation, make sure that shift lever is at "N" position.
2. When installing the gear shift arm and transmission range sensor, use a proper tool to fix them, and then
tighten bolts to specified torque.
3. Components of transmission are of high precision, so take care in removal and installation and do not
scratch or damage any component.
4. When installing the oil seal, apply force evenly and do not cause deformation or damage of oil seal.
5. Keep transmission components clean when removing and installing transmission components to prevent
foreign matter from entering the transmission.
6. When installing the torque converter onto transmission, make sure that oil pump drive slot is installed in
place; otherwise it will cause abnormal damage to the transmission.
7. When assembling engine and transmission, make sure that all connecting bolts are installed correctly and
completely, and torques meet the specifications.
8. When disassembling and assembling engine and transmission, make sure that torque converter does not
drop down.
9. When assembling engine and transmission, make sure that dust baffle is not ignored.
10.When replacing transmission sensors and oil seals, make sure that they are installed in place and bolt
torques meet the specifications.
11. Take measures to avoid foreign matter entering the transmission, when removing or installing the cooling
18 oil pipes and radiator. And check fluid level and make sure that there is no leakage after installation.

18 - QR416AHA
System Function
Hydraulic Torque Converter
1 2 3 4 5
8 7 6
RA13T180060
1 - Pump Wheel 2 - Turbine

3 - Front Case 4 - Bearing
5 - Guide Wheel and One-way Clutch 6 - Clutch Assembly
7 - Welded Hub 8 - Drive Hub
Hydraulic Torque Converter

Torque converter is used to keep stable start, reduce torsional vibration of transmission system and prevent
overload of the transmission system. 18
Torque converter could ensure stable start and even acceleration of the vehicle. The hydraulic vibration
absorption could eliminate or reduce the impact and dynamic load in transmission system, extending the
service life of components of engine and transmission system.
Transmission Control Unit (TCU)

Transmission control unit of QR416AHA transmission is
installed at driver side, behind lower left instrument panel
protector. It collects information from turbine speed sensor,
gear switch, transmission oil temperature, gear shift
mechanism switch and processes the information via CAN
network, and it controls gear up-shift and down-shift by
actuator inside of transmission.
RA13T180070

18 - QR416AHA
Electronic control system consists of components below:

 Transmission Control Unit (TCU)
 Turbine speed sensor
 Gear shift switch
 Gear shift lock solenoid valve
 Hydraulic torque converter lock clutch solenoid valve
 Gear shift solenoid valve
Gear Shift Switch

Transmission range sensor is located at the top of
transmission. It is used to input current gear signal into TCU, 4
5
6
7
and the TCU will output operation requirements to control 3
2
8
9
0
the clutch and transmission for gear shifting. Engine can be 1
started only when the gear shift lever is at parking (P) and
neutral (N) gears, thus avoiding misoperation.
RA13T180080
Turbine Speed Sensor

TCU controls locking time of lock clutch according to turbine
speed supplied by turbine speed sensor.
RA13T180090
Gear Shift Solenoid Valve

Gear shift lock solenoid valve (arrow) is installed in the
18 transmission gear shift control mechanism. Before moving
out of "P" gear, brake pedal should be fully depressed and
the ignition switch set to "ON" position.
RA13T180100

18 - QR416AHA
Sport Mode Switch
Mode Switching Button Sport Mode ECO mode
RA13T180110
This transmission is equipped with sport mode and ECO mode. Default mode is ECO mode. After pressing
mode switching button manually, transmission will response the status under different modes and instrument
cluster will display different mode indicator. Sport mode switch is integrated into top of rear view mirror
adjustment panel.
System Control Logic
S1 Solenoid Valve
Turbine Speed Sensor
S2 Solenoid Valve
ST Solenoid Valve
oil temperature sensor TCU
18
SL1 Solenoid Valve
SLT Solenoid Valve
gear position switch Shift Lock Solenoid
CAN
RA13T180120

18 - QR416AHA
Specifications

Coupling Bolt Between Transmission and Engine 50 ± 5
Coupling Bolt Between Drive Plate and Hydraulic 55 ± 5
Torque Converter
Transmission Control Flexible Shaft Bracket Set Bolt 22 ± 3.5
Drain plug 44 ± 4
Turbine Speed Sensor Fixing Bolt 5.4 ± 0.5
Gear Switch Assembly Fixing Bolt 5.4 ± 0.5
Oil Outlet Pipe Set Hollow Bolt 30 ± 3
Transmission Oil Dipstick Sleeve Set Bolt 11 ± 1
Oil Pressure Detection Port Plug 7.8 ± 1
TCU Fixing Bolt 9 ± 1.5
Gear Switch Lock Nut 6.9 ± 2
Gear Shift Arm Fixing Bolt 13 ± 0.6
Basic Parameters
Item Parameter
Model QR416HA
Type Hydraulic automatic torque converter (AT)
Arrangement Type Transverse FWD
Clutch Type at Driving Hydraulic torque converter
Central Distance (mm) 185
Maximum Input Torque (N·m) 160
18 1st 2.848
2nd 1.553
Speed Ratio at Gears 3rd 1.000
4th 0.701
Rev 2.344
Primary Reduction Ratio 1.019
Fluid Type C6AT-15 (referred to as ATF)
Transmission Oil Capacity (L) 6.35 ~ 6.81 L

18 - QR416AHA
Tools
Special Tools
ཽ⪔⊳䖜
RCH0000001
Puller
RCH0000059
RCH0000009
18

18 - QR416AHA
General Tools
Engine Equalizer
RCH0000026
RCH0000005
Digital Multimeter
RCH0000002
18

18 - QR416AHA
Circuit Diagram
Transmission Management System (Page 1 of 2)
BATTERY IGNITION SEITCH

ON OR START
ENGINE
COMPARTMENT
EF26 EF07
FUSE AND
10A 15A RELAY BOX
E-067
75 39 TO CAN
SYSTEM
RW
R
G
Y
RW
R
45 47 46 48 31 32
CAN1-L CAN1-H
TCU
E-069
26 33 25 5 42 20
GW
B
E-029
12
I-035
P
G
GW
B
4
COMMAND
E-068 GEAR SHIFT
1 2 3 I-022
11 3
TURBINE SPEED
BrW
B
18
SENSOR
E-071 ILLUMINTION
I-004
1 2 3 4 5 6 7 8 9 10 41 42
11 12 13 14 15 16 17 18 19 20 43 44 3 2 1 1 2 3 4
8 7 6 5 4 3 2 1
21 22 23 24 25 26 27 28 29 30 45 46
E-071 16 15 14 13 12 11 10 9
5 6 7 8 9 10 11
31 32 33 34 35 36 37 38 39 40 47 48 B
I-022
E-069 E-029
B
B W
EA13T180010

18 - QR416AHA
Transmission Management System (Page 2 of 2)
TCU
E-069
1 3 43 24 2 11 37 40 41 30 28 13 7
IGNITION
ECM(A)
SWITCH
E-041
I-025
4 A25
GW
GW
RW
WB
VW
LW
RB
Gr
Lg
Br
W
O
Y
GW
13 I-035
E-029
GW
GR
1 2 4 5 6 7 8 9 2 3 4 5 6 9 10
GEAR RANGE SWITCH 3 1 SOLENOID VALVE AND

TEMPERATURE SENSOR
B
E-073
E-072
B
E-070
1 2 3 4 5 6 7 8 9 10 41 42
18 11 12 13 14 15 16 17 18 19 20 43 44 1 2 3
21 22 23 24 25 26 27 28 29 30 45 46
4 5 6
31 32 33 34 35 36 37 38 39 40 47 48
A56 A55 A54 A53 A52 A51 A50 A49
I-025
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
E-069 W
B
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13 8 7 6 5 4 3 2 1
6 5 4 3 2 1
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 16 15 14 13 12 11 10 9
10 9 8 7
E-029
W E-072
Gr
4 3 2 1
E-073
E-041 5 6 7 8 9 10 B
B
EA13T180020

18 - QR416AHA
TCU Terminal Definition

TCU Connector
Terminal No. Description Terminal No. Description

1 Reverse Switch 25 Turbine Speed Sensor Ground
2 Neutral Switch 26 Turbine Speed Sensor Power
Supply
3 D Gear Switch 27 -
4 Manual Mode Switch 28 ST Solenoid Valve
5 GND 29 -
6 - 30 S1 Solenoid Valve
7 Oil Temperature Sensor Ground 31 CAN Low
8 - 32 CAN High
9 - 33 Turbine Speed Sensor Signal
10 - 34 Vehicle Speed Sensor Signal
11 P Gear Switch 35 PADDLE_DOWN Switch
12 3rd Gear Switch 36 -
13 Oil Temperature Sensor Signal 37 SL1 Solenoid Valve Switch
14 TIP_DOWN Switch 38 -
15 TIP_UP Switch 39 -
16 Winter Mode Switch 40 SLT Solenoid Valve Switch
17 - 41 S2 Solenoid Valve
18 - 42 -
19 Winter Mode LED 43 L Gear Switch
20 Shift Lock Solenoid Valve 44 -
21 PADDLE_UP Switch 45 VBATT Monitor
22 Sport Mode Switch 46 VIGN 18
23 Sport Mode Indicator 47 VBATT
24 2nd Gear Switch 48 VIGN Monitor

18 - QR416AHA
DIAGNOSIS & TESTING

Transmission Oil Level and Quality Inspection
1. Run vehicle so that transmission oil temperature will reach normal working conditions (80 ± 5 ℃ ).
2. Park vehicle on a flat ground and pull parking brake lever.
3. Under idling status, depress and hold brake pedal and
move shift lever at each gear. Finally, place the lever at
"P" or "N" position.
+ - 1 2 3 4 5 6 7 8 9 10 41 42
4. Pull out oil dipstick and clean it with non-wool paper; then 11 12 13 14 15 16 17 18 19 20 43 44
insert the dipstick in place again and then pull out to 21 22 23 24 25 26 27 28 29 30 45 46
observe whether it reaches the "HOT" position. 31 32 33 34 35 36 37 38 39 40 47 48
5. When transmission oil temperature is at 20 ～ 30 ℃ ,

E-069
perform inspection at "COLD". Inspection method is the
same as above: pull out oil dipstick and clean it with non-
wool paper; then insert the transmission oil dipstick in
place again and then pull out to observe whether it 6 5 4 3 2 1
reaches the "COLD" position. 10 9 8 7
E-072
RA13T180200
6. Check the transmission fluid status:

 If fluid becomes black with irritating burnt flavor, replace ATF and check vehicle conditions.
 If fluid becomes milk white or cloudy, or there is water in the fluid, replace ATF and check for leaking point.
 If fluid becomes black with a lot of powders and there is abnormal wear in 4AT, replace ATF and check
vehicle for normal working.
CAUTION
 If ATF level is lower than Min "HOT", fill ATF from filler until fluid level reaches center position within
"HOT" range.
 Use non-wool paper to wipe the dipstick, never use cloth or other items.
 Flush oil cooler simultaneously when replacing oil.
18
Gear Shift Cable Adjustment and Inspection
Shift gear lever from "N" gear to other gears to check whether the lever can be shifted to other gears smoothly
and precisely, and also check whether gear indicators can indicate the gear correctly.
If gear indicators indicate incorrectly, adjust them as shown below:
1. Park vehicle at a safe place and pull parking brake lever.
2. Change shift lever to "N" position.
5. Remove battery, battery tray and tray bracket (See page 16-9).
6. Remove connecting nut (3) of gear shift cable (1) and shift arm (2). Disconnect gear shift cable from shift
arm.
7. Loosen transmission range sensor fixing bolts, and adjust relative position of transmission range sensor
and shift arm to make the holes of gear shift arm (1) and transmission range sensor (2) coincident.

18 - QR416AHA
8. Use a proper tool to fix gear shift arm and transmission range sensor, and then tighten bolts to specified
torque.
9. Start engine only when gear lever is at "P" or "N" gear.
CAUTION
 Ledge of gear shift cable must be placed into slot of shift arm.
Gear Switch Assembly Inspection

3. Remove air filter assembly, and disconnect gear switch assembly wire harness connector.
4. Using a digital multimeter, measure internal of gear switch assembly and circuit in continuity corresponding
to each gear.
Gear Position Terminal Detection Condition

P 1 - 2, 3 - 9 Continuity
R 3-4 Continuity
N 1 - 2, 3 - 8 Continuity
D 3-5 Continuity
2 3-7 Continuity
L 3-6 Continuity
If detection result is error, replace the gear switch assembly.
Transmission Oil Temperature Sensor

3. Remove air filter assembly, and disconnect transmission wire harness assembly connector.
4. Using a digital multimeter, measure terminals "9" and "10" of transmission wire harness assembly, and
observe the resistance. For relationship of resistance and temperature, refer to table below. Resistance
18
error should be about 10%.
Terminal Temperature (°C) Resistance (kΩ)

-40 100.9
-20 28.6
0 9.4
20 3.5
9-10 40 1.5
60 0.67
80 0.33
100 0.18
120 0.1

18 - QR416AHA
If detection result is error, replace the transmission wire harness assembly.
Turbine Speed Sensor Inspection

3. Disconnect the turbine speed sensor connector.
RA13T180521
4. Using a digital multimeter, measure terminals of transmission wire harness assembly, and observe the
resistance according to table below.
Terminal Temperature (°C) Resistance (MΩ)

1-3 38.1 ± 2
25
2-3 29.4 ± 2
The measurement result cannot be completely used for troubles caused by turbine speed sensor, and it is
necessary to combine combined with other detection methods.

HINT:
With ignited, P gear cannot be Brake switch or circuit 26-24

released after applying brake
18 Gear shift lock solenoid valve -
Turbine speed sensor 18-20
High impact during static gear
Circuit or connector -
shifting
Solenoid valve -
Vehicle fails to run when reverse Transmission planetary gear
Continuity
gear is engaged system
Radiator oil pipes (incorrectly
Vehicle stalls when D/R gear is Continuity
assembled, bent or folded)
engaged
Locking clutch (abnormal) -
Reduced power and speed in high
Thermal protection of transmission Continuity
speeding driving
Abnormal noise of transmission in
Transmission fluid (insufficient) 18-74
acceleration
If detection result is error, replace the gear switch assembly.

18 - QR416AHA
Diagnostic Help
4. Only use a digital multimeter to measure the voltage of electronic system.
6. Visually check related wire harness.
7. Check and clean all Transmission Control Module (TCU) ground that are related to latest DTC.
8. If multiple trouble codes were set, use circuit diagrams and look for any common ground circuit or power
supply circuit applied to DTC.

If malfunction is intermittent, perform the following:
 Use data recorder and/or oscilloscope to help diagnose intermittent malfunctions.
 Remove Transmission Control Module (TCU) from malfunctioning vehicle and install it to a new vehicle to
perform a test. If DTC cannot be cleared, TCU is malfunctioning. If DTC can be cleared, reinstall TCU to
original vehicle.
Ground Inspection
moisture, dirt and other corrosive environments. Corrosion (rust) can increase resistance which will change
the way in which a circuit works.
Electrical control circuits are very sensitive to proper grounding. A loose or corroded ground point can 18
seriously affect control circuit. Check the ground points as follows:
6. If several wire harnesses are crimped into one ground eyelet terminal, check if they are installed correctly.
Make sure that all wires are clean, securely fastened and good contacted without crimping any excessive
insulation coat.
Stall Test
Preparations before stall test:
 Check engine oil level, add oil as necessary.
 Warm up the engine after driving about 10 minutes, so that ATF temperature reaches 50 to 80°. Check
ATF level, add ATF as necessary.

18 - QR416AHA
 Apply parking brake, and block wheel with stopper so that wheel cannot rotate.
Stall test method:
 Start engine, depress brake pedal and move shift lever to "D".
 Depress and hold brake pedal, and gradully depress accelerator pedal simultaneously.
 Rapidly read stall speed, then move away the foot from accelerator pedal quickly.
CAUTION
During test, time for depressing accelerator pedal should not be more than 5 seconds.
 Run engine at least 1 minute and cool down the transmission oil temperature.
 Set shift lever in "R" and repeat above procedures.
Reference values for stall test:
Turn ignition switch off and then to ON. Wait for 1 minute to finish throttle self-learning.
D R Prospective Trouble Area

H O Low speed clutch and brake
O H Reverse clutch and reverse brake
Stall Speed L L Engine and hydraulic torque converter
one-way clutch
H H Low line pressure, clutch, brake
Reference values for stall speed: 2500 rpm

 O: stall speed is within standard value.
 H: stall speed is more than standard value.
 L: stall speed is less than standard value.
WARNING
Be care to perform stall test, because it may damage the internal of transmission.
18
P0750-72 Gear Shift Solenoid Valve "A" Abnormal Open
P0750-73 Gear Shift Solenoid Valve "A" Abnormal Close
P0750-11 Gear Shift Solenoid Valve "A" Control Cir. Short to Ground
P0750-15 Gear Shift Solenoid Valve "A" Control Cir. Short to Power Supply or Open
P0755-72 Gear Shift Solenoid Valve "B" Abnormal Open
P0755-73 Gear Shift Solenoid Valve "B" Abnormal Close
P0755-11 Gear Shift Solenoid Valve "B" Control Cir. Short to Ground
P0755-15 Gear Shift Solenoid Valve "B" Control Cir. Short to Power Supply or Open
P0705-29 Transmission Abnormal Gear Position Signal
P0710-11 Transmission Temperature Sensor Cir. Short to Ground

18 - QR416AHA
P0710-15 Transmission Temperature Sensor Cir. Short to Power Supply or Open

P0715-00 Turbine Speed Abnormal Signal Range
P0785-11 Gear Shift Solenoid Valve "C" Control Cir. Short to Ground
P0785-15 Gear Shift Solenoid Valve "C" Control Cir. Short to Power Supply or Open
P0745-00 Pressure Control Solenoid Valve Abnormal
P0745-11 Pressure Control Solenoid Valve Control Cir. Short to Ground
P0745-15 Pressure Control Solenoid Valve Control Cir. Short to Power Supply
P0743-72 Hydraulic Torque Converter Lock Clutch Solenoid Valve Abnormal Open
P0743-73 Hydraulic Torque Converter Lock Clutch Solenoid Valve Abnormal Close
P0743-11 Hydraulic Torque Converter Lock Clutch Solenoid Valve Control Cir. Short to
Ground
P0743-15 Hydraulic Torque Converter Lock Clutch Solenoid Valve Control Cir. Short to
Power Supply or Open
P0731-00 1st Gear Ratio Abnormal
P0732-00 2nd Gear Ratio Abnormal
P0733-00 3rd Gear Ratio Abnormal
P0734-00 4th Gear Ratio Abnormal
P0736-00 R Gear Ratio Abnormal
P0930-11 Gear Shift Lock Solenoid Valve Control Cir. Short to Ground
P0930-15 Gear Shift Lock Solenoid Valve Control Cir. Short to Power Supply or Open
C0031-86 Front Left Wheel Speed Signal Invalid
C0034-86 Front Right Wheel Speed Signal Invalid
C0037-86 Rear Left Wheel Speed Signal Invalid
C003A-86 Rear Right Wheel Speed Signal Invalid
P0500-29 Vehicle Speed Signal Invalid
P0504-00 Brake Speed Signal Invalid
P0725-00 Engine Speed Signal Abnormal
18
U0073-88 CAN Bus Off
U0401-86 Received EMS Signal Abnormal
U0121-87 Lost Communication With ABS
U0100-87 Lost Communication With EMS
P0863-00 TCU Communication Abnormal

18 - QR416AHA
TCU Power Supply Circuit & Ground Circuit Testing

Power Supply Circuit

ON OR START
ENGINE
COMPARTMENT
EF26 EF07
FUSE AND
10A 15A RELAY BOX
E-067
75 39
RW
R
RW
R
45 47 46 48
TCU
E-069
5 42
B
B
B
E-068
18
1 2 3 4 5 6 7 8 9 10 41 42
11 12 13 14 15 16 17 18 19 20 43 44
21 22 23 24 25 26 27 28 29 30 45 46
31 32 33 34 35 36 37 38 39 40 47 48
E-069
B
EA13T180030

18 - QR416AHA

Step 1.
 If datastream is detected, malfunction indicated by datastream is intermittent (See page 18-21).
Diagnosis Procedure
1 Check TCU power supply circuit

5
b. Disconnect the TCU connector E-069. 4
3
6
7
8
9
2
c. Check voltage between terminal of TCU connector E-069
0
1
and body ground.
Condition
E-069 Always 11 to 14 V
(46,48,47,45) - RA13T180080
Body ground
OK OK
NG
2 Check TCU fuse
a. Unplug TCU fuses EF07 (15A) and EF26 (10A) from

engine compartment fuse and relay box.
18
NG Replace TCU fuse
OK

18 - QR416AHA
3 Check wire harness and connector (TCU - engine compartment fuse and relay box)

connector E-067.
b. Check wire harness between connector terminals on wire 1 2 3 4 5 6 7 8 9 10 41 42
harness side. 11 12 13 14 15 16 17 18 19 20 43 44
+ - 21 22 23 24 25 26 27 28 29 30 45 46
Check for Open
31 32 33 34 35 36 37 38 39 40 47 48
Specified E-069
Condition
E-069 (46,48) - E-067 (39) Continuity
E-069 (45,47) - E-067 (75) Continuity
Check for Short
EF07 15A
Specified
Condition
RA13T180081
E-069 (46,48) or E-067 (39) - Body
ground
E-069 (46, 28) or E-067 (39) - Battery
positive
No continuity
E-069 (45, 47) or E-067 (75) - Body
ground
E-069 (45, 47) or E-067 (75) - Battery
positive

connector
OK
18 4 Check engine fuse and relay box
NG Repair or replace engine fuse and relay

box
OK
Replace TCU

18 - QR416AHA
DTC P0750-72 Gear Shift Solenoid Valve "A" Abnormal Open
DTC P0750-73 Gear Shift Solenoid Valve "A" Abnormal Close
Gear Shift Solenoid Valve "A" Control Cir. Short to

DTC P0750-11
Ground
Gear Shift Solenoid Valve "A" Control Cir. Short to Power

DTC P0750-15
Supply or Open
18

18 - QR416AHA
TCU
E-069
37 40 41 30 28 13 7
RW
WB
VW
RB
Lg
Br
O
2 3 4 5 6 9 10
SOLENOID VALVE A
1 SOLENOID VALVE AND

TEMPERATURE SENSOR
B
E-072
E-070
18
1 2 3 4 5 6 7 8 9 10 41 42
11 12 13 14 15 16 17 18 19 20 43 44
6 5 4 3 2 1
21 22 23 24 25 26 27 28 29 30 45 46
10 9 8 7
31 32 33 34 35 36 37 38 39 40 47 48
E-072 E-069
Gr B
EA13T180040

18 - QR416AHA
DTC Detection
Condition
Gear Shift Solenoid Ignition switch ON
P0750-72 Valve "A" Abnormal Engine runs, target
Open gear position and
Gear Shift Solenoid actual gear position
P0750-73 Valve "A" Abnormal information is not  Gear shift control solenoid valve wire
Close consistent
harness failure
Gear Shift Solenoid Ignition switch ON  Gear shift control solenoid valve A
P0750-11 Valve "A" Control Cir. Engine runs, target failure
Short to Ground gear position and  Gear shift control solenoid valve A
actual gear position related circuit failure
Gear Shift Solenoid information is not
Valve "A" Control Cir. consistent, driver chip
P0750-15
Short to Power Supply input signal is low level
or Open and detection signal is
high level

 Using X-431 3G diagnostic tester, record and clear DTCs stored in TCU.
 Start engine, move shift lever to D gear, slightly depress accelerator pedal so that vehicle speed reaches
70 km/h, then release accelerator pedal and hold it for 5 seconds.
 Check DTC again, if DTC is detected, malfunction indicated by DTC is current. Go to diagnosis procedure
- Step 1.
CAUTION
 When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and
component information. Clear DTCs after repair is finished.
18
Diagnosis Procedure
1 Check TCU ground point

b. Check the TCU ground point E-068.

ground point
OK

18 - QR416AHA
2 Check wire harness assembly connector
a. Disconnect the solenoid valve and temperature sensor

connector E-072.
b. Check the solenoid valve and temperature sensor
connector.
RA13T180160
OK
3 Check solenoid valve "A" control circuit

b. Disconnect the TCU wire harness connector E-069.
c. Disconnect the solenoid valve and temperature sensor
connector E-072. + - 1 2 3 4 5 6 7 8 9 10 41 42
d. Check wire harness between wire harness connector 11 12 13 14 15 16 17 18 19 20 43 44

terminal and solenoid valve and temperature sensor 21 22 23 24 25 26 27 28 29 30 45 46
connector terminal. 31 32 33 34 35 36 37 38 39 40 47 48
Condition
E-069 (30) - E- 10 9 8 7
Always Continuity
072 (5)
E-072
Check for Short

RA13T180140
18 Multimeter
Condition
Specified
E-069 (30) or E-
ground
E-069 (30) or E-
positive
OK

18 - QR416AHA
4 Check solenoid valve "A"

connector E-072.
b. Measure resistance between solenoid valve and
temperature sensor connector E-072 and transmission
case ground. + -
Standard Resistance
6 5 4 3 2 1
Condition
Connection Condition (Ω)
E-072
E-072 (5) - Case Resistance
13 ± 1
ground measurement
 Resistance error should be about 10%.
NG Repair or replace solenoid valve "A"
RA13T180150
OK
5 Check for DTCs
a. Using X-431 3G diagnostic tester, read TCU DTC.

c. Check if DTC P0750-72, P0750-73, P0750-11, P0750-15
still exist.
NG Replace TCU
OK
System is operating normally. Reassemble vehicle and perform a road test to confirm that 18

18 - QR416AHA
DTC P0755-72 Gear Shift Solenoid Valve "B" Abnormal Open
DTC P0755-73 Gear Shift Solenoid Valve "B" Abnormal Close
Gear Shift Solenoid Valve "B" Control Cir. Short to

DTC P0755-11
Ground
Gear Shift Solenoid Valve "B" Control Cir. Short to Power

DTC P0755-15
Supply or Open
18

18 - QR416AHA
TCU
E-069
37 40 41 30 28 13 7
RW
WB
VW
RB
Lg
Br
O
2 3 4 5 6 9 10
SOLENOID VALVE B

TEMPERATURE SENSOR
B
E-072
E-070
18
1 2 3 4 5 6 7 8 9 10 41 42
11 12 13 14 15 16 17 18 19 20 43 44
6 5 4 3 2 1
21 22 23 24 25 26 27 28 29 30 45 46
10 9 8 7
31 32 33 34 35 36 37 38 39 40 47 48
E-072 E-069
Gr B
EA13T180050

18 - QR416AHA
DTC Detection
Condition
Gear Shift Solenoid Ignition switch ON
P0755-72 Valve "B" Abnormal Engine runs, target
Open gear position and
Gear Shift Solenoid actual gear position
P0755-73 Valve "B" Abnormal information is not  Gear shift control solenoid valve wire
Close consistent
harness failure
Gear Shift Solenoid Ignition switch ON  Gear shift control solenoid valve B
P0755-11 Valve "B" Control Cir. Engine runs, target failure
Short to Ground gear position and  Gear shift control solenoid valve B
actual gear position related circuit failure
Gear Shift Solenoid information is not
Valve "B" Control Cir. consistent, driver chip
P0755-15
Short to Power Supply input signal is low level
or Open and detection signal is
high level

- Step 1.
CAUTION
18
Diagnosis Procedure


ground point
OK

18 - QR416AHA

connector E-072.
connector.
RA13T180160
OK
3 Check solenoid valve "B" control circuit

connector E-072. + - 1 2 3 4 5 6 7 8 9 10 41 42

Condition
E-069 (41) - E- 10 9 8 7
Always Continuity
072 (4)
E-072
Check for Short

RA13T180170
Multimeter
Condition
Specified 18
E-069 (41) or E-
ground
E-069 (41) or E-
positive
OK

18 - QR416AHA
4 Check solenoid valve "B"

connector E-072.
case ground. + -
Standard Resistance
6 5 4 3 2 1
Condition
Connection Condition (Ω) E-072
13±1
ground measurement
NG Repair or replace solenoid valve "B"
RA13T180180
OK
5 Check for DTCs

still exist.
NG Replace TCU
OK
18 System is operating normally. Reassemble vehicle and perform a road test to confirm that

18 - QR416AHA
Gear Shift Solenoid Valve "C" Control Cir. Short to

DTC P0785-11
Ground
Gear Shift Solenoid Valve "C" Control Cir. Short to Power

DTC P0785-15
Supply or Open
18

18 - QR416AHA
TCU
E-069
37 40 41 30 28 13 7
RW
WB
VW
RB
Lg
Br
O
2 3 4 5 6 9 10
SOLENOID
VALVE C

TEMPERATURE SENSOR
B
E-072
E-070
18
1 2 3 4 5 6 7 8 9 10 41 42
11 12 13 14 15 16 17 18 19 20 43 44
6 5 4 3 2 1
21 22 23 24 25 26 27 28 29 30 45 46
10 9 8 7
31 32 33 34 35 36 37 38 39 40 47 48
E-072 E-069
Gr B
EA13T180060

18 - QR416AHA
DTC Detection
Condition
Gear Shift Solenoid
P0785-11 Valve "C" Control Cir. Ignition switch ON
Short to Ground  Gear shift control solenoid valve wire
Driver chip input signal harness failure
Gear Shift Solenoid is low level and  Gear shift control solenoid valve C
Valve "C" Control Cir. detection signal is high failure
P0785-15
Short to Power Supply level
or Open

- Step 1.
CAUTION
Diagnosis Procedure

b. Check the TCU ground point E-068. 18
ground point
OK

18 - QR416AHA

connector E-072.
connector.
RA13T180160
OK
3 Check solenoid valve "C" control circuit

connector E-072. + - 1 2 3 4 5 6 7 8 9 10 41 42

Condition
E-069 (28) - E- 10 9 8 7
Always Continuity
072 (6)
E-072
Check for Short

RA13T180200
18 Multimeter
Condition
Specified
E-069 (28) or E-
ground
E-069 (28) or E-
positive
OK

18 - QR416AHA
4 Check solenoid valve "C"

connector E-072.
case ground. + -
Standard Resistance
6 5 4 3 2 1
10 9 8 7
Condition

13±1
ground measurement
NG Repair or replace solenoid valve "C"
RA13T180210
OK
5 Check for DTCs

c. Check if DTC P0785-11, P0785-15 still exist.
NG Replace TCU
OK
malfunction reported by customer has been repaired. 18

18 - QR416AHA
DTC P0745-00 Pressure Control Solenoid Valve Abnormal
Pressure Control Solenoid Valve Control Cir. Short to

DTC P0745-11
Ground
Pressure Control Solenoid Valve Control Cir. Short to

DTC P0745-15
PowerSupply
18

18 - QR416AHA
TCU
E-069
37 40 41 30 28 13 7
RW
WB
VW
RB
Lg
Br
O
2 3 4 5 6 9 10
PRESSURE SOLENOID VALVE

TEMPERATURE SENSOR
B
E-072
E-070
18
1 2 3 4 5 6 7 8 9 10 41 42
11 12 13 14 15 16 17 18 19 20 43 44
6 5 4 3 2 1
21 22 23 24 25 26 27 28 29 30 45 46
10 9 8 7
31 32 33 34 35 36 37 38 39 40 47 48
E-072 E-069
Gr B
EA13T180070

18 - QR416AHA
DTC Detection
Condition
Pressure Control
P0745-00 Solenoid Valve
Abnormal
Difference between
Pressure Control  Pressure solenoid valve wire harness
actual current and
P0745-11 Solenoid Valve Control failure
target current of
Cir. Short to Ground
solenoid valve is too  Pressure control solenoid valve failure
Pressure Control large
Solenoid Valve Control
P0745-15
Cir. Short to Power
Supply

- Step 1.
CAUTION
Diagnosis Procedure
18 1 Check TCU ground point


ground point
OK

18 - QR416AHA

connector E-072.
connector.
RA13T180160
OK
3 Check pressure solenoid valve control circuit

connector E-072. + - 1 2 3 4 5 6 7 8 9 10 41 42

Condition
E-069 (40) - E- 10 9 8 7
Always Continuity
072 (3)
E-072
Check for Short

RA13T180230
Multimeter
Condition
Specified 18
E-069 (40) or E-
ground
E-069 (40) or E-
positive
OK

18 - QR416AHA
4 Check pressure control solenoid valve

connector E-072.
case ground. + -
Standard Resistance
6 5 4 3 2 1
10 9 8 7
Condition

5.3 ± 0.3
ground measurement
NG Repair or replace pressure control

solenoid valve
RA13T180240
OK
5 Check for DTCs

c. Check if DTC P0745-00, P0745-11, P0745-15 still exist.
NG Replace TCU
OK
18 malfunction reported by customer has been repaired.

18 - QR416AHA
Hydraulic Torque Converter Lock Clutch Solenoid Valve

DTC P0743-72
AbnormalOpen

DTC P0743-73
AbnormalClose

DTC P0743-11
ControlCir. Short to Ground

DTC P0743-15
Control Cir. Short to Power Supply or Open
18

18 - QR416AHA
TCU
E-069
37 40 41 30 28 13 7
RW
WB
VW
RB
Lg
Br
O
2 3 4 5 6 9 10
LOCKING CLUTCH SOLENOID VALVE

TEMPERATURE SENSOR
B
E-072
E-070
18
1 2 3 4 5 6 7 8 9 10 41 42
11 12 13 14 15 16 17 18 19 20 43 44
6 5 4 3 2 1
21 22 23 24 25 26 27 28 29 30 45 46
10 9 8 7
31 32 33 34 35 36 37 38 39 40 47 48
E-072 E-069
Gr B
EA13T180080

18 - QR416AHA
DTC Detection
Condition
Hydraulic Torque
Converter Lock Clutch
P0743-72
Solenoid Valve Slip speed is still more
Abnormal Open than a certain value
after hydraulic torque
Hydraulic Torque converter request
Converter Lock Clutch locks
P0743-73
Solenoid Valve
 Hydraulic torque converter failure
Abnormal Close
 Hydraulic torque converter lock control
Hydraulic Torque solenoid valve
Converter Lock Clutch
P0743-11  Wire harness failure
Solenoid Valve Control Ignition switch ON
Cir. Short to Ground When driver chip input
Hydraulic Torque signal is high level,
Converter Lock Clutch detection signal is low
P0743-15 Solenoid Valve Control level
Cir. Short to Power
Supply or Open

- Step 1.
CAUTION
18
Diagnosis Procedure


ground point
OK

18 - QR416AHA

connector E-072.
connector.
RA13T180160
OK
3 Check lock clutch solenoid valve controlcircuit

connector E-072. + - 1 2 3 4 5 6 7 8 9 10 41 42
d. Check wire harness between TCU wire harness 11 12 13 14 15 16 17 18 19 20 43 44

connector terminal and solenoid valve and temperature 21 22 23 24 25 26 27 28 29 30 45 46
sensor connector terminal. 31 32 33 34 35 36 37 38 39 40 47 48
Condition
E-069 (37) - E- 10 9 8 7
Always Continuity
072 (2)
E-072
Check for Short

RA13T180260
18 Multimeter
Condition
Specified
E-069 (37) or E-
ground
E-069 (37) or E-
ground
OK

18 - QR416AHA
4 Check lock clutch solenoid valve

connector E-072.
case ground. + -
Standard Resistance
6 5 4 3 2 1
10 9 8 7
Condition

13 ± 1
ground measurement
NG Repair or replace lock clutch solenoid

valve
RA13T180270
OK
5 Check for DTCs

still exist.
NG Replace TCU
OK
System is operating normally. Reassemble vehicle and perform a road test to confirm that 18

18 - QR416AHA
DTC P0710-11 Transmission Temperature Sensor Cir. Short to Ground
Transmission Temperature Sensor Cir. Short to Power

DTC P0710-15
Supplyor Open
18

18 - QR416AHA
TCU
E-069
37 40 41 30 28 13 7
RW
WB
VW
RB
Lg
Br
O
2 3 4 5 6 9 10
OIL TEMPERATURE SENSOR

TEMPERATURE SENSOR
B
E-072
E-070
18
1 2 3 4 5 6 7 8 9 10 41 42
11 12 13 14 15 16 17 18 19 20 43 44
6 5 4 3 2 1
21 22 23 24 25 26 27 28 29 30 45 46
10 9 8 7
31 32 33 34 35 36 37 38 39 40 47 48
E-072 E-069
Gr B
EA13T180090

18 - QR416AHA
DTC Detection
Condition
Transmission
P0710-11 Temperature Sensor When resistance
Cir. Short to Ground monitored by oil  Oil temperature sensor failure
Transmission temperature sensor is  Signal circuit is short to ground
Temperature Sensor less than given  TCU signal processing circuit failure
P0710-15 minimum value
Cir. Short to Power
Supply or Open

- Step 1.
CAUTION
Diagnosis Procedure

18 b. Check the TCU ground point E-068.

ground point
OK

18 - QR416AHA

connector E-072.
connector.
RA13T180160
OK
3 Check oil temperature sensor circuit

connector E-072. + - 1 2 3 4 5 6 7 8 9 10 41 42

connector terminal and solenoid valve and temperature 21 22 23 24 25 26 27 28 29 30 45 46
sensor connector terminal. 31 32 33 34 35 36 37 38 39 40 47 48
Condition
E-069 (13) - E- 10 9 8 7
072 (9)
E-069 (07) - E-
072 (10)
RA13T180290
Check for Short 18

Condition
E-069 (13) or E-
ground
E-069 (07) or E-
positive
OK

18 - QR416AHA
4 Check transmission temperature sensor

connector E-072.
case ground. + -
Standard Resistance (See page 18-19)
NG Repair or replace transmission

temperature sensor 6 5 4 3 2 1
10 9 8 7
E-072
RA13T180600
OK
5 Check for DTCs

c. Check if DTC P0710-11, P0710-15 still exist.
NG Replace TCU
OK
18 malfunction reported by customer has been repaired.

18 - QR416AHA
DTC P0705-29 Transmission Abnormal Gear Position Signal
TCU
E-069
1 3 43 24 2 11
GW
GW
LW
Gr
W
Y
4 5 6 7 8 9
GEAR RANGE SWITCH 3

E-073
B
E-070
18
1 2 3 4 5 6 7 8 9 10 41 42
4 3 2 1
11 12 13 14 15 16 17 18 19 20 43 44
21 22 23 24 25 26 27 28 29 30 45 46
E-073
5 6 7 8 9 10 B
31 32 33 34 35 36 37 38 39 40 47 48
E-069
B
EA13T180100

18 - QR416AHA
DTC Detection
Condition
When there are more
Transmission gear position signals  Poor matching of gear shift cable
P0705-29 Abnormal Gear that are read or there  Gear shift switch failure
Position Signal are no gear position  Gear shift cable wire harness failure
signals

 Start engine, change gear position in order of P-R-N-D-2-L-2-D-N-R-P and hold each gear for 15 seconds.
 Check DTC again, if DTC is detected, malfunction indicated by DTC is current. Go to diagnosis procedure -
Step 1.
CAUTION
Diagnosis Procedure


ground point
18
OK
2 Check gear shift switch connector
a. Disconnect the gear shift switch connector E-073.

b. Check the gear shift switch connector.
RA13T180610

18 - QR416AHA
OK
3 Check gear shift switch circuit

connector E-072. + - 1 2 3 4 5 6 7 8 9 10 41 42

connector and solenoid valve and temperature sensor 21 22 23 24 25 26 27 28 29 30 45 46
Condition 4 3 2 1
5 6 7 8 9 10
E-069 (1) - E-073
(4)
E-069 (3) - E-073 E-073
(5)
RA13T180620
E-069 (43) - E-
073 (6)
Always Continuity
E-069 (24) - E-
073 (7)
E-069 (2) - E-073
(8)
E-069 (11) - E-
073 (9)
Check for Short
Condition
E-073
(4,5,6,7,8,9) or E- 18
063 Always No continuity
(1,3,43,24,2,11) -
Body ground
E-073
(4,5,6,7,8,9) or E-
063 Always No continuity
(1,3,43,24,2,11) -
Battery positive
OK

18 - QR416AHA
4 Check gear switch assembly
a. Disconnect the gear switch assembly E-073.

b. Check for internal continuity of gear switch assembly.
NG Repair or repalce gear switch assembly
RA13T180630
OK
5 Check for DTCs

NG Replace TCU
OK
18

18 - QR416AHA
DTC P0715-00 Turbine Speed Abnormal Signal Range

ON OR START
ENGINE
COMPARTMENT
EF26 EF07
FUSE AND
10A 15A RELAY BOX
E-067
75 39
RW
R
RW
R
45 47 46 48
TCU
E-069
26 33 25 5 42
B
B
P
G
E-068
1 2 3
TURBINE SPEED
SENSOR
E-071
18
1 2 3 4 5 6 7 8 9 10 41 42
11 12 13 14 15 16 17 18 19 20 43 44 3 2 1
21 22 23 24 25 26 27 28 29 30 45 46
E-071
31 32 33 34 35 36 37 38 39 40 47 48 B
E-069
B
EA13T180110

18 - QR416AHA
DTC Detection
Condition
Turbine speed is  Oil temperature sensor failure
Turbine Speed invalid or more than
 Sensor circuit is poorly contacted or
P0715-00 Abnormal Signal maximum value, or
short
Range less than minimum
value during driving  Sensor failure

 Start engine, move shift lever to any position of D, R, 2, L, slightly depress accelerator pedal so that vehicle
speed reaches 20 km/h, and hold it for more than 30 seconds.
- Step 1.
CAUTION
Diagnosis Procedure


18 ground point
OK
2 Check turbine speed sensor connector
a. Disconnect the turbine speed sensor connector E-071.

b. Check the turbine speed sensor connector.
RA13T180640

18 - QR416AHA
OK
3 Check turbine speed sensor circuit

c. Disconnect the turbine speed sensor connector E-071.
d. Check wire harness between TCU wire harness + - 1 2 3 4 5 6 7 8 9 10 41 42
connector terminal and turbine speed sensor connector 11 12 13 14 15 16 17 18 19 20 43 44

terminal. 21 22 23 24 25 26 27 28 29 30 45 46
Check for Open 31 32 33 34 35 36 37 38 39 40 47 48
E-069
Condition
3 2 1
E-069 (26) - E-
071 (1) E-071
E-069 (33) - E-
Always Continuity
071 (2)
E-069 (25) - E- RA13T180650
071 (3)
Check for Short
Condition
E-069 (26,33,25)
or E-071 (1,2,3) - Always No continuity
Body ground
E-069 (26,33,25)
or E-071 (1,2,3) - Always No continuity
Battery positive

18
OK
4 Turbine Speed Sensor
a. Disconnect the turbine speed sensor connector E-072.

b. Measure resistance of turbine speed sensor connector E-
072.
NG Repair or replace turbine speed sensor

connector
OK

18 - QR416AHA
5 Check for DTCs

NG Replace TCU
OK
18

18 - QR416AHA
DTC P0863-00 TCU Communication Abnormal
ECM(A) E-041
CAN1-L CAN1-H
CAN1-L CAN1-H
CAN1-H CAN1-L
A23 A11
32 G G 14
TCU ESP
E-069 31 Y Y 2 E-051
G
Y
E-054
6 5
I-018
CAN1-H CAN1-L
CAN1-L CAN1-H
STEERING 1 Y Y 2
SRS CONTROL
ANGLE
MODULE
SENSOR 2 G G 17
I-020
I-028
G
Y
CAN1-L CAN1-H
CAN1-H CAN1-L
DIAGNOSTIC 14 Y OB B3
INTERFACE BCM (B)
I-033 G G B16 I-034
6
1 2 3 4 5 6 7 8 9 10 41 42
11 12 13 14 15 16 17 18 19 20 43 44 E-069
21 22 23 24 25 26 27 28 29 30 45 46 B
31 32 33 34 35 36 37 38 39 40 47 48
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37 E-041
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
B
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13 18
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I-020
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 Gr
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034

B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
E-051 16 15 14 13 12 11 10 9
12 11 10 9 8 7 6 5 4 3 2 I-033
13 1
B 8 7 6 5 4 3 2 1 B
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
4 3 E-054 6 5 4 3 2 1 I-028
2 1
W B
10 9 8 7 6 5
EA13T180120

18 - QR416AHA
DTC Detection
Condition
When TCU cannot  TCU wire harness failure
TCU Communication
P0863-00 communicate with
Abnormal  TCU failure
other control units

 Start engine for more than 10 seconds.
- Step 1.
CAUTION
Diagnosis Procedure


ground point
18 OK
2 Check TCU wire harness connector
a. Disconnect the TCU wire harness connector E-069.

b. Check the TCU wire harness connector.
RA13T180581

18 - QR416AHA
OK
3 Check for DTCs

NG Replace TCU
OK
18

18 - QR416AHA
DTC U0100-87 Lost Communication With EMS
ECM(A) E-041
CAN1-L CAN1-H
A23 A11
G
Y
31 32
CAN1-L CAN1-H
TCU
E-069
18
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37

1 2 3 4 5 6 7 8 9 10 41 42
E-041
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
B 11 12 13 14 15 16 17 18 19 20 43 44 E-069
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13 21 22 23 24 25 26 27 28 29 30 45 46 B
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 31 32 33 34 35 36 37 38 39 40 47 48
EA13T180121

18 - QR416AHA
DTC Detection
Condition
Engine speed and
Lost Communication torque signals, etc. are  Engine speed sensor failure
U0100-87
With EMS sent by vehicle CAN  CAN circuit failure
network

 Start engine and wait for at least 1 minute.
- Step 1.
CAUTION
Diagnosis Procedure


ground point
18
OK
2 Check engine speed sensor
a. Check engine speed sensor in engine management

system (See page 06-111).
NG Repair or replace engine speed sensor
OK
3 Check CAN network circuit
a. Check ECU connector and circuit.

18 - QR416AHA
OK
4 Check for DTCs

NG Replace TCU or ECU.
OK
18

18 - QR416AHA
DTC U0121-87 Lost Communication With ABS
CAN1-L CAN1-H
CAN1-H CAN1-L
32 G 14
TCU ESP
E-069 31 Y 2 E-051
18
12 11 10 9 8 7 6 5 4 3 2 1 2 3 4 5 6 7 8 9 10 41 42
13 1
24 23 22 21 20 19 18 17 16 15 14
11 12 13 14 15 16 17 18 19 20 43 44
38 37 36 35 34 33 32 31 30 29 28 27 26 25 21 22 23 24 25 26 27 28 29 30 45 46
31 32 33 34 35 36 37 38 39 40 47 48
E-069
B
E-051
B
EA13T180130

18 - QR416AHA
DTC Detection
Condition
When ABS signal
Lost Communication value received from  ABS signal sensor failure
U0121-87
With ABS TCM equals to default  CAN signal circuit failure
failed value

 Start engine and wait for at least 1 minute.
- Step 1.
CAUTION
Diagnosis Procedure


ground point
18
OK
2 Check ABS singal sensor
a. Check the ABS signal sensor (See page 25-14).
NG Repair or replace ABS signal sensor
OK
3 Check CAN network circuit
a. Check ABS connector and circuit

18 - QR416AHA
OK
4 Check for DTCs

NG Replace TCU or ECU.
OK
18

18 - QR416AHA
ON-VEHICLE SERVICE
Automatic Transmission Fluid (ATF) Replacement
CAUTION
 Replace transmission oil only when engine stops and transmission cools down.
 Before installation, replace drain/retaining plug washer with a new one.
Draining
2. Raise the vehicle to a proper height.
3. Place a recovering container under transmission drain hole.
4. Using a wrench, loosen the transmission oil filler plug
(arrow).
RA13T180300
5. Using a wrench, remove the transmission drain plug

(arrow). Replace drain plug washer and tighten drain plug
after draining transmission oil.
18 RA13T180310

18 - QR416AHA
Filling Transmission Oil
CAUTION
 Only use transmission oil approved by Chery Automobile Co., Ltd.
1. Make sure that transmission drain plug has been tightened in place.
2. Using a filling tool, fill transmission oil into transmission
filler, and filling amount should be drained ATF level.
RA13T170320
HINT:
If transmission is spare part, it is not necessary to drain oil. Fill a certain amount of ATF after installing new
transmission.
Transmission Oil Type
Transmission Oil Type C6AT-15 (ATF)

Filling Capacity 6.58 ± 0.23 L
CAUTION
 Genuine C6AT-15 fluid must be used for 4AT.

 Avoid fluid splashing to high temperature part during filling, and leaked part should be wiped off after
filling.
HINT:
18
It is recommended to replace ATF once after driving at 40000 km, and it is not necessary to replace ATF in
later maintenance.

18 - QR416AHA
Differential Oil Seal

Removal
1. Remove the left wheel (See page 24-7).
1
RA13T180330
2. Remove the left drive shaft assembly (See page 20-5).
WARNING
3. Using a special tool (1), remove the differential oil seal (2).
HINT:
Do not damage joint surface of oil seal and housing during removal.
Installation
1. Apply an appropriate amount of transmission oil to new oil seal outer race.
2. Using a special tool and hammer, tap in oil seal and
install it in place. 3
18 2
RA13T180331
CAUTION
 Do not scratch oil seal mounting hole during disassembly.

 When assembling, apply force evenly and prevent oil seal from deformation and damage.
 Keep transmission oil seal clean, to avoid foreign matter entering transmission. Do not apply other
sealant or adhesive on oil seal. Use clean gloves or clean hands during operation.

Other procedures are in the reverse order of removal.

18 - QR416AHA
Transmission Oil Cooling Line Set

Removal
6. Drain transmission oil.
7. Separate transmission oil cooling line set and radiator assembly.
a. Remove 2 hollow bolts between transmission oil
cooling line set and radiator assembly.
b. Separate transmission oil cooling line set from
radiator assembly.
RA13T180340
8. Remove 3 fixing bolts from transmission oil cooling line

set.
RA13T180350
9. Remove transmission oil inlet/outlet cooling line set and

transmission cooling pipe assembly.
a. Remove clamping ring from transmission cooling pipe 18
assembly.
b. Separate the transmission cooling pipe assembly.
RA13T180360
10.Remove the oil cooling pipe set.
Installation

18 - QR416AHA
CAUTION
 Confirm that transmission oil inlet and return cooling pipes are not twisted, crossed or deformed, etc.
 When installing hose to pipe, first apply a small amount of clean automatic transmission oil to inner wall
of hose for assembly.
 When installing hose to pipe joint, install hose to inner limit.
18

18 - QR416AHA
Gear Select and Shift Cable

Removal
6. Remove fixing bolt between gear select and shift cable and engine block (See page 07-57).
7. Remove the exhaust pipe front heat insulator (See page 11-14).
8. Remove fixing bolt between gear select and shift cable
and body chassis.
RA13T180370
9. Remove coupling bolt between gear select and shift cable and gear switch (See page 07-57).
10.Remove the auxiliary fascia console assembly (See page 46-8).
11. Remove fixing bolts (arrow) between gear select and shift
cable and body.
RA13T180390
12.Disconnect gear select and shift cable from gear shift control mechanism. 18
RA13T180400

18 - QR416AHA
b. Remove gear select and shift cable from gear shift

control mechanism assembly.
RA13T180410
13.Remove the gear select and shift cable.
Installation
18

18 - QR416AHA

Removal
4. Separate gear shift control mechanism and gear select and shift cable.
5. Remove the gear shift control mechanism.
a. Unplug wire harness connector (arrow) from gear shift
control mechanism.
RA13T180420
b. Remove 4 tightening bolts (arrow) from gear shift

control mechanism, and remove gear shift control
mechanism.
RA13T180430
Installation
18

18 - QR416AHA
Transmission Assembly
Disassembly
7. Remove the front wheels (See page 24-7).
8. Remove the drive shaft (See page 20-5).
9. Remove wire harness connector between power assembly and engine compartment (See page 07-59).
10.Remove mounting bolt, cooling hose, gear select and shift cable, etc., and then remove power assembly
from vehicle (See page 07-57).
11. Remove 2 fixing bolts (arrow) from transmission control
flexible shaft bracket set, and remove transmission
control flexible shaft bracket set.
RA13T180440
12.Loosen 2 fixing bolts from lower baffle plate, and remove

lower baffle plate.
18
RA13T180450
13.Rotate crankshaft, turn coupling bolts between drive plate

and hydraulic torque converter to center position of U-
groove, then lock the crankshaft and remove 4 bolts.
RA13T180460

18 - QR416AHA
14.Loosen 2 coupling bolts between engine and

transmission on both sides.
RA13T180470
15.Loosen 2 coupling bolts between engine and upper part

of transmission, then separate engine and transmission.
RA13T180480
CAUTION
During separation, hydraulic torque converter should not fall down. If it falls down, contact the after-sale
service department.
Assembly
CAUTION
 Before assembling components, wash them clean.

 Remove seal gum residues from cases.
 Make sure joint surface of case and shift assembly is free of oil, and uniformly apply seal gum. 18
 Tighten bolts to specified torques.

18 - QR416AHA
1. For spare transmission, first loosen 2 bolts and remove

shift lever (arrow).
RA13T180490
2. Install upper baffle plate to rear end surface of engine,

and align two engine dowel pins.
RA13T180500
3. For easy assembly, tighten coupling bolt between

hydraulic torque converter and drive plate. Rotate
hydraulic torque converter so that one bolt hole of torque
converter is roughly at positon indicated by arrow; rotate
drive plate so that one unthreaded hole of drive plate is
roughly at center positon of engine U-groove.
18
RA13T180510
4. Assemble engine and transmission assembly, and locate

them with 2 engine dowel pins.
a. Install 2 coupling bolts to transmission side.
b. Install 2 coupling bolts to engine side.
(Tightening torque: 50 ± N·m)
RA13T180520

18 - QR416AHA
CAUTION
 During assembly, hydraulic torque converter should not fall down. If it falls down, contact the after-sale
service department.
CAUTION
 After installation, add transmission oil and check transmission oil level.
18

18 - QR416AHA
Transmission External Accessory

Removal of Turbine Speed Sensor
1. Remove the turbine speed sensor.
a. Remove turbine speed sensor fixing bolts (arrow)
from transmission assembly, and remove turbine
speed sensor.
RA13T180520
Installation
1. Apply ATF to O-ring of turbine speed sensor set, then insert it into case mounting hose, to make sure that
sensor end surface and case end surface are attached firmly and secured with bolt.
CAUTION
 Make sure no dirt or foreign matter enters transmission from sensor mounting hole.
 When connecting connector, check that pin is not bent or damaged, then connect the connector.
Removal of Gear Switch Assembly

1. Remove the gear shift arm.
a. Remove a fixing bolt from gear shift arm, and remove
elastic washer (1) and gear shift arm (2).
18
2 1
RA13T180530
b. Remove lock nut from gear switch, and remove thrust

washer (1).
RA13T180540

18 - QR416AHA
c. Remove bolt elastic washer and plate washer set from

gear switch, and remove gear switch assembly (1).
RA13T180550
Installation
1. Install the gear switch assembly.
a. Install new thrust washer and gear shift arm, rotate
gear shift arm counterclockwise until it cannot be
rotated. After loosing gear shift arm, it should be at P 4
3
5
6
7
8
gear. 2
1
9
0
RA13T180560
b. Rotate gear shift arm clockwise, and set it at N gear in

order of P → R → N. Center longer pointer protruded 5
on thrust washer and mark line protruded on gear 4 6

7
3 8
9
switch assembly. Tighten 2 bolt elastic washer and

2 0
1
plate washer sets to secure the gear switch assembly.

4
3
2
5
6
7
8
9
18
0
1
RA13T180570
2. Remove gear shift arm, tighten gear switch lock nut, turn over thrust washer (except for N gear pointer) to
clamp the lock nut, whicl will prevent loosening.
3. Install gear shift arm and elastic washer, and tighten fixing nut.

18 - QR416AHA
Removal of Oil Dipstick and Oil Dipstick Sleeve Set

1. Pull out transmission oil dipstick set, and check O-ring for damage. If damaged, replace O-ring.
2. Unplug the ventilation plug rubber pipe set.
3. Remove fixing bolt from transmission oil dipstick sleeve
set, remove plate washer, pull out transmission oil
dipstick sleeve set, and check O-ring for damage. If
damaged, replace O-ring.
RA13T180580
Installation
1. Apply ATF to O-ring of oil dipstick sleeve set, and insert it into case mounting hole. Install plate washer set
and tighten fixing bolt.
2. Install ventilation plug rubber pipe set, to make sure rubber pipe covers the protrusion.
3. Apply ATF to O-ring of transmission oil dipstick set and insert it into transmission oil dipstick sleeve set.
18

18 - QR416AHA
TCU
Removal
3. Remove the lower left instrument panel protector.
4. Disconnect the TCU wire harness connector.
RA13T180581
5. Remove 4 fixing bolts from TCU, and remove TCU

assembly.
RA13T180582
Installation
CAUTION
 Be careful when connecting and disconnecting TCU connector, do not bend or damage the pin.
18

- MEMO -

CLUTCH
Description 19-3 Master Cylinder Inlet Pipe 19-11
Tools 19-6 Clutch Release Cylinder Assembly 19-14
Removal 19-14
Installation 19-15
Clutch Pedal 19-16
Clutch Switch 19-8 Installation 19-16
Removal 19-8 Clutch Unit 19-17
Inspection 19-8 Removal 19-17
Clutch Master Cylinder Assembly 19-9 Installation 19-18
Removal 19-9 Bleeding Hydraulic Clutch 19-21
19

19

19 - CLUTCH
GENERAL INFORMATION
CLUTCH
Description
1
4
5 6
7 8
10
RA13T190010
19
1 - Front Clutch Pedal Assembly 2 - Elastic Clamp
3 - Master Cylinder Inlet Hose 4 - Clutch Master Cylinder Assembly
5 - Clutch Pipe I 6 - Single Pipe Clamp
7 - Hose Assembly II 8 - Holding Spring
9 - Clutch Pipe Assembly II 10 - Clutch Release Cylinder Assembly

19 - CLUTCH
×6
3
4
7
6
19 RA13T190020
1 - Flywheel 2 - Clutch Driven Disc

3 - Clutch Pressure Plate 4 - Release Bearing
5 - Clutch Fork 6 - Return Spring
7 - Wear Bushing 8 - Clutch Arm

19 - CLUTCH
Operation
Hydraulic Clutch System: It mainly consists of clutch pedal, clutch master cylinder, clutch release cylinder,
clutch hydraulic line, etc. When depressing clutch pedal, clutch master cylinder generates pressure, and
transmits it to the release bearing that is fitted with pressure plate diaphragm spring. As external force is
applied, release bearing squeezes diaphragm spring release finger inward until it reaches fulcrum. This
operation moves pressure plate backward, thus releasing the clamping force from clutch driven disc. Clutch
Master Cylinder Assembly: It consists of piston, cylinder block, push rod and hydraulic line. When depressing
pedal, push rod pushes the piston in master cylinder so that fluid in the hydraulic line is drained into release
cylinder.
Specifications

Clutch Pedal Fixing Nut 25 ± 3
Clutch Pressure Plate 23 ± 2
Release Fork Fixing Bolt 32 ± 3
Clutch Master Cylinder Fixing Nut 25 ± 3
Hose Assembly II Bracket 10 ± 2
Clutch Pipe I 18 ± 2
Clutch Pipe Assembly II 18 ± 2
Clutch Release Cylinder Assembly 25 ± 3
Clutch Driven Disc Specifications

Clutch Driven Disc Standard Thickness 7.6 ± 0.3
Minimum rivet depth 0.8
19

19 - CLUTCH
Tools
Special Tool
Clutch Pressure Plate Installer
RCH0000018
General Tools
Vernier Caliper
RCH0000019
Digital Multimeter
RCH0000002
19

19 - CLUTCH
DIAGNOSIS & TESTING

HINT:
Recommended
Symptom Possible Cause
Repair Method
Engine mounting (loose) Tighten bracket
Clutch driven disc (oily) Clean or replace
Clutch driven disc (worn) Replace
Clutch chatters Clutch driven disc torsion spring
Replace
(damaged)
Clutch driven disc (glazed) Replace
Diaphragm spring tip (out of alignment) Replace
Clutch release bearing (worn, dirty or
Clean or replace
damaged)
Clutch is noisy
Clutch driven disc torsion spring
Replace
(damaged)
Clutch pedal free play (out of adjustment) Replace
Clutch driven disc (worn) Replace
Clutch slips
Diaphragm spring (damaged) Replace
Pressure plate (distorted) Replace
Flywheel (distorted) Replace
Clutch driven disc (improperly installed) Adjustment
Clutch driven disc runout (excessive) Clean or replace
Clutch driven disc lining (broken) Replace
Clutch disengages incompletely
Clutch driven disc (dirty or burned) Clean or replace 19
Clutch pedal free play (out of adjustment) Replace

19 - CLUTCH
ON-VEHICLE SERVICE
Clutch Switch
Removal
3. Remove the clutch switch.
a. Disconnect clutch switch connector (1) and remove
clutch switch (2).
1
2
RA13T190030
Inspection
Check for continuity between terminals when clutch switch is
turned on or off.
+ -
1 2
Specified
Switch Position
Condition
ON (not pushed) Continuity
OFF (pushed) No continuity
RA13T190040
Installation
19

19 - CLUTCH
Clutch Master Cylinder Assembly

Removal
WARNING
 Brake fluid in master cylinder is harmful to your skin, so be sure to wear protective gloves before
operation.
 Once brake fluid contacts with your skin, wash it off with water immediately.
CAUTION
 Be careful when removing clutch master cylinder from engine compartment. Incorrect operation may
damage hydraulic line, also cause clutch to separate improperly.
 DO NOT allow brake fluid to spray onto body surface. Brake fluid may damage painted surface. If any
brake fluid adheres to painted surface, wash it off with water immediately.

2. Drain the brake fluid .
HINT:
Collect brake fluid with a container.
5. Remove the battery tray bracket.
6. Remove the clutch master cylinder.
a. Disconnect the master cylinder inlet hose (arrow).
19
RA13T190041
b. Remove coupling bolt (arrow) between clutch pipe I

and clutch master cylinder.
RA13T190050

19 - CLUTCH
c. Remove cotter pin stopper plate (1), pull out center

pin (2), and remove clutch master cylinder push rod
from clutch pedal.
RA13T190060
d. Remove 2 fixing nuts (arrow) from clutch master

cylinder.
RA13T190070
Installation
WARNING
 Connect hose mark straight line end to reservoir outlet joint with straight line mark in Z farward direction,
and tighten it with elastic clamp (AQ60115). Connect hose end with cross mark to master cylinder inlet
joint and tighten it with elastic clamp (AQ60115). The cross mark should be in Z forward direction and
aligned with master cylinder parting line.
 Add brake fluid to "MAX".
 Perform bleeding procedure for hydraulic clutch and check brake fluid for leakage after installation.
19

19 - CLUTCH
Master Cylinder Inlet Pipe

Removal
WARNING
 Brake fluid in master cylinder is harmful to your skin, so be sure to wear protective gloves before
operation.
CAUTION
 Be careful when removing clutch master cylinder from engine compartment. Incorrect operation may
damage hydraulic line, also cause clutch to separate improperly.

2. Drain the brake fluid .
HINT:
Collect brake fluid with a container.
5. Remove the battery tray bracket.
6. Remove the clutch pipe I.
a. Remove coupling bolt (arrow) between clutch pipe I
and clutch master cylinder.
19
RA13T190050
b. Remove coupling bolt (arrow) between clutch pipe I

and hose assembly II.
RA13T190311
c. Remove pipe from single pipe clamp.

19 - CLUTCH
7. Remove the clutch hose assembly II.

a. Remove coupling bolt (1) between clutch pipe I and
hose assembly II.
Remove fixing nut (2) from clutch hose assembly II
2
bracket. 1
RA13T190321
b. Remove coupling bolt (1) between clutch hose II and

pipe II.
c. Remove holding spring (2) from clutch hose II, and
remove hose II from hole of transmission hose fixing
bracket.
1
RA13T190312
d. Remove the clutch hose II.

8. Remove the clutch pipe assembly II.
a. Remove coupling bolt (arrow) between clutch pipe II
and hose assembly II.
RA13T190180
b. Remove coupling bolt (arrow) between clutch pipe

assembly II and release cylinder.
19
RA13T190210
c. Remove the clutch pipe II.

19 - CLUTCH
Installation
WARNING
 Make sure to align master cylinder inlet pipe with installation hole, and retighten bolt to specified value.
Perform bleeding procedure for hydraulic clutch and check system line for leakage after installation.
 When installing fixing bracket to hose assembly II, make sure to insert hose bracket into battery
mounting bracket anti-rotating hole.
19

19 - CLUTCH
Clutch Release Cylinder Assembly

Removal
WARNING
 Brake fluid in release cylinder is harmful to your skin, so be sure to wear protective gloves before
operation.
CAUTION
 Collect brake fluid with a container when repairing.

 After replacing release cylinder, it is necessary to make sure that fluid level in brake reservoir is always
close to "MAX" mark.
 DO NOT allow brake fluid to spray onto body surface. Brake fluid may damage the painted surfaces. If
any brake fluid adheres to painted surface, wash it off with water immediately.
CAUTION

 Check if safety lock of lift is locked when repairing under the vehicle.
2. Remove coupling bolt (arrow) between clutch pipe

assembly II and release cylinder.
19
RA13T190210
3. Remove fixing bolt (1) between clutch release cylinder

and transmission.
Disconnect the clutch release cylinder connector (2).
RA13T190220
4. Remove the clutch release cylinder.

19 - CLUTCH
Installation
CAUTION
 Connect pipe joint of pipe assembly II to clutch release cylinder assembly, retighten it after installation.
 Make sure to align push rod of clutch release cylinder assembly with hole in transmission release fork,
and tighten bolt to specified value. Perform bleeding procedure for hydraulic clutch and check system
line for leakage after installation.
19

19 - CLUTCH
Clutch Pedal
Removal
3. Remove instrument panel lower left protector (See page 46-12).
4. Remove fixing nut from clutch master cylinder.
5. Remove the clutch pedal.
a. Disconnect clutch pedal and clutch master cylinder push rod (See page 19-10).
b. Remove the clutch switch (See page 19-8).
c. Remove 5 fixing nuts (arrow) from clutch.
RA13T190090
6. Remove the clutch pedal.
Installation
CAUTION
 Be sure to tighten nuts to specified value.

 Check fluid level in reservoir after installation.
19

19 - CLUTCH
Clutch Unit
Removal
1. Remove the transmission assembly (See page 17-20).
2. Remove the release fork fixing bolt (arrow).
RA13T190314
3. Pull out the clutch arm (arrow).
RA13T190320
4. Remove clutch fork and release bearing.
RA13T190315
5. Remove the wear bushing.

19
RA13T190326

19 - CLUTCH
6. Remove the clutch pressure plate bolts (arrow).

1
6
3
4
5
2
RA13T190318
7. Remove clutch pressure plate and clutch driven disc.
Inspection
1. Check the clutch driven disc.
a. Visually check clutch driven disc for dirt or glazing.
Clean or replace clutch driven disc as necessary.
b. Use a vernier caliper to measure thickness of clutch
driven disc.
Standard thickness: 7.3 ± 0.3 mm
Minimum rivet depth: 0.8 mm
If result is not as specified, replace the clutch driven disc.
RA13T190325
2. Check the clutch release bearing assembly.

a. Visually check surface of release bearing for dirt,
glazing or damage. Clean or replace release bearing
assembly as necessary.
b. Check that bearing operates smoothly by rotating the
sliding part of bearing (the side contacting with clutch).
Replace release bearing assembly if necessary.
RA13T190310
19 Installation
1. Insert a special tool into clutch driven disc, and insert it
into flywheel.
RA13T190319

19 - CLUTCH
2. Install clutch pressure plate and tighten bolts in order

1
6
3
4
5
2
RA13T190313
3. Install the wear bushing.
RA13T190324
4. Install clutch fork and release bearing.
RA13T190315
CAUTION
 Secure clutch fork in place, without being reversed.

 During installation, apply an appropriate amount grease to release bearing inner race.
19
5. Insert the clutch arm (arrow).
RA13T190323

19 - CLUTCH
6. Install the release fork fixing bolt (arrow).

RA13T190314
19

19 - CLUTCH
Bleeding Hydraulic Clutch

WARNING
 Brake fluid is harmful to your skin, so be sure to wear protective gloves before operation.
CAUTION
 Collect brake fluid with a container.

 Only use brake fluid recommended by Chery Automobile Co., Ltd, otherwise the lines may be subjected
to a severe corrosion.
 Brake fluid type should be DOT4.
HINT:
An assistant will be required to assist when bleeding hydraulic clutch.
2. Check fluid level in brake master cylinder, add DOT4 brake fluid as necessary and keep the cap open.
CAUTION
 Make sure that there is sufficient brake fluid in reservoir before bleeding.

4. Remove discharge port protective cap and connect a
clear plastic hose to bleeder screw, and submerge the
end of hose into clear container that is full of new brake
fluid.
19
RA13T190322
5. Release the discharge port.
RA13T190327

19 - CLUTCH
6. Depress clutch pedal until brake fluid is drained from discharge port.
 A container to collect brake fluid.
7. Depress clutch pedal and tighten discharge port.

8. Depress clutch pedal until there is pressure in clutch system.
9. Depress clutch pedal, then loosen discharge port and bleed air from fluid in brake master cylinder.
10.Repeat steps 6 to 9 for several times, until there is no air in hydraulic clutch system any more.
CAUTION
 Never drain brake fluid while bleeding hydraulic clutch.

 During bleeding, make sure brake fluid level is always at "MAX" mark.
11. Tighten discharge port, then remove discharge hose and replace discharge port dust cover.
12.Check brake fluid, and add DOT4 brake fluid to "MAX" as necessary, then tighten reservoir cap.
13.Inspect the clutch pedal stroke. If clutch pedal stroke is excessive or condition does not improve, it
indicates that some air is still kept in system. Bleed clutch again as necessary.
14.Test vehicle and make sure clutch operates normally and depressing feel is good.
19

DRIVE SHAFT
GENERAL INFORMATION 20-3 Inner Ball Cage 20-7
Description 20-3 Disassembly 20-7
Operation 20-4 Inspection 20-8
Specifications 20-4 Assembly 20-8
Outer Ball Cage 20-9
Disassembly 20-9
Drive Shaft Assembly 20-5
Inspection 20-10
Removal 20-5
Assembly 20-10
Installation 20-6
20

20

20 - DRIVE SHAFT
GENERAL INFORMATION
DRIVE SHAFT
Description
5
6
7
12
8 13
9
14
10
11
20
RA13T200010
1 - Nut 2 - Outer Ball Cage

3 - Outer Dust Boot Clamp 4 - Outer Dust Boot
5 - Outer Dust Boot Clamp 6 - Right Drive Shaft
7 - Left Drive Shaft 8 - Inner Dust Boot Clamp
9 - Inner Dust Boot 10 - Inner Dust Boot Clamp
11 - Tripod 12 - Positioning Snap Spring
13 - Inner Ball Cage 14 - Set Ring

20 - DRIVE SHAFT
Operation
Drive shaft is a solid shaft for torque transmission between differential and drive wheels. Generally, the inner
end of drive shaft is connected with drive shaft gear by spline, and the outer end is connected with wheel hub.
Drive shaft transmits torque from differential to wheels, thus rotating the wheels to run vehicle.
Specifications

Drive Shaft Fixing Nut 240 ± 20
Coupling Nut Between Steering Knuckle and Control
120 ± 10
Arm Ball Pin
20

20 - DRIVE SHAFT
ON-VEHICLE SERVICE
Drive Shaft Assembly
Removal
HINT:
3. Remove the left drive shaft.
a. Using a nut punch and a hammer, loosen staked part
of nut.
RA13T200020
CAUTION
 Loosen staked part of nut completely, otherwise it will damage threads of drive shaft assembly.
b. Remove front drive shaft assembly locking nut and

washer (arrow) while applying brake firmly.
RA13T200030 20
c. Remove coupling nut between steering knuckle and
control arm ball pin.
RA13T200050

20 - DRIVE SHAFT
d. Disconnect steering knuckle from control arm ball pin.

Move drive shaft from steering knuckle.
RA13T200060
e. Pry out the drive shaft.
RA13T200070
f. Remove the set ring.
RA13T200210
Installation
CAUTION
 DO NOT damage constant velocity universal joint dust boot.

 DO NOT use excessive force to pull drive shaft, to prevent inner constant velocity universal joint from
20 dropping.
 Use crowbar carefully to prevent damage to oil seal.
 Adjust wheel alignment if necessary.

20 - DRIVE SHAFT
Inner Ball Cage

Disassembly
HINT:
Use same disassembly and assembly procedures for left and right drive shaft assemblies.
CAUTION
 DO NOT put matchmarks on rotating surface of rotary drum.

 Operate carefully to prevent dust boot from being damaged.
1. Remove the drive shaft assembly (See page 20-5).

2. Remove the inner ball cage dust boot clamp.
a. Using needle nose pliers, remove the inner ball cage
dust boot clamps.
RA13T200080
3. Remove the inner ball cage.

a. Separate dust boot from inner ball cage in direction of
arrow.
20
RA13T200090
b. Remove inner ball cage in direction of arrow, and

place it on a piece of clean cloth.
RA13T200100

20 - DRIVE SHAFT
4. Remove the tripod.

a. Using snap spring calipers, remove the tripod
positioning snap spring.
RA13T200110
b. Put matchmarks on tripod and drive shaft, and

remove tripod.
Matchmark
RA13T200120
5. Remove the dust boot.

a. Wrap tape around drive shaft spline, and remove dust
boot.
7DSH
RA13T200130
b. Remove the tape.
Inspection
1. Check if drive shaft spline is in good condition. If it is deformed or damaged, replace it.
2. Check if dust boot is in good condition. If it is scratched or damaged, replace it.
20 3. Check if tripod positioning snap spring is deformed. If it is deformed, replace it.
Assembly
CAUTION
 Refill grease during installation.


20 - DRIVE SHAFT
Outer Ball Cage

Disassembly
HINT:
Use same disassembly and assembly procedures for outer ball cage of left and right drive shaft assemblies.
1. Remove the drive shaft assembly.
2. Remove the outer ball cage dust boot outer clamp.
a. Using a screwdriver, pry out striker of outer ball cage
dust boot outer clamp and remove outer ball cage
dust boot outer clamp.
RA13T200140
3. Remove the outer ball cage dust boot inner clamp.

a. Using a screwdriver, pry out striker of outer ball cage
dust boot inner clamp and remove outer ball cage
dust boot inner clamp.
RA13T200150
4. Remove the outer ball cage.

a. Carefully slide outer dust boot into inner ball cage side
in direction of arrow.
20
RA13T200160
b. Put matchmarks (1) on the area at same height as

drive shaft assembly (2) and the edge of outer ball
2
cage (3) for correct installation. 1
RA13T200170

20 - DRIVE SHAFT
c. Wrap drive shaft assembly with a piece of cloth, and

secure it in a vise so that it does not wobble. Strike 1
outer ball cage (1) forcefully with a hammer, and
remove outer ball cage (1).
RA13T200180
5. Remove left drive shaft from vise.

6. Remove the retaining ring (1).
RA13T200190
7. Remove the outer ball cage dust boot.

a. Wrap tape around drive shaft spline, and remove dust
boot.
7DSH
RA13T200200
b. Remove the tape.
Inspection
1. Check if drive shaft spline is in good condition. If it is deformed or damaged, replace it.
2. Check if dust boot is in good condition. If it is scratched or damaged, replace it.
20
Assembly
CAUTION
 Refill grease during installation.

 Install clamps with new ones.

DIFFERENTIAL
Description 21-3 Final Drive Driven Gear 21-7
Tools 21-5 Differential Bearing 21-8
Removal 21-8
Installation 21-8
Differential Gear Clearance 
Inspection 21-6 Differential Planetary Gear 21-9
Removal 21-9
Installation 21-9
Differential Components Inspection 21-9
21

21

21 - DIFFERENTIAL
GENERAL INFORMATION
DIFFERENTIAL
Description
1
2
3
5
14
6
7
8
10
11
12
13 21
RA13T210010

21 - DIFFERENTIAL
1 - Differential Tapered Roller Bearing Outer Race 2 - Differential Tapered Roller Bearing
3 - Final Drive Driven Gear 4 - Differential Case
5 - Dowel Pin 6 - Odometer Drive Gear
7 - Differential Tapered Roller Bearing 8 - Differential Tapered Roller Bearing Outer Race
9 - Planetary Gear Washer 10 - Planetary Gear
11 - Planetary Gear Shaft 12 - Drive Shaft Gear
13 - Drive Shaft Gear Washer 14 - Bolt
Differential case contains 2 drive shaft gears, planetary gear shaft and 2 planetary gears. Final drive driven
gear is linked up with the differential case by bolts. Planetary gear shaft, which is fixed on differential case,
drives planetary gears to rotate when differential operates, thus driving the drive shaft gears to turn. Drive
shaft gears are connected with drive shaft to transmit effort to wheels.
Operation
 When driving on a bumpy road or turning, the travel distance of outside wheels is longer than that of inside
wheels, so the speed of outside wheels is faster, which breaks the balance of vehicle drive train.
 The planetary gear mechanism in differential can transmit the speed difference between outside and inside
wheels via drive shaft when rotating. It forces the planetary gears to rotate, thus allowing inside and
outside wheels to spin at two different speeds in order to balance the speed difference and keep vehicle
moving smoothly.
 Final drive is a component to reduce the rotation speed and increase the torque of drive train.
Specifications

Final Drive Driven Gear Bolt 137 ± 3
Clearance Specification
Description Acceptable Range (mm)

Clearance Between Differential Case and Planetary
0.025 - 0.150
Gear
21

21 - DIFFERENTIAL
Tools
Special Tools
Bearing Remover
RCH0000011
Punch
RCH0000015
General Tools
20
10
30
0
40
90
50

80
60
70
RCH0000023
Hydraulic Press
RCH0000012
21

21 - DIFFERENTIAL
DIAGNOSIS & TESTING

Differential Gear Clearance Inspection
Inspection Method
1. Remove the differential.
2. Check clearance of differential drive shaft gear (2) with a
dial indicator (1).
Gear clearance: 0.025 - 0.150 mm 1
2 RA13T210020
CAUTION
 If clearance is not as specified, replace and adjust the drive shaft gear washer.
 After replacing drive shaft gear washer, measure and adjust the clearance again to ensure that it is as
specified.
21

21 - DIFFERENTIAL
ON-VEHICLE SERVICE
Final Drive Driven Gear
Removal
1. Remove the differential (See page 17-26).
2. Hold differential in a vise.
3. Remove the final drive driven gear bolts.
RA13T210030
Installation
CAUTION
 Apply seal gum to the bolts during installation.
21

21 - DIFFERENTIAL
Differential Bearing
Removal
2. Remove the differential bearing.
a. Using a hydraulic press (1), separate bearing (2) from
differential.
1
2
RA13T210040
Installation
1. Install the differential bearing.
a. Using a hydraulic press, press bearing (1) into
differential.
RA13T210050
21

21 - DIFFERENTIAL
Differential Planetary Gear

Removal
2. Remove the differential planetary gear.
a. Tap out dowel pin (2) with a punch (1).
1
RA13T210060
b. Remove planetary gear shaft (1), planetary gear (2)

and drive shaft gear (3).
1
3
2
RA13T210070
Installation
CAUTION
 Adjust clearance until gear clearances of both sides are the same during installation.
 Drive shaft gears and planetary gears should operate normally after tapping in dowel pin.
Differential Components Inspection

1. Clean all the components.
2. Check following components for wear:
 Final drive driven gear
21
 Planetary gear washer
 Drive shaft gear
 Planetary gear
 Planetary gear shaft
 Drive shaft gear washer

- MEMO -

AXLE
GENERAL INFORMATION 22-3 Removal 22-15
Description 22-3 Installation 22-16
Specifications 22-5 Front Sub Frame Welding Assembly 22-17
Installation 22-19
Rear Hub Bearing Assembly 22-20
Front Steering Knuckle 22-9 Installation 22-21
Removal 22-9 Rear Hub Shaft 22-22
Disassembly 22-11 Removal 22-22
Assembly 22-12 Rear Shaft Assembly 22-24
Front Hub Assembly 22-14 Installation 22-25
22

22

22 - AXLE
GENERAL INFORMATION
AXLE
Description
Front Axle
×3
×3
6
3
×4
4 2
1
×3
×2
×2
×3
RA13T220010
1 - Front Left Control Arm Ball Pin Assembly 2 - Front Left Control Arm Assembly
3 - Front Sub Frame Welding Assembly 4 - Rubber Bushing
5 - Front Right Control Arm Assembly 6 - Front Right Control Arm Ball Pin Assembly
7 - Front Right Steering Knuckle
22

22 - AXLE
Rear Axle
2 3
5 6
7
11
8 9
×3
10
×3
RA13T230020
1 - Rear Right Brake Disc 2 - Rear Right Hub Bearing

3 - Rear Right Brake Bottom Plate Assembly 4 - Rear Right Hub Shaft
5 - Rear Shaft Assembly 6 - Rear Left Hub Shaft
7 - Rear Left Brake Bottom Plate Assembly 8 - Rear Left Hub Bearing
9 - Rear Left Brake Disc 10 - Rear Left Shaft Bracket Assembly
11 - Rear Right Shaft Bracket Assembly
Axles are connected to the integral body through suspensions, and wheels are installed at both ends. Its
function is to transmit force in all directions between integral body and wheels.
22

22 - AXLE
Specifications

Front Drive Shaft Assembly Locking Nut 330 ± 20
Fixing Bolt Between Front Dust Guard and Front
9 ± 11
Coupling Bolt Between Front Wheel Speed Sensor
10 ± 1
and Front Steering Knuckle Assembly
Assembly
100 ± 10
110 ± 10
110 ± 10
Coupling Bolt Between Front Stabilizer Bar
20 ±2
Assembly and Front Sub Frame Welding Assembly
100 ± 10
180 ± 10
180 ± 10
Assembly Lower Body
Coupling Nut Between Rear Mounting Cushion
Assembly Lower Body
Assembly Lower Body and Front Sub Frame 105 ± 5
Welding Assembly
Rear Shaft Assembly Locking Nut 240 ± 20
22
Coupling Bolt Between Rear Wheel Speed Sensor
10 ± 1
and Rear Steering Knuckle Assembly
Coupling Bolt Between Rear Brake Line Fixing
18 ± 2
Bracket and Rear Steering Knuckle Assembly
Coupling Bolt Between Parking Brake Cable
Assembly Fixing Bracket and Rear Steering Knuckle 10 ± 1.5
Assembly

22 - AXLE

Coupling Bolt Between Lower Part of Rear Shock
Absorber Assembly and Rear Steering Knuckle 160 ± 10
Assembly
90 ± 5
160 ± 10
160 ± 10
160 ± 10
Coupling Bolt Between Rear Shaft Welding
135 ± 10
Assembly and Body
Clearance Specifications
Description Specified Condition (mm)

Front Hub Bearing Looseness 0.032-0.057
Front Hub Bearing Runout 0.02
Rear Hub Bearing Looseness 0.035-0.055
Rear Hub Bearing Runout 0.05
Tools
Special Tool
Ball Pin Separator
RCH0000024
22

22 - AXLE
General Tools
20
10
30
0
40
90
50
80
60
70
RCH0000023
RCH0000005
Hydraulic Press
RCH0000012
Bearing Remover
RCH0000011
Engine Equalizer
22
RCH0000026

22 - AXLE
DIAGNOSIS & TESTING

HINT:

Tire (worn or improperly inflated) 24-3
Front wheel alignment (incorrect) 23-33
Rear wheel alignment (incorrect) 23-33
Pulls Front hub bearing (loose or worn) 22-16
Rear hub bearing (loose or worn) 22-21
Steering gear (misaligned or damaged) 29-21
Suspension component (worn) 23-9
Wheel (imbalanced) 24-10
Front shock absorber assembly (stuck or damaged) 23-9
Front wheel shimmy Front wheel alignment (incorrect) 23-33
Control arm assembly ball pin (stuck or damaged) 23-19
Front hub bearing (loose or worn) 22-16
Wheel (imbalanced) 23-33
Rear wheel shimmy Rear shock absorber assembly (stuck or damaged) 23-31
Rear hub bearing (loose or worn) 22-21
22

22 - AXLE
ON-VEHICLE SERVICE
Front Steering Knuckle
Removal
HINT:
WARNING

 Check if safety lock of lift is locked when repairing chassis parts.
 It is not permitted to weld or modify bearing parts of wheel suspension and guide parts of wheel.
 When removing chassis parts, replace self-locking nuts and rusted nuts for safety.

2. Remove the front drive shaft assembly locking nut.
a. Using a nut punch and a hammer, loosen staked part
of nut.
RA13T220030
CAUTION
 Loosen staked part of nut completely, otherwise it will damage threads of drive shaft assembly.
b. Remove front drive shaft assembly locking nut and

washer (arrow) while applying brake securely.
22
RA13T220040

22 - AXLE
3. Remove the front left brake caliper assembly (See page 26-27).
CAUTION
 Place front brake caliper assembly to a proper position after removal, and be careful not to extend front
brake hose excessively.
4. Remove the front left brake disc (See page 26-28).

5. Remove the front left steering knuckle assembly.
a. Remove coupling nut (arrow) between front left
control arm assembly ball pin and front left steering
knuckle assembly.
RA13T220050
b. Remove 3 fixing bolts (arrow) between front left dust

guard and front left steering knuckle assembly, and
remove front left dust guard (1).
RA13T220060
c. Remove coupling bolt (arrow) between front left wheel

speed sensor and front left steering knuckle
assembly, and disengage front left wheel speed
sensor carefully.
RA13T220070
d. Remove self-locking nut (arrow) between left steering

22 tie rod assembly ball pin and front left steering knuckle
assembly.
RA13T220080

22 - AXLE
e. Install ball pin separator (1), and tighten ball pin

1
separator bolt with a wrench (2) to separate steering
tie rod ball pin from steering knuckle assembly.
RA13T220090
f. Remove 2 coupling bolts and nuts (arrow) between

front left shock absorber assembly and front left
steering knuckle assembly.
RA13T220100
g. Disengage left drive shaft and remove front left steering knuckle assembly.
Disassembly
1. Remove front steering knuckle assembly, front hub and front hub bearing.
a. Remove front hub bearing retainer (arrow) with snap
spring pliers.
RA13T220110
b. Place front steering knuckle assembly on a hydraulic

press, install bearing remover and adapter, and press
out front hub with hydraulic press.
22
RA13T220120

22 - AXLE
c. Remove the front hub carefully.
RA13T220130
d. Place steering knuckle assembly on a hydraulic press,

install bearing remover and adapter, and press out
front hub bearing with hydraulic press.
RA13T220140
e. Remove the front hub bearing carefully.
RA13T220150
Inspection
1. Check the front steering knuckle and dust guard.
a. Check front steering knuckle for wear, cracks, deformation or damage. Replace as necessary.
b. Check dust guard for dirt, wear, cracks, deformation or damage. Replace as necessary.
Assembly
CAUTION
22  Please note that opening of retainer must face opening of front wheel speed sensor, when installing front
hub bearing retainer.

22 - AXLE
Installation
CAUTION
 Be sure to tighten coupling bolts and nuts to specified torque.

 Check wheel alignment after installation is completed. Adjust wheel alignment to standard range as
necessary.
22

22 - AXLE
Front Hub Assembly

1. Remove the front wheel (See page 24-7).
2. Remove the front brake caliper assembly (See page 26-27).
3. Remove the front brake disc (See page 26-28).
4. Check the front hub bearing looseness.
a. Check looseness near the center of front hub
assembly with a dial indicator.
Maximum looseness: 0.032 - 0.057 mm
RA13T220160
CAUTION
 Ensure that dial indicator is perpendicular to measurement surface.
If looseness exceeds maximum value, replace front hub bearing.

5. Check the front hub bearing runout.
a. Check runout of front hub assembly surface with a dial
indicator.
Maximum runout: 0.02 mm
RA13T220170
If runout exceeds maximum value, replace front hub bearing.

6. Install the front brake disc (See page 26-28).
7. Install the front brake caliper assembly (See page 26-28).
8. Install the front wheel (See page 24-7).
22

22 - AXLE
Removal
WARNING

HINT:
2. Remove the front drive shaft assembly locking nut (See page 22-9).
3. Remove the front left brake caliper assembly (See page 26-27).
4. Remove the front left brake disc (See page 26-28).
5. Remove the front left steering knuckle assembly (See page 22-10).
6. Remove the front hub assembly.
a. Remove front hub bearing retainer (arrow) with snap
spring pliers.
RA13T220110
b. Place front steering knuckle assembly on a hydraulic

press, install bearing remover and adapter, and press
out front hub with hydraulic press.
RA13T220120
c. Remove the front hub carefully. 22
RA13T220130

22 - AXLE
d. Place steering knuckle assembly on a hydraulic press,

install bearing remover and adapter, and press out
front hub bearing with hydraulic press.
RA13T220140
e. Remove the front hub bearing carefully.
RA13T220150
Installation
CAUTION
 Please note that opening of retainer must face opening of front wheel speed sensor, when installing front
hub bearing retainer.
 Check that hub assembly rotates smoothly and there is no seizuring after installation.
22

22 - AXLE
Front Sub Frame Welding Assembly

Removal
WARNING

 When removing front sub frame welding assembly, it is necessary to securely support engine and
transmission assembly with engine equalizer to avoid damage.

2. Remove the front sub frame welding assembly.
a. Using an engine equalizer, support engine and transmission assembly securely.
b. Disengage exhaust pipe fixing rubber lifting eyes
(arrow) from front sub frame welding assembly.
RA13T220180
c. Remove 4 fixing bolts (arrow) between power steering

gear with tie rod assembly and sub frame.
RA13T220210
22

22 - AXLE
d. Remove 2 fixing bolts (arrow) between engine right

mounting cushion and sub frame.
RA13T220190
e. Remove fixing bolt (arrow) between transmission left

mounting cushion and left mounting bracket.
RA13T220200
f. Remove 4 fixing bolts (arrow) between sub frame and

and body.
(Tightening torque for front bolt: 135 ± 5 N·m)
(Tightening torque for rear bolt: 160 ± 16 N·m)
RA13T220220
22

22 - AXLE
g. Remove 4 stabilizer bar fixing nuts from sub frame.
RA13T220230
h. Using a transmission carrier, support front sub frame

welding assembly.
RA13T220240
3. Remove the front control arm assembly (See page 23-17).

4. Remove the front sub frame welding assembly.
Installation
CAUTION

necessary.
22

22 - AXLE
Rear Hub Bearing Assembly

1. Remove the rear wheel (See page 24-7).
2. Remove the rear brake caliper assembly (See page 26-38).
3. Remove the rear brake disc (See page 26-39).
4. Check the rear hub bearing looseness.
a. Check looseness near the center of rear hub bearing
with a dial indicator.
Maximum looseness: 0.035 - 0.055 mm
RA13T220250
CAUTION
If looseness exceeds maximum value, replace rear hub bearing assembly.

5. Check the rear hub bearing runout.
a. Check runout of rear hub bearing assembly surface
with a dial indicator.
Maximum runout: 0.05 mm
RA13T220260
CAUTION
22
If runout exceeds maximum value, replace rear hub bearing assembly.
6. Install the rear brake disc (See page 26-39).
7. Install the rear brake caliper assembly (See page 26-38).
8. Install the rear wheel (See page 24-7).

22 - AXLE
Removal
HINT:
1. Remove the rear left wheel (See page 24-7).
2. Remove the rear left brake caliper assembly (See page 26-38).
3. Remove the rear left brake disc (See page 26-39).
4. Remove the rear left hub bearing assembly.
a. Using a flat tip screwdriver wrapped with protective
tape, carefully pry out rear left bearing end cover
(arrow).
RA13T220270
b. Remove the rear shaft assembly left locking nut

(arrow).
RA13T220280
c. Slightly wiggle rear left hub bearing assembly and pull

it out.
RA13T220290
Installation
22
CAUTION
 Be sure to tighten locking nut to specified torque.

 Make sure that rear hub assembly rotates smoothly and freely after installation.

22 - AXLE
Rear Hub Shaft

Removal
WARNING

HINT:
2. Remove coupling bolt (arrow) between rear wheel speed
sensor and rear steering knuckle assembly, and
disengage rear wheel speed sensor.
RA13T220310
3. Remove the rear brake caliper assembly (See page 26-27).

4. Remove the rear brake disc (See page 26-39).
5. Remove the rear hub bearing assembly (See page 26-39).
6. Remove the rear hub assembly.
a. Remove 4 fixing bolts (arrow) between rear hub shaft
and brake plate assembly.
22 RA13T220300
b. Remove wallboard and rear hub shaft.

22 - AXLE
Installation
CAUTION

 Check and adjust wheel alignment after installation is completed. Adjust wheel alignment to standard
range as necessary.
22

22 - AXLE
Rear Shaft Assembly

Removal
WARNING

1. Remove the rear wheel. (See page 24-7).

2. Drain the brake fluid . (See page 26-15).
3. Remove the wheel speed sensor (See page 22-22).
4. Remove the parking brake cable. (See page 27-13).
5. Remove the rear brake disc. (See page 26-39).
6. Remove the rear hub shaft assembly. (See page 22-22).
7. Remove the rear shaft assembly.
a. Remove coupling bolt and nut (arrow) between rear
left shock absorber assembly and rear shaft
assembly. Use same removal procedure for right side.
RA13T220320
b. Remove 2 coupling bolts (arrow) between rear brake

pipe and rear brake hose, and remove rear brake pipe 1
and rear brake hose. 2
RA13T220330
22 c. Install transmission carrier to support rear shaft.
RA13T220340

22 - AXLE
d. Remove coupling bolt (arrow) between left of rear

shaft assembly and body. Use same removal
procedure for right side.
RA13T220350
e. Remove the rear shaft assembly.
Installation
CAUTION

 Bounce vehicle up and down several times to stabilize rear suspension after installation.
22

- MEMO -

SUSPENSION
Description 23-3 Front Stabilizer Link Assembly 23-25
Installation 23-26
Rear Shock Absorber Assembly 23-27
Removal 23-28
Front shock absorber assembly 23-9 Inspection 23-31
On-vehicle Inspection 23-10 Assembly 23-31
Disassembly 23-12 Disposal 23-32
Inspection 23-15
WHEEL ALIGNMENT 23-33
Assembly 23-15
Description 23-33
Installation 23-15
Disposal 23-16
Inspection before Wheel Alignment 23-34
Front Control Arm Assembly 23-17
Front Wheel Camber 23-35
Removal 23-17
Inspection 23-35
Installation 23-18
Adjustment 23-35
Front Control Arm Ball Pin Assembly 23-19
Front Wheel Toe-in 23-36
Removal 23-19
Inspection 23-36
Inspection 23-19
Adjustment 23-36
Installation 23-20
Kingpin Caster & Kingpin Inclination 23-37
Front Stabilizer Bar Assembly 23-21
Rear Wheel Camber & Rear Wheel 
Removal 23-21 Toe-in 23-37
Inspection 23-24
23

23

23 - SUSPENSION
GENERAL INFORMATION
SUSPENSION
Description
Front Suspension
2
×2
×2 ×2
3
13 4 ×2
×3
5
6
10
×3
12
9
×4
11 8
7
×3
×2
×2
×3
RA13T230010
1 - Front Shock Absorber Assembly 2 - Front Right Stabilizer Link Assembly

23
3 - Horizontal Stablizer Bar Bracket 4 - Front Stabilizer Bar Assembly
5 - Front Stabilizer Bar Bushing 6 - Front Left Stabilizer Link Assembly
7 - Front Left Control Arm Ball Pin Assembly 8 - Front Left Control Arm Assembly
9 - Front Sub Frame Assembly 10 - Front Right Control Arm Assembly
11 - Control Arm Front Bushing 12 - Front Right Control Arm Ball Pin Assembly
13 - Front Steering Knuckle

23 - SUSPENSION
Front suspension of this model uses Macpherson independent suspension (height is non-adjustable), which is
equipped with cylindrical coil spring, double action telescopic shock absorber with lateral stabilizer. Front
suspension has driving and steering functions. Upper end of suspension connects with vehicle body, and
lower end with front steering knuckle. Sub frame is connected with the body by bolts, thus improving driving
stability and safety.
Rear Suspension
1
12
2 3
13
5 6
7
11
8 9
×3
10
×3
RA13T230020
1 - Rear Right Brake Disc 2 - Rear Right Hub Bearing

3 - Rear Right Brake Bottom Plate Assembly 4 - Rear Right Hub Shaft
5 - Rear Shaft Assembly 6 - Rear Left Hub Shaft
7 - Rear Left Brake Bottom Plate Assembly 8 - Rear Left Hub Bearing
9 - Rear Left Brake Disc 10 - Rear Left Shaft Bracket Assembly
11 - Rear Right Shaft Bracket Assembly 12 - Rear Right Shock Absorber Assembly
13 - Rear Left Shock Absorber Assembly
23 Rear suspension of this model uses torsion beam, half-independent suspension (height is non-adjustable),
which is equipped with cylindrical coil spring, double action telescopic shock absorber without lateral
stabilizer. Upper end of suspension connects with vehicle body, and lower end with rear shaft assembly, thus
ensuring the driving stability and safety.

23 - SUSPENSION
Specifications

Coupling Nut Between Front Stabilizer Link
50 ± 5
Assembly and Front Shock Absorber Assembly
110 ± 10
110 ± 10
50 ± 5
Assembly and Body
100 ± 10
Coupling Bolt Between Front Part of Front Control
Assembly
Coupling Nut Between Front Part of Front Control
Assembly
Coupling Bolt Between Rear Part of Front Control
Assembly
Coupling Nut Between Rear Part of Front Control
Assembly
Coupling Nut Between Front Control Arm Ball Pin
50 ± 5
Coupling Bolt Between Front Control Arm Ball Pin
50 ± 5
Coupling Nut Between Front Stabilizer Bar Assembly
50 ± 5
and Front Stabilizer Link Assembly
100 ± 10
180 ± 10
180 ± 10
Assembly and Vehicle Body
50 ± 5 23
160 ± 10
Assembly and Rear Shaft Assembly
Coupling Bolt Between Rear Shaft Assembly and
90 ± 5
Rear Support Assembly
Steering Tie Rod Locking Nut 50 ~ 60
Steering Wheel Locking Nut 35 ± 3

23 - SUSPENSION
Tools
Special Tools
Spring Compressor
RCH0000021
Shock Absorber Nut Remover
RCH0000022
General Tools
RCH0000005
Engine Equalizer
RCH0000026
23

23 - SUSPENSION
DIAGNOSIS & TESTING

HINT:
Front Suspension
Symptom Suspected Area See Page

Front tire (worn or improperly inflated) 24-5
Control arm ball pin assembly (loose) 23-19
Vehicle pulls Steering tie rod (loose or worn) 22-10
Front hub bearing (excessively worn) 22-14
Front suspension components (excessively worn or
23-10
deformed)
Vehicle (overloaded) -
Front coil spring (too soft) 23-14
Droop Front shock absorber assembly (worn or damaged) 23-12
Front suspension components (excessively worn or
23-9
deformed)
Sways/pitches Front stabilizer bar assembly (bent or broken) 23-24
Front shock absorber assembly (worn or damaged) 23-12
Front wheel (out of balance) 24-10
Front shock absorber assembly (worn or damaged) 23-12
Wheel shimmy Front wheel alignment (incorrect) 23-33
Control arm ball pin assembly (loose) 23-19
Front hub bearing (excessively worn) 22-14
Front tire (improperly inflated) 24-5
Droop
Front wheel alignment (incorrect) 23-33 23
Front shock absorber assembly (worn or deformed) 23-12
Front suspension components (worn or deformed) 23-10

23 - SUSPENSION
Rear Suspension

Rear tire (worn or improperly inflated) 24-5
Vehicle pulls
Rear hub bearing (excessively worn) 22-21
Rear suspension components (worn or deformed) 23-4
Vehicle (overloaded) -
Rear coil spring (too soft) 23-30
Droop Rear shock absorber assembly (worn or damaged) 23-27
Rear suspension components (excessively worn or
23-4
deformed)
Sways/pitches
Rear shock absorber assembly (worn or deformed) 23-28
Rear wheel (out of balance) 24-10
Wheel shimmy Rear shock absorber assembly (worn or damaged) 23-28
Rear hub bearing (worn) 22-21
Rear tire (improperly inflated) 24-5
Droop Rear wheel alignment (incorrect) 23-33
Rear suspension components (worn or deformed) 23-4
23

23 - SUSPENSION
ON-VEHICLE SERVICE
Front shock absorber assembly
2
8
10
6
RA13T230030
1 - Front Shock Absorber Cover Cap 2 - Front Strut Upper Connecting Plate Assembly (w/
Insulator)
3 - Bearing Assembly 4 - Front Spring Upper Tray
5 - Front Spring Upper Cushion 6 - Front Spring Upper Cushion
7 - Front Buffer Block 8 - Front Coil Spring
9 - Front Spring Lower Cushion 10 - Front Strut Assembly
Front suspension of this model uses Macpherson independent suspension (height is non-adjustable), which is
equipped with cylindrical coil spring, double action telescopic shock absorber with lateral stabilizer. Front 23
suspension has driving and steering functions. Upper end of suspension connects with vehicle body, and
lower end with front steering knuckle. Sub frame is connected with the body by bolts, thus improving driving
stability and safety.

23 - SUSPENSION
1. Check the front shock absorber assembly.
a. Park the vehicle on a level ground and bounce it up and down, then check if vehicle shakes up and
down when vehicle body bounds. If vehicle shakes up and down consecutively, shock absorber
assembly may be damaged and should be replaced.
2. Check front shock absorber assembly for leakage.
a. As shock absorber assembly operates frequently during vehilce driving, oil gas is formed due to
temperature rise of shock absorber, which then adheres to dust boot. This is a normal phenomenon,
and it is not necessary to replace the shock absorber assembly.
b. Shock absorber is designed with a thin layer of oil film on the surface of piston rod. While the shock
absorber is being compressed, the oil film will be scraped off by dust plate on shock absorber oil seal
and a small amount of oil will deposit on the upper part of oil seal at the same time. Due to high oil
permeability, the oil deposited on the upper part of oil seal spreads slowly from upper part of shock
absorber to lower part of shock absorber, thus forming a thin coat of oil film.
When any of the following conditions occurs:
 Oil film is between dust boot and spring seat.
 Oil traces in circumferential direction are even.
For above conditions, oil traces are formed through volatilization, so we can judge it as minor leakage.
This is a normal phenomenon, and it is not necessary to replace the shock absorber assembly.
c. If following conditions occur:
 Oil traces in circumferential direction are uneven.
 Oil traces reach lower connecting positions.
Above conditions indicate that there may be a leakage in shock absorber assembly, and it is necessary
to replace the shock absorber assembly.
d. If it is difficult to accurately judge if shock absorber assembly has leakage from appearance. Perform
road test after wiping off oil on the surface of malfunctioning shock absorber. Under normal road
conditions, drive vehicle for 5 to 10 minutes and perform inspection. If there are oil traces on the
surface of shock absorber assembly, it indicates that oil leakage exists, and it is necessary to replace
the shock absorber assembly.
Removal
WARNING

 Make sure that safety lock of lift has been locked, when removing and installing chassis parts.
 It is not permitted to weld or modify suspension bearing parts and guide parts.
 When removing and installing chassis parts, replace self-locking nuts and rusted nuts for safety.
 Operate carefully when removing and installing coil spring, to prevent spring from jumping out and
causing personal injury.
23 HINT:
 Use same procedures for right and left sides.
 Procedures listed below are for left side.

23 - SUSPENSION
2. Remove the front left shock absorber assembly.

stabilizer link assembly and front left shock absorber
assembly.
RA13T230040
b. Remove front brake pipe fixing bolt (1) from front left
shock absorber assembly, and detach front left wheel
speed sensor wiring harness (arrow).
RA13T230050
c. Remove 2 coupling bolts and nuts (arrow) between

front left shock absorber assembly and front left
steering knuckle assembly.
RA13T230060
d. Remove the front wiper arm (See page 36-29).

e. Remove the front windshield trim cover plate (See page 49-29).
f. Remove 3 coupling nuts (arrow) between front left
shock absorber assembly and vehicle body.
RA13T230070
23
g. Remove the front left shock absorber assembly with front coil spring.

23 - SUSPENSION
Disassembly
HINT:
1. Remove the front shock absorber cover cap.
a. Remove the front shock absorber cover cap (arrow)
from front left shock absorber assembly.
RA13T230080
2. Remove locking nut from front shock absorber assembly.

a. Using spring compressor and wrench, tighten the end
lever of spring compressor to compress front coil
spring.
RA13T230090
WARNING
 When removing front coil spring, compress spring until locking nut can be rotated. DO NOT compress
spring more than necessary to avoid spring damage and personal injury.
b. Hold the end of front left shock absorber assembly

lever with a shock absorber nut remover (1), and then
remove locking nut from front left shock absorber
assembly with a wrench (2).
2
23 RA13T230100

23 - SUSPENSION
3. Remove the front strut upper connecting plate assembly (w/ insulator).
a. Remove the front strut upper connecting plate
assembly (w/ insulator) (arrow) from the upper part of
front left shock absorber assembly.
RA13T230110
4. Remove the bearing assembly.

a. Remove the bearing assembly (arrow) from the upper
part of front left shock absorber assembly.
RA13T230120
5. Remove the front spring upper tray.

a. Remove the front spring upper tray (arrow) from the
upper part of front left shock absorber assembly.
RA13T230130
6. Remove the front spring upper cushion.

a. Remove the front spring upper cushion (arrow) from
the upper part of front left shock absorber assembly.
23
RA13T230140

23 - SUSPENSION
7. Remove the front coil spring.

a. Remove the front coil spring (1) with spring
compressor (arrow) from front left shock absorber
assembly.
1
RA13T230150
b. Slowly loosen the spring compressor, and carefully remove the front coil spring.
8. Remove the front dust boot.
a. Remove the front dust boot (arrow) from the upper
part of front left shock absorber assembly.
RA13T230160
9. Remove the front buffer block.

a. Detach the front buffer block (arrow) from front left
shock absorber assembly, and remove it.
RA13T230170
10.Remove the front spring lower cushion.

a. Remove the front spring lower cushion (arrow) from
the lower end of front left shock absorber assembly
strut.
23
RA13T230180

23 - SUSPENSION
Inspection
1. Check front shock absorber assembly
Manual check:
a. Install locking nut (1) to upper end of front shock
absorber assembly strut, and then install T-wrench (2)
or equivalent.
b. Compress and extend front shock absorber assembly
strut several times by hands in direction of arrow as
shown in illustration. Check that there is no abnormal
resistance or unusual sound during operation.If there
is any abnormality, replace the front shock absorber
assembly with a new one.
RA13T230180
2. Check the other components of front shock absorber assembly

a. Check front shock absorber cover cap, front spring upper cushion, front dust boot, front buffer block
and front spring lower cushion for cracks, wear or deformation. Replace as necessary.
b. Check front strut upper connecting plate assembly (w/ insulator) and bearing assembly for damage.
Replace as necessary.
c. Check front coil spring for wear, cracks or deformation. Replace as necessary.
Assembly
CAUTION
 Please note that opening of retainer must face opening of the front wheel speed sensor, when installing
front hub bearing retainer.
Installation
CAUTION

necessary.
23

23 - SUSPENSION
Disposal
CAUTION
 Shock absorber assembly contains nitrogen and oil, which are under negative pressure. Before handling,
be sure to wear goggles and release pressure inside the shock absorber assembly to avoid personal
injury.
1. Dispose the front shock absorber assembly.

a. Extend the front shock absorber assembly strut fully, and clamp it in a vise at an angle.
b. Using a drill or equivalent, make a hole slowly at area
A shown in illustration to discharge gas from front
shock absorber assembly.
A
RA13T230190
c. Gas discharged from shock absorber is colorless and harmless. Be careful when drilling, because iron
chips may fly out.
 Recycle disposed front shock absorber assembly according to local environmental regulations.
23

23 - SUSPENSION
Front Control Arm Assembly

Removal
WARNING

HINT:
2. Remove the front left control arm assembly.
knuckle assembly.
RA13T230200
CAUTION
 If it is difficult to remove control arm ball pin end from steering knuckle, detach ball pin by striking the end
of steering knuckle uniformly and slightly with a hammer or equivalent.
b. Remove coupling bolt and nut (arrow) between front

part of front left control arm assembly and front sub
frame welding assembly.
23
RA13T230210

23 - SUSPENSION
c. Remove coupling bolt and nut (arrow) between rear

part of front left control arm assembly and front sub
frame welding assembly.
RA13T230220
d. Remove the front left control arm assembly with ball pin.
Installation
CAUTION

 Make sure that ball pin assembly rotates smoothly and there is no seizuring after installation.
necessary.
23

23 - SUSPENSION
Front Control Arm Ball Pin Assembly

Removal
WARNING

HINT:
2. Remove the front left control arm ball pin assembly.
knuckle assembly.
RA13T230200
b. Remove 3 coupling bolts and nuts (arrow) between

front left control arm and front left control arm ball pin.
RA13T230230
c. Remove the front left control arm ball pin assembly.
Inspection
1. Check the control arm ball pin assembly.
a. Check control arm assembly ball pin bushing for wear, cracks, deformation, damage or grease leakage.
23
b. Check if control arm assembly ball pin rotates smoothly. Replace as necessary.

23 - SUSPENSION
Installation
CAUTION

 Make sure that ball pin assembly rotates smoothly and there is no seizuring after installation.
necessary.
23

23 - SUSPENSION
Front Stabilizer Bar Assembly

Removal
CAUTION

 It is not permitted to weld or modify suspension bearing parts.
 When lowering front sub frame welding assembly, you need to support engine and transmission
assembly securely with engine equalizer to avoid damage.

2. Remove the front stabilizer bar assembly.
a. Remove fixing nut (arrow) connecting stabilizer bar
and small connecting rod.
RA13T230310
b. Using an engine equalizer, support the engine and transmission assembly securely.
c. Detach exhaust pipe fixing rubber lugs (arrow) from
front sub frame welding assembly.
RA13T230240
d. Remove 4 fixing bolts (arrow) between power steering

with tie rod assembly and sub frame.
23
RA13T230250

23 - SUSPENSION
e. Remove 2 fixing bolts (arrow) between engine right

RA13T230260
f. Remove fixing bolt (arrow) between transmission left

RA13T230270
g. Remove 4 fixing bolts (arrow) between sub frame and

vehicle body.
RA13T230280
23

23 - SUSPENSION
h. Remove 4 fixing nuts between sub frame and

stabilizer bar.
RA13T230290
i. Using a transmission carrier, support front sub frame

welding assembly.
RA13T230300
j. Lower front sub frame welding assembly, remove front stabilizer bar assembly.
k. Detach left and right fixing clamps (arrow) from front
stabilizer bar assembly.
RA13T230320
l. Detach left and right rubber supports (arrow) from

front stabilizer bar assembly.
23
RA13T230330

23 - SUSPENSION
Inspection
1. Check front stabilizer bar assembly
a. Check fixing clamps of front stabilizer bar assembly for wear, cracks or damage.Replace as necessary.
b. Check rubber supports of front stabilizer bar assembly for dirt, wear, cracks, deformation or damage.
Installation
CAUTION
23

23 - SUSPENSION
Front Stabilizer Link Assembly

Removal
CAUTION

HINT:
2. Remove the front left stabilizer link assembly.
a. Hold lower end of front left stabilizer link assembly
with an inner hexagon wrench, and remove coupling
nut (arrow) between front left stabilizer bar assembly
and front left stabilizer link assembly with a fixing
wrench.
RA13T230310
b. Hold lower end of front left stabilizer link assembly

with an inner hexagon wrench, and remove coupling
nut (arrow) between front left stabilizer bar assembly
and front left stabilizer link assembly with a fixing
wrench.
RA13T230040
c. Remove the front left stabilizer link assembly.
Inspection
1. Check the front stabilizer link assembly.
a. Check front stabilizer link assembly bushing for wear, cracks, deformation, damage or grease leakage. 23
b. Check if the end of front stabilizer link assembly rotates smoothly. Replace as necessary.

23 - SUSPENSION
Installation
CAUTION

 Make sure that end of front stabilizer link assembly rotates smoothly and there is no seizuring after
installation.
23

23 - SUSPENSION
Rear Shock Absorber Assembly
8
9
7
6 10
11
5
12
4
13
14
1
3
15
16
2
RA13T230340
1 - Rear Shock Absorber Assembly 2 - Rear Dust Boot

3 - Shock Absorber Dust Cover 4 - Rear Coil Spring
5 - Rear Spring Upper Cushion 6 - Rear Spring Upper Tray
7 - Set Ring 8 - Supporting Sleeve
9 - Nut 10 - Bowl Washer
11 - Rubber Supporting Pad Ⅱ 12 - Rubber Supporting Pad Ⅰ
13 - Bowl Washer 14 - Nut
11 - Rubber Bushing 12 - Rubber Bushing
23
13 - Front Right Control Arm Assembly 14 - Front Right Control Arm Ball Pin Assembly
15 - Dish Washer 16 - Nut

23 - SUSPENSION
Removal
CAUTION

HINT:
1. Remove the tonneau cover assembly (See page 50-13).
2. Remove rear left speaker cover assembly from C-pillar upper protector (See page 39-37).
3. Remove the rear left lugguage compartment trim cover assembly.
4. Remove the rear left shock absorber assembly.
a. Remove the rear shock absorber cover cap (arrow).
RA13T230350
b. Remove the pressure plate fixing bolt (arrow) from

upper part of rear left shock absorber assembly.
RA13T230360
c. Remove the rubber cushion pressure plate fixing bolt

(arrow) from upper part of rear left shock absorber
assembly.
23
RA13T230370

23 - SUSPENSION
d. Remove the rubber cushion (arrow) from upper part of

rear left shock absorber assembly.
RA13T230380
e. Raise vehicle to an appropriate position.

f. Remove coupling bolt (arrow) between lower part of
rear left shock absorber assembly and rear left shaft
assembly.
RA13T230390
g. Remove the rear left shock absorber assembly.
Disassembly
1. Disassemble the rear left shock absorber assembly.
a. Remove the rear left shock absorber clamping nut
(arrow).
RA13T230400
b. Remove the rear left shock absorber spring upper tray

(arrow).
23
RA13T230410

23 - SUSPENSION
c. Remove front spring upper cushion (arrow) from

upper part of rear left shock absorber assembly.
RA13T230420
d. Remove the rubber cushion (arrow) from rear left

shock absorber assembly.
RA13T230430
e. Remove front dust boot and buffer block (arrow) from

the upper part of rear left shock absorber assembly.
RA13T230440
f. Remove coil spring (arrow) from rear left shock

absorber.
RA13T230450
g. Remove dust shim (arrow) from rear left shock

absorber.
23
RA13T230460

23 - SUSPENSION
Inspection
1. Check rear shock absorber assembly
Manual check:
a. Install nut (1) to upper end of rear shock absorber
assembly strut, and then install T-wrench (2) or 2
equivalent. 1
b. Compress and extend the rear shock absorber

assembly strut several times by hands in direction of
arrow as shown in illustration. Check that there is no
abnormal resistance or unusual sound during
operation. If there is any abnormality, replace the rear
shock absorber assembly with a new one.
RA13T230470
2. Check the other components of rear shock absorber assembly.

a. Check rear shock absorber cover cap, front spring upper cushion, front dust boot, front buffer block and
front spring lower cushion for cracks, wear or deformation. Replace as necessary.
b. Check front coil spring for wear, cracks or deformation. Replace as necessary.
Assembly
Installation
CAUTION

 Bounce vehicle up and down several times to stabilize rear suspension after installation.
23

23 - SUSPENSION
Disposal
1. Dispose the rear shock absorber assembly.
a. Extend the rear shock absorber assembly strut fully.
b. Using a drill, a hole between points A and B on the
strut as shown in illustration, to discharge gas from
rear shock absorber assembly.
A B
RA13T230480
c.
CAUTION
 Be careful when drilling, because metal chips may fly about. Always perform operations with proper
safety equipment to avoid personal injury.
 Gas discharged from shock absorber is colorless, odorless and nonpoisonous.
d. After discharging gas from rear shock absorber assembly, handle the rear shock absorber assembly
properly.
 Recycle disposed rear shock absorber assembly according to local environmental regulations.
23

23 - SUSPENSION
WHEEL ALIGNMENT
Description
CAUTION
 Be sure to perform wheel alignment procedures according to operating instructions of four-wheel

alignment device.
 Periodic maintenance and service for four-wheel alignment device should be performed.
In general, wheel alignment has the following 6 parameters:

1. Check the front wheel camber.
2. Check the front wheel toe-in.
3. Check the kingpin inclination.
4. Check the rear wheel camber.
5. Check the rear wheel toe-in.
If following components have been removed, installed or replaced, check and perform wheel alignment
procedures:
 Front control arm assembly
 Front control arm ball pin assembly
 Front steering knuckle
 Front shock absorber assembly
 Steering gear and steering tie rod
 Drive shaft
 Front sub frame welding assembly
 Rear torsion beam welding assembly
Specifications (Standard for Four-wheel Alignment Parameters)
Item Specified Value

Front Wheel Camber -0°36′ ± 30′
Front Wheel Toe-in -0.0° ± 3′
Front Wheel
Kingpin Inclination 12°17′ ± 45′
Kingpin Caster 4°03′ ± 45′
Rear Wheel Camber -1°30′ ± 30′
Rear Wheel
Rear Wheel Toe-in 0°10′ ± 20′
Sideways Sliding ≤ 3 m/km
23

23 - SUSPENSION

HINT:

Vehicle pulls
Wheel shimmy
Abnormal tire wear Front wheel alignment (incorrect) 23-33
Inspection before Wheel Alignment

1. Vehicle is in unloaded state.
2. Use a lift to support and raise vehicle to a proper height.
3. Check hub bearing for excessive clearance, and replace hub bearing as necessary.
4. Check suspension components, steering tie rod and ball pin for wear, deformation or damage. Replace
malfunctioning parts as necessary.
5. Check shock absorber assembly for proper operation.
6. Check if tire pressure is within specified range and adjust it to specified pressure as necessary.
Item Front Wheel Rear Wheel Spare Tire

Tire (Unloaded) 220 220 250
7. Check the rim and tire.

a. Visually check rim and tire for scratches, wear or damage.
b. Perform wheel dynamic balance procedures (See page 24-10).
23

23 - SUSPENSION
Front Wheel Camber

Incorrect front wheel camber will cause abnormal tire wear. Check and adjust front wheel camber as
necessary.
In normal conditions, it is not necessary to adjust camber after assembling the independent suspension and
wheel steering knuckle. If wheel camber is not within the tolerance due to other reasons, adjust through the
coupling bolt between independent suspension and steering knuckle.
Specified Value for Front Wheel Camber

Front Wheel Camber -0°36′ ± 30′
Inspection
1. Visually check driving system components for deformation and damage before adjustment. Replace
deformed or damaged components as necessary.
2. Install wheel alignment device onto front wheel, and perform inspection procedures according to operating
instructions for wheel alignment device.
Adjustment
1. If front wheel camber is not within the tolerance of
specified value, loosen the coupling bolts (1) between
front shock absorber assembly and front steering
knuckle, and move wheel to adjust.
1
2. Tighten coupling bolts to specified torque after adjusting
front wheel camber.
RA13T230490
23

23 - SUSPENSION
Front Wheel Toe-in

Incorrect front wheel toe-in will cause wheel pull and abnormal tire wear. Check and adjust front wheel toe-in
as necessary.
If front wheel toe-in is not within the tolerance due to other reasons, adjust the length of steering tie rod to
return the toe-in to specified value.
Specified Value for Front Wheel Toe-in

Front Wheel Toe-in 0° ± 3′
Inspection
1. Perform inspection with four-wheel alignment device (perform inspection procedures referring to operating
instructions for four-wheel alignment device).
2. Manual check:
a. Park vehicle on level ground, check if front tire pressure is within the specified range and adjust it to
specified value as necessary.
b. Place marks on center position in front of front wheels, and measure distance A between marks with a
tape measure.
c. Push vehicle to rotate wheels 180°, and measure distance B between marks with a tape measure when
marks are turned to rear of wheels.
d. Calculation method: front wheel toe-in = A - B ≤ 1
mm
B
A
RA13T230500
Adjustment
1. Make adjusting preparation for wheel alignment according to requirement of tester.
2. Loosen steering tie rod locking nut (1), and turn tie rod to
adjust length as required until front wheel toe-in reaches
1
specified value.
23
RA13T230510
3. Tighten steering tie rod locking nut and reinstall boot elastic snap ring. Check if locking nut is tightened in
place and if jacket position is correct.

23 - SUSPENSION
CAUTION
 If elasticity of boot elastic snap ring is not enough, replace it.
4. After adjusting front wheel toe-in, check steering wheel for eccentricity. If necessary, loosen steering wheel
locking nut and adjust steering wheel to horizontal position, and then tighten steering wheel locking nut to
specified torque.
Kingpin Caster & Kingpin Inclination

1. Kingpin caster and kingpin inclination can only be checked by using four-wheel alignment device.
2. Kingpin caster and kingpin inclination are assured by design structure and cannot be adjusted. If
measured value is not within the specified range, check if other components that connect to steering
knuckle are deformed or damaged. Also, check if connected part of steering knuckle is deformed or
damaged. If so, replace corresponding components.
Specified Value for Front Wheel Toe-in

Kingpin Caster 4°03′ ± 45′
Kingpin Inclination 12°17′ ± 45′
Rear Wheel Camber & Rear Wheel Toe-in

Rear wheel camber and rear wheel toe-in are assured by design structure and cannot be adjusted. If
measured value is not within specified range, check if rear suspension components are deformed or
damaged. If rear shaft assembly is deformed due to large shock, causing rear wheel alignment parameters
change beyond specified range, replace rear shaft assembly.

Rear Wheel Camber -1°30′ ± 30′
Rear Wheel Toe-in 0°10′ ± 20′
23

- MEMO -

TIRE AND WHEEL
Precautions 24-3 Tire Replacement 24-7
Tire Identification 24-3 Wheel 24-9
Installation 24-9
Wheel Balance 24-10
Adjustment 24-10
Inspection 24-5
Tire Rotation 24-12
Description 24-12
Rotation Method 24-12
24

24

24 - TIRE AND WHEEL
GENERAL INFORMATION
TIRE AND WHEEL
Precautions
 Only use tires with standard specification and type, because they have excellent reliability and grip
performance. Using a non-standard tire may lead to vehicle malfunction, which may cause an accident,
resulting in serious injury or even death.
 Contact surface between rim and tire should be cleaned before installing a new tire.
 When installing wheel bolts, first pre-tighten the bolts by hand, and then tighten them to the specified
torque with a torque wrench.
 Do not apply grease to wheel bolts.
 Some bad driving habits may shorten the tire life:
- Rapid acceleration
- Depressing brake pedal suddenly and firmly
- High-speed driving
- Turning at excessive speed
- Striking curbs or other obstacles
- Excessive tire pressure when driving vehicle
Tire Identification
 Letter and number code of tire type, size, load index and
speed level are stamped on the side wall of tire as shown
in illustration. 205/55
R1
69
1V
RT11240010
Specifications

Tire Type
Tire Type 205 /55 R16 91V
24
Rim Type
Wheel Mounting Bolt 16 × 6.5J

24 - TIRE AND WHEEL
Cold Tire Pressure Specifications
Description Pressure (kPa)

Front Tire (Unloaded) 230
Rear Tire (Unloaded) 220
Spare Tire 420
24

24 - TIRE AND WHEEL
DIAGNOSIS & TESTING

HINT:

Wear on one side of tire Wheel alignment (incorrect) 23-33
Wear on both sides of tire Tire pressure (insufficient) 24-4
Tire center wear Tire pressure (excessive) 24-4
Serrated wear Wheel alignment (incorrect) 23-33
Severe wear on some area of tire Braking (too hard) 26-27
Scratches on side wall of tire Sharp objects on road (scratched) 24-5
Tire pressure (incorrect) 24-4
Excessive tire noise
Tire (worn) 24-4
Inspection
CAUTION
 When installing non-standard tire and rim, always refer to instructions.

 Use tires with standard specification and type.
1. Check if tires are scratched or damaged as shown in illustration.

2. Check if rims are scratched or damaged as shown in
illustration.
24
RA13T240020

24 - TIRE AND WHEEL
3. Check if tires are worn abnormally as shown in

illustration.
Wear on Both Sides Center Wear
Serrated Wear Wear on One Side

RA13T240030
4. Check tread wear indicators (arrow) as shown in

illustration. When tires are worn to the indicating mark,
replace them.
RA13T240040
5. Use tire pressure gauge to check if pressures of all tires (including spare tire) are normal. Inflate tires to
specified tire pressure as necessary.
6. Check air valve for leakage.
24

24 - TIRE AND WHEEL
ON-VEHICLE SERVICE
Tire Replacement
WARNING
 Speed level of new replaced tire must meet the specified values for safe operation; otherwise tire may
blow out.
1. Remove the wheel (See page 24-9).

2. Use a tire remover to remove tires according to instructions.
CAUTION
 Before installing air valve, check if air valve hole of wheel is smooth without any burrs, and apply glycerin
to air valve rubber surface or soak air valve into glycerin fluid, and then pull or press the locating ring of
air valve by force to pass it through the air valve hole and install it into place (it is possible to use soapy
water instead of glycerin).
 Apply glycerin or soapy water around tire before assembly.
 When there is "dark point" mark on rim, align the dynamic balance testing mark on tire with "dark point"
mark on rim.
 When there is no "dark point" mark on rim, align the dynamic balance testing mark on tire with the air
valve.
3. When installing tire, white point on tire edge must be

aligned with air valve on rim as shown in illustration.
RA13T240050
4. Adjust tire pressure to specified value.
CAUTION
 Be sure to inflate tires to specified air pressure. The maximum air pressure cannot exceed 10% of rated
air pressure during air inflation.
 Please replace tires with standard specification and type.
24
5. Check contact surface among air valve, tire and rim for leakage.
6. Using a dynamic balancer, adjust the wheel balance (See page 24-10).
7. Install the wheel (See page 24-9).

24 - TIRE AND WHEEL
CAUTION
 Avoid scratching tires and rims when removing tires.

 Contact surface between tire and rim should be cleaned when installing tires.
24

24 - TIRE AND WHEEL
Wheel
Removal
1. Remove the wheel.
a. Stop vehicle on level surface and apply parking brake.
b. Using a wheel wrench, loosen the wheel mounting bolts.
c. Firmly support and raise vehicle to a proper height.
d. Using a wheel wrench, remove 5 wheel mounting
bolts.
RA13T240060
e. Remove the wheel.
Installation
1. Install the wheel.
a. Perform anticorrosion treatment on contact surface between wheel and brake disc.
b. Install wheel and pre-tighten wheel mounting bolts by hand.
c. Using a torque wrench, tighten wheel mounting bolts
evenly to specified torque in order shown in
illustration.
3
4
5
2
RA13T240070
CAUTION
 DO NOT attempt to repair wheels by striking, heating or welding.

 Replace with special wheel mounting bolts, rather than those with different specifications or inferior
quality.
 Be careful not to damage coating on wheel.
 To avoid damage to tire or over/under tightening wheel mounting bolts, never use an impact wrench.
 DO NOT apply grease to wheel mounting bolts.
 To ensure wheel mounting bolts are tightened in place, wheel mounting bolts should be tightened after 24
driving 800 km at the first time.

24 - TIRE AND WHEEL
Wheel Balance
Adjustment
CAUTION
 Dynamic balancer must be calibrated before adjusting wheel balance.

 Remove impurities inside tread pattern and original balance weights to ensure wheel balance.
1. Remove the wheel (See page 24-9).

2. Adjust tire pressure to specified value.
3. Install wheel with balance weight removed to balancer. Install balance shaft with mounting surface of wheel
facing inward, choose a suitable taper body, and firmly lock the wheels using a locking device (align the
taper body with center hole, otherwise data may be incorrect).
4. Turn on power source of balancer, and input measured parameters such as distance from rim to balancer,
rim width and rim diameter.
5. Put down wheel protector, and proceed to balance test procedure automatically (start button should be
pushed for some balancers). When measurement is completed, the unbalanced weight for both sides of
tire will be displayed on the balancer automatically, and wheel brakes automatically until it stops. Do not
open the protector before stopping. Failure to do this may lead to an accident.
6. According to the measurement result, corresponding
balance weights should be installed on the outside (1)
and inside (2) of rim edge as shown in illustration.
2
RA13T240080
7. Perform test again after assembly is completed, until the balancer displays 0.
8. After dynamic balance is completed, remove wheel.
24

24 - TIRE AND WHEEL
CAUTION
 When installing balance weights, final unbalanced degree of assembly should be as follows: clamp type
balance weight side is 8 g or less, and paste type balance weight side is 10 g or less.
 Either side of each wheel is permitted to use only one clamp type balance weight at most, and paste type
balance weight should be applied as needed.
 Single side weight of clamp type balance weight and paste type balance weight is less than 65 g and 80
g separately.
 DO NOT tap balance weights forcibly during installation, in order to prevent balance weights from being
deformed.
 DO NOT reuse deformed balance weights. Replace them in time.
24

24 - TIRE AND WHEEL
Tire Rotation
Description
Front and rear tires operate at different loads and perform different steering, driving and braking functions. For
these reasons, different wear rates are formed, causing irregular wear patterns. These effects can be reduced
by rotating tires at regular time.
Advantages of tire rotation:
 Improving tread life
 Maintaining traction levels
 Maintaining a smooth and quiet drivability
CAUTION
 Chery recommends you to rotate the tires every 10000 km. However, the best time suitable for tire
rotation differs depending on driver's driving habits and road conditions.
Rotation Method
Perform tire rotation as shown in illustration.
Front
RA13T240090
24

GENERAL INFORMATION 25-3 C1004-04 25-64
Description 25-3 C0044-01 25-68
Operation 25-4 C0044-28 25-68
Specifications 25-9 C0069-54 25-73
Tools 25-10 C0069-09 25-73
Circuit Diagram 25-11 C0069-64 25-73
C0069-86 25-73
C0040-14 25-78
U1300-55 25-82
Diagnosis Procedure 25-14
U0140-87 25-82
Problem Repair (No DTC) 25-16
U0101-87 25-82
DTC Confirmation Procedure 25-16
U0100-87 25-82
U0126-87 25-82
U0401-81 25-82
ESC Control Module Assembly 25-18
U0402-81 25-82
U0428-81 25-82
C0031-14 25-21
U0422-81 25-82
C0031-03 25-21
U0073-00 25-82
C0034-14 25-26
C0034-03 25-26 ON-VEHICLE SERVICE 25-89
C0037-14 25-31 ABS Bleeding 25-89
C0037-03 25-31 ABS/ESC Control Module Assembly 25-90
C003A-14 25-36 Removal 25-90
C003A-03 25-36 Installation 25-91
C0031-02 25-41 Front Wheel Speed Sensor (Take Front Left
C0034-02 25-41 Wheel As An Example) 25-93
C0037-02 25-41 Removal 25-93
C003A-02 25-41 Inspection 25-94
C0051-54 25-45 Installation 25-94
C0051-28 25-45 Rear Wheel Speed Sensor (Take Rear Left
Wheel As An Example) 25-95
C0089-04 25-49
Removal 25-95
C1000-16 25-52
Inspection 25-96
C1000-17 25-52
Installation 25-96
C1001-04 25-56
Steering Angle Sensor 25-97
C0020-04 25-60
Removal 25-97
C1003-04 25-64
Installation 25-97
25

25

25 - BRAKE CONTROL SYSTEM
GENERAL INFORMATION
Description
3
4
6
2
RA13T250010
1 - ABS/ESC Control Module Assembly 2 - Front Right Wheel Speed Sensor

3 - Rear Right Wheel Speed Sensor 4 - Steering Angle Sensor
5 - Front Left Wheel Speed Sensor 6 - Rear Left Wheel Speed Sensor
Brake control system equipped on this model is ABS (Anti-lock Brake System) + EBD (Electronic Brake Force
Distribution) or ESC (Electronic Stability Program). It mainly consists of following components:
 ABS/ESC control module assembly (hydraulic control module and electronic control module)
 Wheel speed sensors (each wheel has one sensor)
 Steering angle sensor (if equipped with ESC)
 Yaw rate sensor (if equipped with ESC) (built in ESC control module assembly)
Primary purpose of ABS is to prevent wheels from being locked during sudden braking. It has following effects
when braking:
1. Improving vehicle driving stability.
2. Improving vehicle steering ability.
3. Maintaining optimal brake pressure. 25
4. Shortening brake distance efficiently.

Operation
ABS Braking
1. If ABS system detects that wheels may be locked when applying brake, brake system will enter ABS
braking mode. During braking, ABS/ESC control module outputs signals from each wheel speed sensor to
each solenoid valve after analysis in order to adjust fluid pressure in each line, to prevent wheels from
being locked.
2. There are some operating symptoms of ABS/ESC that seem to be abnormal at first, but in fact it is normal.
The symptoms are as follows:
a. If electronic control module is malfunctioning, fail-safe function will be activated, ABS/ESC system will
not operate and ABS/ESC warning light will come on.
b. After vehicle is powered on or engine is started, short "buzz" sound can be heard. This is normal sound
from ABS/ESC self-check.
c. Motor, solenoid valve, and return pump movement in hydraulic unit will cause noise when ABS/ESC is
operating normally, but this is normal.
d. Brake pedal may vibrate slightly and mechanical noise can be heard during ABS/ESC operation, but
this is normal.
e. Bumping sound between suspension and vehicle body can be caused by sudden brake.
25

ABS Control Mode
MC1 MC2
NO NO EME NO
NO
NC NC NC NC
FL RR RL FR
LPA LPA
RA13T250020
Description Definition Description Definition

MC1 Master Cylinder Outlet 1 LPA Low Pressure Accumulator
MC2 Master Cylinder Outlet 2 FL Front Left Wheel
EME Return Pump RR Rear Right Wheel
NO Normal Open (Solenoid Valve) RL Rear Left Wheel
NC Normal Close (Solenoid Valve) FR Front Right Wheel
25

1. Normal Brake Operating Condition

For vehicles equipped with ABS, if brake pressure applied to wheels is not enough to lock wheels, fluid
pressure generated by master cylinder will be delivered to wheel cylinder through normal open valve,
producing regular braking effect. When it is not necessary to continue braking, and if driver reduces
pressure to brake pedal, brake fluid of each wheel returns to master cylinder and brake pressure
decreases.
Solenoid Valve Powered Condition Solenoid Valve Condition

Normal Open Valve OFF OPEN
Normal Close Valve OFF CLOSE
MC1 MC2
NO NO NO NO
EME
NC NC NC NC
FL RR RL FR
LPA LPA
RA13T250030
25

2. ABS Operating (Relief) Condition

For vehicles equipped with ABS, if brake pressure is applied excessively, friction coefficient between
wheels and road will decrease, and wheels will be decelerated earlier than vehicle, which could cause
wheels to be locked first. In this case, ECU commands HCU to reduce wheel pressure. In other words,
normal open valve cuts off oil passage and the oil passage of normal close valve is open, in order to
reduce wheel cylinder pressure. At this time, brake fluid drained from wheel cylinder is temporarily stored
in low pressure accumulator (LPA). Then, the brake fluid stored in low pressure accumulator (LPA) returns
to master cylinder with rotation of motor. The brake fluid returns to high pressure accumulator (HPA), and
reduce high pressure pulse caused by operation of oil pump with orifice fluid resistance.

Normal Open Valve ON CLOSE
Normal Close Valve ON OPEN
MC1 MC2
NO NO NO NO
EME
NC NC NC NC
FL RR RL FR
LPA LPA
RA13T250030
25

3. ABS Operating (Holding) Condition

Apply appropriate pressure to wheel cylinder by reducing pressure or increasing pressure, normal open
valve and normal close valve are closed to maintain pressure of wheel cylinder. During steps (2) ~ (4), ABS
system operates until vehicle is completely stopped, ensuring vehicle braking and steering performance.

Normal Open Valve ON CLOSE
MC1 MC2
NO NO NO NO
EME
NC NC NC NC
FL RR RL FR
LPA LPA
RA13T250031
25

4. ABS Operating (Boost) Condition

When ABS operates under pressurerelief condition, if brake fluid is drained excessively or friction
coefficient between wheels and road increases, each wheel pressure needs to be increased. In this case,
ECU commands HCU to increase wheel pressure. As a result, normal open valve opens its passage and
normal close valve shuts off oil passage, in order to increase wheel cylinder pressure. Under pressure
relief condition, motor is rotated by brake fluid stored in Low Pressure Accumulator (LPA) in boost pressure
condition to drain brake fluid. At this time, fluid is supplied to each wheel cylinder through master cylinder
and normal open valve. The brake fluid returns to High Pressure Accumulator (HPA), and reduce high
pressure pulse caused by operation of oil pump using orifice fluid resistance.

Normal Open Valve OFF OPEN
MC1 MC2
NO NO NO NO
EME
NC NC NC NC
FL RR RL FR
LPA LPA
RA13T250032
ABS system operates circularly under relief, maintaining and boost pressure conditions until vehicle is
completely stopped, so vehicle braking and steering performance will be guaranteed.
ESC adjustment procedure is similar to ABS adjustment procedure. Brake fluid is supplied to wheel cylinders
that need to increase pressure by pump, when traction control and stability control are realized and HSV valve
opens and USV valve closes.
Specifications

25
Brake Pipe Coupling Plug 12 - 16
Coupling Bolt Between ABS/ESC Control Module 10 ± 3
Assembly and Mounting Bracket


Coupling Nut Between ABS/ESC Control Module 10 ± 1
Assembly Mounting Bracket and Body
Front Wheel Speed Sensor Fixing Bolt 10 ± 1
Rear Wheel Speed Sensor Fixing Bolt 10 ± 1
Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002
25

Circuit Diagram
Brake Control System (Page 1 of 3)
IGNITION SWITCH
BATTERY
ON OR START
ENGINE
COMPARTMENT IP FUSE AND
SB08 SB01 EF24 EF06 EF07 RF03 RELAY BOX
FUSE AND
40A 30A 15A 7.5A 15A RELAY BOX 10A I-032
E-067
112 105 73 38 39 11
RW
RB
W
6 A
RB
11 B
E-030 I-036
3
STEERING
ANGLE SENSOR
R
I-028
4 1 2
G
B
TO CAN
I-006 SYSTEM
G
Y
1 25 29 2 14
CAN1 L CAN1 H
ESP
E-051
1 2 3 4 5 6 7 8 9
6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 10 11 12 13 14 15 16 17 18
13 1
24 23 22 21 20 19 18 17 16 15 14
I-028
38 37 36 35 34 33 32 31 30 29 28 27 26 25 B
E-030
B
25
E-051
B
EA13T250010

RW
RB
4 1
BRAKE
SWITCH
INTEGRATED
I-013
SWITCH
I-023
2 3 16 15
BR
V
L
I-036 I-018
12 1 7 8 E-054
E-030
BR
V
L
E-056
A5 A17
ECM(A)
B
E-041
16 3 26 13 38
ESP
E-051
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
A56 A55 A54 A53 A52 A51 A50 A49 38 25

37 36 35 34 33 32 31 30 29 28 27 26
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
E-041 E-051
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B B
1
B8 B7 B6 B5 B4 B3 B2 B1 I-023 I-013
4 2
B B
3
B16 B15 B14 B13 B12 B11 B10 B9
1 2 3 4 5 6 7 8 9
25 4 3 2 1 E-054
E-030
W
10 9 8 7 6 5 10 11 12 13 14 15 16 17 18 B
EA13T250020

ESP
E-051
21 34 31 18 20 33 32 19
Gr
Br
G
V
P
L
L
10 9 6 7 E-053
B-024
P
1 2 1 2 2 1 2 1
FRONT LEFT FRONT RIGHT REAR LEFT REAR RIGHT

ABS WHEEL ABS WHEEL ABS WHEEL ABS WHEEL
SPEED SENSOR SPEED SENSOR SPEED SENSOR SPEED SENSOR
E-034 E-052 B-010 B-029
1 2 3 4 5 6 7 8 E-053
12 11 10 9 8 7 6 5 4 3 2 W
13 1 9 10 11 12 13 14 15 16
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
2 1 2 1 2 1 2 1
E-051 E-034 E-052 B-010 B-029 25

B B B W W
EA13T250030

DIAGNOSIS & TESTING

HINT:

Fuse 55-30
When turning ignition switch ON, ABS/ Wire harness or connector -

ESC warning light does not come on ABS/ESC Control Module Assembly 25-90
Fuse 55-30
Wire harness or connector -
ABS/ESC warning light remains on
ABS/ESC Control Module Assembly 25-90
Center Control Integration Panel
30-28
Assembly
ESC OFF indicator does not come on or Wire harness or connector -
remains on
Wheel speed sensor (damaged,
improperly installed, foreign matter 25-93
attached)
Hub ring gear (damaged, improperly
-
installed, foreign matter attached)
ABS/ESC operation is abnormal Hub ring gear (damaged, improperly
-
installed, foreign matter attached)
Brake line (blocked or leaked) -
Fuse 55-30
Communication with ABS/ESC control
module cannot be performed
Diagnosis Procedure
25 HINT:
Use following procedures to troubleshoot the brake control system.

1 Vehicle brought to workshop
NEXT
Standard voltage: 11 to 14 V
If voltage is below 11 V, recharge or replace the battery before proceeding to next step.
NEXT
3 Customer problem analysis
NEXT
4 Check and clear DTCs
NEXT
Confirm and duplicate malfunction: accelerate vehicle to 15 km/h or above, simulate

5 malfunction conditions and read DTCs again
DTC
For current DTC, go to step 7
occurs
NO
For history DTC, go to step 8
DTC
6 Problem repair (no DTC), then go to step 9
NEXT
7 Troubleshoot according to Diagnostic Trouble Code (DTC) chart, then go to step 9
NEXT
8 Troubleshoot according to Problem Symptoms Table, then go to step 9
NEXT 25

9 Conduct test and confirm malfunction has been repaired
NEXT
10 End
Problem Repair (No DTC)

If there is a problem in brake system, but no DTC is stored in ABS/ESC control module assembly, this
problem is called a problem without DTC. A problem without DTC is caused by basic brake system
malfunction. For example:
1. Brake fluid leakage (it may result in weak braking, excessive brake pedal travel or even ineffective
braking).
2. Using inferior brake fluid (it can result in corrosion of brake line and ABS hydraulic regulating module
internal elements, or even ineffective braking).
3. Air in brake line (it may result in weak braking or even ineffective braking).
4. Brake line blockage (it may result in hard braking or even ineffective braking).
5. Excessive wear of brake disc (it may result in weak braking, excessive brake pedal travel).
6. Brake booster malfunction (it may result in weak or hard braking, brake pedal overtravel or even ineffective
braking).
7. Wrong brake line connection (it may result in ABS/ESC braking performance decreasing, drift, long braking
distance etc.).
ABS/ESC no power supply or power supply abnormality will cause ABS/ESC warning light remains on without
storing DTC.
Troubleshooting method: check corresponding component according to the malfunction, and repair or replace
as necessary.

Confirm that battery voltage is normal before performing following procedures.
 Using X-431 3G diagnostic tester, record and clear DTCs stored in ABS/ESC control module assembly.
 Turn ignition switch to LOCK and wait for a few seconds.
 Start engine, drive vehicle at 20 km/h or more and perform road test with X-431 3G diagnostic tester
connected to Data Link Connector (DLC).
 Use X-431 3G diagnostic tester to read DTCs.
 If DTC is detected, malfunction indicated by DTC is current.Go to diagnosis procedure - Step 1.
 If no DTC is detected, malfunction indicated by DTC is intermittent. Please refer to Intermittent DTC
Troubleshooting.

25 If malfunction is intermittent, perform the followings:
 If possible, try to duplicate conditions under which DTC was set.

 Look for the data that has changed or the DTC to reset during wiggle test.
 Check for broken, bent, protruded or corroded terminals.
 Inspect wheel speed sensors and mounting areas for damage, foreign matter, etc. that will cause incorrect
signals.
 Check and clean all wire harness connectors and grounding parts related to the current DTC.
 If multiple trouble codes were set, refer to the circuit diagram to look for any common ground circuit or
power supply circuit applied to the DTC.
 Refer to any Technical Bulletin that may apply to the malfunction.
Ground Inspection
moisture, dirt and other corrosive environments.Corrosion (rust) may increase load resistance. This situation
may change the way in which a circuit works.
Circuits are very sensitive to proper grounding. A loose or corroded ground can affect the control circuit.
Check the ground points as follows:
4. Reinstall the ground bolt or nut securely.
Make sure all wire harnesses are clean, securely fastened and providing a good ground path.
25

ESC Control Module Assembly

Terminal No. Terminal Definition Terminal No. Terminal Definition
1 Battery Power Supply (Pump Motor) 20 Rear Left Wheel Speed Sensor
2 CAN1-L 21 Front Left Wheel Speed Sensor
3 ESC Switch Indicator 22 -
4 - 23 -
5 - 24 -
6 - 25 Battery Power Supply (Valve)
7 - 26 ESC Switch Input
8 - 27 -
9 - 28 -
10 - 29 Ignition Switch Power Supply
11 - 30 -
12 - 31 Front Right Wheel Speed Sensor
13 Ground 32 Rear Right Wheel Speed Sensor
14 CAN1-H 33 Rear Left Wheel Speed Sensor
15 - 34 Front Left Wheel Speed Sensor
16 Brake Switch Input 35 -
17 - 36 -
18 Front Right Wheel Speed Sensor 37 -
19 Rear Right Wheel Speed Sensor 38 Ground
25


DTC DTC Definition
C0031-14 FL Open/Short To BAT/GND
C0034-14 FR Open/Short To BAT/GND
C0037-14 FL Open/Short To BAT/GND
C003A-14 RR Open/Short To BAT/GND
C0031-02 FL Air-Gap ERROR And Long Term ABS Mode
C0034-02 FR Air-Gap ERROR And Long Term ABS Mode
C0037-02 RL Air-Gap ERROR And Long Term ABS Mode
C003A-02 RR Air-Gap ERROR And Long Term ABS Mode
C0031-03 FL Speed Jump And Wrong Exciter, Missing Teeth
C0034-03 FR Speed Jump And Wrong Exciter, Missing Teeth
C0037-03 RL Speed Jump And Wrong Exciter, Missing Teeth
C003A-03 RR Speed Jump And Wrong Exciter, Missing Teeth
C1003-04 Valve Relay Open, Short To GND, Valve Relay Short To BAT
Solenoid Valve Open, Short To GND, Solenoid Valve Short To BAT, Leakage
C1004-04
Current
Motor Relay Open, Motor Short To GND, Motor Open, Motor Short To BAT, Motor
C0020-04
Lock (Stuck), Motor GND Open
C1000-16 Low Voltage
C1000-17 Over Voltage
C1001-04 ECU H/W error
C0044-01 Master Pressure Sensor Open, Short To BAT/GND
C0044-28 Master Pressure Sensor Noisy Signal, Offset
C0051-54 SAS Offset Calibration
C0051-28 SAS Offset Error, Noisy Signal
C0069-54 The Zero Value Calibration For G Sensor Is Not Done
C0069-09 Sensor Initialization Error
C0069-64 Sensor Abnormal Signal
C0069-86 G Sensor Sensor Fail
C0040-14 Brake Light Switch Open, Short To BAT/GND
C0089-04 ESC Switch Short To BAT
C0072-4B Excessive temperature of brake disc
C008B-12 DBC Switch short to BAT
C008C-12 AVH Switch short to BAT
25
U1300-55 Software Configuration Error
U0140-87 Lost Communication With BCM
U0101-87 Lost Communication With TCU

DTC DTC Definition

U0126-87 Lost Communication With SAM
U0401-81 Invalid Data Received From EMS
U0402-81 Invalid Data Received From TCU
U0428-81 Invalid Data Received From SAM
U0422-81 Invalid Data Received From BCM
U0073-00 Control Module Communication Bus Off
25

DTC C0031-14 FL Open/Short To BAT/GND
DTC C0031-03 FL Speed Jump And Wrong Exciter, Missing Teeth
ESP
E-051
21 34
V
1 2
FRONT LEFT
ABS WHEEL
SPEED SENSOR
E-034
12 11 10 9 8 7 6 5 4 3 2
13 1 2 1
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25 E-034
B
E-051 25
B
EA13T250040

DTC Detection
Condition
FL Open/Short To BAT/ This DTC occurs when
C0031-14
GND any of following
 Wheel speed sensor signal wire is
conditions is met:
connected with power supply wire in
ABS/ESC control reverse.
module assembly
 Signal wire is short to ground.
detects that wheel
speed sensor signal  Wheel speed sensor line is open,
wire is short to ground. connector is loose or broken.
Wheel speed sensor  Wheel speed sensor power supply
line is open. wire is short to ground.
ABS/ESC control  Ring gear is not installed, dirty,
module assembly demagnetized, off center or it has
FL Speed Jump And detects that wheel teeth missing.
C0031-03 Wrong Exciter, Missing speed sensor signal  Clearance between sensor and ring
Teeth wire is short to power gear is excessive.
supply.  Wheel speed sensor is interfered by
ABS/ESC control magnetic field outside. (wheel or axle
module assembly is not demagnetized)
detects that wheel  Wheel speed sensor body is
speed sensor power malfunctioning.
supply wire is short to
 Tire size is not as specified.
ground.
 ECU is damaged.
Wheel speed sensor
signal is invalid.
CAUTION
 When performing electrical equipment diagnosis and test, always refer to circuit diagram for related
circuit and component information.
Diagnosis Procedure
1 Check front left wheel speed sensor wire harness and connector

b. Disconnect the negative battery cable.
c. Disconnect the front left wheel speed sensor connector E-034.
d. Check if wire harnesses are worn, pierced, pinched or partially broken.
e. Check for broken, bent, protruded or corroded terminals.
f. Check if terminal contact pins of related connectors are in good condition.
NG Repair or replace front left wheel speed

sensor harness and connector
25
OK

2 Check installation of front left wheel speed sensor

c. Check front left wheel speed sensor mounting bolt for looseness.
d. Check if excessive clearance exists between installation position of front left wheel speed sensor and front
steering knuckle.
e. Check installation position of front left wheel speed sensor for dirt.
NG Tighten mounting bolt properly, clean or

replace front left wheel speed sensor
OK
3 Check front left wheel speed sensor
a. Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC).
b. Drive vehicle straight ahead, and read datastream of front left wheel speed sensor with X-431 3G
diagnostic tester.
c. Check if data change of front left wheel speed sensor matches that of other wheel speed sensors.
NG Replace front left wheel speed sensor
OK
4 Check front left hub ring gear.
a. Check front left hub ring gear.

b. Check if there is foreign matter, missing teeth or damage on front left hub ring gear.
c. Check if front left hub assembly is securely installed.
NG Replace front left hub ring gear
OK
25

Check wire harness and connector (front left wheel speed sensor - ABS/ESC control
5 module assembly)

c. Disconnect the ABS/ESC control module assembly
d. Disconnect the front left wheel speed sensor connector 2 1
E-034. E-034
e. Using a digital multimeter, check for continuity between

terminals of connector E-051 and connector E-034 to
check if there is an open in wire harness and connector
according to table below. 12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
Standard Condition
38 37 36 35 34 33 32 31 30 29 28 27 26 25
Condition
E-051
E-051 (21) -
Always Continuity RA13T250050
E-034 (1)
EE-051 (34) -
Always Continuity
E-034 (2)
E-034 (2) - E-034
(1)
f. Using a digital multimeter, check for continuity between

connector E-051 and body ground to check if front left
wheel speed sensor is short to ground according to table
below.
Standard Condition + -
Condition
E-051 (34) - Body 12 11 10 9 8 7 6 5 4 3 2
Always No continuity 13 1
ground
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-051 (21) - Body

ground
E-051
RA13T250060
25

g. Connect the negative battery cable.

h. Turn ignition switch to ON.
i. Using a digital multimeter, measure voltage between
connector E-051 and body ground to check if front left V
+ -
wheel speed sensor is short to power supply according to
table below.
Standard Condition
Multimeter Specified 12 11 10 9 8 7 6 5 4 3 2
Condition
13 1
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-051 (34) - Body

Ignition switch ON Approx. 0 V
ground
E-051 (21) - Body E-051
ground
RA13T250070
NG Repair or replace wire harness and
connector between front left wheel speed
sensor and ABS/ESC control module
assembly
OK
6 Reconfirm DTCs
a. Use X-431 3G diagnostic tester to clear DTCs.

b. Start the engine.
c. Drive vehicle at 15 km/h or above, read ABS/ESC control module assembly DTC again with X-431 3G
diagnostic tester.
d. Check if same DTC is still output.
NO System operates normally
YES
Replace ABS/ESC control module assembly
25

DTC C0034-14 FR Open/Short To BAT/GND
DTC C0034-03 FR Speed Jump And Wrong Exciter, Missing Teeth
ESP
E-051
31 18
Br
1 2
FRONT RIGHT
ABS WHEEL
SPEED SENSOR
E-052
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25 2 1
E-052
B
25 E-051
B
EA13T250050

DTC Detection
Condition
FR Open/Short To This DTC occurs when
C0031-14
BAT/GND any of following
conditions is met:
module assembly
detects that wheel
FR Speed Jump And detects that wheel teeth missing.
C0031-03 Wrong Exciter, Missing speed sensor signal  Clearance between sensor and ring
ground.
 ECU is damaged.
Wheel speed sensor
signal is invalid.
CAUTION
Diagnosis Procedure
1 Check front right wheel speed sensor wire harness and connector

c. Disconnect the front right wheel speed sensor connector E-052.
NG Repair or replace front right wheel speed

25
OK

2 Check installation of front right wheel speed sensor

c. Check front right wheel speed sensor mounting bolt for looseness.
d. Check if excessive clearance exists between installation position of front right wheel speed sensor and
front steering knuckle.
e. Check installation position of front right wheel speed sensor for dirt.

replace front right wheel speed sensor
OK
3 Check front right wheel speed sensor
b. Drive vehicle straight ahead, and read datastream of front right wheel speed sensor with X-431 3G
diagnostic tester.
c. Check if data change of front right wheel speed sensor matches that of other wheel speed sensors.
NG Replace front right wheel speed sensor
OK
4 Check front right hub ring gear
a. Check front right hub ring gear

b. Check if there is foreign matter, missing teeth or damage on front right hub ring gear.
c. Check if front right hub assembly is securely installed.
NG Replace front right hub ring gear
OK
25

Check wire harness and connector (front right wheel speed sensor - ABS/ESC control
5 module assembly)

2 1
d. Disconnect the front right wheel speed sensor connector E-052

E-052.
terminals of connector E-051 and connector E-052 to
12 11 10 9 8 7 6 5 4 3 2
check if there is an open in wire harness and connector 13
24 23 22 21 20 19 18 17 16 15 14
1
according to table below. 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Standard Condition

Condition
E-051 (31) -
E-052 (1)
E-051 (18) -
Always Continuity
E-052 (2)
E-052 (1) - E-052
(2)

connector E-051 and body ground to check if front right
below.
Condition
Connection Condition 12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
E-051 (18) - Body
Always No continuity 38 37 36 35 34 33 32 31 30 29 28 27 26 25
ground
E-051 (31) - Body
ground E-051
RA13T250100
25


connector E-051 and body ground to check if front right V
+ -
table below.
Standard Condition
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
Condition 38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-051 (18) - Body
ground E-051
E-051 (31) - Body

ground
RA13T250110
connector between front right wheel
speed sensor and ABS/ESC control
module assembly
OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

DTC C0037-14 RL Open/Short To BAT/GND
DTC C0037-03 RL Speed Jump And Wrong Exciter, Missing Teeth
ESP
E-051
20 33
P
10 9 E-053
B-024
P
2 1
REAR LEFT
ABS WHEEL
SPEED SENSOR
B-010
1 2 3 4 5 6 7 8 E-053
12 11 10 9 8 7 6 5 4 3 2
13 1 9 10 11 12 13 14 15 16
W
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
2 1
E-051 B-010 25
B W
EA13T250060

DTC Detection
Condition
RL Open/Short To This DTC occurs when
C0031-14
BAT/GND any of following  Wheel speed sensor signal wire is
conditions is met: connected with power supply wire in
module assembly  Signal wire is short to ground.
detects that wheel  Wheel speed sensor line is open,
speed sensor signal connector is loose or broken.
wire is short to ground.
 Wheel speed sensor power supply
Wheel speed sensor wire is short to ground.
line is open.
 Ring gear is not installed, dirty,
ABS/ESC control demagnetized, off center or it has
module assembly teeth missing.
RL Speed Jump And detects that wheel
C0031-03 Wrong Exciter, Missing  Clearance between sensor and ring
speed sensor signal
Teeth gear is excessive.
wire is short to power
magnetic field outside. (wheel or axle
ABS/ESC control
is not demagnetized)
module assembly
supply wire is short to  Tire size is not as specified.
ground.  ABS/ESC control module assembly is
Wheel speed sensor damaged.
signal is invalid.
CAUTION
Diagnosis Procedure
1 Check rear left wheel speed sensor wire harness and connector

c. Disconnect the rear left wheel speed sensor connector B-010.
NG Repair or replace rear left wheel speed

25
OK

2 Check installation of rear left wheel speed sensor

c. Check rear left wheel speed sensor mounting bolt for looseness.
d. Check if excessive clearance exists between installation position of rear left wheel speed sensor and front
steering knuckle.
e. Check installation position of rear left wheel speed sensor for dirt.

replace rear left wheel speed sensor
OK
3 Check rear left wheel speed sensor
b. Drive vehicle straight ahead, and read datastream of rear left wheel speed sensor with X-431 3G
diagnostic tester.
c. Check if data change of rear left wheel speed sensor matches that of other wheel speed sensors.
NG Replace rear left wheel speed sensor
OK
4 Check rear left hub ring gear
a. Check rear left hub ring gear

b. Check if there is foreign matter, missing teeth or damage on rear left hub ring gear.
c. Check if rear left hub assembly is securely installed.
NG Replace rear left hub ring gear
OK
25

Check wire harness and connector (rear left wheel speed sensor - ABS/ESC control module
5 assembly)

connector E-051. + - 2 1
d. Disconnect the rear left wheel speed sensor connector B-
B-010
010.
terminals of connector E-051 and connector B-010 to
according to table below. 12 11 10 9 8 7 6 5 4 3 2
13 1
Standard Condition 24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
Condition
E-051
E-051 (20) -
B-010 (2)
E-051 (33) -
Always Continuity
B-010 (1)
B-010 (1) - B-010
(2)

connector E-051 and body ground to check if rear left
below.
Condition
12 11 10 9 8 7 6 5 4 3 2
1
24 23 22 21 20 19 18 17 16 15 14
E-051 (20) - Body
ground
E-051 (33) - Body
ground E-051
RA13T250140
25


connector E-051 and body ground to check if rear left V
+ -
table below.
Standard Condition
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
Condition 38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-051 (20) - Body
ground E-051
E-051 (33) - Body

ground
RA13T250150
connector between rear left wheel speed
assembly
OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

DTC C003A-14 RR Open/Short To BAT/GND
DTC C003A-03 RR Speed Jump And Wrong Exciter, Missing Teeth
ESP
E-051
32 19
Gr
G
6 7 E-053
B-024
2 1
REAR RIGHT
ABS WHEEL
SPEED SENSOR
B-029
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 E-053 2 1
W
38 37 36 35 34 33 32 31 30 29 28 27 26 25 9 10 11 12 13 14 15 16
B-029
W
25 E-051
B
EA13T250070

DTC Detection
Condition
RR Open/Short To This DTC occurs when
C003A-14
BAT/GND any of following
conditions is met:
module assembly
detects that wheel
RR Speed Jump And detects that wheel teeth missing.
C003A-03 Wrong Exciter, Missing speed sensor signal  Clearance between sensor and ring
ground.
 ECU is damaged.
Wheel speed sensor
signal is invalid.
CAUTION
Diagnosis Procedure
1 Check rear right wheel speed sensor wire harness and connector

c. Disconnect the rear right wheel speed sensor connector B-029.
NG Repair or replace rear right wheel speed

25
OK

2 Check installation of rear right wheel speed sensor

c. Check rear right wheel speed sensor mounting bolt for looseness.
d. Check if excessive clearance exists between installation position of rear right wheel speed sensor and
front steering knuckle.
e. Check installation position of rear right wheel speed sensor for dirt.

replace rear right wheel speed sensor
OK
3 Check rear right wheel speed sensor
b. Drive vehicle straight ahead, and read datastream of rear right wheel speed sensor with X-431 3G
diagnostic tester.
c. Check if data change of rear right wheel speed sensor matches that of other wheel speed sensors.
NG Replace rear right wheel speed sensor
OK
4 Check rear right hub ring gear
a. Check rear right hub ring gear

b. Check if there is foreign matter, missing teeth or damage on rear right hub ring gear.
c. Check if rear right hub assembly is securely installed.
NG Replace rear right hub ring gear
OK
25

Check wire harness and connector (rear right wheel speed sensor - ABS/ESC control
5 module assembly)

2 1
d. Disconnect the rear right wheel speed sensor connector B-029
B-029.
terminals of connector E-051 and connector B-029 to
according to table below.
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
Standard Condition 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Condition
E-051 (32) -
B-029 (2)
E-051 (19) -
Always Continuity
B-029 (1)
B-029 (1) - B-029
(2)

connector E-051 and body ground to check if rear right
below.
Condition
Connection Condition 12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
E-051 (32) - Body
ground
E-051 (19) - Body
ground E-051
RA13T250180
25


connector E-051 and body ground to check if rear left V
+ -
table below.
Standard Condition
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
Condition 38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-051 (32) - Body
ground E-051
E-051 (19) - Body

ground
RA13T250190
connector between rear right wheel speed
assembly
OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

DTC C0031-02 FL Air-Gap ERROR And Long Term ABS Mode
DTC C0034-02 FR Air-Gap ERROR And Long Term ABS Mode
DTC C0037-02 RL Air-Gap ERROR And Long Term ABS Mode
DTC C003A-02 RR Air-Gap ERROR And Long Term ABS Mode
IGNITION SWITCH
ON OR START
ENGINE
COMPARTMENT
EF06
FUSE AND
7.5A RELAY BOX
E-067
38
R
E-056
B
29 13 38
ESP
E-051
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
25
E-051
B
EA13T250080

DTC Detection
Condition
FL Air-Gap ERROR
C0031-02 And Long Term ABS This DTC occurs when
Mode any of following
conditions is met:
FR Air-Gap ERROR
C0034-02 And Long Term ABS ABS receives  Wheel speed difference is excessive.
Mode command to continue
 Sensor signal is incorrect.
operating (more than 1
RL Air-Gap ERROR minute).  ABS/ESC control module assembly is
C0037-02 And Long Term ABS damaged.
ESP receives
Mode
command to continue
RR Air-Gap ERROR operating (more than
C003A-02 And Long Term ABS 10 seconds).
Mode
CAUTION
Diagnosis Procedure
1 Check all wheel speed sensor wire harness and connector

c. Disconnect all wheel speed sensor connector and steering angle sensor connector.
NG Repair or replace abnormal wheel speed

sensor wire harness and connector
OK
2 Check installation of all wheel speed sensors

c. Check all wheel speed sensor mounting bolts for looseness.
25 d. Check if excessive clearance exists between installation position of all wheel speed sensors and front
steering knuckle.
e. Check installation position of all wheel speed sensor for dirt.

replace wheel speed sensor

OK
3 Check wheel speed sensor
b. Drive vehicle straight ahead, and read datastream of rear right wheel speed sensor with X-431 3G
diagnostic tester.
c. Check if data change of each wheel speed sensor matches that of other wheel speed sensors.
NG Replace corresponding wheel speed

sensor
OK
4 Check hub ring gear
a. Remove the hub assembly.

b. Check if there is foreign matter, missing teeth or damage on hub ring gear.
c. Check if hub assembly is securely installed.
NG Replace corresponding hub ring gear
OK
5 Check installation of steering angle sensor

c. Check installation of steering angle sensor
d. Check if steering angle sensor is installed in place.
e. Check installation position of steering angle sensor for dirt.
NG Securely and properly install, clean or

replace steering angle sensor
OK
6 Reconfirm DTCs

c. Drive vehicle at 15 km/h or above, read ABS/ESC control module assembly DTC again with X-431 3G 25
diagnostic tester.

YES
25

DTC C0051-54 SAS Offset Calibration
DTC C0051-28 SAS Offset Error, Noisy Signal
IGNITION SWITCH
ON OR START
IP FUSE AND
RF03 RELAY BOX
10A I-032
11
W
3
STEERING
ANGLE SENSOR
I-028
4 1 2
G
B
E-056
TO CAN
I-006 SYSTEM
B
B
G
Y
2 14 13 38
CAN1 L CAN1 H
ESP
E-051
6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
I-028
38 37 36 35 34 33 32 31 30 29 28 27 26 25 B
E-051 25
B
EA13T250090

DTC Detection
Condition
C0051-54 SAS Offset Calibration This DTC occurs when
any of following
conditions is met:
Calibration for steering
angle sensor is not  Calibration for steering angle sensor is
done (central point is not done.
SAS Offset Error, not found).  Steering angle sensor line is short or
C0051-28 Steering wheel angle open.
Noisy Signal
sensor signal is  Steering angle sensor is damaged.
abnormal
Steering wheel angle
sensor signal is
interrupted
CAUTION
Diagnosis Procedure
1 Steering angle sensor is damaged.

b. Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC).
c. Recalibrate the steering angle sensor according to instruction of diagnostic tester.
d. Use X-431 3G diagnostic tester to clear DTCs.
e. Start the engine.
f. Drive vehicle at 15 km/h or above, read ABS/ESC control module assembly DTC again with X-431 3G
diagnostic tester.
g. Check if same DTC is still output.
NO Calibration for steering angle sensor is

not done
YES
2 Check wire harness and connector

25
c. Disconnect ABS/ESC control module assembly connector E-051 and steering angle sensor connector I-
028.
d. Disconnect the body wire harness connector I-034.
e. Check if wire harnesses are worn, pierced, pinched or partially broken.

f. Check for broken, bent, protruded or corroded terminals.

g. Check if terminal contact pins of related connectors are in good condition.
NG Repair or replace body/instrument panel

wire harness and connector
OK
3 Check CAN communication control circuit (ESC - steering angle sensor)
a. Turn ignition switch to LOCK, disconnect the negative

battery cable and wait for at least 90 seconds.
b. Disconnect the ABS/ESC control module assembly
connector E-051.
+ -
c. Disconnect the steering angle sensor connector I-028. 6 5 4 3 2 1
I-028
d. Using a digital multimeter, check for continuity between
terminals of connectors I-028 and E-051 to check if there
is an open in CAN communication circuit according to
table below.
Standard Condition 13
12 11 10 9 8 7 6 5 4 3 2
1
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
Condition
E-051 (14) - I-028
(2)
RA13T250220
E-051 (2) - I-028
Always Continuity
(1)
e. Disconnect the body wire harness connector I-034.

terminals of connectors I-028 and I-034 to check if there
table below. (See page 53-10) + -
Standard Condition
Multimeter Specified B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12

Condition
Connection Condition B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
I-034
I-034 (B3) - I-028
Always Continuity
(1)
I-034 (B16) - I-028 6 5 4 3 2 1
Always Continuity
(2) I-028
NG Repair or replace instrument panel/body

RA13T250221
OK
25

4 Replace steering angle sensor and recalibrate it
OK
5 Reconfirm DTCs

diagnostic tester.
YES
25

DTC C0089-04 ESC Switch Short To BAT
IGNITION SWITCH
ON OR START
INTEGRATED
SWITCH
ENGINE
COMPARTMENT I-023
EF06
FUSE AND 16 15
7.5A RELAY BOX
E-067
V
38 I-018
7 8 E-054
R
E-056
B
29 3 26 13 38
ESP
E-051
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-051
B
4 3 2 1 E-054
B8 B7 B6 B5 B4 B3 B2 B1 I-023
W
9 8 7 6 5
B
10
B16 B15 B14 B13 B12 B11 B10 B9
25
EA13T250100

DTC Detection
Condition
This DTC occurs when
any of following
conditions is met:
Press and hold ESC  ESC OFF switch is pressed by other
ESC Switch Short To OFF switch for more objects
C0089-04
BAT than 10 seconds.
 ESC OFF switch is damaged
During ignition, ESC
OFF switch active
signal is detected for
more than 2 seconds.
CAUTION
Diagnosis Procedure
1 Check ESC OFF switch

c. Check if ESC OFF switch is stuck or pressed by something.
NG Release ESC OFF switch or move away

other objects
OK

c. Check if wire harnesses are worn, pierced, pinched or partially broken.
d. Check for broken, bent, protruded or corroded terminals.
e. Check if terminal contact pins of related connectors are in good condition.

OK
25

3 Reconfirm DTCs

diagnostic tester.
YES
Replace center control integration panel assembly
25

DTC C1000-16 Low Voltage
DTC C1000-17 Over Voltage
IGNITION SWITCH
BATTERY
ON OR START
ENGINE
COMPARTMENT
SB08 SB01 EF06
FUSE AND
40A 30A 7.5A RELAY BOX
E-067
112 105 38
R
E-056
B
1 25 29 13 38
ESP
E-051
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
25
E-051
B
EA13T250110

DTC Detection
Condition
C1000-16 Low Voltage This DTC occurs when
any of following
conditions is met:
Voltage is below 4.5 V  Fuse malfunction
just after vehicle is  High or low battery voltage
powered on.  Charging system malfunction
C1000-17 Over Voltage Voltage is below 7.7 V  Wire harness or connector
or above 16.8 V with  ABS/ESC control module assembly
ignition switch ON. malfunction
Voltage is 7.7 to 9.2 V
when vehicle speed is
above 6 km/h.
CAUTION
Diagnosis Procedure
1 Check fuse

c. Remove fuse RF06 (7.5 A) from engine compartment fuse and relay box.
d. Check if fuse is blown.
NG Replace fuse RF06
OK
a. Using a digital multimeter, measure voltage between positive battery terminal and negative battery
terminal.
b. Battery voltage should be between 9 and 16 V.
NG Check charging system (See page 16-6)
OK
25
3 Check ABS/ESC control module assembly wire harness and connector


c. Disconnect the ABS/ESC control module assembly connector E-051.

NG Repair or replace ABS/ESC control

module assembly wire harness and
connector
OK
4 Check wire harness and connector (ABS/ESC control module assembly - battery)

connector E-051. V
+ -
d. Connect the negative battery cable.
e. Turn ignition switch to ON.
f. Using a digital multimeter, measure voltage between 13
12 11 10 9 8 7 6 5 4 3 2
1
ABS/ESC control module assembly connector E-051 and
24 23 22 21 20 19 18 17 16 15 14
body ground to check if power supply circuit is normal 38 37 36 35 34 33 32 31 30 29 28 27 26 25

Standard Condition
E-051
Condition
E-051 (29) - Body RA13T250250
ground
NG Repair or replace related wire harness and

connector
OK
25

5 Check wire harness and connector (ABS/ESC control module assembly - body ground)

body ground to check if system ground circuit is normal
12 11 10 9 8 7 6 5 4 3 2
according to table below. 13
24 23 22 21 20 19 18 17 16 15 14
1
Condition
E-051 (13) - Body

Always Continuity
ground
E-051 (38) - Body
ground

connector
OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

DTC C1001-04 ECU H/W error
IGNITION SWITCH
BATTERY
ON OR START
ENGINE
COMPARTMENT
SB08 SB01 EF06
FUSE AND
E-067
112 105 38
R
E-056
B
1 25 29 13 38
ESP
E-051
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
25 E-051
B
EA13T250111

DTC Detection
Condition
any of following  Fuse malfunction
conditions is met:  Wire harness or connector
C1001-04 ECU H/W error
ECU power supply is  ABS/ESC control module assembly
malfunctioning. malfunction
ECU is damaged.
CAUTION
Diagnosis Procedure
1 Check fuse

c. Remove fuse RF06 (7.5 A) from engine compartment fuse and relay box.
NG Replace fuse RF02
OK


connector
OK
25


connector E-051. V
+ -
12 11 10 9 8 7 6 5 4 3 2
1
24 23 22 21 20 19 18 17 16 15 14

Standard Voltage
E-051
Condition
E-051 (29) - Body RA13T250270
ground
NG Repair or replace engine wire harness and

connector
OK

12 11 10 9 8 7 6 5 4 3 2
24 23 22 21 20 19 18 17 16 15 14
1
Condition
E-051 (13) - Body

Always Continuity
ground
E-051 (38) - Body
ground
25 NG Repair or replace ABS/ESC control

connector

OK
5 Reconfirm DTCs

diagnostic tester.
YES
25

Motor Relay Open, Motor Short To GND, Motor Open,

DTC C0020-04 Motor Short To BAT, Motor Lock (Stuck), Motor GND
Open
IGNITION SWITCH
BATTERY
ON OR START
ENGINE
COMPARTMENT
SB08 SB01 EF06
FUSE AND
E-067
112 105 38
R
E-056
B
1 25 29 13 38
ESP
E-051
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
25
E-051
B
EA13T250120

DTC Detection
Condition
any of following
conditions is met:
Pump motor operates
with overload, and
temperature is too
high. (overheat
protection)
Return pump monitor  Fuse malfunction
Motor Relay Open, still cannot detect  Pump motor has poor ground
Motor Short To GND, voltage signal after connection
Motor Open, Motor return pump motor  System overheat protection
C0020-04
Short To BAT, Motor relay operates for 60
Lock (Stuck), Motor ms.  Abnormal pump motor power supply
GND Open Return pump monitor  Pump motor relay malfunction
detects voltage for  Pump motor malfunction
more than 2.5 s when
return pump motor
relay stops operating.
Return pump monitor
detects that voltage
does not drop when
return pump motor
relay does not operate.
CAUTION
Diagnosis Procedure
1 Cool engine down to check if malfunction is repaired
YES System overheat protection
NO
2 Check fuse

25
c. Remove fuse SB01 (30A) from engine compartment fuse and relay box.
NG Replace fuse SB01

OK


connector
OK

connector E-051. V
+ -
e. Using a digital multimeter, measure voltage between
ABS/ESC control module assembly connector E-051 and 12 11 10 9 8 7 6 5 4 3 2
body ground to check if power supply circuit is normal 13
24 23 22 21 20 19 18 17 16 15 14
1
according to table below. 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Standard Voltage

Condition
E-051 (25) - Body
Always 9 to 16 V
ground RA13T250300

connector
OK
25


12 11 10 9 8 7 6 5 4 3 2
24 23 22 21 20 19 18 17 16 15 14
1
Condition
E-051 (13) - Body

Always Continuity
ground
E-051 (38) - Body
ground

connector
OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

Valve Relay Open, Short To GND, Valve Relay Short To

DTC C1003-04
BAT
Solenoid Valve Open, Short To GND, Solenoid Valve

DTC C1004-04
Short To BAT, Leakage Current
IGNITION SWITCH
BATTERY
ON OR START
ENGINE
COMPARTMENT
SB08 SB01 EF06
FUSE AND
E-067
112 105 38
R
E-056
B
1 25 29 13 38
ESP
E-051
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
25
E-051
B
EA13T250130

DTC Detection
Condition
Valve Relay Open, This DTC occurs when
C1003-04 Short To GND, Valve any of following
Relay Short To BAT conditions is met:
Valve power supply is
malfunctioning. (power
supply is short to
ground or ground wire
is open)  Abnormal valve relay power supply
Solenoid valve  ECU has poor ground connection
temperature is too  Fuse malfunction
Solenoid Valve Open, high. (overheat  Solenoid valve is short to power
Short To GND, protection) supply or ground, or circuit is open.
C1004-04 Solenoid Valve Short 5 or more solenoid
To BAT, Leakage  System overheat protection
valves are short. (fuse)
Current  ABS/ESC damaged.
Activate corresponsive
solenoid valve, but no
feedback.
Solenoid valve itself is
malfunctioning.
Valve set relay is
malfunctioning.
CAUTION
Diagnosis Procedure
1 Cool engine down to check if malfunction is repaired
YES System overheat protection
NO
2 Check fuse

c. Remove fuse SB01 (30 A) from engine compartment fuse and relay box.
d. Check if fuse is blown. 25
NG Replace fuse SB01 (30 A)

OK


connector
OK

connector E-051. V
+ -
12 11 10 9 8 7 6 5 4 3 2
1
24 23 22 21 20 19 18 17 16 15 14

Standard Voltage
E-051
Condition
E-051 (25) - Body RA13T250330
Always 9 to 16 V
ground

connector
OK
25


12 11 10 9 8 7 6 5 4 3 2
24 23 22 21 20 19 18 17 16 15 14
1
Condition
E-051 (38) - Body

Always Continuity
ground
E-051 (13) - Body
ground

connector
OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

DTC C0044-01 Master Pressure Sensor Open, Short To BAT/GND
DTC C0044-28 Master Pressure Sensor Noisy Signal, Offset
25

IGNITION SWITCH
BATTERY
ON OR START
ENGINE
COMPARTMENT
EF24 EF06 EF07
FUSE AND
15A 7.5A 15A RELAY BOX
E-067
73 38 39
RW
RB
11
RB
RW
RB
E-030 I-036
4 1
BRAKE
SWITCH
I-013
R
2 3
BR
L
I-036
12 1
E-030
BR
E-056
L
L
B
A5 A17
ECM(A)
E-041
29 13 38 16
ESP
E-051
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
A56 A55 A54 A53 A52 A51 A50 A49
38 37 36 35 34 33 32 31 30 29 28 27 26 25
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
E-051 A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1

B
1 2 3 4 5 6 7 8 9 1
I-013
10 11 12 13 14 15 16 17 18 4 2
B
3
E-030 E-041 25
B B EA13T250160

DTC Detection
Condition
Master Pressure This DTC occurs when
C0044-01 Sensor Open, Short To any of following
BAT/GND conditions is met:
 Brake light switch is short or open
Pressure signal is
 Pressure sensor malfunction
Master Pressure interrupted.
 ESC module malfunction
C0044-28 Sensor Noisy Signal, Pressure value is
Offset abnormal. (less than
initial value)
CAUTION
Diagnosis Procedure
1 Check fuse

c. Remove fuse EF24 (15 A) from engine compartment fuse and relay box.
NG Replace fuse EF24 (15 A)
OK


connector
25 OK

3 Check brake light switch circuit (brake switch connector I-013 - battery power supply)

c. Disconnect the brake switch connector I-013.
V
d. Connect the negative battery cable. + -

brake switch connector I-013 and body ground to check if 4 2
3
power supply circuit is normal according to table below.
I-013
Standard Voltage
Condition
I-013 (4) - Body
Always 9 to 16 V
ground
RA13T250360
I-013 (1) - Body
Always 9 to 16 V
ground

connector
OK
4 Check wire harness and connector for an open or short failure

A56 A55 A54 A53 A52 A51 A50 A49
d. Disconnect ECM (A) connector E-041. + - A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25 E-041
e. Disconnect the ABS/ESC control module assembly A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
connector E-051. A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1

brake switch connector I-013 and wire harness connector
to check if system circuit is normal according to table
below.
1
Standard Condition 12 11 10 9 8 7 6 5 4 3 2 4 2
13 1
24 23 22 21 20 19 18 17 16 15 14
3
38 37 36 35 34 33 32 31 30 29 28 27 26 25
I-013
Condition
E-051
E-041 (A5) - I-013 RA13T250370
Always Continuity
(2)
E-041 (A17) and 25
E-051 (16) - I-013 Always Continuity
(3)
I-013 (4) - I-013
(1)

Condition
I-013 (2) - I-013
(3)

connector
OK
5 Replace brake switch
OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

DTC C0069-54 The Zero Value Calibration For G Sensor Is Not Done
DTC C0069-09 Sensor Initialization Error
DTC C0069-64 Sensor Abnormal Signal
DTC C0069-86 G Sensor Sensor Fail
25

IGNITION SWITCH
BATTERY
ON OR START
ENGINE
COMPARTMENT
SB08 SB01 EF06
FUSE AND
E-067
112 105 38
R
E-056
B
1 25 29 13 38
ESP
E-051
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-051
25 B
EA13T250150

DTC Detection
Condition
The Zero Value This DTC occurs when
C0069-54 Calibration For G any of following
Sensor Is Not Done conditions is met:
Sensor Initialization Calibration for yaw rate
C0069-09  Calibration for G sensor is not done
Error sensor is not done
 ESC module malfunction
Yaw rate sensor signal
Sensor Abnormal
C0069-64 is abnormal.
Signal
Yaw rate sensor is
C0069-86 G Sensor Sensor Fail malfunctioning.
CAUTION
Diagnosis Procedure
1 Check fuse

c. Remove fuse EF06 (7.5A) from engine compartment fuse and relay box.
NG Replace fuse EF06 (7.5A)
OK
2 Calibrate yaw rate sensor
OK Calibration for sensor is not done
NG
3 Check ESC control module assembly wire harness and connector

c. Disconnect the ESC control module assembly connector E-051.
25


connector
OK

connector E-051. V
+ -
12 11 10 9 8 7 6 5 4 3 2
1
24 23 22 21 20 19 18 17 16 15 14

Standard Voltage
E-051
Condition
E-051 (29) - Body RA13T250390
Always 9 to 16 V
ground

connector
OK
25


c. Disconnect the ESC control module assembly connector
E-051. + -
12 11 10 9 8 7 6 5 4 3 2
24 23 22 21 20 19 18 17 16 15 14
1
Condition
E-051 (13) - Body

Always Continuity
ground
E-051 (38) - Body
ground

connector
OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

DTC C0040-14 Brake Light Switch Open, Short To BAT/GND
IGNITION SWITCH
BATTERY
ON OR START
ENGINE
COMPARTMENT
EF24 EF06 EF07
FUSE AND
15A 7.5A 15A RELAY BOX
E-067
73 38 39
RW
RB
11
RB
RW
RB
E-030 I-036
4 1
BRAKE
SWITCH
I-013
R
2 3
BR
L
I-036
12 1
E-030
BR
E-056
L
L
B
A5 A17
ECM(A)
E-041
29 13 38 16
ESP
E-051
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
A56 A55 A54 A53 A52 A51 A50 A49
38 37 36 35 34 33 32 31 30 29 28 27 26 25
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
E-051 A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1

B
25
1 2 3 4 5 6 7 8 9 1
I-013
10 11 12 13 14 15 16 17 18 4 2
B
3
E-030 E-041
B B EA13T250160

DTC Detection
Condition
any of following
Brake Light Switch conditions is met:  BLS line is short or open.
C0040-14 Open, Short To BAT/ BLS signal is  Incorrect BLS installation
GND abnormal.  BLS damaged
BLS signal is
interrupted.
CAUTION
Diagnosis Procedure
1 Check fuse

c. Remove fuse EF24 (15 A) from engine compartment fuse and relay box.
NG Replace fuse RF02 EF24 (15 A)
OK

c. Disconnect the brake light switch connector.
d. Disconnect the ABS/ESC control module assembly connector E-051.

connector
OK
25

3 Check BLS installation, jig and wire harness
NG Install BLS, jig and wire harness properly
OK
4 Check brake light switch circuit for an open, short failure

V
d. Connect the negative battery cable. + -

brake switch connector I-013 and body ground to check if 4 2
3
power supply circuit is normal according to table below.
I-013
Standard Voltage
Condition
I-013 (4) - Body
Always 9 to 16 V
ground
RA13T250420
I-013 (1) - Body
Always 9 to 16 V
ground

connector
OK
25

5 Check wire harness and connector for an open or short failure

A56 A55 A54 A53 A52 A51 A50 A49
d. Disconnect ECM (A) connector E-041. + - A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25 E-041
e. Disconnect the ESC control module assembly connector A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
E-051. A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1

brake switch connector I-013 and wire harness connector
to check if system circuit is normal according to table
below.
1
Standard Condition 12 11 10 9 8 7 6 5 4 3 2 4 2
13 1
24 23 22 21 20 19 18 17 16 15 14
3
38 37 36 35 34 33 32 31 30 29 28 27 26 25
I-013
Condition
E-051
E-041 (A5) - I-013 RA13T250430
Always Continuity
(2)
E-041 (A17) and
E-051 (16) - I-013 Always Continuity
(3)
I-013 (4) - I-013
(1)
I-013 (2) - I-013
(3)
NG Repair or replace brake light switch, wire

harness and connector
OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

DTC U1300-55 Software Configuration Error
DTC U0140-87 Lost Communication With BCM
DTC U0101-87 Lost Communication With TCU
DTC U0100-87 Lost Communication With EMS
DTC U0126-87 Lost Communication With SAM
DTC U0401-81 Invalid Data Received From EMS
DTC U0402-81 Invalid Data Received From TCU
DTC U0428-81 Invalid Data Received From SAM
DTC U0422-81 Invalid Data Received From BCM
DTC U0073-00 Control Module Communication Bus Off
25

BATTERY
R
ENGINE
COMPARTMENT
MF05 FUSE AND IP FUSE
RELAY BOX AND
40A RF15
E-067 RELAY BOX
E-063 7.5A I-032
E-028
R 40
R
16
DIAGNOSTIC
INTERFACE BCM (B)
I-033 I-034
CAN2-L CAN2-H
CAN2-H CAN2-L B2 B15
3 11 4 5
B
G
Y
B
G
CAN2-L CAN2-H
I-004
Y C7
AUDIO (C)
G C1 I-016
G
Y
CAN2-L CAN2-H
CAN2-H CAN2-L
RADAR 5 G G G 30 INSTRUMENT
CONTROL 6
CLUSTER
MODULE 13 Y Y Y 29
5 I-011
B-004
B-019 I-002
16 15 14 13 12 11 10 9 C6 C5 C4 C3 C2 C1
I-033 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034 I-016
8 7 6 5 4 3 2 1 B B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W C12 C11 C10 C9 C8 C7 L
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I-011
1 2 3 4 5 6 7 8 B-004 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 L
9 10 11 12 13 14 15 16 W
25
EA13T530010

ECM(A) E-041
CAN1-L CAN1-H
CAN1-L CAN1-H
CAN1-H CAN1-L
A23 A11
32 G G 14
TCU ESP
E-069 31 Y Y 2 E-051
G
Y
E-054
6 5
I-018
CAN1-H CAN1-L
CAN1-L CAN1-H
STEERING 1 Y Y 2
SRS CONTROL
ANGLE
MODULE
SENSOR 2 G G 17
I-020
I-028
G
Y
CAN1-L CAN1-H
CAN1-H CAN1-L
INTERFACE BCM (B)
I-033 G G B16 I-034
6
1 2 3 4 5 6 7 8 9 10 41 42
11 12 13 14 15 16 17 18 19 20 43 44 E-069
21 22 23 24 25 26 27 28 29 30 45 46 B
31 32 33 34 35 36 37 38 39 40 47 48
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37 E-041
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
B
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I-020

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 Gr
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034

B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
E-051 16 15 14 13 12 11 10 9
12 11 10 9 8 7 6 5 4 3 2 I-033
13 1
B 8 7 6 5 4 3 2 1 B
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
4 3 E-054 6 5 4 3 2 1 I-028
2 1
W B
10 9 8 7 6 5
25
EA13T530020

DTC Detection
Condition
Software Configuration
U1300-55
Error
Lost Communication
U0140-87
With BCM
Lost Communication
U0101-87
With TCU This DTC occurs when  CAN controller malfunction
Lost Communication any of following  CAN configuration information
U0100-87 conditions is met: unmatched
With EMS
Vehicle CAN bus  CAN communication off
Lost Communication communication,
U0126-87  CAN bus line malfunction
With SAM configuration
Invalid Data Received information and line  ECM software version unmatched
U0401-81 malfunction  ECM damaged
From EMS
Invalid Data Received ECM overtime  TCU software version unmatched
U0402-81 ECM error  TCU software version unmatched
From TCU
Invalid Data Received TCU overtime  BCM damaged
U0428-81 TCU error  ESC (ABS) damaged
From SAM
Invalid Data Received
U0422-81
From BCM
Control Module
U0073-00 Communication Bus
Off
CAUTION
Diagnosis Procedure

d. Disconnect the Engine Control Module (ECM) connector E-041.
e. Disconnect the Body Control Module (BCM) connector I-034.
f. Disconnect the Transmission Control Module (BCM) connector E-069.
g. Disconnect the steering angle sensor connector I-028.
h. Disconnect the SRS control module (SRS) connector I-020. 25
i. Check if wire harnesses are worn, pierced, pinched or partially broken.
j. Check for broken, bent, protruded or corroded terminals.
k. Check if terminal contact pins of related connectors are in good condition.


connector
OK
Check CAN communication control circuit (ABS/ESC control module assembly - Engine
2 Control Module (ECM) )

A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37

E-041
d. Disconnect the Engine Control Module (ECM) connector A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
E-041. A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1

terminals of connectors E-051 and E-041 to check if
there is an open in CAN communication circuit according
to table below.
Standard Condition 12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
Multimeter Specified 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Condition
E-051 (14) - E-051
E-041 (A11)
E-051 (2) - E-041
(A23)

connector
OK
25

Check CAN communication control circuit (ABS/ESC control module assembly -

3 Transmission Control Unit (TCU))

1 2 3 4 5 6 7 8 9 10 41 42
connector E-051. + - 11 12 13 14 15 16 17 18 19 20 43 44
d. Disconnect the Transmission Control Module (BCM) 21 22 23 24 25 26 27 28 29 30 45 46
connector E-069. 31 32 33 34 35 36 37 38 39 40 47 48
e. Using a digital multimeter, check for continuity between E-069

terminals of connectors E-051 and E-069 to check if
there is an open in CAN communication circuit according
to table below.
12 11 10 9 8 7 6 5 4 3 2
24 23 22 21 20 19 18 17 16 15 14
1
38 37 36 35 34 33 32 31 30 29 28 27 26 25
Condition
E-051 (2) - E-069 E-051
(31)
E-051 (14) -
Always Continuity
E-069 (32)

connector
OK
Check CAN communication control circuit (ABS/ESC control module assembly - Body
4 Control Module (BCM))

connector E-051. + - B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
d. Disconnect the Body Control Module (BCM) connector I- B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
034. I-034
terminals of connectors E-051 and I-034 to check if there
table below.
12 11 10 9 8 7 6 5 4 3 2
24 23 22 21 20 19 18 17 16 15 14
1
38 37 36 35 34 33 32 31 30 29 28 27 26 25
Condition
25
E-051 (14) - I-034 E-051
(B16)
E-051 (2) - I-034
Always Continuity
(B3)


OK
Check other wire harness and connector of CAN communication control circuit (See page
5 53-10)

connector
OK
6 Check module software version information
a. Connect the negative battery cable.

c. Use X-431 3G diagnostic tester to read ECM/TCU software version information.
d. Check if there is any abnormality.
NG ECM/TCM software version is unmatched
OK
7 Reconfirm DTCs

diagnostic tester.
YES
25

ON-VEHICLE SERVICE
ABS Bleeding
WARNING
 When bleeding brake system, wear safety glasses.If brake fluid gets on your eyes or skin, wash off with
water completely.
 If brake fluid gets on your eyes or skin, wash off with water completely.
CAUTION
 Brake fluid should meet Chery specified type (DOT4). DO NOT mix brake fluid with other types of brake
fluid.
 Brake fluid has strong water absorbability, so be sure to place it in original sealed container.
 To prevent dust and other foreign matter from entering reservoir, wipe it off before removing reservoir
cap.
Bleeding procedures for brake system with X-431 3G diagnostic tester are as follows:
1. Make sure all brake lines are installed and tightened properly.
2. Check that battery voltage is normal.
4. Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC).
5. Turn ignition switch to ON.
6. Using X-431 3G diagnostic tester, read and clear DTCs stored in ABS/ESC control module assembly.
7. Using X-431 3G diagnostic tester, enter brake control system, select manual bleeding, and then perform
operation according to information and procedures displayed on diagnostic tester.
HINT:
 If bleeder plug is open, never depress brake pedal repeatedly. Doing so will increase the amount of air in
system.
 DO NOT drain brake fluid from brake fluid reservoir while bleeding the system.Otherwise, low fluid level in
brake reservoir will cause additional air to enter the brake system.
 Always check brake fluid level at all times to ensure that brake fluid level in brake reservoir is always close
to MAX level.
8. For X type brake circuit, the bleeding order is: rear left wheel, front left wheel, front right wheel, rear right
wheel.
9. After bleeding is completed, fill brake reservoir with brake fluid to MAX level.
10.Drive vehicle to perform a road test, and confirm that ABS/ESC system operates normally and brake pedal
feel is good.
25

ABS/ESC Control Module Assembly

Removal
WARNING
 When repairing ABS/ESC system, first release the pressure of high pressure brake fluid in accumulator,
to prevent high pressure brake fluid from spraying out and causing injury.
 Operation procedures: turn ignition switch to LOCK first, and then depress and release brake pedal
repeatedly until brake pedal becomes hard.
 In addition, never turn ignition switch to ON before ABS/ESC system is installed completely to prevent
hydraulic pump from energizing and running.

3. Drain brake fluid (See page 26-15).
 Drained brake fluid should be well kept in a container. Never discard it at will.
CAUTION
 Wash off brake fluid immediately if it contacts with any paint surface.
4. Remove the engine trim cover assembly.

5. Remove the ABS/ESC control module assembly.
a. Press lock area of ABS/ESC control module assembly
connector, toggle connector lock bracket downward
and disconnect ABS/ESC control module assembly
connector (arrow).
RA13T250510
25

b. Using a fixing wrench, carefully disconnect 6 brake

pipe coupling plugs (arrow).
RA13T250510
CAUTION
 When removing brake line, prevent foreign matter form entering ABS/ESC control module assembly
threaded holes.
 After disconnecting brake line, sealing measure should be taken to prevent foreign matter form entering.
c. Disengage insulators (arrow) from mounting bracket.

d. Remove the ABS/ESC control module assembly.
RA13T250520
6. Remove the ABS/ESC control module assembly mounting bracket.

a. Remove 3 coupling nuts (arrow) between ABS/ESC
control module assembly mounting bracket and body.
RA13T250530
b. Remove the ABS/ESC control module assembly mounting bracket.
Installation
25

CAUTION
 ABS/ESC control module assembly contains hydraulic control module and electronic control module.As
a unit, they cannot be repaired or replaced individually.
 Check insulator for aging or damage.Replace if necessary.
 When installing fixing bolts and screws, be sure to tighten them to specified torque.
 Perform ABS bleeding procedures for brake system after completing installation (See page 26-12).
 Using X-431 3G diagnostic tester, enter brake control system, record and clear trouble code, then drive
vehicle to perform a road test, confirming that ABS/ESC system operates normally and feeling to
depress brake pedal is good.
25

Front Wheel Speed Sensor (Take Front Left Wheel As An Example)

Removal
CAUTION
 Keep wheel speed sensor away from oil or other foreign matter. Otherwise, speed signal generated by
wheel speed sensor may be inaccurate, and system may even fail to operate normally.
HINT:
4. Remove the front left wheel speed sensor.
a. Remove the coupling bolt (arrow) between front left
wheel speed sensor and front left steering knuckle
assembly, and disengage front left wheel speed
sensor carefully.
RA13T250540
CAUTION
 Keep head and installation hole of sensor free of foreign matter.
b. Disengage attachment parts (arrow) of front left wheel

speed sensor wire harness.
HINT:
Observe winding direction of sensor wire harness to
prevent incorrect installation.
RA13T250550
25

c. Disconnect the front left wheel speed sensor wire

harness connector (arrow).
RA13T250580
d. Detach wire harness connector fixing clip and remove front left wheel speed sensor.
Inspection
1. Check the rear wheel speed sensor.
a. Check rear wheel speed sensor surface for breakage, dents or notch.
b. Check rear wheel speed sensor connector or wire harness for scratches, breakage or damage.
c. If any of above conditions occurs, replace rear wheel speed sensor with a new one.
Installation
CAUTION
 When installing coupling bolts, be sure to tighten them to specified torque.
25

Rear Wheel Speed Sensor (Take Rear Left Wheel As An Example)

Removal
CAUTION
 Keep wheel speed sensor away from oil or other foreign matter. Otherwise, speed signal generated by
wheel speed sensor may be inaccurate, and system may even fail to operate normally.
HINT:
4. Remove the rear left wheel speed sensor.
a. Remove coupling bolt (arrow) between rear left wheel
speed sensor and rear left steering knuckle assembly,
and disengage rear left wheel speed sensor carefully.
RA13T250610
CAUTION
 Keep head and installation hole of sensor free of foreign matter.
b. Disengage attachment parts (arrow) of rear left wheel

speed sensor wire harness.
HINT:
Observe winding direction of sensor wire harness to
prevent incorrect installation.
RA13T250620
c. Remove rear seat and turn over carpet (See page 47-15).
25

d. Disconnect the rear left wheel speed sensor wire

RA13T250630
e. Disengage wire harness fixing rubber ring and remove rear left wheel speed sensor.
Inspection
1. Check the rear wheel speed sensor.
a. Check rear wheel speed sensor surface for breakage, dents or notch.
b. Check rear wheel speed sensor connector or wire harness for scratches, breakage or damage.
c. If any of above conditions occurs, replace rear wheel speed sensor with a new one.
Installation
CAUTION
 When installing coupling bolts, be sure to tighten them to specified torque.
25

Steering Angle Sensor

Removal
CAUTION
 Wait at least 90 seconds after disconnecting the negative battery cable to disable supplementary
restraint system.
3. Position the front wheels straight ahead.

4. Remove the steering wheel assembly (See page 28-8).
5. Remove the combination switch cover assembly (See page 28-11).
6. Remove the combination switch (See page 28-13).
7. Remove the steering angle sensor.
a. Detach fixing claws (arrow) between combination
switch and spiral cable.
RA13T310590
b. Detach angle sensor fixing claws (arrow) and

separate spiral cable and angle sensor.
RA13T250650
Installation
25

CAUTION
 Always install spiral cable correctly according to specified operating instructions.

 DO NOT rotate the spiral cable over specified turns to prevent it from breaking.
 Be sure to install fixing claws in place when installing spiral cable.
 Check that horn operates normally after installation.
 Check SRS warning light after installation, and make sure that supplemental restraint system operates
normally.
25

BRAKE
GENERAL INFORMATION 26-3 Brake Pedal Assembly 26-23
Front Disc Brake Assembly 26-26
Removal 26-27
Inspection 26-11
Disassembly 26-28
ON-VEHICLE SERVICE 26-12 Inspection 26-31
Brake Bleeding 26-12 Assembly 26-32
Brake Fluid Replacement 26-15 Installation 26-34
Brake Fluid Reservoir Assembly 26-16 Front Brake Hose Assembly 26-35
On-vehicle Inspection 26-16 Removal 26-35
Installation 26-17 Rear Disc Brake Assembly 26-37
Brake Master Cylinder Assembly 26-18 On-vehicle Inspection 26-37
Installation 26-19 Disassembly 26-39
Vacuum Booster with Brake Master  Inspection 26-42
Cylinder Assembly 26-20 Assembly 26-43
On-vehicle Inspection 26-20 Installation 26-46
Removal 26-21 Rear Brake Hose Assembly 26-47
Installation 26-22 Installation 26-48
26

26

26 - BRAKE
GENERAL INFORMATION
BRAKE
Description
Front Ventilated Disc Brake Assembly
4
6
5
RA13T260010
1 - Front Brake Caliper Assembly 2 - Front Brake Disc

3 - Front Hub 4 - Front Hub Bearing
5 - Bearing Retainer 6 - Front Dust Guard
7 - Front Steering Knuckle
26

26 - BRAKE
Rear Disc Brake Assembly
1 3
4
5
RA13T260020
1 - Bearing End Cover 2 - Locking Nut

3 - Rear Brake Disc 4 - Rear Hub Bearing Assembly
5 - Rear Dust Guard 6 - Rear Hub Shaft
7 - Rear Brake Caliper Assembly
Brake system uses following configuration: a ventilated disc brake is used for front wheel, and a solid disc
brake is used for rear wheel (parking brake can adjust automatically as rear brake lining is worn, press brake
caliper against brake lining with mechanical force, so apply pressure to brake disc).
Using lever principle, brake pedal pushes pushrod into vacuum booster, which boosts force of pushrod by
using vacuum and then transmits force to brake master cylinder assembly. Hydraulic pressure, produced in
brake master cylinder assembly, is transmitted to ABS Hydraulic Control Unit (HCU) through brake line, and
then distributed to individual brake calipers. Brake calipers apply force to brake linings using hydraulic
pressure. Depending on amount of brake pressure applied to brake linings, wheels will slow down or stop.
26

26 - BRAKE
Specifications

Coupling Plug Between Brake Master Cylinder
16 ± 1
Assembly and Brake Pipe
Coupling Nut Between Brake Master Cylinder
23 ± 2
Assembly and Vacuum Booster Assembly
Coupling Nut Between Vacuum Booster Assembly
23 ± 2
and Brake Pedal Assembly
Coupling Bolt Between Brake Pedal Assembly and
23 ± 2
Body
Coupling Plug Between Front Brake Caliper
16 ± 1
Assembly and Front Brake Hose Assembly
Coupling Bolt Between Front Brake Caliper
70 ± 5
Front Brake Disc Locating Screw 4.5 ± 0.5
Front Brake Caliper Bleeder Plug 9 - 11
Guide Bolt Between Front Brake Caliper Fixing
22 - 32
Bracket and Front Brake Cylinder Assembly
Coupling Plug Between Front Brake Hose Assembly
16 ± 1
and Front Brake Pipe
16 ± 1
Assembly and Rear Brake Hose Assembly
Assembly and Brake Caliper Mounting Board 70 ± 5
Assembly
Rear Brake Disc Locating Screw 4.5 ± 0.5
Rear Brake Caliper Bleeder Plug 9 - 11
Guide Bolt Between Rear Brake Caliper Fixing
23 ± 2
Bracket and Rear Brake Cylinder Assembly
Coupling Plug Between Rear Brake Hose Assembly
16 ± 1
and Brake Pipe
Rear Hub Shaft Locking Nut 300 ± 20
Rear Left and Right Hub Shaft Fixing Bolt 70 ± 5
26

26 - BRAKE
Front Disc Brake

(mm) (mm)
Front Brake Disc 25 20 0.06
Front Brake Lining 11.2 2.2 -
Rear Disc Brake

(mm) (mm)
Rear Brake Disc 9 7 0.06
Rear Brake Lining 9.5 2 -
26

26 - BRAKE
Tools
Special Tool
Brake Caliper Piston Pressing Tool
RCH0000053
General Tools
20
10
30
0
40
90
50
80
60
70
RCH0000023
Vernier Caliper
RCH0000019
Digital Multimeter
RCH0000002
26

26 - BRAKE
Circuit Diagram
Brake System

ON OR START
IP FUSE AND
RF10 RF01 RELAY BOX
10A 10A I-032
33 7
RY
R
11 13
INSTRUMENT
CLUSTER
I-011
26 3
LY
I-035
3 E-029
LY
5 E-035
E-007
I-005
LY
2
BRAKE FLUID
LEVEL
SENSOR
E-004
1
B
E-005
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I-011 E-035
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 6 5 4 3 2 1
L B
12 11 10 9 8 7
26 1 2 3 4 5 6 7 8
I-035
W
1 2 E-004
9 10 11 12 13 14 15 16 B
EA13T260010

26 - BRAKE
DIAGNOSIS & TESTING

HINT:

Front brake lining (cracked, deformed, dirty
26-31
or burnished)
Rear brake lining (cracked, deformed, dirty
26-42
or burnished)
Front disc brake guide bolt guide pin (worn) 26-29
Rear disc brake guide bolt guide pin (worn) 26-40
Front brake caliper assembly fixing bolt
26-27
(loose)
Rear brake caliper assembly fixing bolt
Noise in brake 26-38
(loose)
Front brake disc (scored) 26-27
Rear brake disc (scored) 26-37
Brake disc runout (excessive) 26-27
Parking brake return tension spring
26-38
(damaged or insufficient elasticity)
Front brake disc (foreign matter) 26-32
Rear brake disc (foreign matter) 26-43
Front brake lining (worn, cracked,
26-31
deformed, oily or burnished)
Rear brake lining (worn, cracked,
26-42
deformed, oily or burnished)
Hard pedal but braking inefficient Front brake disc (unevenly worn) 26-27
Rear brake disc (unevenly worn) 26-37
Vacuum booster pushrod position
26-23
(incorrect)
Booster system (vacuum leaks) 26-21
Hard pedal (firm-depress unable to lock-up Vacuum booster (bounce)
26-21
wheels)
Brake system (air ingress) 26-12
Pedal overtravel (vehicle stops normally)
Brake system (leaked) 26-12
Pedal pulsates/bounces during braking Brake disc (unevenly worn) 26-27
26

26 - BRAKE

Brake system (air ingress) 26-12
Brake system (leaked) 26-12
Front brake piston seal (worn or damaged) 26-30
Low or spongy pedal Rear brake piston seal (worn or damaged) 26-42
Brake master cylinder assembly
26-18
(malfunction)
26-23
(incorrect)
Front brake piston (catching or frozen) 26-30
Rear brake piston (catching or frozen) 26-41
Front brake lining (dirty, cracked or
26-31
deformed)
Vehicle pulls during braking
Rear brake lining (dirty, cracked or
26-42
deformed)
Front brake disc (unevenly worn) 26-27
Rear brake disc (unevenly worn) 26-37
Brake pedal free play (minimum) 26-23
Parking brake control mechanism stroke
26-38
(in need of adjustment)
Parking brake cable (catching) 27-13
Front brake lining (cracked or deformed) 26-31
Rear brake lining (cracked or deformed) 26-42
Front brake piston (catching or frozen) 26-30
Brake catching
Rear brake piston (catching or frozen) 26-41
Rear parking brake return tension spring
26-38
(loose or damaged)
26-23
(incorrect)
Booster system (vacuum leaks) 26-21
Brake master cylinder assembly (malfunction) 26-18
26

26 - BRAKE
Inspection
CAUTION
 Use well-sealed brake fluid DOT4 or equivalent. DO NOT use oily solution, otherwise brake system seal
may be damaged.
 Brake fluid may damage paint surface. If brake fluid spills on paint surface, wash it off immediately with
water.
 DO NOT use gasoline, kerosene, alcohol, engine oil, transmission oil or any other fluid that contains
mineral oil to clean the system components. These kinds of fluid will damage the rubber cover and seal.
 During servicing, be sure to clean the grease or other foreign matter on the outer surface of brake caliper
assembly, brake lining, brake disc and wheel hub.
 When operating brake disc and brake caliper, be careful not to damage brake disc and brake caliper and
scratch or cut brake linings.
1. Check conditions of tires and wheels. Damaged or worn wheels and tires can cause a pull, shudder,
vibration and a condition similar to sudden braking.
2. If noise occurs while braking, check suspension components. Bounce the vehicle up and down several
times and check suspension or steering components for any looseness, wear or damage.
3. Check brake fluid level and condition.
a. If brake fluid level is too low, check ABS/ESP control unit assembly, brake caliper, brake line, brake
master cylinder assembly and brake fluid reservoir, etc. for leakage.
b. If brake fluid is contaminated, drain a certain amount of fluid for inspection. Replace with new fluid as
necessary.
HINT:
It is normal that brake fluid will become dark after being used for a period of time. Do not mistake this for
contamination.
26

26 - BRAKE
ON-VEHICLE SERVICE
Brake Bleeding
Be sure to perform brake bleeding and clutch bleeding after replacing hydraulic parts related to brake and
clutch. For details about clutch bleeding, See page 26-12. There are 2 methods for brake bleeding, and
specific operation procedures are as follows:
Method 1: perform bleeding brake manually
WARNING
 When bleeding brake system, wear safety glasses.

 Be careful when bleeding air, as brake fluid at high pressure may spray out from bleeder plug.
CAUTION
 Before removing brake fluid reservoir, wipe off any dust and other foreign matters on brake fluid reservoir
to prevent them from entering.
 Use fresh, clear and well-sealed brake fluid with specified type or equivalent.
 DO NOT allow the brake fluid to adhere to any paint surface, such as vehicle body. If brake fluid leaks
onto any paint surface, immediately wash it off.
 During bleeding, do not depress brake pedal repeatedly whenever bleeder plug is opened. Otherwise, air
amount in the system will increase to make an extra bleeding.
 DO NOT drain the brake fluid in brake fluid reservoir while bleeding brake system.
HINT:
An assistant will be required to assist when bleeding brake system.
1. Fill brake fluid reservoir with brake fluid to a proper level.
2. Loosen bleeder plug cap and connect a clear plastic hose to bleeder plug. Submerge the end of hose into
clear container filled with new brake fluid.
3. Have an assistant depress brake pedal 3 to 4 times
repeatedly; and then depress and hold it at a lower
position. Then loosen bleeder plug at least one turn.
RA13T260030
26

26 - BRAKE
4. Tighten bleeder plug every time brake pedal goes down

quickly. Then release brake pedal.
RA13T260040
5. Repeat above steps, and use the same procedures to bleed brake line of each wheel in order of rear left
wheel, front left wheel, front right wheel and rear right wheel, until no air exists in brake system.
Empty sign: a stream of fresh brake fluid flows into clear container without bubbles.
HINT:
During bleeding brake system, make sure brake fluid level in
brake fluid reservoir is always near "MAX" mark. Check
brake fluid level at all times during bleeding. Add brake fluid
as necessary.
RA13T260050
6. Check and adjust brake fluid level to "MAX" mark.

7. Check the brake pedal effect. If braking effect is poor or pedal is spongy, air may still exist in system.
Perform bleeding procedures for brake system again as necessary.
8. Test vehicle to confirm that brakes operate properly with good depressing feel.
Method 2: bleeding brake using diagnostic tester
CAUTION
 Check that battery voltage should not be lower than 10 V.

 Bleeding order must be rear left / front left / front right / rear right. If it is necessary to repeat part or whole
bleeding procedure, be sure to wait for 5 minutes to cool solenoid valve down, otherwise solenoid valve
may be damaged due to overheat.
Method 2: bleeding brake using diagnostic tester
CAUTION
 Check that battery voltage should not be lower than 10 V.

 Bleeding order must be rear left / front left / front right / rear right. If it is necessary to repeat part or whole
bleeding procedure, be sure to wait for 5 minutes to cool solenoid valve down, otherwise solenoid valve
may be damaged due to overheat.
In order to reach sufficient pressure in hydraulic regulator, depress brake pedal repeatedly during whole 26
process.
1. Fill brake fluid reservoir with brake fluid to a proper level.

26 - BRAKE
2. Depress brake pedal 20 times or more with engine stopped.

3. Turn ignition switch to ON, and enter A13T "ABS" system using X-431 3G diagnostic tester (the latest
software).
 Please select [ABS] on Diagnostic program screen.
Diagnostic program
ENG
ABS
SRS
BCM
ICM
PEPS
IMMO
AT
RA13T260051
 Please select [Special function] on Diagnostic program

screen.
Diagnostic program
Version information
DTC
Clear DTC
Data stream
Freeze Frame Data
Special function
RA13T260052
 Please select [Repair Bleed] on Special function screen.

Special function
Write software configuration information (ESP Only)
Write automatly software configuration information (ESP Only)
Repair Bleed
Write E&F Process Control Byte
Yaw Sensor Calibration (ESP Only)
RA13T260053
 Please select [phase 1: Bleed the wheel rear left] on

Repair Bleed screen, then perform bleeding operation for
rear left wheel.
Repair Bleed
Phase 1:Bleed the wheel rear left
Phase 2:Bleed the wheel front left
Phase 2:Bleed the wheel front right
Phase 2:Bleed the wheel rear right
RA13T260054
26

26 - BRAKE
4. Loosen bleeder plug cap of rear left wheel and connect a

clear plastic hose to bleeder plug. Submerge the end of
hose into clear container filled with fresh brake fluid.
RA13T260030
5. Use same bleeding procedures as rear left wheel to bleed air for brake lines of front left wheel, front right
wheel and rear right wheel, until no air exists in brake system.
Empty sign: a stream of fresh brake fluid flows into clear container without bubbles.
HINT:
During bleeding brake system, make sure brake fluid level in
brake fluid reservoir is always near "MAX" mark. Check the
brake fluid level at all times during bleeding. Add brake fluid
as necessary.
RA13T260050
6. Check and adjust brake fluid level to "MAX" mark.

7. Check the brake pedal effect. If braking effect is poor or pedal is spongy, air may still exist in system.
Perform bleeding procedures for brake system again as necessary.
8. Test vehicle to confirm that brakes operate properly with good depressing feel.
Brake Fluid Replacement

1. Drain the brake fluid.
a. Start engine and run it at idle.
b. Unscrew filler cap of brake fluid reservoir assembly. Loosen bleeder plug cap and connect a clear
plastic hose to bleeder plug. Submerge the end of hose into clear container filled with new brake fluid.
c. Loosen bleeder plug, and depress brake pedal
continuously until no brake fluid comes out.
RA13T260030
2. Add the brake fluid.

a. Tighten bleeder plug after confirming that brake fluid has been drained. Fill brake fluid reservoir with
new brake fluid to a proper level.
3. Perform bleeding procedures. 26
a. After replacing with new brake fluid, be sure to bleed brake system for normal operation. For details
about brake system bleeding, See page 26-12.

26 - BRAKE
Brake Fluid Reservoir Assembly

1. Check the brake fluid level warning switch.
a. Remove the brake fluid reservoir filler cap.
b. Disconnect the brake fluid level warning switch wire + -
harness connector.
c. Using ohm band of digital multimeter, check for
continuity between brake fluid level warning switch 1 2
terminals according to conditions shown in table
below.
Standard Condition
RA13T260060
Condition
Terminal 1 - Float upward
No continuity
Terminal 2 (switch ON)
Terminal 1 - Float downward
Continuity
Terminal 2 (switch OFF)
HINT:
 There is a float in fluid reservoir. Position of float changes as brake fluid level rises or drops.
 If result is not as specified, replace brake fluid reservoir assembly.
d. Add brake fluid to the level 0 - 5 mm below "MAX" mark.
Removal
1. Drain the brake fluid (See page 26-15).
CAUTION
 Wash off brake fluid immediately if it comes in contact with any paint surface.
26

26 - BRAKE
2. Remove the brake fluid reservoir assembly.

a. Disconnect the brake fluid level warning switch
connector (arrow).
RA13T260070
b. Disconnect clutch hose and master cylinder inlet pipe

(arrow) from brake fluid reservoir assembly (for MT
model).
RA13T260080
c. Remove 2 fixing nuts (arrow) from brake fluid

reservoir assembly.
RA13T260090
d. Remove brake fluid reservoir assembly from brake master cylinder assembly.
Installation
HINT:
Perform bleeding procedures for brake system and add brake fluid to a proper level after completing
installation.
26

26 - BRAKE
Brake Master Cylinder Assembly

Removal
CAUTION
 Release vacuum in vacuum booster before removing brake master cylinder assembly to avoid damaging
brake master cylinder assembly and prevent booster from sucking in any pollutant.
 When engine is not running, release vacuum by pumping brake pedal until brake pedal can be
depressed firmly.
 When removing brake line, sealing measures should be taken to prevent foreign matter from entering.
CAUTION
2. Remove the air filter with intake hose (See page 10-10).
3. Remove the brake fluid reservoir assembly (See page 26-16).
4. Remove the brake master cylinder assembly.
a. Loosen 2 coupling plugs (arrow) between brake
master cylinder assembly and brake pipes.
RA13T260095
b. Loosen 2 coupling nuts and washers (arrow) between

brake master cylinder assembly and vacuum booster.
26
RA13T260100
c. Slide brake master cylinder assembly straight out of vacuum booster carefully.

26 - BRAKE
CAUTION
 The design of brake master cylinder assembly and piston could make piston easy to fall out. To prevent
this, make sure that master cylinder is horizontal or end surface faces down (piston surface faces
upward) when handling brake master cylinder assembly.
 Make sure that no foreign matter adheres to brake master cylinder assembly piston. If foreign matter
adheres, clean it off with a piece of clean cloth. Then, apply grease to entire periphery of contact surface
of master cylinder piston.
 Master cylinder should be handled carefully. Avoid any impact to master cylinder, such as dropping. It
cannot be reused if dropped.
 DO NOT tap or pinch master cylinder piston, and avoid damaging master cylinder piston in any other
ways.
Installation
CAUTION
 Make sure to tighten coupling bolts and nuts to specified torque during installation.
 Perform bleeding procedures for brake system and add brake fluid to a proper level after completing
installation.
26

26 - BRAKE
Vacuum Booster with Brake Master Cylinder Assembly

1. Check the vacuum booster assembly.
a. Check the air tightness.
 Start engine and stop it after 1 or 2 minutes. Slowly depress the brake pedal several times.
 Make sure that booster is airtight. Check that pedal depression amount gradually decreases,
compared to previous. If pedal operation is not as specified, check the check valve. If check valve is
normal, replace vacuum booster assembly.
 Start the engine. Depress and hold the pedal, and then stop engine.
 Make sure that booster is airtight. Depress and hold pedal for 30 seconds, and check that pedal
reserve distance does not change.
b. Check the operation.
 Stop the engine.
 Depress the pedal several times, and check that
pedal reserve distance does not change.
RA13T260110
 Depress and hold pedal, and then start engine.

Check that pedal can only be depressed slightly.
If pedal operation is not as specified, check the
check valve. If check valve is normal, replace
vacuum booster assembly.
RA13T260120
26

26 - BRAKE
Removal
CAUTION

5. Remove the brake fluid reservoir assembly (See page 26-16).
6. Remove the accelerator pedal assembly (See page 10-17).
7. Remove the accelerator pedal bracket.
8. Remove the vacuum booster with brake master cylinder assembly.
a. Loosen 2 coupling plugs (arrow) between brake
master cylinder assembly and brake pipes.
RA13T260095
b. Detach vacuum hose assembly with check valve

(arrow) from vacuum booster assembly.
RA13T260130
26

26 - BRAKE
c. Using needle-nose pliers, remove locking pin (arrow)

and pushrod pin (1) from vacuum booster pushrod
and detach brake pedal assembly.
RA13T260140
d. Remove 4 coupling nuts (arrow) between vacuum

booster assembly and brake pedal assembly.
RA13T260150
e. Remove vacuum booster with brake master cylinder assembly from engine compartment.
Inspection
1. Check the check valve.
a. Remove check valve from vacuum hose assembly.
b. Check that there is airflow (A) from vacuum booster to
engine, and no airflow (B) from engine to vacuum
booster.
A B
If result is not as specified, replace vacuum hose
assembly.
RA13T260160
Installation
CAUTION
 Make sure to tighten coupling bolts and nuts to specified torque during installation.
 Perform bleeding procedures for brake system and add brake fluid to a proper level after completing
installation.
26

26 - BRAKE
Brake Pedal Assembly

1. Check the brake pedal free play.
a. Stop the engine. Depress brake pedal several times until no vacuum is left in vacuum booster, then
release brake pedal.
b. Depress brake pedal until resistance is felt.
c. As shown in illustration, check brake pedal free play
by measuring distance between pedal position in
previous step and pedal position after released.
Standard brake pedal free play: 1 - 9 mm
Pedal Free Play
RA13T260170
2. Adjust the brake pedal free play.

a. As shown in illustration, loosen vacuum booster
pushrod locking nut (arrow) and rotate vacuum
booster pushrod clockwise or counterclockwise to
adjust brake pedal free play to specified value.
RA13T260180
3. Check the brake pedal height.

a. As shown in illustration, turn over carpet and measure
brake pedal height between brake pedal center and
dash panel.
Standard brake pedal height: 139.9 mm
Pedal Height
RA13T260190
4. Adjust the brake pedal height.

a. As shown in illustration, loosen vacuum booster
pushrod locking nut (arrow) and rotate vacuum
booster pushrod clockwise or counterclockwise to
adjust brake pedal height to specified value.
26
RA13T260180

26 - BRAKE
Removal
1. Remove the accelerator pedal assembly (See page 10-17).
2. Remove the accelerator pedal bracket.
3. Remove the brake light switch assembly.
a. Disconnect the brake light switch assembly wire
RA13T260200
b. Remove brake light switch assembly by rotating it 90°

clockwise or counterclockwise.
RA13T260210
4. Remove the brake pedal assembly.

a. Using needle-nose pliers, remove locking pin (arrow)
and pushrod pin (1) from vacuum booster pushrod
and detach brake pedal assembly.
RA13T260140
b. Remove 4 coupling nuts (arrow) between vacuum

booster assembly and brake pedal assembly.
RA13T260150
26

26 - BRAKE
c. Remove coupling bolt (arrow) between brake pedal

assembly and body.
RA13T260220
d. Remove brake pedal assembly from inside of vehicle.
Inspection
1. Check the brake light switch assembly.
a. Using ohm band of digital multimeter, check for
continuity between each terminal of brake light switch
+ - 3
assembly according to table below.
Standard Condition
4 2
Brake pedal
Terminal 1 - 1
depressed (switch Continuity
pin released)
Brake pedal
Terminal 2 -
depressed (switch No continuity
Terminal 4
pin released)
Brake pedal
Terminal 1 -
released (switch No continuity
Terminal 3
pin pushed)
Brake pedal
Terminal 2 -
released (switch Continuity
Terminal 4
pin pushed)
If result is not as specified, replace brake light switch assembly.
Installation
CAUTION
 Make sure to tighten fixing nuts to specified torque during installation.

 Check that brake light operates properly after installation.
26

26 - BRAKE
Front Disc Brake Assembly
1
2
3 5
6
4 7
8
13
14
9 10
12
11
RA13T260240
1 - Brake Caliper Guide Bolt 2 - Front Disc Brake Cylinder

3 - Front Disc Brake Piston Seal Ring 4 - Front Disc Brake Piston
5 - Brake Caliper Guide Bolt Guide Pin 6 - Brake Caliper Guide Pin Rubber Dust Boot
7 - Front Disc Brake Caliper Fixing Bracket 8 - Upper Support Shim
9 - Inner Brake Lining 10 - Outer Brake Lining
11 - Lower Support Shim 12 - Front Disc Brake Piston Dust Boot
13 - Bleeder Plug 14 - Bleeder Plug Cap
26

26 - BRAKE
1. Check the brake disc runout.
a. Remove the front wheel (See page 24-9).
b. Secure a dial indicator (1) to a proper position. Then
position dial indicator pointer approximately 10 mm
from outer edge of brake disc.
c. Slowly rotate brake disc (2) and check its runout. Mark 2
the lowest and highest points and record these
measured values.
RA13T260250
d. Check runout on opposite side of brake disc in the same way. Mark the lowest and highest points and
record these measured values.
e. Compare recorded runout value with limit value.
Maximum runout for front brake disc: 0.06 mm
f. If runout exceeds the maximum value, replace brake disc.
Removal
HINT:
CAUTION

3. Remove the front left brake caliper assembly.
a. Remove coupling plug (arrow) between front left
brake caliper assembly and front left brake hose
assembly.
b. Remove 2 coupling bolts (arrow) between front left
1
brake caliper assembly and front left steering knuckle.
26
RA13T260260

26 - BRAKE
CAUTION
 DO NOT allow brake fluid to be sprayed on your clothes or skin when removing brake hose, as brake
fluid is corrosive.
c. Remove the front left brake caliper assembly.

4. Remove the front left brake disc.
a. Remove locating screw (arrow) and front left brake
disc.
RA13T260280
Disassembly
HINT:
WARNING
 Never use high pressure when removing piston from the bore of brake caliper. Otherwise, this may
cause personal injuries.
 If it is needed to remove piston with compressed air, do not allow piston to face yourself or place your
hands around brake caliper and piston.
1. Remove the bleeder plug (w/ bleeder plug cap).

a. Remove bleeder plug (w/ bleeder plug cap) (arrow)
from brake caliper assembly.
(Tightening torque: 5.88 - 9.8 N·m)
RA13T260290
26

26 - BRAKE
2. Remove the brake cylinder assembly.

a. Remove 2 guide bolts (arrow) between brake caliper
fixing bracket and brake cylinder assembly.
RA13T260300
b. Separate brake cylinder assembly and brake caliper fixing bracket.

3. Remove the front brake caliper guide bolt guide pin (w/ dust boot).
a. Remove 2 brake caliper guide bolt guide pins (w/ dust
boot) (arrow) from brake caliper fixing bracket.
RA13T260310
4. Remove the front brake lining.

a. Remove inner brake lining and outer brake lining
(arrow) from brake caliper fixing bracket.
RA13T260320
5. Remove the brake lining support shim.

a. Remove 2 brake lining support shims (arrow) from
brake caliper fixing bracket.
RA13T260330
26

26 - BRAKE
6. Remove the brake cylinder dust boot.

tape, pry out dust boot (arrow) carefully.
RA13T260340
CAUTION
 Be careful not to damage brake piston and brake cylinder.
7. Remove the front disc brake piston.

a. Place a wooden board (1) between front disc brake
piston and front disc brake cylinder.
b. Use compressed air (2) to carefully press out piston 1
from front disc brake cylinder through attachment
hole.
2
RA13T260350
CAUTION
 Be careful not to splash brake fluid.

 DO NOT hold piston by hands to prevent injury.
 DO NOT remove or install brake piston by yourself, and always perform these operations by a
professional.
c. Clean piston bore with alcohol or proper solution, and then wipe it with a piece of lint.
8. Remove the front disc brake piston seal ring.
tape, carefully pry out front disc brake piston seal ring
(arrow) from brake cylinder rear ring groove.
26 RA13T260360

26 - BRAKE
Inspection
1. Check brake cylinder and piston.
a. Check piston and bore for scratches or corrosion. If there are scratches or corrosion, remove them with
fine sand cloth.
b. Remove dirt on piston with a soft brass wire brush and coarse cloth. Do not clean piston with polishing
cloth or sand cloth, as this may damage its surface. If surface of piston is damaged, replace it. If piston
is stuck or bore is worn or corroded, replace entire brake caliper assembly. Using polishing cloth,
remove the small pitting inside bore.
2. Check brake caliper fixing bracket and brake caliper guide pin set.
a. Clean contact surfaces of brake caliper fixing bracket and brake lining support shims with brake
cleaner. Check for deformation, cracks, rust and foreign matter which is difficult to remove.
b. Check brake caliper guide pin rubber dust boot for deformation, cracks, wear and foreign matter which
is difficult to remove.
c. Install brake caliper guide pin and its rubber dust boot to brake caliper fixing bracket. Brake caliper
guide pin set should move smoothly without sticking when pushing it by hand; otherwise replace it.
d. After installing brake lining, check if it is easy to fall out (due to weak elasticity of support shim). Replace
it as necessary.
3. Check the brake lining.
a. Visually check brake lining for flatness, and also check for excessive wear. If condition of lining cannot
be confirmed accurately only by visual inspection, perform physical inspection as necessary.
b. Measure the minimum brake lining thickness. When
minimum thickness of brake lining is 2.2 mm or less,
replace brake linings.
RA13T260370
c. When replacing the excessive worn brake linings (inner and outer), it is also necessary to replace the
linings on opposite side of vehicle as well as unchecked linings to maintain proper braking
performance. If it is unnecessary to replace brake linings, be sure to reinstall them to original positions.
4. Check the brake disc.
a. Minor scratch or wear on brake disc surface is acceptable. If severe scratch or deformation exists,
brake disc must be replaced.
b. Excessive wear of brake disc may cause poor contact between brake lining and surface of brake disc. If
protrusion on brake disc is not removed before installing new brake lining, it will cause abnormal wear
of brake disc.
c. It is normal that surface of brake disc is worn when replacing brake lining. If cracks or burned spots
exist, brake disc must be replaced.
26

26 - BRAKE
5. Check the brake disc thickness.

a. Using a vernier caliper, measure brake disc thickness
at center of brake lining contact surface as shown in
illustration.
Standard thickness: 25 mm
Minimum thickness: 20 mm
RA13T260380
b. If it is less than the minimum thickness due to wear of brake disc, replace brake disc.
CAUTION
 DO NOT machine brake disc, because it may make brake disc thickness less than the minimum.
Assembly
HINT:
CAUTION
 When assembling brake caliper assembly, always keep your hands clean.
 When assembling brake caliper assembly, always use new clean brake fluid.
 Never use old front disc brake piston seal ring.
1. Install the front disc brake piston seal ring.

a. Apply a light coat of grease to entire inner and outer
circumferences of new front disc brake piston seal
ring.
b. Install front disc brake piston seal ring to brake
cylinder.
Grease RA13T260390
CAUTION
 Securely install front disc brake piston seal ring into rear groove of brake cylinder.
26

26 - BRAKE
2. Install the front disc brake piston.

a. Apply a light coat of grease to inner and outer
circumferences, and entire periphery of outer flange
top/bottom surfaces of new brake cylinder dust boot
b. Apply a light coat of grease to entire outer
circumference (part contacting with brake cylinder
dust boot and front disc brake cylinder) of front disc
brake piston.
Grease
RA13T260400
c. Install brake cylinder dust boot to front disc brake piston.

3. Install the brake cylinder dust boot.
a. Install front disc brake piston to front disc brake cylinder.
CAUTION
 DO NOT install piston forcibly to brake cylinder.
b. Install brake cylinder dust boot to brake cylinder.
RA13T260410
CAUTION
 Securely install brake cylinder dust boot into front ring groove of disc brake cylinder.
 DO NOT damage the brake cylinder dust boot.
26

26 - BRAKE
Installation
CAUTION
 Make sure contact surface of lining and brake disc is free of oil and grease.
 Make sure to tighten fixing bolt and nut to specified torque during installation.
 Before installing brake linings, completely retract the brake caliper piston back into bore of brake caliper.
 Depress brake pedal several times to secure brake linings to brake disc in order to ensure safety, after
installing brake linings and before moving vehicle.
 Replace the brake linings in pairs. DO NOT replace one alone.
 DO NOT install inner brake lining and outer brake lining reversely.
 Be sure to check brake system for leakage after installation. Repair or replace malfunctioning parts as
necessary.
 Be sure to perform bleeding procedures for brake system after installation.
 Be sure to add brake fluid to a proper level after installation.
26

26 - BRAKE
Front Brake Hose Assembly

Removal
CAUTION

HINT:
CAUTION
3. Remove the front left brake hose assembly.

a. Loosen coupling plug (1) between front left brake
hose assembly and front left brake pipe, and detach
fixing clip (arrow).
1
RA13T260430
CAUTION
 DO NOT bend or damage brake tube.

 DO NOT allow any foreign matter such as dirt and dust to enter the brake tube from joint parts.
 After removing brake line, perform sealing treatment to prevent foreign matter from entering.
26

26 - BRAKE
b. Remove fixing bolt (arrow) from brake hose bracket.
RA13T260440
c. Remove coupling plug and washer (arrow) between

front left brake caliper assembly and front left brake
hose assembly.
RA13T260445
CAUTION
fluid is corrosive.
d. Remove the front left brake hose assembly.
Installation
CAUTION
 Make sure to tighten coupling plug to specified torque during installation.

necessary.
26

26 - BRAKE
Rear Disc Brake Assembly
2
5
6
7 8
1 3 9 14
10
11 13
12
RA13T260450
1 - Outer Brake Lining 2 - Upper Support Shim

3 - Inner Brake Lining 4 - Lower Support Shim
5 - Rear Disc Brake Caliper Fixing Bracket 6 - Brake Caliper Guide Pin Rubber Dust Boot
7 - Rear Disc Brake Piston Dust Boot 8 - Brake Caliper Guide Bolt Guide Pin
9 - Rear Disc Brake Piston 10 - Rear Disc Brake Piston Seal Ring
11 - Rear Disc Brake Cylinder 12 - Brake Caliper Guide Bolt
13 - Bleeder Plug 14 - Bleeder Plug Cap
1. Check the brake disc runout.
a. Remove the rear wheel (See page 24-9).
b. Secure a dial indicator (1) to a proper position. Then
position dial indicator pointer approximately 10 mm
from outer edge of rear brake disc.
2
26
1
RA13T260460

26 - BRAKE
c. Slowly rotate brake disc (2) and check its runout. Mark the lowest and highest points and record these
measured values.
d. Check runout on opposite side of brake disc in the same way. Mark the lowest and highest points and
record these measured values.
e. Compare recorded runout value with limit value.
Maximum runout for rear brake disc: 0.06 mm
f. If runout exceeds the maximum value, replace brake disc.
Removal
HINT:
CAUTION

3. Remove the rear left brake caliper assembly.
a. Remove coupling bolt and washer (arrow) between
rear left brake caliper assembly and rear left brake
hose assembly.
RA13T260470
CAUTION
fluid is corrosive.
26

26 - BRAKE
b. Disconnect connection between parking brake rear

cable ball and rear brake assembly.
RA13T260471
c. Remove coupling bolts (arrow) between rear left

brake caliper assembly and left brake caliper
mounting board assembly.
RA13T260480
d. Remove the rear left brake caliper assembly.

4. Remove the rear left brake disc.
a. Remove locating screw (arrow) and rear left brake
disc.
RA13T260490
Disassembly
HINT:
WARNING
 Never use high pressure when removing piston from the bore of brake caliper. Otherwise, this may
cause personal injuries.
 If it is needed to remove piston with compressed air, do not allow piston to face yourself or place your
hands around brake caliper and piston.
26

26 - BRAKE
1. Remove the bleeder plug (w/ bleeder plug cap).

a. Remove bleeder plug (w/ bleeder plug cap) (arrow)
from brake caliper assembly.
RA13T260500
2. Remove the brake cylinder assembly.

a. Remove 2 guide bolts (arrow) between brake caliper
fixing bracket and brake cylinder assembly.
RA13T260510
b. Separate brake cylinder assembly and brake caliper fixing bracket.

3. Remove the rear brake caliper guide bolt guide pin (w/ dust boot).
a. Remove 2 brake caliper guide bolt guide pins (w/ dust
boot) (arrow) from brake caliper fixing bracket.
RA13T260520
4. Remove the rear brake lining.

a. Remove inner brake lining and outer brake lining
(arrow) from brake caliper fixing bracket.
RA13T260530
26

26 - BRAKE
5. Remove the brake lining support shim.

a. Remove 2 brake lining support shims (arrow) from
brake caliper fixing bracket.
RA13T260540
6. Remove the brake cylinder dust boot.

tape, pry out dust boot carefully.
RA13T260550
CAUTION
 Be careful not to damage the brake piston and brake cylinder.
7. Remove the rear disc brake piston.

a. Place a wooden board (1) between rear disc brake
piston and rear disc brake cylinder. 1
b. Use compressed air (2) to carefully press out piston
from rear disc brake cylinder through attachment hole.
RA13T260560
CAUTION
 Be careful not to splash brake fluid.

 DO NOT hold piston by hands to prevent injury.
 DO NOT remove or install brake piston by yourself, and always perform these operations by a
professional.
26
c. Clean piston bore with alcohol or proper solution. Then wipe it with a piece of lint.

26 - BRAKE
8. Remove the rear disc brake piston seal ring.

tape, carefully pry out rear disc brake piston seal ring
(arrow) from brake cylinder rear ring groove.
RA13T260570
Inspection
1. Check brake cylinder and piston.
a. Check piston and bore for scratches or corrosion. If there are scratches or corrosion, remove them with
fine sand cloth.
b. Remove dirt on piston with a soft brass wire brush and coarse cloth. Do not clean piston with polishing
cloth or sand cloth, as this may damage its surface. If surface of piston is damaged, replace it. If piston
is stuck or bore is worn or corroded, replace entire brake caliper assembly. Using polishing cloth,
remove the small pitting inside bore.
2. Check brake caliper fixing bracket and brake caliper guide pin set.
a. Clean contact surfaces of brake caliper fixing bracket and brake lining support shims with brake
cleaner. Check for deformation, cracks, rust and foreign matter which is difficult to remove.
b. Check brake caliper guide pin rubber dust boot for deformation, cracks, wear and foreign matter which
is difficult to remove.
c. Install brake caliper guide pin and its rubber dust boot to brake caliper fixing bracket. Brake caliper
guide pin set should move smoothly without sticking when pushing it by hand; otherwise replace it.
d. After installing brake lining, check if it is easy to fall out (due to weak elasticity of support shim). Replace
it as necessary.
3. Check the brake lining.
a. Visually check brake lining for flatness, and also check for excessive wear. If condition of lining cannot
be confirmed accurately only by visual inspection, perform physical inspection as necessary.
b. Measure the minimum brake lining thickness. When
minimum thickness of brake lining is 2 mm or less,
replace brake linings.
RA13T260580
c. When replacing the excessive worn brake linings (inner and outer), it is also necessary to replace the
linings on opposite side of vehicle as well as unchecked linings to maintain proper braking
performance. If it is unnecessary to replace brake linings, be sure to reinstall them to original positions.
4. Check the brake disc.
26 a. Minor scratch or wear on brake disc surface is acceptable. If severe scratch or deformation exists,
brake disc must be replaced.

26 - BRAKE
b. Excessive wear of brake disc may cause poor contact between brake lining and surface of brake disc. If
protrusion on brake disc is not removed before installing new brake lining, it will cause abnormal wear
of brake disc.
c. It is normal that surface of brake disc is worn when replacing brake lining. If cracks or burned spots
exist, brake disc must be replaced.
5. Check the brake disc thickness.
a. Using a vernier caliper, measure brake disc thickness
at center of brake lining contact surface as shown in
illustration.
Standard thickness: 9 mm
Minimum thickness: 7 mm
RA13T260590
b. If it is less than the minimum thickness due to wear of brake disc, replace brake disc.
CAUTION
 DO NOT machine brake disc, because it may make brake disc thickness less than the minimum.
Assembly
HINT:
CAUTION
 When assembling brake caliper assembly, always keep your hands clean.
 When assembling brake caliper assembly, always use new clean brake fluid.
 Never use old front disc brake piston seal ring.
1. Install the rear disc brake piston seal ring.

a. Apply a light coat of grease to entire inner and outer
circumferences of new rear disc brake piston seal
ring.
b. Install rear disc brake piston seal ring to brake
cylinder.
Grease RA13T260600
26

26 - BRAKE
CAUTION
 Securely install the rear disc brake piston seal ring into rear groove of brake cylinder.
2. Install the rear disc brake piston.

a. Apply a light coat of grease to inner and outer
circumferences, and entire periphery of outer flange
top/bottom surfaces of new brake cylinder dust boot
b. Apply a light coat of grease to entire outer
circumference (part contacting with brake cylinder
dust boot and rear disc brake cylinder) of rear disc
brake piston.
Grease
RA13T260400
c. Install brake cylinder dust boot to rear disc brake piston.

3. Install the brake cylinder dust boot.
a. Install rear disc brake piston to rear disc brake cylinder.
CAUTION
 DO NOT install piston forcibly to brake cylinder.
b. Install brake cylinder dust boot to brake cylinder.
RA13T260610
CAUTION
 Securely install brake cylinder dust boot into front ring groove of disc brake cylinder.
 DO NOT damage the brake cylinder dust boot.
26

26 - BRAKE
4. Install the brake lining support shim.

a. Securely install upper and lower support shims
(arrow) to brake caliper fixing bracket.
RA13T260540
5. Install the rear brake lining.

a. Securely install inner brake lining and outer brake
lining (arrow) to brake caliper fixing bracket. Make
sure they are clamped in place.
RA13T260530
CAUTION
 Make sure contact surface of lining and brake disc is free of oil and grease.
6. Install the rear brake caliper guide bolt guide pin (w/ dust boot).
a. Apply a small amount of grease to contact surface
between guide bolt guide pin and guide pin rubber
dust boot (arrow), and securely install them to brake
caliper fixing bracket.
RA13T260520
7. Install the brake cylinder assembly.

a. Using brake cylinder piston pressing tool, slightly
retract brake cylinder piston.
26
RA13T260620

26 - BRAKE
b. Align brake caliper guide bolts (arrow) with guide pin

holes and securely install brake cylinder assembly.
RA13T260510
8. Install the bleeder plug (w/ bleeder plug cap).

a. Securely install bleeder plug (w/ bleeder plug cap)
(arrow) to rear brake caliper assembly.
RA13T260500
Installation
CAUTION
 Make sure to tighten fixing bolt and nut to specified torque during installation.
 Before installing brake linings, completely retract the brake caliper piston back into bore of brake caliper.
 Depress brake pedal several times to secure brake linings to brake disc in order to ensure safety, after
installing brake linings and before moving vehicle.
 Replace the brake linings in pairs. DO NOT replace one alone.
 DO NOT install inner brake lining and outer brake lining reversely.
necessary.
26

26 - BRAKE
Rear Brake Hose Assembly

Removal
CAUTION

HINT:
CAUTION
2. Remove the rear left wheel

3. Remove the rear left brake hose assembly.
a. Remove coupling bolt and washer (arrow) between
rear left brake caliper assembly and rear left brake
hose assembly.
RA13T260470
CAUTION
fluid is corrosive.
26

26 - BRAKE
b. Detach fixing clip (arrow) and loosen coupling plug (1)

between rear left brake hose assembly and rear brake
pipe.
1
RA13T260630
CAUTION
 DO NOT bend or damage brake tube.

 DO NOT allow any foreign matter such as dirt and dust to enter the brake tube from joint parts.
 After removing brake line, perform sealing treatment to prevent foreign matter from entering.
c. Remove the rear left brake hose assembly.
Installation
CAUTION
 Be sure to tighten coupling bolt and plug in place.

necessary.
26

PARKING BRAKE
GENERAL INFORMATION 27-3 Parking Brake Switch Assembly 27-10
Parking Brake Control Mechanism 
DIAGNOSIS & TESTING 27-7 Assembly 27-12
Parking Brake Cable Adjustment 27-8 Parking Brake Rear Cable Assembly 27-13
Judgement Standard of Correctly  Removal 27-13
Adjusting Parking Brake Cable 27-9 Installation 27-14
Parking Brake System Readjustment 
Method 27-9
27

27

27 - PARKING BRAKE
GENERAL INFORMATION
PARKING BRAKE
Description
Parking Brake Assembly
×3
RA13T270010
1 - Parking Brake Control Mechanism Assembly 2 - Parking Brake Switch Assembly

3 - Rear Left Parking Brake Cable Assembly 4 - Rear Right Parking Brake Cable Assembly
5 - Rear Left Parking Brake Assembly 6 - Rear Right Parking Brake Assembly
A13T vehicles are equipped with a manual-operated parking brake control mechanism assembly, which is
mounted between front seats. Each rear wheel has an individual parking brake rear cable assembly, which is
respectively connected with parking brake control mechanism assembly and rear brake assembly. Parking
brake cable is made of flexible wire.
27

27 - PARKING BRAKE
Specifications

Locking Nut Between Parking Brake Cable and Rear
7±1
Cable
Coupling Nut Between Parking Brake Control
22 ± 2
Mechanism Assembly and Body
Coupling Bolt Between Parking Brake Rear Cable
6±1
Assembly Fixing Bracket and Body
Rear Disc Brake

Rear Brake Disc 9 7

Rear Brake Disc 9.5 2
27

27 - PARKING BRAKE
Tools
General Tools
Digital Multimeter
RCH0000002
Vernier Caliper
RCH0000019
27

27 - PARKING BRAKE
Circuit Diagram
Parking Brake System

ON OR START
IP FUSE AND
RF10 RF01 RELAY BOX
10A 10A I-032
33 7
RY
R
11 13
INSTRUMENT
CLUSTER
I-011
18 3
LW
I-001
12 B-017
LW
I-005
1
PARKING
BRAKE
SWITCH
B-018
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 1
18 17 16 15 14 13 12 11 10
B-018
W
I-001
I-011 W
L
27 EA13T270010

27 - PARKING BRAKE
DIAGNOSIS & TESTING

HINT:

Parking brake control mechanism stroke
27-8
(incorrect)
Parking brake drag Rear brake disc (worn) 26-42
Parking brake shoe return tension spring
26-38
(damaged)
Parking brake disc (worn) 26-42
Rear brake disc (excessively worn) 26-43
Parking brake control mechanism
27-12
Abnormal parking brake operation assembly (improperly fixed)
Parking brake control mechanism
27-12
assembly (sticking)
Parking brake cable assembly (improperly
27-13
fixed)
Brake warning light does not come on
Warning light circuit (faulty) 27-10
when parking brake is applied
27

27 - PARKING BRAKE
ON-VEHICLE SERVICE
Parking Brake Cable Adjustment
Parking brake is acted on rear wheels with parking brake cable. A13T rear brake assembly is integrated park
type with clearance adjusted automatically, it is unnecessary to adjust manually when brake lining is worn.
Specific adjustment procedures are as follows:
1. Pre-tighten front cable adjusting nut so that screw can be exposed to a certain length (approximately 10
mm).
2. Firmly depress brake pedal 5 times after adding brake fluid (push brake position with hydraulic to attach
brake linings to brake disc closely, thus eliminating the clearance between them).
3. Pull up parking brake level to maximum stroke 4 times (fully release parking brake level to release cable
stress fully);
4. Pull up 8 notches manually, using a torque wrench (4 ± 1
N·m) to tighten front cable adjusting nut (arrow) through
parking brake adjusting hole cover under cup holder
which is opened previously.
RA13T270030
5. This is key step: Check it with parking brake adjustment assistive device, when pulling up parking brake
level 8 to 9 notches, a click sound should be heard from torque wrench of assistive device I (it indicated
that desired torque is achieved), that is 8 ≤ alarm notches ＜ 10. If it is not alarmed within this range, finely
adjust it as follows, check again with assistive device after adjusting until it is as specified.
a. If it is alarmed when parking brake level is pulled up 10 notches or more, it indicates that it is too loose,
tighten adjusting nut with a wrench.
b. If it is alarmed when parking brake level is pulled up 7 notches or less, it indicates that it is too tight,
loosen adjusting nut with a wrench.
CAUTION
Following conditions meet alarm requirements with 8 to 9 notches.

 alarm when pulling up to 8th notch, alarm between 8th to 9th notch, alarm when pulling up to 9th notch,
alarm between 9th to 10th notch.
 Torque of torque wrench of parking brake adjustment assistive device is 20 ± 2 N·m.
 Assistive device should be used as specified direction, if not, it will not alarm.
6. Finally, install parking brake adjusting hole cover to its original position.
27

27 - PARKING BRAKE
Judgement Standard of Correctly Adjusting Parking Brake Cable

1. When parking brake control mechanism is fully released with the vehicle is on flat ground, it should be no
blocking force when one person is pushing vehicle; and vehicle can be pushed with one person when
pulling up parking brake level to 1st notch (this is empirical method, not as inspection requirements).
2. When pulling up parking brake level 10 notches or less with vehicle is being driving, vehicle can be parked
on a inclined road with an inclination of 20% (on both directions of uphill and downhill) and parking control
force is less than 400 N (inspection standard).
3. Check vehicle on drum tester, rear wheel drag force meets requirements of GB7258 (inspection standard).
Parking Brake System Readjustment Method

If assembled vehicle needs to be readjusted, perform the following:
1. Open parking brake adjusting hole cover under rear cup holder, pull up parking brake level 8 notches so
that adjusting nut can be seen;
2. Using a wrench to tighten or loosen parking brake adjusting nut, adjust according to key step 5 in Parking
Brake Cable Adjustment until it is as specified.
3. Finally, install parking brake adjusting hole cover to its original position.
27

27 - PARKING BRAKE
Parking Brake Switch Assembly

1. Disconnect parking brake switch assembly connector,
and check continuity of parking brake switch assembly
with ohm band of digital multimeter as shown in table
below.
RA13T270040
Standard Condition
+ -
Condition
Multimeter
Condition Specified
Connection
Condition 1
Parking brake
applied (switch Continuity
Terminal 1 - Body pin released)
ground Parking brake
RA13T270041
pin pushed)
If result is not as specified, replace parking brake switch

assembly.
Removal
CAUTION

1. Secure the rear wheel assembly.

2. Remove the auxiliary fascia console assembly (See page 46-8).
3. Remove the parking brake switch assembly.
a. Disconnect parking brake switch assembly wire
harness connector (arrow) as shown in illustration.
RA13T270040
27

27 - PARKING BRAKE
b. Loosen fixing bolt (arrow) from parking brake switch

assembly.
RA13T270050
c. Remove the parking brake switch assembly.
Inspection
1. Check the parking brake switch assembly.
a. Check parking brake switch assembly for wear or breakage. Replace parking brake switch assembly as
necessary.
b. Check parking brake switch assembly compression spring for damage or weak in elasticity. Replace
parking brake switch assembly as necessary.
Installation
27

27 - PARKING BRAKE
Parking Brake Control Mechanism Assembly

Removal
CAUTION

1. Secure the wheel assembly.

3. Remove the parking brake switch assembly (See page 27-10).
4. Remove the parking brake control mechanism assembly.
a. Fully release the parking brake control mechanism.
b. Loosen locking nut (1) and adjusting nut (2) from left
and right parking brake cables separately, release
tension of parking brake cable assembly.
1 2
RA13T270060
c. Remove 3 coupling nuts (arrow) between parking

brake control mechanism assembly and body.
RA13T270270
d. Remove the parking brake control mechanism assembly.
Installation
CAUTION
 Be sure to tighten coupling nuts to specified torque.
HINT:
Be sure to check parking brake control mechanism stroke, after installing parking brake control mechanism
assembly. Adjust parking brake control mechanism stroke to proper position by adjusting parking brake
27 control mechanism locking nut as necessary.

27 - PARKING BRAKE
Parking Brake Rear Cable Assembly

Removal
CAUTION


3. Remove the parking brake rear cable assembly.
a. Fully release the parking brake control mechanism.
b. Loosen locking nut (1) and adjusting nut (2) from left
and right parking brake cables separately, release
tension of parking brake cable assembly.
1 2
RA13T270060
c. Disengage parking brake rear cable assembly from

body lower positioning hole (arrow), and remove 3 1
coupling nuts (1) between parking brake rear cable
assembly fixing bracket and body fixing bolt.
1
RA13T270080
d. Disconnect connection between cable rear ball joint

and parking pulling arm (arrow), and remove cable
1
protection pipe rear joint (1) from guide plate .
RA13T270090
e. Remove the left parking brake rear cable assembly.
27

27 - PARKING BRAKE
Installation
CAUTION
 Be sure to tighten coupling nuts to specified torque.
HINT:
Parking brake should be adjusted after replacing parking brake cable assembly. Check if parking brake
functions properly after adjustment. Check the parking brake control mechanism stroke. Release parking
brake control mechanism and check if rear wheels rotate freely. If wheels are difficult to rotate freely, repeat
adjustment procedure.
27

STEERING COLUMN
GENERAL INFORMATION 28-3 Inspection 28-9
Specifications 28-4 Combination Switch Cover 28-11
28
Inspection 28-12
Installation 28-12
Steering Column with Intermediate 
Steering Wheel Free Play Inspection 28-7 Shaft Assembly 28-13
Steering Wheel Centering/Returnability Removal 28-13
Inspection 28-7
Disassembly 28-14
Steering Wheel Assembly 28-8 Assembly 28-17

28

28 - STEERING COLUMN
GENERAL INFORMATION
STEERING COLUMN
Description
Steering Column
28
7
4
8 9
×2
10
×2
11
RA13T280010

1 - Driver Airbag 2 - Steering Wheel Assembly

3 - Spiral Cable 4 - Combination Switch
5 - Clamp 6 - Combination Switch Upper Cover
7 - Ignition Switch 8 - ignition switch fixing clamp
28 9 - Lower Cover 10 - Steering Column with Intermediate Shaft
Assembly
11 - Steering Lower Boot
Specifications
Description Tightening Torque (N·m)

Steering Wheel Assembly Fixing Nut 35 ± 3
Combination Switch Cover Fixing Screw 1.5 ± 0.5
Steering Column Assembly Upper Bracket Fixing
25 + 3
Bolt
Steering Column Assembly Lower Bracket Fixing
25 + 3
Bolt
Coupling Bolt Between Steering Column with
Intermediate Shaft Assembly and Steering Gear 25 ± 3
Input Shaft
Ignition Starting Switch Fixing Screw 13 ± 2
Data Specifications
Description Standard Value

Steering Wheel Free Play (Rotation Angle) ≤ 15°
Steering Wheel Centering/Returnability (Rotation
＞ 70°
Angle)

Tools
Special Tool
28
RCH0000014
General Tool
Electric Drill
RCH0000013

DIAGNOSIS & TESTING

HINT:
28 Repair or adjust faulty components, or replace as necessary.
Steering System
Steering wheel assembly cannot lock or Ignition key cylinder 28-16

unlock Ignition switch lock body 28-15
Front axle hub bearing (seriously worn) 22-14
Intermediate shaft with universal joint
28-13
assembly (seriously worn)
Steering wheel assembly has no free play
Ball pin assembly (worn or loosen) 29-17
or free play is too large
Steering tie rod assembly 29-19
Steering gear assembly (improper
29-21
engagement gap of rack and pinion)
Front tire (improperly inflated or unevenly
24-5
worn)
Front sub frame welding assembly 22-17
Hard steering 28-13
assembly (insufficiently lubricated)
Ball pin assembly (insufficiently lubricated) 29-17
Steering column assembly 29-19
Steering gear assembly 29-21
Front tire (improperly inflated or unevenly
24-5
worn)
Front suspension 23-3
Ball pin assembly (loosen, insufficiently
29-17
Poor returnability lubricated)
28-13
assembly (loosen, insufficiently lubricated)
Steering column assembly (stuck) 29-19
Steering gear assembly (stuck) 29-21


28-13
assembly
Control arm ball pin 23-19
Knocking (or clunking) sound occurs when
steering wheel is turned while steering Control arm 23-19
system is in operation 28
Front strut upper connecting plate
23-12
assembly (w/ insulator)
Steering column assembly 29-19
Friction sound occurs when steering wheel
is turned during low speed driving Front strut upper connecting plate
23-12
Steering wheel vibrates and noise occurs Steering column assembly 29-19
when steering wheel is turned with vehicle Front strut upper connecting plate
stopped 23-12
Steering Wheel Free Play Inspection

1. Stop vehicle and position front wheels straight ahead.
2. Gently turn steering wheel left and right, and check
rotation angle of steering wheel when wheels start to
rotate.
Standard value of free play (rotation angle): a ≤ 15°.
a RA13T280020
3. If measured value exceeds standard value, check steering system.
Steering Wheel Centering/Returnability Inspection

Steering wheel centering/returnability inspection should be performed during road test.
1. Perform slow turn and sharp turn test.
Check for steering effect required for steering wheel and deviation of centering/returnability during left/right
turn.
2. When vehicle speed is between 20 and 30 km/h, turn
steering wheel either to left or right by 90° and keep it for
1 or 2 seconds, and then release the steering wheel. If
steering wheel turns back more than 70°, it is determined
that steering wheel centering/returnability is in good 70° 70°
condition.
RA13T280030
3. If steering wheel returning angle is not as specified, check tire pressure, steering system and suspension
system.

ON-VEHICLE SERVICE
Steering Wheel Assembly
Removal
28
CAUTION
 Be sure to read precautions for SRS airbag before removing steering wheel (See page 31-45).
1. Set steering wheel to straight-ahead position.

CAUTION
 Wait at least 90 seconds after disconnecting the negative battery cable to prevent airbag and belt
pretensioner from being activated.
4. Remove the driver airbag assembly (See page 31-45).

5. Remove the steering wheel assembly .
a. Secure steering wheel assembly, and put matchmarks
on steering wheel assembly and steering column
assembly, then remove steering wheel assembly
fixing nut (arrow).
RA13T280040
b. As shown in illustration, install steering wheel

remover, and then tighten it with a wrench to loosen
steering wheel assembly from steering column
assembly.
RA13T280050

c. Disconnect the steering wheel quick button connector

(arrow).
28
RA13T280060
d. Remove the steering wheel assembly.
CAUTION
 Be careful when removing steering wheel assembly, to prevent damage to airbag connector and horn
connector on spiral cable.
Inspection
1. Check steering wheel assembly for damage or deformation. Replace steering wheel assembly if
necessary.
2. Check spline in steering wheel assembly for damage. Replace steering wheel assembly if necessary.
Installation
CAUTION
 Check that front wheels are in straight-ahead position before installing steering wheel assembly.
1. Adjust spiral cable to correct position (arrow).

HINT:
Fully turn spiral cable inner circle clockwise when
realigning the center, and then turn it counterclockwise to
align with ►◄ while yellow ball (arrow) occurs in the
clear vertical window. Failure to follow these instructions
may affect normal function of airbag system and cause
injury to driver.
RA13T280070
2. Pass airbag connector and horn connector through the hole of steering wheel assembly, and connect
steering wheel quick button connector. Then align matchmarks on steering wheel assembly and steering
column assembly to install the steering wheel assembly.

CAUTION
 Tighten steering wheel assembly fixing nut to specified torque.

 Install each connector in place.
 After repairing, check that airbag system operates normally.
28

Combination Switch Cover

Removal
3. Remove the combination switch cover. 28
a. Remove lower fixing screw (arrow) from combination
switch cover.
RA13T280080
b. Disengage connecting clip between upper cover and

lower cover, and separate upper cover and lower
cover, then remove lower cover.
MO
OE
SET
RA13T280090
c. Separate 3 clips between upper cover and steering

column dust gasket, and then remove upper cover.
RA13T2800100

CAUTION
 Operate carefully to prevent damage to components during installation.
28 Inspection
1. Check combination switch upper and lower covers for damage or deformation. Replace upper and lower
covers if necessary.
2. Check if upper and lower cover clips are normal. Replace upper and lower covers if necessary.
Installation
1. Loosen steering wheel adjusting handle, and adjust steering column assembly to uppermost position, then
tighten adjusting handle to uppermost position.
2. Insert steering column lower cover from right side of ignition switch at an angle, and then install adjusting
handle into cover hole.
3. After adjusting lower cover, install upper cover and fix upper and lower cover clips in place, then install self-
tapping screws.
CAUTION
 Tighten self-tapping screws in place.

 Operate carefully to prevent damage to components during installation.

Steering Column with Intermediate Shaft Assembly

Removal
4. Remove the airbag (See page 31-45).
6. Remove the combination switch cover (See page 28-11).
7. Remove the spiral cable (See page 31-48).
8. Remove the combination switch assembly.
a. Disconnect steering switch connector (1) and wiper
switch connector (2).
1 2
RA13T280110
b. Loosen combination switch clamp, pull combination

switch outward, disconnect combination switch and
steering column, then remove combination switch.
RA13T280120
9. Remove the lower left protector assembly (See page 33-24)

10.Remove the steering column with intermediate shaft assembly.
a. Remove coupling bolt between steering column with
intermediate shaft assembly and steering gear input
shaft.
RA13T280130

b. Disconnect key travel switch connector (1) and anti-

theft module connector (2).
28
1
RA13T2800140
c. Disconnect ignition switch connector (1) and ignition

switch illumination light connector (2).
1
RA13T280150
d. Remove 2 fixing nuts (arrow) from steering column

upper bracket.
RA13T280160
e. Remove 1 fixing bolt (arrow) from steering column

lower bracket.
RA13T280170
f. Remove the steering column with intermediate shaft assembly.
CAUTION
 DO NOT touch interior ornaments when removing steering column with intermediate shaft assembly, to
avoid scratching interior ornaments.
Disassembly
1. Remove the ignition switch lock body.
a. Set steering column assembly onto a vise.

CAUTION
 DO NOT tighten vise excessively.
b. Using an electric drill (1), drill a hole on ignition switch 28

lock body anti-theft bolt (arrow).
1
RA13T280180
c. Using a screw remover, remove the ignition switch

lock body anti-theft bolt.
RA13T280190
2. Remove the ignition switch illumination light.

a. Disconnect key travel switch connector (arrow), and
detach fixing clip of ignition switch illumination light
connector from ignition switch.
RA13T280200
b. Remove the ignition switch illumination light cover

(arrow).
RA13T280210

c. Remove ignition switch illumination light in direction of

arrow from ignition switch lock body.
28
RA13T280220
3. Remove the ignition switch.

a. Remove 2 fixing screws (arrow) from ignition starting
switch, and remove ignition starting switch.
RA13T280230
4. Remove the key travel switch.
CAUTION
 Be careful not to allow the spring to pop out when removing key travel switch.
a. Remove the key travel switch spring pressure plate

(arrow).
RA13T280240
b. Remove spring (1) and key travel switch (2).
RA13T280250

5. Remove the ignition switch key cylinder.

a. Turn ignition switch key cylinder to ACC with key, and
insert a small screwdriver or similar tool into ignition
switch lock body hole, then pull out ignition key
cylinder.
28
RA13T280260
b. Detach fixing clip of anti-theft module from ignition key

cylinder and remove anti-theft module (1).
RA13T280270
Inspection
1. Check if ignition switch lock body and key cylinder are normal. Replace ignition switch lock body and key
cylinder if necessary.
2. Check steering column assembly for wear, cracks or deformation. As welding or correction is not allowed,
replace steering column assembly if necessary.
3. Check steering column bearing for looseness, wear or sticking. Replace steering column assembly if
necessary.
Assembly
1. Install the ignition switch assembly.
a. Set steering column assembly onto a vise.
CAUTION
 DO NOT tighten vise excessively.
b. Install ignition switch assembly to steering column assembly with new anti-theft bolts of ignition switch
lock body, and then tighten the anti-theft bolts until bolt heads break off.

2. Install the ignition key cylinder.

a. Push ignition key cylinder into ignition switch lock
body until ignition key cylinder fixing block locks in
place.
28
RA13T280290
b. Check ignition key cylinder for proper operation:

When key is removed, steering lock is locked; when key is inserted and ignition switch is turned to
"ACC" or "ON", steering lock is unlocked.
Installation
CAUTION
 Before installing steering column assembly, slide the spline at lower part of steering column assembly
onto intermediate shaft upper universal joint first.
 Tighten fixing nuts, bolts and screws in place.
 Install each connector in place.

Operation 29-4 Power Steering Pump Assembly 29-15
Tool 29-5 Inspection 29-16 29
Installation 29-16
Ball Pin Assembly 29-17
Removal 29-17
Steering Fluid Replacement 29-8
Inspection 29-18
Steering Fluid Draining 29-8
Installation 29-18
Steering Fluid Adding 29-9
Steering Tie Rod Assembly 29-19
Bleeding Procedures 29-9
Removal 29-19
Steering Fluid Reservoir Assembly 29-10 Installation 29-20
Removal 29-10 Power Steering Gear with Tie Rod Assembly
Inspection 29-11 29-21
Steering Fluid Pipe 29-12 Inspection 29-23

29

29 - HYDRAULIC ASSIST STEERING
GENERAL INFORMATION
Description
1
4
5
29
×3
6
7
8
9
2
11
10 12
15
13
16 14
17
21
×3
20
22
×2
18
19
×2
RA13T290010

1 - Steering Gear Heat Insulator 2 - Steering Gear Fixing Bracket

3 - Steering Gear Fixing Rubber Block 4 - Steering Tie Rod Ball Pin Locking Nut
5 - Right Steering Tie Rod Assembly 6- Elastic Clamp
7 - Right Steering Tie Rod Boot 8 - Clamping Ring
9 - Right Steering Tie Rod Assembly 10 - Steering Gear
29 11 - Left Steering Tie Rod Assembly 12 - Left Steering Tie Rod Boot
13 - Steering Tie Rod Fixing Nut 14 - Left Steering Tie Rod Assembly
15 - Hollow Bolt 16 - Fluid Return Pipe
17 - High Pressure Fluid Pipe 18 - Fluid Suction Pipe
19 - Steering Pump 20 - Steering Fluid Reservoir Bracket
21 - Steering Fluid Reservoir Fixing Worm Clamp 22 - Steering Fluid Reservoir
Hydraulic assist steering system consists of power steering pump assembly, steering gear assembly, steering
fluid pipe and steering fluid reservoir assembly and so on. This system can reduce steering force when driver
operates steering wheel, thus improving operation convenience and driving safety.
Steering Gear Assembly

Steering gear assembly is rack & pinion type, which is characterized by simple and compact construction and
high steering sensitivity. Piston rod is integrated with rack, and there is a boot at the connection between
steering tie rod assembly and rack. Length of steering tie rod can be adjusted properly to match with toe-in.
Tie rod ball pin assembly and steering knuckle are connected and tightened by a locking nut.
Power Steering Pump Assembly

Power steering pump assembly is connected with steering gear assembly by high pressure fluid pipe, and
connected with steering fluid reservoir assembly by fluid suction pipe. Never operate power steering pump
assembly without fluid. Try to avoid turning steering wheel to limit position for more than 5 seconds during
operation.
Steering Fluid Pipe

Steering fluid pipe is used to deliver power steering fluid. Steering fluid pipes are divided into steel pipe, hose
and hybrid type according to the length and operating features of each component. Ferrule connection is
adopted between steel pipe and hose on high pressure fluid pipe assembly and sealed reliably. Steel pipe and
component are connected with joint bolt, and sealed by O-ring. Tighten bolt to guarantee reliable sealing.
Hose and component are connected by hose and tightened with clamp.
Steering Fluid Reservoir Assembly

Main functions of steering fluid reservoir assembly are to store fluid and supply it to steering pump and
system.
Operation
Steering gear assembly converts the circular motion of steering wheel into linear motion of rack by engaging
the rack and pinion inside. Power steering pump assembly delivers fluid into steering gear assembly to drive
pistons move toward the direction made by driver. Piston transmits force to steering knuckle by steering tie
rod assembly, thus reducing steering effort when driver turns steering wheel. If steering assist is ineffective,
more steering effort is needed.

Specifications

Coupling Bolt Between Steering Column Lower Yoke
25 ± 3
and Steering Gear
Tie Rod Assembly Locking Nut 55 ± 5 29
Fixing Bolt Between Steering Gear and Sub Frame 30 ± 3
Locking Nut Between Ball Pin Assembly and
10 ± 1
Assembly
Steering Gear Heat Insulator Fixing Nut 9±1
Steering Gear Heat Insulator Fixing Bolt 25 ± 3
Power Steering Pump Pulley Fixing Bolt 25 ± 3
Power Steering Pump Fixing Bolt 25 ± 3
Fixing Clamp Between Steering Fluid Reservoir and
5±1
Bracket
Fluid Reservoir Bracket Fixing Bolt 7±1
High Pressure Fluid Pipe Clamping Bolt 30 ± 3
Hollow Bolt 45 ± 3
Fixing Bolt Between High/Low Pressure Line and
25 ± 3
Intake Manifold
Fluid Return Pipe Clamping Bolt 30 ± 3
Fluid Suction Pipe Fixing Bolt 9 ± 1.5
Tool
Special Tool
Ball Pin Separator
RCH0000024

DIAGNOSIS & TESTING

HINT:
29
Steering fluid (insufficient or dirty) 29-10
Steering tie rod boot (damaged or worn) 29-19
Stuck or sticking in
some position occurs Steering tie rod assembly (rust) 29-19
when turning
Power steering pump drive belt (loose) 29-15
Steering gear assembly (incorrect clearance) 29-19
Ball pin assembly (worn or loose) 29-17
Steering tie rod assembly (worn or loose) 29-19
Steering wheel is not Intermediate shaft (twisted and deformed) or universal 28-13
centered or centered joint (worn, loose or insufficiently lubricated)
improperly
Front sub frame welding assembly -
Steering knuckle assembly 29-21
Front strut upper connecting plate assembly 
-
(w/ insulator)
Steering gear assembly (incorrect clearance) -
Ball pin assembly (worn or loose) 29-17
Brake disc and lining (deformed) 26-26
Steering shudders Intermediate shaft (twisted and deformed) or universal 28-13
joint (worn, loose or insufficiently lubricated)
Front sub frame welding assembly -
Steering knuckle assembly 29-21


Tire (improperly inflated) -
Steering fluid (insufficient) 29-8
Fluid pipe (leaked or blocked) 29-12
Steering wheel turns
heavily or steering
Ball pin assembly (worn or loose) 29-17 29
effort is uneven Steering tie rod assembly (worn or loose) 29-19
Front suspension 23-9
Power steering pump drive belt (loose or damaged) 29-15
Power steering pump assembly 29-15
Steering fluid (insufficient, air existing or dirty) 29-8
Steering fluid (insufficient, air existing or dirty) 29-8
Front strut upper connecting plate assembly 
-
(w/ insulator)
Abnormal noises from
steering system Ball pin assembly (worn or loose) 29-17
Steering tie rod assembly (worn or loose) 29-19
Power steering pump assembly 29-15

Steering Fluid Replacement

Steering Fluid Draining
1. Set the steering wheel to straight-ahead position.
29 4. Turn ignition switch to ACC.

5. Open the steering fluid reservoir cap.
6. Disconnect fluid suction pipe from power steering pump assembly.
a. Disconnect the power steering pump connector (1).
b. Disconnect fixing clip (2) of power steering pump 3 2
connector from fluid suction pipe.
c. Loosen the elastic clamp (3).
RA13T290020
7. Place a fluid container under fluid suction pipe, and disconnect fluid suction pipe joint to collect steering
fluid flowing out of fluid suction pipe and steering pump.
8. Turn steering wheel left and right to limit positions, and repeat the operation several times to drain steering
fluid in steering system.
WARNING
 If steering fluid sprays on your skin, immediately wash it off with water.
 Steering wheel should not be in limit positions for more than 5 seconds.
 Wasted power steering fluid should be handled according to local environmental regulations.

Steering Fluid Adding

Proper steering fluid level should be between "MAX" and
"MIN" marks. It affects power steering system performance
directly whether fluid level of the fluid reservoir is proper. If
fluid level drops below "MIN" mark, it is necessary to add
steering fluid.
29
RA13T290030
CAUTION
 DO NOT apply foaming or expired steering to vehicle. Otherwise it may damage power steering pump
assembly.
1. Open steering fluid reservoir cap, and add steering fluid to reservoir until the level reaches "MAX" mark.
2. Start engine and run it at idle to drive power steering pump assembly, thus filling the whole steering system
with steering fluid.
3. Observe fluid level of fluid reservoir while engine is running. If fluid level drops below "MIN" mark, add
steering fluid to a proper level in time to prevent fluid level from dropping excessively and avoid air entering
power steering pump assembly.
4. If bubbles occur in steering fluid reservoir, perform bleeding procedures. Check that level is between
"MAX" and "MIN" marks when there are no bubbles in fluid reservoir and fluid level does not change any
longer.
WARNING
 If steering fluid sprays on your skin, immediately wash it off with water.
 It is harmful to your skin if contacting with power steering fluid for a long time.
Bleeding Procedures
It is necessary to perform bleeding procedures when bubbles occur in steering fluid reservoir assembly and
fluid has emulsified or there is excessive noise in power steering pump assembly. Bleeding procedures are as
follows:
1. Open the steering fluid reservoir cap.
2. Raise vehicle with a lift (with front wheels off ground).
3. Start engine (idling) and turn steering wheel left and right to limit positions (do not stay at limit positions
more than 2 seconds). Repeat several times to completely bleed air in system from the reservoir. Observe
fluid level of fluid reservoir during bleeding. If fluid level drops below "MIN" mark, add steering fluid to a
proper level in time.
4. After repeatedly turning steering wheel to limit positions several times, center the steering wheel, run
engine at idle for 3 to 5 minutes and observe whether there still exist bubbles in fluid reservoir. If problem
still exists, perform above procedures again until no bubbles are bled. If there are still problems, perform
steering system inspection.
5. If bubbles occur in steering fluid reservoir, perform bleeding procedures. Check that level is between
"MAX" and "MIN" marks when there are no bubbles in fluid reservoir and fluid level does not change any
longer.

ON-VEHICLE SERVICE
WARNING

 When removing and installing high temperature components and surrounding components, wait and
29 operate until they drop to normal temperature to avoid being burned.
 Prevent skin and eyes from contacting with steering fluid.
CAUTION
 After disconnecting steering line, seal it immediately to prevent foreign matter from entering.
 Never run power steering pump assembly when steering fluid is insufficient.
 Steering wheel should not be in the limit position for more than 5 seconds.
 Never start engine with hose loosened or disconnected.
 Never allow hose to contact with high temperature exhaust pipe.
Steering Fluid Reservoir Assembly

Removal
2. Remove the steering fluid reservoir assembly.
a. Remove fluid suction pipe clamp (1) on steering fluid
reservoir, and disconnect fluid suction pipe assembly
and steering fluid reservoir assembly.
b. Remove fluid return pipe clamp (2) on steering fluid
reservoir, and disconnect fluid return pipe assembly 3
and steering fluid reservoir assembly.
c. Loosen fixing worm clamp (3) of steering fluid 2 1
reservoir, and remove steering fluid reservoir from
steering fluid reservoir bracket.
(Tightening torque: 5 ± 1 N·m) RA13T290040
CAUTION
 Using a plug, clog the disconnected pipe to prevent foreign matter from entering.

Inspection
1. Check steering fluid reservoir assembly for breakage or deformation. Replace fluid reservoir if necessary.
2. Check if there is contamination in steering fluid reservoir assembly. Clean or replace if necessary.
Installation
CAUTION 29
 Install fluid suction pipe clamp and fluid return pipe clamp in place.
 Never tap or hit the fluid reservoir.
 After adding power steering fluid, perform bleeding procedures and check system for leakage.

Steering Fluid Pipe

Removal
 Collect steering fluid residue in line with a container when disconnecting the line.
29
3. Remove the fluid suction pipe.
a. Remove fluid suction pipe clamp (arrow) on steering
fluid reservoir, and disconnect fluid suction pipe and
steering fluid reservoir assembly.
RA13T290050
b. Disconnect the power steering pump connector (1).

c. Disconnect fixing clip (2) of power steering pump 3 2
d. Loosen elastic clamp (3) and disconnect fluid suction
pipe and power steering pump.
RA13T290020
e. Remove fluid suction pipe fixing bolt (arrow) from

mounting fitting board II assembly.
RA13T290060

f. Remove fluid suction pipe fixing bolt (arrow) from tank

crossmember welding assembly.
g. Remove the fluid suction pipe.
29
RA13T290070
4. Remove high pressure fluid pipe and fluid return pipe.

a. Remove high pressure fluid pipe joint hollow bolt
(arrow) from power steering pump assembly.
RA13T290080
CAUTION
 Using a plug, clog the disconnected steering system line to prevent foreign matter from entering.
b. Remove fluid return pipe clamp (arrow) from steering

fluid reservoir assembly.
RA13T290090
c. Remove high pressure fluid pipe clamping bolt (1) and

fluid return pipe clamping bolt (2) from power steering
gear.
(Tightening torque for high pressure fluid pipe
clamping bolt: 30 ± 3 N·m)
2
1
RA13T290100

d. Remove 2 high/low pressure line fixing bolts (arrow)

from intake manifold, and detach fixing clip (1).
(Tightening torque for fluid return pipe clamping bolt:
25 ± 3 N·m)
1
29
RA13T290110
e. Remove high pressure pipe fixing bolt (arrow) from

engine right mounting bracket.
(Tightening torque for fluid return pipe clamping bolt:
25 ± 3 N·m)
RA13T290120
f. Detach clip (arrow) from front right side rail, and

remove high pressure fluid pipe and fluid return pipe.
RA13T290130
Inspection
1. Check steering fluid pipe for cracks, wear or blockage. Replace steering fluid pipe assembly if necessary.
2. Check steering fluid pipe joint and O-ring for deformation or damage. Replace steering fluid pipe assembly
if necessary.
3. Check if steering fluid pipe bracket is normal. Replace if necessary.
Installation
CAUTION
 Never tap or squeeze steering fluid pipe.

 Tighten fixing nut and bolt to specified torque.
 After adding power steering fluid, perform bleeding procedures and check system for leakage.

Power Steering Pump Assembly

Removal
 Collect steering fluid flowing from line with a container when disconnecting the line.
29
2. Remove the power steering pump assembly.
a. Disconnect the power steering pump connector (1).
b. Disconnect fixing clip (2) of power steering pump 3 2
c. Loosen elastic clamp (3) and disconnect fluid suction
pipe and steering pump.
RA13T290020
d. Remove high pressure fluid pipe joint hollow bolt

(arrow) from power steering pump assembly.
RA13T290080
CAUTION
 Using a plug, clog the disconnected steering system line to prevent foreign matter from entering.
e. Loosen 3 fixing bolts (arrow) of steering pump pulley.

f. Remove the steering pump V-ribbed belt (1).
RA13T290140

g. Remove 3 fixing bolts (arrow) from steering pump

pulley.
29
RA13T290150
h. Remove 3 fixing bolts (arrow) from steering pump.

RA13T290160
i. Remove the steering pump.
Inspection
1. Check power steering pump assembly for blockage or damage, and power steering pump bearing for
looseness and abnormal noise. Replace if necessary.
2. Check if power steering pump pulley is normal. Replace if necessary.
Installation
CAUTION
 Tighten fixing bolts to the specified torque.

 DO NOT tap or hit power steering pump assembly.

Ball Pin Assembly

Removal
HINT:
 Use same procedures for right and left sides. Procedures listed below are for left side.
2. Turn off all electrical equipment and the ignition switch. 29
5. Remove the ball pin assembly.
a. Remove locking nut (arrow) between left steering tie
rod ball pin assembly and front left steering knuckle
assembly.
RA13T290170
b. Install ball pin separator (1), and tighten ball pin

tie rod ball pin from steering knuckle assembly. 1
2
RA13T290180
c. Loosen steering tie rod adjustment nut (1), and turn

ball pin assembly (2) counterclockwise to remove it.
1
2
RA13T290190
HINT:
When removing ball pin assembly, record revolutions during removal, to make front wheel toe-in closer to
setting value after installation.

Inspection
1. Check tie rod ball pin for looseness. Replace ball pin assembly if necessary.
2. Check tie rod ball pin rubber bush for damage. Replace ball pin assembly if necessary.
Installation
29 CAUTION
 After installing tie rod ball pin assembly, it is necessary to perform wheel alignment procedure (See page
24-12).

Steering Tie Rod Assembly

Removal
HINT:
1. Remove the front wheel (See page 24-7). 29
2. Remove the tie rod ball pin assembly (See page 29-17).
3. Remove the steering tie rod assembly.
a. Remove the steering tie rod boot elastic clamp (1).
RA13T290200
b. Remove steering tie rod boot clamping ring (1) and

remove steering tie rod boot.
RA13T290210
c. Using a wrench, remove tie rod assembly (arrow).
RA13T290220

Inspection
1. Check steering tie rod boot for damage, and if clamp is normal. Replace steering tie rod boot and clamp if
necessary, to prevent water and micro dust from entering and causing parts failure prematurely.
2. Check steering tie rod assembly for deformation or wear and ball for insufficient lubrication. Replace
steering tie rod assembly or add grease if necessary.
Installation
29 Installation is in the reverse order of removal.
CAUTION
 It is necessary to apply thread locker to ball.

 It is necessary to fit steering tie rod ball face and rack face closely.
 After installing steering tie rod assembly, it is necessary to perform wheel alignment procedure.

Power Steering Gear with Tie Rod Assembly

Removal
4. Drain the steering fluid (See page 29-8). 29
6. Open steering boot assembly and remove coupling bolt
between steering column lower yoke and steering gear.
RA13T290230
7. Separate ball pin assembly and steering knuckle.

HINT:
a. Remove locking nut (arrow) between left steering tie
rod ball pin assembly and front left steering knuckle
assembly.
RA13T290170
b. Install ball pin separator (1), and tighten ball pin

tie rod ball pin from steering knuckle assembly. 1
2
RA13T290180

9. Support front sub frame welding assembly with a transmission carrier.

10.Remove the power steering gear with tie rod assembly.

a. Remove high pressure fluid pipe clamping bolt (1) and
fluid return pipe clamping bolt (2) from power steering
gear.
2
29
1
RA13T290100
b. Remove 3 fixing bolts (arrow) from steering gear heat

insulator.
RA13T290240
c. Remove 1 fixing nut (arrow) from steering gear heat

insulator.
RA13T290250
d. Remove 2 fixing bolts (arrow) between engine right

RA13T290260

e. Remove fixing bolt (arrow) between transmission left

29
RA13T290270
f. Remove 4 fixing bolts (arrow) between power steering

gear with tie rod assembly and sub frame.
RA13T290280
g. Remove 4 fixing bolts (arrow) between sub frame and

body.
RA13T290290
h. Lower front sub frame welding assembly (descending distance is about 40 mm), and remove steering
gear with tie rod assembly.
Inspection
1. Check steering gear assembly housing for damage or deformation, and rack and pinion for sticking.
Replace steering gear assembly if necessary.
2. Check if steering tie rod boot, clamp and clamping ring are normal. Replace them if necessary to prevent
water and micro dust from entering and causing parts failure prematurely.
3. Check steering tie rod assembly and ball pin assembly for serious wear. Replace steering tie rod assembly
and ball pin assembly if necessary.
Installation
CAUTION
 After installing steering gear assembly, perform front wheel alignment procedure (See page 24-12).

- MEMO -

AIR CONDITIONING
GENERAL INFORMATION 30-3 (for Power A/C) 30-33
Description 30-3 Removal 30-33
1.System composition 30-4 Installation 30-33
2. Operation 30-4 Inner/Outer Circulation Damper 
Specifications 30-5 Servo Motor (for Power A/C) 30-34
Refrigerant Charging Specification 30-5 Removal 30-34
Refrigerant Oil Charging Specifications 30-5 Inspection 30-34 30
Circuit Diagram 30-7 Mix Damper Servo Motor 
(for Power A/C) 30-36
DIAGNOSIS & TESTING 30-15 Removal 30-36
Problem Symptoms Table 30-15 Inspection 30-36
Diagnosis Procedure 30-17 Installation 30-37
A/C System Function 30-19 Face Damper Servo Motor 
Ground Inspection 30-19 (for Power A/C) 30-38
Removal 30-38
Inspection 30-39
Installation 30-39
Compressor Assembly Noise Ins
Defrost Damper Servo Motor 
pection 30-21
(for Power A/C) 30-40
Refrigerant Leakage Inspection 30-22
Removal 30-40
Refrigerant Recovering/Draining 30-24
Inspection 30-41
Vacuum Pumping 30-25
Installation 30-41
Refrigerant Recharging 30-25
HVAC Assembly 30-42
Refrigerant Oil Recovering 30-26
Removal 30-42
Refrigerant Oil Charging 30-27
Disassembly 30-44
Refrigerant Oil Charging Amount 
Inspection 30-49
Assembly 30-51
A/C Control Panel Assembly 
(for Manual A/C) 30-28 Installation 30-51
Removal 30-28 A/C Low Pressure Line 30-52
A/C Control Panel Assembly  Installation 30-53
(for Power A/C) 30-30 A/C High Pressure Line 30-54
A/C Element 30-31 Compressor Assembly 30-56
Blower Assembly 30-31 Condenser Assembly 
Removal 30-31 (w/ Receiver Drier) 30-58
Blower Speed Resistor  Installation 30-59

30

30 - AIR CONDITIONING
GENERAL INFORMATION
AIR CONDITIONING
Description
1
30
3 ×2
4
5
6
×4
×4
×4
RA13T300010

1 - HVAC Assembly 2 - Expansion Valve

3 - O-ring 4 - Evaporator to Compressor Line Assembly
5 - Compressor Assembly 6 - Condenser to Evaporator Line Assembly
7 - Compressor to Condenser Line Assembly 8 - Center Control Integration Panel Assembly
9 - Condenser Assembly (w/ Receiver Drier)
1.System composition
30 Power A/C and automatic A/C are available for this model. A/C system consists of following four parts:
Air conditioning and distribution system: air mixing and distributor part of HVAC, inner/outer circulation inlet,
outlet and air filter. Control system: center control integration panel assembly, A/C control module assembly
(for automatic A/C), inner/outer circulation damper servo motor, defroster damper servo motor, face damper
servo motor, mix damper servo motor, blower, blower speed resistance, A/C pressure sensor, evaporator
temperature sensor, room temperature sensor (for automatic A/C), outside temperature sensor (for automatic
A/C) and solar sensor (for automatic A/C).
Heating system: heater core assembly, heating inlet hose, heating outlet hose and engine cooling circulation
system.
Cooling system: compressor assembly, condenser assembly (w/ receiver drier), expansion valve, evaporator
core assembly and A/C high/low pressure line.
2. Operation
High-pressure Low-pressure
Gas Liquid
High-pressure Low-pressure
Liquid Gas
Compressor
Outside Air
Condenser
Evaporator
Blower Motor
A/C Pressure Sensor Expansion Valve
RA13T300020

Outside fresh air enters air inlet filter assembly through cowl top opening at the left side of windshield base.
Fresh air flows through evaporator core and heater core, and then enters vehicle through outlets on
instrument panel and floor. Intake air volume can be adjusted by blower speed switch on center control
integration panel assembly. Turn on the compressor assembly by pressing A/C switch on center control
integration panel assembly. Refrigerant is compressed by compressor assembly and converted into high
temperature/pressure gas, which is then condensed into high pressure liquid in the condenser. Then the liquid
is filtered and dried by receiver drier (integrated with condenser) and delivered to expansion valve and
becomes low-pressure liquid through throttling and depressurization. Finally the liquid enters evaporator in
vehicle and absorbs heat and evaporates, thus refrigeration is achieved. A/C heating is realized by engine
coolant circulation system. Heater core is a main component of heating system. With engine running, engine
coolant flows from engine water pump to heater core, and the heater core transmits the heat from engine
coolant to the air that flows through heater core. At this time, A/C switch is off. The air flowing through heater
30
core becomes hot wind through heat exchanging, thus providing heating. Temperature adjustment control
mechanism can be controlled by rotating temperature adjustment knob. Mix damper closes when temperature
adjustment knob is rotated counterclockwise to MAX COOL position. If airflow does not flow through heater
core, the heat transmission will not occur. When rotating temperature adjustment knob clockwise from MAX
COOL position, the mix damper will open slowly, allowing air to flow through gap of heater core. Most of
airflow is heated in this way and discharged air becomes warmer. When temperature adjustment knob is
rotated counterclockwise to MAX HOT position, the mix damper is fully opened and all air flows through heat
core, thus air is heated. Mode knob on A/C control panel is used to direct air with temperature adjusted
through selected outlets.
Specifications

A/C Line l Fixing Bolt at HVAC 9±1
Hose Clamp Fixing Bolt 9±1
Connecting Pressure Plate Fixing Nut 9±1
Compressor Fixing Bolt 25 ± 3
Compressor Intake and Exhaust Line Fixing Bolt 25 ± 3
Condenser Fixing Nut 5±1
A/C Line Fixing Bolt 9±1
Refrigerant Charging Specification
Description Charging Capacity (g)

R134a Refrigerant 350 ± 10g
Refrigerant Oil Charging Specifications
Description Charging Capacity (ml)

Evaporator Replacement 10
Compressor Assembly Replacement 108-135
Condenser Replacement 10
A/C Line Replacement 5

Tools
Special Tool
Refrigerant Recycling Machine
30
RCH0000046
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Power A/C System (Page 1 of 5)
IGNITION SWITCH IGNITION SWITCH

ON OR ACC BATTERY ON OR START
30
R
SB09 EF02 SB06 RF24 RF15
MF05 IP FUSE
20A 7.5A 30A ENGINE AND
30A 7.5A
40A COMPARTMENT
30 86 RELAY
86 30 FUSE AND BOX
BLOWER RELAY BOX DEFROST I-032
RF09 RF18 RELAY RF07
RELAY E-067 E-028
E-063 10A 10A 10A
85 87 87 85
32 43 28 25 19
123 124
P
GR
R
LW
E-029
9 10 I-001 I-019
I-035 TO REAR VIEW I-002
18 18 12
MIRROR HEATER B-019 B-017 K-006
LW
R
L
GR
I-019 2 B-001
P
K-006 4 11 1 T-001
R
A29
LW
1 T-003
L
BCM(A)
RY
T-007
B-022
R
A
1
DEFROSTER
T-008
T-009
1
B
T-010
A9 A14 B10 A21
BLOWER BATTERY DEFROSTER IGNITION
RELAY POWER SWITCH POWER
INDICATION
ELECTRICAL A/C PANEL INTEGRATED SWITCH

K-004 I-023
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 5 4 3 2 1
10 9 8 7 6
B-001 1 2 3 4 5 6 7 8
B-022 W
B 9 10 11 12 13 14 15 16
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52 I-035
W
9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
B8 B7 B6 B5 B4 B3 B2 B1 I-023 T-007
18 17 16 15 14 13 12 11 10 B W
20 19 18 17 16 15 14 13 12 11
B16 B15 B14 B13 B12 B11 B10 B9
I-002 1
I-001
W
W
T-008 T-009
A16 A15 A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 K-004 8 7 6 5 4 3 2 1 K-006 B B
L 15 14 13 12 11 10 9 W
A32 A31 A30 A29 A28 A27 A26 A25 A24 A23 A22 A21 A20 A19 A18 A17
EA13T300040

L
1
BLOWER
M K-008
30 2
BrB
1
BrB
BrB
t° EVAPORATOR
TEMPERATURE
SENSOR
2 K-002
2
1 SPEED
MODULE
K-007
B
K-010
BrR
YG
YO
A22 A24 A32 A31
ELECTRICAL A/C PANEL

K-004
1 5 B6 B5 B4
2 1 1 2 3
2 1 3
2 4 B3 B2 B1
K-002 K-008 K-011 K-013 K-007

W W W W B
A16 A15 A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 K-004

L
EA13T300050

INNER/OUTER
CIRCULATION DEFROSTER/FOOT
30
ACTUATOR FLAP ACTUATOR VENT FLAP ACTUATOR MIX FLAP ACTUATOR
K-009 K-001 K-003 K-005
M M M M
1 3 1 2 3 5 6 1 2 3 5 6 1 2 4 5 6
VB
VB
VB
VB
VB
RL
RL
RL
BL
BL
BL
V
V
RL
BL
A4 A5 A3 A28 A2 A17 A18 A7 A29 A6 A8 A1 A27
ELECTRICAL A/C PANEL

K-004
5 6 7 7 6 5 7 6 5
1 2 3 4 6 5 4 3 2 1
4 3 2 1 4 3 2 1
K-005
K-009 K-001 K-003 W
W W W
A16 A15 A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 K-004

L
EA13T300060

BCM(B) ESP ECM(A)

I-034 E-051 E-041
B14 B11 B9 3 26 B9
BW
Y
V
ILLUMINTION
7 8 E-054 5 E-029
30 I-018 I-035
BW
Br
B
I-019
14 5 9
K-006
I-006
BW
YR
YL
Br
Y
B
L
B6 B5 B9 B16 B15 A20 A17 A13

HAZARD HAZARD REAR ESP OFF ESP OFF A/C ILLU PANEL
SWITCH SWITCH DEFROSTER SWITCH SWITCH SWITCH GROUND
INDICATION SWITCH INDICATION
ELECTRICAL A/C PANEL INTEGRATED SWITCH

K-004 I-023
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034

W
B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24
8 7 6 5 4 3 2 1 K-006
A56 A55 A54 A53 A52 A51 A50 A49 15 14 13 12 11 10 9 W
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
E-041
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25 B
1 2 3 4
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13 1 2 3 4 5 6 7 8
5 6 7 8 9 10
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 9 10 11 12 13 14 15 16
I-018
I-035
W
W
K-004
L
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14 E-051
B B8 B7 B6 B5 B4 B3 B2 B1 I-023
38 37 36 35 34 33 32 31 30 29 28 27 26 25
B
B16 B15 B14 B13 B12 B11 B10 B9
EA13T300070

BATTERY
IGNITION SWITCH
ON OR START
86 30
EF30
10A
30
ECM EF08 ENGINE
MAIN COMPARTMENT
10A
RELAY 86 30 FUSE AND
EF26 EF22 A/C
85 87 RELAY BOX
CLUTCH
10A 10A RELAY E-067
EF37 85 87
10A
75 20 115 98 99 40
R
R
RG
E-035
8
E-007
R
3 1
R
1
A/C
COMPRESSOR PRESSURE
RG
RG
RG
CLUTCH SWITCH
R
E-018 E-055
2
B
4 2
E-005
L
E-035
2
E-007
LR
A54 A42 A55 A56 A44 A4 B15
ECM(A)
E-041
1 2 3 4 5 6
E-007
7 8 9 10 11 12 B
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37

E-041
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25 B
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
1 E-018
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 4 3 E-055 2 1
2 B
Gr
EA13T300080

Manual A/C system (Page 1 of 3)

ON OR ACC BATTERY ON OR START
R
SB09 EF02 SB06 RF24 RF15
MF05 IP FUSE
20A 7.5A 30A ENGINE
30A 7.5A AND
30 86 30
40A COMPARTMENT
FUSE AND 30 86 RELAY
BOX
BLOWER RELAY BOX DEFROST I-032
RF18 RELAY RF07
RELAY E-067 E-028
E-063 10A 10A
85 87 87 85
43 28 25 19
RY
123 124
P
GR
R
LW
E-029
9 10 I-001 I-019
I-035 I-002
TO REAR VIEW 18 18 12
B-019 B-017 K-006
MIRROR HEATER
LW
R
L
GR
I-019 2 B-001
P
K-006 4 11 13 T-001
R
A29
LW
1 T-003
L
BCM(A)
RY
T-007
B-022
R
A
1
DEFROSTER
T-008
T-009
1
B
T-010
A14 A10 A12
BLOWER RELAY DEFROSTER SWITCH INDICATION PANEL POWER
MANUAL A/C PANEL (A)

K-012
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 5 4 3 2 1
10 9 8 7 6
B-001 1 2 3 4 5 6 7 8
B-022 W
B 9 10 11 12 13 14 15 16
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52 I-035
W
9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
10 9 8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
18 17 16 15 14 13 12 11 10 20 19 18 17 16 15 14 13 12 11
K-006
I-002 W
I-001
W
W
A8 A7 A6 A5 A4 A3 A2 A1 K-012 1 T-007
1 T-008 T-009
A9 A10 A11 A12 A13 A14 A15 A16 W B B W
EA13T300010

L
1
M BLOWER
K-008
30
2
BrB
BrB
BrB
B6 B5 4
t° EVAPORATOR
TEMPERATURE
SENSOR
B
B1 R1 K-002
GR
B2 2 2
K-010
R2
B3 BrG INNER/OUTER
M
1 CIRCULATION
B4 R3 ACTUATOR
K-009
VB 1 3
5
MANUAL A/C SPEED
PANEL (B) RESISTOR
K-013 K-011
BO
YG
YO
VB
V
A6 A1 A15 A3 A2
BLOWER RELAY
K-012
1 5
5 6 7 A8 A7 A6 A5 A4 A3 A2 A1 B6 B5 B4
2 1 2 1 3
1 2 3 4 2 4 B3 B2 B1
A9 A10 A11 A12 A13 A14 A15 A16
K-002 K-008 K-009 K-011 K-012 K-013

W W W W W W
EA13T300020

BCM(B) ECM(A) ESP

I-034 E-041 E-051
B14 B11 B9 B9 3 26
BW
V
ILLUMINTION
E-029 E-054
30
YR
5 7 8
YL
L
I-035 I-018
BW
Br
Y
B
I-019
8 7 10 14 1 15 5 9
K-006
I-006
BW
YR
YL
Br
Y
B
L
A4 A5 A11 A8 A9 A7 A13 A16

HAZARD HAZARD REAR A/C ESP OFF ESP OFF ILLU PANEL
SWITCH SWITCH DEFROSTER SWITCH INDICATION SWITCH GROUND
INDICATION SWITCH

K-012
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24
I-034
A56 A55 A54 A53 A52 A51 A50 A49 W
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
E-041
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25 B
1 2 3 4
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13 1 2 3 4 5 6 7 8
5 6 7 8 9 10
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 9 10 11 12 13 14 15 16
I-018
I-035
W
W
8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
K-006
W
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14 E-051 A8 A7 A6 A5 A4 A3 A2 A1
B
38 37 36 35 34 33 32 31 30 29 28 27 26 25 A9 A10 A11 A12 A13 A14 A15 A16
K-012
W
EA13T300030

DIAGNOSIS & TESTING

HINT:

30
Blower fuse (damaged) 55-30
Blower relay (damaged) 55-30
Blower speed switch (damaged) 30-28
Blower motor (damaged) 30-31
Mix damper control mechanism (stuck
A/C no heating 30-36
or damaged)
Heating pipe (blocked or damaged) 30-46
Heater core assembly (blocked or
30-46
damaged)
Wire harness or connector (open or
-
short)
Leak in system 30-22
Refrigerant (overcharged) 30-25
A/C pressure sensor (damaged) 30-54
Evaporator temperature sensor
30-49
(damaged)
A/C switch (damaged) 30-28
Compressor assembly fuse (damaged) 55-30
Compressor assembly relay (damaged) 55-30
A/C no cooling
Compressor assembly belt (loose) 30-56
Compressor assembly (damaged) 30-56
Condenser assembly (blocked or
30-58
damaged)
Expansion valve (blocked or frosted) 30-42
Evaporator core assembly (blocked or
30-42
damaged)
Wire harness or connector (open or
-
short)
A/C intermittent cooling Moisture in system -


Leak in system 30-22
Refrigerant (insufficient) 30-25
Refrigerant (overcharged) 30-25
Air in refrigerant 30-22
Moisture in refrigerant 30-25
Condenser (dirty or blocked)
30 30-58
A/C insufficient cooling Expansion valve (dirty or blocked) 30-42
Evaporator core (dirty or blocked) 30-42
A/C high/low pressure line (dirty or
30-54
blocked)
Blower speed switch (damaged) 30-31
Blower motor (damaged) 30-31
Compressor assembly belt (loose) 30-56
Compressor assembly belt (slip) 30-56
Compressor assembly clutch bearing
-
(worn and excessive clearance)
Compressor assembly solenoid coil
-
(faulty or loose joint)
Too much noise in system Compressor assembly belt (over
30-56
tightened)
Compressor assembly mounting bolt
30-56
(loose)
Cooling fan blade (distorted) 12-23
Refrigerant oil (insufficient) 30-27
Pressure at low pressure side switches
between normal and vacuum during Moisture in refrigerant (excessive) 30-25
operation
Pressure is low for low pressure side A/C system (leaked) 30-22
and high pressure side, cooling
performance is insufficient Refrigerant (insufficient) 30-25
Pressure is low for low pressure side

and high pressure side, frost exists on Condenser (dirty or blocked) 30-58
line from condenser to A/C unit
Vacuum occurs at low pressure side, Moisture in refrigerant (excessive) 30-25
and pressure at high pressure side is
too low, frost exists on lines on both Expansion valve (dirty or blocked) 30-42
sides of condenser or expansion valve
Pressure is too high for low pressure Expansion valve (faulty) -

side and high pressure side Refrigerant oil (excessive) 30-27


Condenser surface (dirty) 30-58
Cooling fan (not operating) -
Pressure at low pressure side is normal
or slightly low, and pressure at high Refrigerant (overcharged) 30-25
pressure side is too high
Air in refrigerant 30-25
Engine (overheating) -
Pressure at low pressure side is too Compressor assembly belt (slip) 07-20
high and pressure at high pressure side 30
is too low Compressor assembly (faulty) 30-56
Pressure at low pressure side is too A/C high pressure line (blocked) 30-54
low, and pressure at high pressure side
is too high Expansion valve (faulty) -
Diagnosis Procedure
HINT:
HINT: Use following procedures to troubleshoot the A/C system.
NEXT
If voltage is below 11 V, recharge or replace battery before
proceeding to next step.
NEXT
NEXT
4 Check for DTCs (current DTC and history DTC)
DTC
occurs
NO
DTC

5 Problem repair (for no DTC), then go to step8
NEXT
6 Troubleshoot according to Diagnostic TroubleCode (DTC) chart, then go to step 8
NEXT
30
7 Troubleshoot according to Problem SymptomsTable, then go to step 8
NEXT
8 Adjust, repair or replace
NEXT
9 Conduct test and confirm malfunction hasbeen repaired
NEXT
10 End

A/C System Function

1. Self-diagnosis Function
a. Power A/C
 Enter self-diagnosis button definition: Inner circulation + AC, starting method: long press
combination button 5S.
 Enter self-diagnosis conditions: with A/C blower ON.
 Enter self-diagnosis successfully: A/C and inner/outer circulation indicator remains on until self-
diagnosis ends.
 Deactivation condition: Air speed adjustment knob operation is not available during self-diagnosis, 30
and exit self-diagnosis mode only when knob is rotated to OFF.
 Self-diagnosis ends: Panel AC and inner/outer circulation indicator blink 3 times with 0.5 s interval
after malfunction displays for 5 s, and then exit self-diagnosis mode.
Self-diagnosis DTC definition:
AC and Inner/Outer Circulation Indicator

Definition
Condition
Indicator off System is normal
AC indicator comes on, and circulation indicator Blower malfunction
goes off
AC indicator goes off, and circulation indicator Mix damper adjustment fails
comes on
AC indicator comes on, and circulation indicator (Face) mode damper adjustment fails
blinks once
AC indicator comes on, and inner/outer circulation (Defrost) mode damper adjustment fails
indicator blinks twice
AC indicator comes on, and inner/outer circulation Inner/outer circulation damper adjustment fails
indicator blinks 3 times
AC indicator comes on, and inner/outer circulation Evaporator temperature sensor malfunction (open or
indicator blinks 4 times short)
Ground Inspection
Groundings are very important to entire circuit system, which are normal or not can seriously affect the entire
circuit system. Ground points are often exposed to moisture, dirt and other corrosive environments.
Corrosion (rust) and oxidation may increase load resistance. This situation will seriously affect normal
operation of circuit. Check the ground points as follows:
6. If several wire harnesses are crimped into one ground terminal, check for proper crimps. Make sure all
wire harnesses are clean, securely fastened and providing a good ground path.

ON-VEHICLE SERVICE
HINT:
 A/C refrigerant lines and hoses are used to transfer refrigerant among A/C system components. Any twist
or bend in refrigerant lines and hoses will reduce performance of A/C system and refrigerant flow in
system.
 There remains high pressure in refrigerant when A/C compressor assembly is operating. It is necessary to
30 ensure that each connecting part in A/C system is sealed well. Check all system lines at least once a year
to ensure that they are in good condition and properly routed. Refrigerant lines and hoses cannot be
repaired and must be replaced if leakage or damage exists.
1. General inspection
a. Check if there is any oil or dust in each joint of A/C line. If this occurs, there may be leakage.
b. Check if condenser surface is dirty and if fins are deformed.
c. Check if there are harsh noises while compressor assembly is operating normally.
d. Temperature difference should be noticeable by touching intake line and exhaust line of compressor
assembly with hand. Normally, temperature of low pressure line is relatively low and that of high
pressure line is relatively hot. If you feel the temperature of intake duct and exhaust duct of condenser
with hand, under normal conditions, temperature of intake duct is higher than that of exhaust duct. If
you feel the temperature difference between expansion valve inlet and outlet line with hand, under
normal conditions, temperature of expansion valve inlet line is relatively hot and that of outlet line is
relatively cool, and the temperature difference between them is noticeable.Using pressure gauge set,
check the refrigerant pressure. If you feel the temperature difference between expansion valve inlet
and outlet line with hand, under normal conditions, temperature of expansion valve inlet line is relatively
hot and that of outlet line is relatively cool, and the temperature difference between them is noticeable.
2. Using pressure gauge set, check the refrigerant pressure.
a. Connect manifold pressure gauge set. After following conditions are met, read pressure values on
pressure gauge. Measurement Condition:
 Inner/Outer circulation switch is in outer circulation position.
 Engine runs at approximately 2000 rpm.
 Adjust temperature knob to Max. Cool.
 Set blower speed control switch to highest band.
 Turn on A/C switch.
Observe pressure values on pressure gauge. In normal condition, low pressure value is 0.15 - 0.20
Mpa and high pressure value is 1.3 - 1.7 Mpa.

Compressor Assembly Noise Inspection

When checking noise related to A/C system, you must first know the conditions under which the noise occurs.
These conditions include: weather, vehicle speed, engine speed, engine temperature and any other special
conditions. Loud noises during A/C operation can often mislead someone. For example, some sounds, like a
failed bearing, may be caused by loose bolts, mounting brackets or a loose compressor assembly.
CAUTION
 A/C compressor assembly must be replaced if any abnormal noise is heard from compressor assembly.
 Noise may occur from drive belt at different engine speeds, and you may mistake it for a noise from A/C 30
compressor assembly.
1. Select a quiet place for testing.

2. Duplicate customer's feedback information as much as possible.
3. Turn A/C system on and off several times to clearly identify compressor assembly noise.
4. Check the condition of compressor assembly belt.
5. Check compressor assembly hub, pulley and bearing assembly. Make sure hub and pulley are aligned
correctly, and pulley bearing is securely installed to A/C compressor assembly.
6. Check if refrigerant line routes incorrectly, and if it is damaged or has an interference that could result in an
abnormal noise. Also, check refrigerant line for twist or bend, otherwise the refrigerant will be limited to
flow, which will cause a noise.
7. Loosen all compressor assembly tightening bolts and retighten them.
8. If noise occurs when liquid refrigerant in A/C suction line is under a slugging condition, replace the
condenser and check refrigerant oil level and charging condition for refrigerant.
9. If slugging condition still exists after replacing condenser, replace A/C compressor assembly.
WARNING
 DO NOT race engine when vacuum pump operates or vacuum exists in A/C system. Failure to do so
may result in a serious damage to A/C compressor assembly.

Refrigerant Leakage Inspection

WARNING
 DO NOT perform pressure test or leakage test to R134a service device or vehicle A/C system with
compressed air. Mixture of air and R134a is inflammable at high pressure. This mixture has potential
danger, and it may cause a fire or explosion, resulting in vehicle damage, personal injury or death.
 Avoid inhaling vapor or moisture from the A/C refrigerant and refrigerant oil.
 Only use special service device to discharge R134a system. If system discharges unexpectedly,
30 ventilate work place before servicing.
CAUTION
 If A/C refrigerant filling amount is empty or low, A/C system may have leak. Check all A/C lines, joints
and parts for remaining oil. The remaining oil is indication mark of A/C system leaking position.
Check refrigerant for leakage.

1. After recharging refrigerant, use gas leak detector to check refrigerant gas for leakage.
2. Perform operations under following conditions:
 Stop engine.
 Ensure ventilation is well (gas leak detector may react to volatile gases which are not from refrigerant,
such as gasoline vapor or exhaust gas).
 Repeat test for 2 or 3 times.
 Make sure there is some refrigerant remaining in refrigeration system.
RA13T300030
3. Place gas leak detector near the joint of A/C line, and check A/C line for leakage. If gas leak detector
makes a sound, it indicates that a leakage exists. Repair or replace leaked A/C line as necessary.
4. Disconnect A/C pressure sensor connector, and use same procedures to check A/C pressure sensor for
leakage. Replace A/C pressure sensor as necessary.
5. Insert gas leak detector into evaporator tank assembly, and use same procedures to check evaporator for
leakage. Clean or replace evaporator core assembly as necessary.
6. Use same procedures to check condenser for leakage. Clean or replace evaporator assembly as
necessary.

30
RA13T300040

Refrigerant Recovering/Draining
WARNING
 Take extra care when servicing A/C system under high pressure.
 There is refrigerant under high pressure in A/C system. It must be serviced by professional technician.
Otherwise, a wrong service procedure may cause a serious danger or fatal injury.
 If A/C system pressure is released unexpectedly, ventilate work area before servicing. In a closed work
place, if a large amount of refrigerant is discharged, it may cause oxygen reduction and result in
30 smothering, causing a serious or fatal injury.
 Never drain refrigerant in A/C system into the atmosphere directly, and avoid environmental
contamination.
CAUTION
 It is necessary to recover refrigerant with R134a refrigerant special recycling machine.

 DO NOT work near open flames.
 Always dispose of recovered refrigerant as specified.
 Never charge R-12 to refrigerant system which is designed to use R134a. The refrigerants are
incompatible, which could damage A/C system.
 DO NOT race engine when vacuum pump operates or vacuum exists in A/C system. Otherwise, A/C
compressor assembly will be damaged seriously.
1. Open hood and loosen joint cover of A/C high/low pressure line.
2. Connect refrigerant recycling machine to A/C high/low pressure line joint.
a. Connect red connector to A/C high pressure line joint
(1).
b. Connect blue connector to A/C low pressure line joint
(2).
1 2
RA13T300050
3. Open high pressure valve and low pressure valve of refrigerant recycling machine.
4. Choose "recovering" item on machine and make it start to operate.
5. Check low pressure value on pressure gauge to ensure that recycling is completed, and then turn off
machine.
6. Disconnect the connection between refrigerant recycling machine and A/C line joint.
7. Reinstall cover onto refrigerant line joint.

Vacuum Pumping
1. Open hood and loosen joint cover of A/C high/low pressure line.
(1).
(2).
1 2 30
RA13T300050
4. Choose "vacuum pumping" item on machine and the time setting is 15 minutes, then choose OK and make
it start to operate.
5. Wait for 10 minutes after completing operation, and check if there is any change in A/C system vacuum. If
there is any change, A/C system leakage may exist, you should check and repair the A/C system. If there
is no change, proceed to perform refrigerant charging procedures.
Refrigerant Recharging
CAUTION
 A small amount of refrigerant oil in A/C system will be discharged when recovering and draining
refrigerant. When filling A/C system, be sure to supplement refrigerant oil, as some amount of oil are lost
during recovering.
 DO NOT fill excessive refrigerant. Otherwise, it will cause excessive pressure to compressor assembly,
resulting in compressor assembly noise and A/C system failure.
 Always perform vacuum pumping before recharging refrigerant.
1. Perform vacuum pumping with a vacuum pump.

2. Add refrigerant oil after checking that there is no leakage in A/C system.
3. Perform vacuum pumping for 3 minutes again after adding refrigerant oil, then charge refrigerant.
4. Choose "charging" item on machine and set the amount of charging to specified value, then choose "OK"
and make it start to operate.
5. Open suction valve and close discharging valve, and then open the charging valve to allow refrigerant to
flow into system.
6. When delivery of refrigerant has stopped, close charging valve.
7. If charged refrigerant is not delivered to specified position, start engine to operate A/C compressor
assembly.
8. Open charging valve to deliver the remaining refrigerant to A/C system.

WARNING
 At this time, do not open exhaust (high pressure) valve. Failure to do so may result in personal injury or
even death.
9. Perform A/C system pressure test after charging.

10.Remove connecting pipe for refrigerant charging after test is completed.
30 11. Reinstall cover onto A/C line joint.
Refrigerant Oil Recovering

CAUTION
 Special service equipment for R134a refrigerant must be used.

 Always keep work area in good ventilation, because A/C system is easy to leak.
 Always dispose of recovered refrigerant as specified.
 Refrigerant oil must be charged after replacing A/C system components or recovering refrigerant.
1. Open engine hood and loosen joint cover of A/C high/low pressure line.
(1).
(2).
1 2
RA13T300050
4. Recover refrigerant oil according to instructions on machine.
5. Record amount of recovered refrigerant oil.
6. Disconnect the connection between refrigerant recycling machine and A/C line joint.
7. Reinstall joint cover onto refrigerant line joint.

Refrigerant Oil Charging

Refrigerant Oil Charging Amount Specifications
Item A/C Compressor Condenser Evaporator Line Replacement

Assembly Replacement Replacement
Replacement
It is necessary to
pour out 50 ml of
Refrigerant Oil
Charging Amount
refrigerant oil from 10 ml 10 ml 5 ml 30
new compressor
assembly
1. Perform vacuum pumping with a vacuum pump. Wait for 10 minutes after completing operation, and check
if there is any change in A/C system pressure. If there is any change, A/C system leakage may exist, you
should check and repair the A/C system. If there is no change, proceed to perform refrigerant charging
procedures.
2. Open suction valve and close exhaust valve, and then open the charging valve to allow refrigerant oil to
flow into system.
3. Close charging valve after refrigerant oil charging is completed.
4. Perform vacuum pumping again for 3 minutes.
5. Continue to perform refrigerant charging procedures after operation is completed.

A/C Control Panel Assembly (for Manual A/C)

Removal
3. Remove the A/C control panel.
30
OFF
A/C
OFF
RA13T300060
a. Using an interior crow plate, pry up the A/C control panel cover (arrow).
b. Remove 4 fixing screws (arrow) from A/C control
panel.
RA13T300070
c. Remove the auxiliary fascia console front left extension panel assembly (See page 46-8).
d. Pry off select cable holder from mix damper servo mechanism, and press bottom pin of servo
mechanism and then remove connector .
e. Remove the glove box assembly (See page 46-12).
f. Pry off select cable holder from mode damper servo mechanism, and press bottom pin of servo
mechanism and then remove connector .
g. Disconnect A/C control panel assembly connector
(arrow) and remove A/C control panel assembly.
RA13T300100
Installation

CAUTION
 Be sure to install fixing clips on upper part of center control integration panel assembly in place during
installation.
 Be sure to align positioning pin on upper part of center control integration panel assembly with
positioning hole on instrument panel when installing.
30

A/C Control Panel Assembly (for Power A/C)

Removal
3. Remove the A/C control panel.
30
OFF
A/C
OFF
RA13T300060
a. Using an interior crow plate, pry up the A/C control panel cover (arrow).
b. Remove 4 fixing screws (arrow) from A/C control
panel.
RA13T300070
c. Disconnect 2 A/C control panel assembly connectors

(arrow) and remove A/C control panel assembly.
RA13T300120
Installation
CAUTION
 Be sure to install fixing clips on upper part of center control integration panel assembly in place during
installation.
 Be sure to align positioning pin on upper part of center control integration panel assembly with
positioning hole on instrument panel when installing.

A/C Element
Removal
1. Remove the front windshield support cover plate (See page 49-29).
2. Remove the A/C element (arrow).
30
RA13T300140
Installation
CAUTION
 Be sure to check A/C element for dirt when installing. Clean it as necessary.
 If A/C element is too dirty or damaged, replace it with a new one.
Blower Assembly
Removal
3. Remove the glove box assembly (See page 46-12).
4. Remove the blower assembly.
a. Disconnect the blower assembly connector (arrow).
RA13T300150

b. Remove 3 fixing screws (arrow) from blower

assembly.
30 RA13T300160
c. Remove the blower assembly.
Inspection
1. Check the blower motor.
a. Remove the blower assembly.
b. Connect positive (+) battery lead to terminal 1 and
-
negative (-) battery lead to terminal 2. Check that +
blower motor operates smoothly. 1

2
RA13T300170
Installation
CAUTION
 Tighten fixing screws to specified torque.

Blower Speed Resistor (for Power A/C)

Removal
WARNING
 During normal operation, blower speed resistor may be very hot. Turn off blower and wait for a few
minutes to cool it before diagnosing or servicing, in order to avoid burns.
30
CAUTION
 DO NOT operate blower assembly, when removing blower speed resistor from vehicle. Failure to do so
may result in damage to blower assembly.

4. Remove the blower speed resistor.
a. Disconnect blower speed resistor connectors (arrow),
and remove blower speed resistor fixing screw (1).
RA13T300180
b. Remove the blower speed resistor.
Installation
CAUTION

Inner/Outer Circulation Damper Servo Motor (for Power A/C)

Removal
1. Recover refrigerant from A/C system (See page 30-22).
4. Remove the driver airbag (See page 31-45).
30 6. Remove the steering column (See page 28-13).
8. Remove the instrument panel assembly (See page 46-11).
9. Remove the instrument panel crossmember assembly (See page 46-17).
10.Remove the HVAC assembly.
11. Remove the inner/outer circulation damper servo motor (for power A/C).
a. Disconnect the inner/outer circulation damper servo
motor connector (arrow).
RA13T300190
b. Remove 3 fixing screws (arrow) and detach clip (1)

from inner/outer circulation damper servo motor.
RA13T300200
c. Remove the inner/outer circulation damper servo motor.
Inspection
1. Check the inner/outer circulation damper servo motor.
a. Connect a few dry batteries (approximately 5 V) in
series. Connect positive (+) battery lead to terminal 1 - +
and negative (-) lead to terminal 3. Check that inner/ 7 6 5
outer circulation damper servo motor operates 4 3 2 1
smoothly clockwise.
b. Connect a few dry batteries (approximately 5 V) in
series. Connect positive (+) battery lead to terminal 3
and negative (-) lead to terminal 1. Check that inner/
outer circulation damper servo motor operates
smoothly counterclockwise. RA13T300210

If there are any abnormalities, replace inner/outer circulation damper servo motor.
Installation
CAUTION

 When installing, apply a small amount of grease to contact surface between inner/outer circulation
damper servo motor lever and inner/outer circulation damper set, to ensure the motor operates smoothly. 30

Mix Damper Servo Motor (for Power A/C)

Removal
11. Remove the mix damper servo motor.
a. Disconnect the mix damper servo motor connector
(arrow).
RA13T300220
b. Remove 3 fixing screws (arrow) and detach lever (1)

from mix damper servo motor.
RA13T300230
c. Remove the mix damper servo motor.
Inspection
1. Check the mix damper servo motor.
and negative (-) lead to terminal 4. Check that mix

damper servo motor operates smoothly clockwise.
6 5 4 3 2 1
and negative (-) lead to terminal 6. Check that mix
damper servo motor operates smoothly
counterclockwise.
RA13T300240

If there are any abnormalities, replace mix damper servo motor.
Installation
CAUTION

 When installing, apply a small amount of grease to contact surface between mix damper servo motor
lever and inner/outer circulation damper set, to ensure the motor operates smoothly. 30

Face Damper Servo Motor (for Power A/C)

Removal
11. Remove 3 fixing screws (arrow) from foot fan shield, and
remove foot fan shield.
RA13T300390
12.Remove the face damper servo motor.

a. Disconnect the face damper servo motor connector
(arrow).
RA13T300250

b. Remove 3 fixing screws (arrow) and detach lever clip

(1) from face damper servo motor.
1
RA13T300260
30
c. Remove the face damper servo motor.
Inspection
1. Check the face damper servo motor.
5 6 7
and negative (-) lead to terminal 4. Check that face
1 2 3 4
damper servo motor operates smoothly clockwise.
and negative (-) lead to terminal 6. Check that face
damper servo motor operates smoothly
counterclockwise.
RA13T300270
If there are any abnormalities, replace face damper servo motor.
Installation
CAUTION

 When installing, apply a small amount of grease to contact surface between face damper servo motor
lever and inner/outer circulation damper set, to ensure the motor operates smoothly.

Defrost Damper Servo Motor (for Power A/C)

Removal
11. Remove the foot fan shield (See page 30-38).
12.Remove the defrost damper servo motor.
a. Disconnect the defrost damper servo motor connector
(arrow).
RA13T300280
b. Remove 3 fixing screws (arrow) and detach lever clip

(1) from defrost damper servo motor.
RA13T300290
c. Remove the face damper servo motor.

Inspection
1. Check the defrost damper servo motor.
and negative (-) lead to terminal 4. Check that defrost 5 6 7

damper servo motor operates smoothly clockwise. 1 2 3 4
and negative (-) lead to terminal 6. Check that defrost
damper servo motor operates smoothly 30
counterclockwise.
RA13T300300
If there are any abnormalities, replace defrost damper servo motor.
Installation
CAUTION

 When installing, apply a small amount of grease to contact surface between defrost damper servo motor
lever and inner/outer circulation damper set, to ensure the motor operates smoothly.

HVAC Assembly
Removal
CAUTION
 Special service equipment for R134a refrigerant must be used to recover/charge refrigerant.
 Be careful not to damage hoses during removal and installation.
 Always keep work area in good ventilation.
30  Disconnected A/C line and connecting part should be sealed, to prevent foreign matter from entering.

6. Remove the steering column (See page 28-13).
a. Disconnect A/C high/low pressure switch connector
(arrow), and remove fixing bolt (1) between A/C high/
low pressure line and expansion valve.
1
RA13T300310
b. Remove 2 fixing bolts (arrow) between expansion

valve and expansion valve mounting pressure plate.
RA13T300320

c. Remove 1 fixing nut (arrow) from A/C low pressure

line.
RA13T300340
30
d. Remove 1 fixing bolt (arrow) from A/C high pressure
line.
RA13T300350
e. Remove 2 fixing nuts from defroster duct assembly,

and remove defroster duct assembly.
RA13T300330
f. Using snap spring calipers, disengage fixing clamps

(arrow) from heating inlet and outlet hoses, to detach
inlet and outlet hoses.
RA13T300380
g. Remove fixing nut (arrow) from A/C wire harness

ground point, and disengage ground wire.
RA13T300360

h. Remove 4 fixing nuts (arrow) between HAVC and

body.
30 RA13T300370
i. Carefully remove HVAC assembly from cabin.
Disassembly
1. Remove the blower assembly (See page 30-31).
2. Remove the blower speed resistor (See page 30-33).
3. Remove the inner/outer circulation damper servo motor (See page 30-34).
4. Remove the mix damper servo motor (See page 30-36).
5. Remove the face damper servo motor (See page 30-38).
6. Remove the defrost damper servo motor (See page 30-40).
7. Remove the air inlet connecting duct assembly.
a. Remove 2 fixing screws (arrow) from air inlet
connecting duct assembly.
RA13T300400
b. Remove the air inlet connecting duct assembly.

8. Remove 1 fixing bolt (arrow) from HAVC fixing bracket.
RA13T300410

9. Remove the power A/C wire harness assembly.

a. Remove fixing screw (arrow) from mix damper motor
wire harness clip.
30
RA13T300420
b. Remove 3 fixing clips (arrow) from power A/C wire

harness.
RA13T300430
c. Remove 3 fixing screws (arrow) from power A/C wire

harness clip, and disconnect evaporator temperature
sensor (1).
RA13T300440
10.Separate evaporator housing assembly from blower housing assembly.

a. Remove 1 coupling clip (arrow) between evaporator
housing assembly and blower housing.
RA13T300450

b. Remove 2 coupling clips (arrow) between evaporator

30 RA13T300460
c. Remove 1 coupling clip (arrow) between evaporator

RA13T300470
d. Remove 2 coupling clips (arrow) between evaporator

RA13T300480
11. Remove the heater core.

a. Remove 2 fixing screws (arrow) from heater core.
RA13T300490
b. Remove the heater core.

12.Remove mix damper, defrost damper and face damper set.

a. Remove 1 coupling clip (arrow) from heater core
housing.
30
RA13T300500
b. Remove 2 coupling clips (arrow) from heater core

housing.
RA13T300510
c. Disassemble heater core housing and remove mix

damper (1), defrost damper (2) and face damper (3).
3
1
2
RA13T300520
13.Remove 5 coupling clips (arrow) from inner/outer

circulation damper set, and remove inner/outer
circulation damper set.
RA13T300530

14.Remove the evaporator core.

a. Remove 6 coupling clips from evaporator core
housing.
30
RA13T300540
b. Remove 5 coupling clips from evaporator core

housing.
RA13T300550
c. Remove 2 coupling screws (arrow) between

evaporator core housing and body, and remove
blower washer (1).
RA13T300560
d. Remove fixing pressure plate (arrow) from evaporator

core housing.
RA13T300570
e. Remove spacer (arrow) from evaporator core

housing.
RA13T300580

f. Disassemble evaporator core housing and remove

evaporator core (arrow).
RA13T300610
30
g. Remove evaporator temperature sensor (arrow) from
evaporator core.
RA13T300590
Inspection
1. Check the evaporator temperature sensor.
a. Using ohm band of digital multimeter, measure
resistance of evaporator temperature sensor
+ -
Standard Resistance
2 1
RA13T300600
Multimeter Temperature Specified

Connection (℃) Condition (KΩ)
Terminal 1 -
-5 8.6577
Terminal 2
Terminal 1 -
0 6.6500
Terminal 2
Terminal 1 -
5 5.1501
Terminal 2
Terminal 1 -
10 4.0207
Terminal 2
Terminal 1 -
15 3.1630
Terminal 2
Terminal 1 -
20 2.5065
Terminal 2

HINT:
Resistance decreases as temperature increases.
CAUTION
 Resistance value may change even if sensor is touched slightly. Make sure sensor connector is held
firmly.
 During measurement, sensor temperature must be almost the same as ambient temperature.
30
If result is not as specified, replace evaporator temperature sensor.
1. Check the evaporator core assembly.
a. Check if evaporator core assembly is cracked, damaged and leaked.
If any problem is found, replace evaporator core assembly.
b. Check fin for bends.
If any fin is bent, carefully straighten it with a
screwdriver or pliers.
RA13T300620
2. Check the heater core assembly.

a. Check if heater core assembly is cracked, damaged or leaked.
Check if heater core assembly is cracked, damaged or leaked.
b. Check fin for bends.
If any fin is bent, carefully straighten it with a
screwdriver or pliers.
RA13T300630
3. Check the damper control mechanism assembly.

a. Check if inner/outer circulation damper adjustment mechanism is stuck, deformed, damaged or if it has
fallen out. Replace as necessary.
b. Check if temperature damper adjustment mechanism is stuck, deformed, damaged or if it has fallen
out. Replace as necessary.
c. Check if mode damper adjustment mechanism set is stuck, deformed, damaged or if it has fallen out.
d. Check if inner/outer circulation/temperature/face/defrost/foot damper set is stuck, deformed, damaged
or if it has fallen out. Replace as necessary.

Assembly
CAUTION
 If evaporator core is to be reused, do not insert the evaporator temperature sensor into a location where
it was previously inserted. Insert it to a location that is 1 fin to the right or left of its previous location.
 During installation, apply a small amount of grease to contact surface of the inner/outer circulation
damper adjustment mechanism, to ensure that it can operate smoothly.
 During installation, apply a small amount of grease to contact surface of the mix damper adjustment 30
mechanism set, to ensure that it can operate smoothly.
 During installation, apply a small amount of grease to contact surface of the face damper adjustment
mechanism, to ensure that it can operate smoothly.
 During installation, apply a small amount of grease to contact surface of the defrost damper adjustment
mechanism, to ensure that it can operate smoothly.
 Always check that inner/outer circulation damper mechanism assembly operates normally after
installation.
 Always check that mix damper mechanism assembly operates normally after installation.
 Always check that face damper mechanism assembly operates normally after installation.
 Always check that defrost damper mechanism assembly operates normally after installation.
Installation
CAUTION
 Tighten fixing bolts and nuts to specified torques.

 It is necessary to replace refrigerant line O-ring, when installing refrigerant line. Failure to do so may
result in refrigerant leaks.

 Only use specified O-ring, as it is made of special materials for R134a system.
 Only use recommended refrigerant oil which is applicable to A/C compressor assembly on vehicle.
 Be sure to recharge refrigerant and check for refrigerant leakage after installation.
 Recharge engine cooling system and check for coolant leakage after installation.

A/C Low Pressure Line

Removal
CAUTION
 Disconnected A/C line and connecting part should be sealed, to prevent foreign matter from entering.
30

4. Remove the A/C low pressure line (compressor to evaporator).
a. Remove fixing bolt (arrow) between A/C high/low
pressure line and expansion valve, and disengage A/
C high/low pressure line.
RA13T300640
b. Remove 1 fixing nut (arrow) from A/C low pressure

line, and remove coupling bolt (1) between A/C low
pressure line and A/C high pressure line.
RA13T300660
c. Remove the A/C low pressure line Ⅰ .

d. Remove fixing bolt (arrow) between A/C low pressure
line and compressor assembly, and disengage A/C
low pressure line from compressor assembly.
RA13T300650
e. Remove the A/C low pressure line Ⅱ .

Installation
CAUTION

 Lubricate new rubber O-ring with clean refrigerant oil and install it to refrigerant line joint.
 Only use specified O-ring, as it is made of special materials for R134a system. 30
 Perform recharging for A/C system and check for refrigerant leakage.

A/C High Pressure Line

Removal
CAUTION
30

4. Remove the front bumper assembly (See page 49-7).
5. Remove the A/C high pressure line (expansion valve to condenser).
a. Disconnect A/C high/low pressure switch connector
(arrow), and remove fixing bolt (1) between A/C high/
low pressure line and expansion valve.
1
RA13T300310
b. Remove coupling bolt (arrow) between A/C high/low

pressure line set bracket and body, and disengage A/
C high pressure line I.
RA13T300350
c. Remove coupling bolt (arrow) between A/C high/low

pressure line set bracket and body, and disengage A/
C high pressure line I.
RA13T300670

d. Remove fixing bolt (arrow) between A/C high pressure

line I and condenser assembly, and disengage A/C
high pressure line I from condenser assembly.
RA13T300680
30
e. Remove the A/C high pressure line I (condenser to evaporator).
6. Remove the A/C high pressure line II (compressor to condenser).
a. Remove fixing bolt (arrow) between A/C high pressure
line II and condenser assembly, and disengage A/C
high pressure line II from condenser assembly.
RA13T300690
b. Remove fixing bolt (arrow) between A/C high pressure

line II and compressor assembly, and disengage A/C
high pressure line II from compressor assembly.
RA13T300700
c. (Tightening torque: 25 ± 4 N·m)
Installation
CAUTION


Compressor Assembly
WARNING
 Be sure to follow safety precautions before performing this procedure. Failure to do so may result in
serious personal injury or even death.
30 CAUTION
 If A/C compressor assembly has an internal malfunction, it is necessary to replace A/C fluid line. Failure
to do so may result in a serious damage to A/C compressor assembly.
 When replacing compressor assembly, it is necessary to measure the refrigerant oil amount removed
from new A/C compressor assembly.
Removal
4. Remove the accessory drive belt (See page 07-20).
5. Remove the generator assembly (See page 16-10).
7. Remove the tank upper crossmember assembly (See page 12-15).
8. Remove the electromagnetic fan assembly (See page 12-22).
9. Remove the compressor assembly
a. Disconnect compressor assembly wire harness
connector (arrow) and remove A/C compressor.
RA13T300710
b. Remove 2 fixing bolts (arrow) between A/C low pressure line and compressor assembly, and disengage
A/C low pressure line from compressor assembly (See page 30-54).
c. Remove 2 fixing bolts (arrow) between A/C high pressure line and compressor assembly, and
disengage A/C high pressure line from compressor assembly (See page 30-54).

d. Remove 4 fixing bolts (arrow) between compressor

assembly and mounting bracket.
RA13T300720
30
10.Remove the compressor assembly mounting bracket.
a. Remove 3 fixing bolts (arrow) between compressor
mounting bracket and engine.
RA13T300730
b. Remove the compressor assembly mounting bracket.
Installation
CAUTION

 When installing a new compressor assembly, always remove a certain amount of refrigerant oil from new
A/C compressor assembly as specified.

Condenser Assembly (w/ Receiver Drier)

Removal
WARNING
 Be sure to follow safety precautions before performing this procedure. Failure to do so may result in
serious personal injury or even death.
30  Disconnected A/C line and connecting part should be sealed, to prevent foreign matter from entering.

5. Remove the condenser assembly (w/ receiver drier).
a. Remove fixing bolt (arrow) between A/C high pressure
line I and condenser assembly, and disengage A/C
high pressure line I from condenser assembly.
RA13T300680
b. Remove fixing bolt (arrow) between A/C high pressure

line II and condenser assembly, and disengage A/C
high pressure line II from condenser assembly.
RA13T300690
c. Remove 4 fixing bolts (arrow) between radiator

assembly and condenser assembly.
RA13T300740
d. Carefully remove condenser assembly (w/ receiver drier) from below.

Inspection
1. Check the condenser fins.
a. If condenser fins are dirty, wash with water. And then dry fins with compressed air.
CAUTION
 DO NOT damage condenser fins.
30
Installation
CAUTION


- MEMO -

GENERAL INFORMATION 31-3 B0001-12 31-17
Description 31-3 B0001-1A 31-17
Operation 31-4 B0001-1B 31-17
Specifications 31-5 B0001-1C 31-17
Tools 31-5 B0010-11 31-21
Circuit Diagram 31-6 B0010-12 31-21
B0010-1A 31-21
B0010-1B 31-21
SRS Control Module Assembly  31
B0010-1C 31-21
Terminal List 31-7
B1231-12 31-26
B1231-1C 31-26
B1232-12 31-26
B1200-11 31-12
B1232-1C 31-26
B1200-12 31-12
B1232-12 31-31
B1200-4A 31-12
B1232-1C 31-31
B1200-64 31-12
B1250-16 31-36
B1200-86 31-12
B1250-17 31-36
B1200-96 31-12
B1251-49 31-41
B1200-1C 31-12
B1240-96 31-41
B1201-11 31-12
U0073-88 31-41
B1201-12 31-12
U0121-87 31-41
B1201-4A 31-12
U0129-86 31-41
B1201-64 31-12
U0140-87 31-41
B1201-86 31-12
U0155-87 31-41
B1201-1C 31-12
U1300-55 31-41
B1201-96 31-12
U1400-87 31-41
B1204-11 31-12
B1204-12 31-12 ON-VEHICLE SERVICE 31-45
B1204-1C 31-12 Driver Airbag Assembly 31-45
B1204-4A 31-12 On-vehicle Inspection 31-45
B1204-64 31-12 Installation 31-47
B1204-86 31-12 Disposal 31-47
B1204-96 31-13 Spiral Cable 31-48
B1205-11 31-13 Removal 31-48
B1205-12 31-13 Inspection 31-49
B1205-1C 31-13 Installation 31-49
B1205-4A 31-13 Front Passenger Airbag Assembly 31-50
B1205-64 31-13 On-vehicle Inspection 31-50
B1205-86 31-13 Removal 31-50
B1205-96 31-13 Installation 31-51
B0001-11 31-17 Disposal 31-52

31

31 - SUPPLEMENTAL RESTRAINT SYSTEM
GENERAL INFORMATION
Description
This vehicle adopts the passenger restraint system, which includes active and supplemental types. Active
restraint system requires passengers to take some actions, such as fastening seat belt; while supplemental
restraint system requires no actions from passengers.
Active restraint system:

 Driver seat belt and front passenger seat belt
 Rear seat belt
31
Supplemental restraint system:
 Airbag system
 Driver seat belt pretensioner and front passenger seat belt pretensioner
Airbag system consists of following components:
 Driver airbag
Driver airbag is installed in the steering wheel, which will inflate to protect driver in event of a severe collision.
 Front passenger airbag assembly
Front passenger airbag is installed in right upper of instrument panel, which will inflate to protect front
passenger in event of a severe collision. (if equipped)
 Driver side airbag (if equipped)
Driver airbag is installed in steering wheel, which will inflate to protect driver in event of a severe collision.
 Curtain shield airbag (if equipped)
Curtain shield airbag is installed in both sides of roof, which will inflate to protect passengers in event of a
severe collision.
 Side collision sensor (if equipped)
Side collision sensor is installed in lower part of B-pillar on body, which will detect the strength of side collision
and send this signal to SRS control module assembly in event of a severe side collision.
 SRS control module assembly
SRS control module assembly has a built-in collision sensor, which is installed on the body floor of auxiliary
fascia console assembly. It controls the inflation of airbag so as to protect driver and other passengers in
event of a severe collision.
 Spiral cable
It is used to connect driver airbag while ensuring that steering wheel has enough steering angle.
 Airbag malfunction indicator
After ignition switch is turned to ON, if malfunction indicator goes off after coming on for approximately 6
seconds, it means that supplemental restraint system operates normally. If malfunction indicator does not
come on, remains on or flashes, it means that supplemental restraint system has a problem and it is
necessary to perform tests and repairs.
 Wire harness
Generally, it is yellow and used to connect each element of supplemental restraint system. Connector has a
safety mechanism.
Airbag system function:
 Airbag must work together with seat belt, and it cannot be substitute for seat belt. Driver and passengers
should always fasten their seat belts when driving, and adjust the belts to a proper position according to
their size.
 Minor collision will not activate the airbag system. Airbags will quickly inflate to protect driver and front
passenger only when severe frontal collision occurs.
Seat belt pretensioner consists of following components:

 Driver seat belt pretensioner

Driver seat belt pretensioner is located on driver seat belt retractor, which will retract driver seat belt to protect
driver in event of a severe collision.
 Front passenger seat belt pretensioner
Front passenger seat belt pretensioner is located on front passenger seat belt retractor, which will retract front
passenger seat belt to protect front passenger in event of a severe collision.
Seat belt pretensioner function
 At the moment of collision, pretensioner retracts seat belt before passenger moves forward, and restraints
passenger firmly onto seat immediately, then locks seat belt to prevent passenger from leaning forward,
thus protecting passenger.
Front passenger seat belt pretensioner
31  Front passenger seat belt pretensioner is located on front passenger seat belt retractor, which will retract
front passenger seat belt to protect front passenger in event of a severe collision.
Seat belt pretensioner function:
 At the moment of collision, pretensioner retracts seat belt before passenger moves forward, and restraints
passenger firmly onto seat immediately, then locks seat belt to prevent passenger from leaning forward,
thus protecting passenger.
 Seat belt pretensioner works with airbag system. Once a frontal collision impact higher than specified
value is detected, seat belt with pretensioner will work together with airbag system to protect passenger.
Operation
Supplemental restraint system can improve the safety of passengers only when used cooperatively with seat
belts. passengers must fasten their seat belts in order to gain full protection from supplemental restraint
system.
Supplemental restraint system circuit is continuously monitored and controlled by SRS control module
assembly. Airbag indicator on instrument cluster illuminates for approximately 6 seconds for a test each time
ignition switch is turned ON. Airbag indicator goes off after the test is completed. If indicator comes on at any
time other than test time, it indicates that there is a problem in supplemental restraint system circuit.
Whether airbag deploys or not depends on the angle and severity of an impact. When vehicle is subjected to
a severe collision, microprocessor in supplemental restraint system sends signals to corresponding inflation
unit of airbags to deploy the airbags quickly, thus protecting passengers.
HINT:
 Before removing airbag system components, disconnect negative battery cable and wait for at least 90
seconds. Before servicing steering system, remove driver airbag and spiral cable for safekeeping.
 If vehicle has been involved in a minor collision but airbags do not deploy, always inspect airbag
components.
 If airbags may be touched during servicing, remove airbags as necessary for safekeeping before servicing.
 Never use airbag components in another vehicle. New airbag components should be used during
replacement.
 If an airbag component is dropped or if there are any cracks, dents or other defects in the case, bracket or
connector, replace it with a new one.
 Information labels are attached to periphery of airbag components. Always follow the cautions and
instructions on labels.

WARNING
 Never expose airbag components directly to hot air or open flames.

 Never attempt to disassemble or repair airbag components.
 Removed airbag should be kept properly. Never put other objects on it. Otherwise, it may cause personal
injury if triggered accidentally.
 As a disposable component, airbag must be replaced after deployment and avoid being reused.
 Always dispose of vehicle together with airbags, otherwise, they may be triggered accidentally which
could cause personal injury.
31
Specifications

Coupling Bolt Between Front Passenger Airbag
Assembly and Instrument Panel Crossmember 10 ± 2
Assembly
Coupling Bolt Between Curtain Shield Airbag
10 ± 1.5
Assembly and Body
Coupling Bolt Between Side Collision Sensor and
10 ± 2
Body
Coupling Bolt Between SRS Control Module
10 ± 1.5
Assembly and Body
Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Supplemental Restraint System
FRONT
PASSENGER
IGNITION SWITCH
AIRBAG
ON OR START
I-017 DRIVER AIRBAG
TO CAN
31 RF05
IP FUSE AND
RELAY BOX
1 2 1 2 SYSTEM
10A I-032 CLOCK

SPRING
15 I-031
1 9
G
Y
VW
R
R
V
1 5 6 3 4 2 17
CAN1-L CAN1-H
SRS CONTROL
MODULE
I-020
20 25 16
Gr
LW
I-002
9 20 B-019
LW
Gr
1 1
FRONT
PASSENGER
PASSENGER
DETECTION
SEAT BELT
SENSOR
SWITCH
B-026
I-021
2 B-027 2
B
B-025 B-025
2 1
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
16 15 14 13 12 11 10 9
I-020 I-031
Gr I-017 W
BYG
1 2 1 2
10 9 8 7 6 5 4 3 2 1 I-002
W B-027
20 19 18 17 16 15 14 13 12 11 B-026
W B
EA13T310010

DIAGNOSIS & TESTING

SRS Control Module Assembly Terminal List
Terminal No. Description Terminal No. Description
1 IG Power Supply 17 CAN1-H
2 AN1-L 18 -
3 Driver Airbag 19 -
4 Driver Airbag 20 Front Passenger Seat Belt Switch
31
5 Front Passenger Airbag 21 -
6 Front Passenger Airbag 22 -
7 - 23 -
8 - 24 -
9 - 25 Passenger Detection Sensor
10 - 26 -
11 - 27 -
12 - 28 -
13 - 29 -
14 - 30 -
15 - 31 -
16 Ground 32 -

 Use X-431 3G diagnostic tester to record and clear DTCs stored in supplemental restraint system.
 Turn ignition switch to ON, and then select Read Code.
 If no DTC is detected, malfunction indicated by DTC is intermittent.
If malfunction is intermittent, perform the followings:
 Wiggle related wire harnesses and connectors and observe if signal is interrupt in related circuit.
 Look for the data that has changed or the DTC to be reset during wiggle test.
 Inspect airbag components and mounting areas for damage, foreign matter, etc. that will cause incorrect
signals.

 If multiple trouble codes were set, refer to the circuit diagrams to look for any common ground circuit or
Ground Inspection
circuit system. Ground points are often exposed to moisture, dirt and other corrosive environments. Corrosion
(rust) can increase resistance which will change the way in which a circuit works.
Electrical control circuits are very sensitive to proper grounding. A loose or corroded ground can affect
electrical control circuit. Operations to check the ground points are as follows:
31 1. Remove the ground nut or bolt.
3. Clean as necessary to ensure that contacting is in a good condition.
4. Reinstall the ground nut securely.
Diagnosis Procedure
HINT:
Use following procedures to troubleshoot Supplemental Restraint System (SRS).
1 Vehicle is brought to workshop
NEXT
If voltage is below 11 V, recharge or replace the battery
before proceeding to next step.
NEXT
3 Check SRS warning light
NEXT
DTC
occurs
NO
DTC

5 Diagnostic Trouble Code (DTC) Chart
NEXT
6 Circuit inspection
HINT:
 An activation prevention mechanism is built in airbag system connector. When connector is disconnected,
this mechanism cuts off circuit by bringing short spring plate into contact with terminals, thus insulating the
circuit from external power sources to prevent accidental airbag activation. 31
 To release activation prevention mechanism, insert a piece of paper with the same thickness as male
terminal between terminals and short spring plate to disconnect the connection.
WARNING
 DO NOT release the activation prevention mechanism, unless specially directed by troubleshooting
procedure.
 During circuit troubleshooting for airbag system, make sure to cut off battery power source, and wait for
at least 90 seconds to discharge the system condenser.
NEXT
7 Repair
NEXT
8 Clear DTCs (current and history DTCs)
NEXT
9 Check for DTCs (current and history DTCs)
DTC is
Go to step 5
output
No DTC
Go to next step
is output
10 Confirmation test
NEXT

11 End

DTC DTC Definition
B1251-49 Electronic Control Unit (ECU), Internal Electronic Failure
B1200-11 Driver Side Impact Sensor Circuit Short to Ground
31 B1200-12 Driver Side Impact Sensor Circuit Short to Battery
B1200-4A Driver Side Impact Sensor Incorrect Component Installed
B1200-64 Driver Side Impact Sensor Signal Plausibility Failure
B1200-86 Driver Side Impact Sensor Signal Invalid
B1200-96 Driver Side Impact Sensor Component Internal Failures
B1200-1C Driver Side Impact Sensor Circuit Voltage Out of Range
B1201-11 Passenger Side Impact Sensor Circuit Short to Ground
B1201-12 Passenger Side Impact Sensor Circuit Short to Battery
B1201-4A Passenger Side Impact Sensor Incorrect Component Installed
B1201-64 Passenger Side Impact Sensor Signal Plausibility Failure
B1201-86 Passenger Side Impact Sensor Signal Invalid
B1201-1C Passenger Side Impact Sensor Circuit Voltage Out of Range
B1201-96 Passenger Side Impact Sensor Component Internal Failures
B1204-11 UFS (Up Front Sensor) Left Circuit Short to Ground
B1204-12 UFS (Up Front Sensor) Left Circuit Short to Battery
B1204-1C UFS (Up Front Sensor) Left Circuit Voltage Out of Range
B1204-4A UFS (Up Front Sensor) Left Incorrect Component Installed
B1204-64 UFS (Up Front Sensor) Left Signal Plausibility Failure
B1204-86 UFS (Up Front Sensor) Left Signal Invalid
B1204-96 UFS (Up Front Sensor) Left Component Internal Failures
B1205-11 UFS (Up Front Sensor) Right Circuit Short to Ground
B1205-12 UFS (Up Front Sensor) Right Circuit Short to Battery
B1205-1C UFS (Up Front Sensor) Right Circuit Voltage Out of Range
B1205-4A UFS (Up Front Sensor) Right Incorrect Component Installed
B1205-64 UFS (Up Front Sensor) Right Signal Plausibility Failure
B1205-86 UFS (Up Front Sensor) Right Signal Invalid
B1205-96 UFS (Up Front Sensor) Right Component Internal Failures
B0001-11 Front Airbag Passenger Loop Circuit Short to Ground
B0001-12 Front Airbag Driver Loop Circuit Short to Battery
B0001-1A Front Airbag Driver Loop Circuit Resistance Below Threshold

DTC DTC Definition

B0001-1B Front Airbag Driver Loop Circuit Resistance Above Threshold
B0001-1C Front Airbag Driver Loop Circuit Voltage Out of Range
B0010-11 Front Airbag Passenger Loop Circuit Short to Ground
B0010-12 Front Airbag Passenger Loop Circuit Short to Battery
B0010-1A Front Airbag Passenger Loop Circuit Resistance Below Threshold
B0010-1B Front Airbag Passenger Loop Circuit Resistance Above Threshold
B0010-1C Front Airbag Passenger Loop Circuit Voltage Out of Range
B0070-11 Belt Pretensioner Front Driver Loop Circuit Short to Battery 31
B0070-12 Belt Pretensioner Front Driver Loop Circuit Short to Battery
B0070-1A Belt Pretensioner Front Driver Loop Circuit Resistance Below Threshold
B0070-1B Belt Pretensioner Front Driver Loop Circuit Resistance Above Threshold
B0070-1C Belt Pretensioner Front Driver Loop Circuit Voltage Out of Range
B0072-11 Belt Pretensioner Front Passenger Loop Circuit Short to Ground
B0072-12 Belt Pretensioner Front Passenger Loop Circuit Short to Battery
B0072-1A Belt Pretensioner Front Passenger Loop Circuit Resistance Below Threshold
B0072-1B Belt Pretensioner Front Passenger Loop Circuit Resistance Above Threshold
B0072-1C Belt Pretensioner Front Passenger Loop Circuit Voltage Out of Range
B1231-12 Buckle Switch Front Passenger (BLFP) Circuit Short to Battery
B1231-1C Buckle Switch Front Passenger (BLFP) Circuit Voltage Out of Range
B1232-12 PDM (Passenger Detection Mat) Switch Circuit Short to Battery
B1232-1C PDM (Passenger Detection Mat) Switch Circuit Voltage Out of Range
B1250-16 Battery Voltage Circuit Voltage Below Threshold
B1250-17 Battery Voltage Circuit Voltage Above Threshold
B1211-00 BT Deployment
B1210-00 Front Deployment
B125A-00 Crash Counter Reached Max
B1240-96 ICM Airbag Lamp Failed
U0121-87 Lost Communication with BSM
U0129-86 Vehicle Speed Status from BSM
U0140-87 Lost Communication with BCM
U0155-87 Lost Communication with ICM
U1400-87 Lost Communication of ABM

DTC B1200-11 Driver Side Impact Sensor Circuit Short to Ground
DTC B1200-12 Driver Side Impact Sensor Circuit Short to Battery
Driver Side Impact Sensor Incorrect Component

DTC B1200-4A
Installed
DTC B1200-64 Driver Side Impact Sensor Signal Plausibility Failure
31 DTC B1200-86 Driver Side Impact Sensor Signal Invalid
DTC B1200-96 Driver Side Impact Sensor Component Internal Failures
DTC B1200-1C Driver Side Impact Sensor Circuit Voltage Out of Range
DTC B1201-11 Passenger Side Impact Sensor Circuit Short to Ground
DTC B1201-12 Passenger Side Impact Sensor Circuit Short to Battery
Passenger Side Impact Sensor Incorrect Component

DTC B1201-4A
Installed
DTC B1201-64 Passenger Side Impact Sensor Signal Plausibility Failure
DTC B1201-86 Passenger Side Impact Sensor Signal Invalid
Passenger Side Impact Sensor Circuit Voltage Out of

DTC B1201-1C
Range
Passenger Side Impact Sensor Component Internal

DTC B1201-96
Failures
DTC B1204-11 UFS (Up Front Sensor) Left Circuit Short to Ground
DTC B1204-12 UFS (Up Front Sensor) Left Circuit Short to Battery
DTC B1204-1C UFS (Up Front Sensor) Left Circuit Voltage Out of Range
UFS (Up Front Sensor) Left Incorrect Component

DTC B1204-4A
Installed
DTC B1204-64 UFS (Up Front Sensor) Left Signal Plausibility Failure
DTC B1204-86 UFS (Up Front Sensor) Left Signal Invalid

DTC B1204-96 UFS (Up Front Sensor) Left Component Internal Failures
DTC B1205-11 UFS (Up Front Sensor) Right Circuit Short to Ground
DTC B1205-12 UFS (Up Front Sensor) Right Circuit Short to Battery
UFS (Up Front Sensor) Right Circuit Voltage Out of

DTC B1205-1C
Range
UFS (Up Front Sensor) Right Incorrect Component 31

DTC B1205-4A
Installed
DTC B1205-64 UFS (Up Front Sensor) Right Signal Plausibility Failure
DTC B1205-86 UFS (Up Front Sensor) Right Signal Invalid
UFS (Up Front Sensor) Right Component Internal

DTC B1205-96
Failures

DTC Detection
Condition
Driver Side Impact
B1200-11 Sensor Circuit Short to
Ground
Driver Side Impact
B1200-12 Sensor Circuit Short to
Battery
Driver Side Impact
B1200-4A Sensor Incorrect
31 Component Installed
Driver Side Impact
B1200-64 Sensor Signal
Driver Side Impact
B1200-86
Sensor Signal Invalid
Driver Side Impact
B1200-96 Sensor Component
Internal Failures
Driver Side Impact
B1200-1C Sensor Circuit Voltage
Out of Range
Passenger Side
B1201-11 Impact Sensor Circuit  Airbag module damage
Airbag module
Short to Ground
integrated acceleration  Integrated acceleration sensor circuit
Passenger Side sensor is damaged short or open
B1201-12 Impact Sensor Circuit
Short to Battery
Passenger Side
Impact Sensor
B1201-4A
Incorrect Component
Installed
Passenger Side
B1201-64 Impact Sensor Signal
Passenger Side
B1201-86 Impact Sensor Signal
Invalid
Passenger Side
B1201-1C Impact Sensor Circuit
Voltage Out of Range
Passenger Side
Impact Sensor
B1201-96
Component Internal
Failures
UFS (Up Front Sensor)
B1204-11 Left Circuit Short to
Ground

DTC Detection
Condition
B1204-12 Left Circuit Short to
Battery
B1204-1C Left Circuit Voltage Out
of Range
B1204-4A Left Incorrect
Component Installed
31
B1204-64 Left Signal Plausibility
Failure
B1204-86
Left Signal Invalid
B1204-96 Left Component
Internal Failures
UFS (Up Front Sensor) Airbag module  Airbag module damage
B1205-11 Right Circuit Short to integrated acceleration  Integrated acceleration sensor circuit
Ground sensor is damaged short or open
B1205-12 Right Circuit Short to
Battery
B1205-1C Right Circuit Voltage
Out of Range
B1205-4A Right Incorrect
Component Installed
B1205-64 Right Signal
B1205-86
Right Signal Invalid
B1205-96 Right Component
Internal Failures


Step 1.
 If datastream is detected, malfunction indicated by datastream is intermittent.
If above trouble codes still occur by performing above steps, it confirms that internal airbag module
31 malfunctions occur. At this time, it is necessary to replace airbag module.
CAUTION
Because acceleration sensor for A13T is integrated into airbag module, so connector inspection is not
involved in such DTC.

DTC B0001-11 Front Airbag Passenger Loop Circuit Short to Ground
DTC B0001-12 Front Airbag Driver Loop Circuit Short to Battery
Front Airbag Driver Loop Circuit Resistance Below

DTC B0001-1A
Threshold
Front Airbag Driver Loop Circuit Resistance Above

DTC B0001-1B
Threshold
31
DTC B0001-1C Front Airbag Driver Loop Circuit Voltage Out of Range

DRIVER AIRBAG
1 2
31
CLOCK
SPRING
I-031
1 9
R
B
3 4
SRS CONTROL
MODULE
I-020
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
16 15 14 13 12 11 10 9
I-020 I-031
Gr W
EA13T310020

DTC Detection
Condition
Front Airbag
Passenger Loop
B0001-11
Circuit Short to
Ground
Front Airbag Driver
B0001-12 Loop Circuit Short to
Battery
Front Airbag Driver  Driver side airbag
Loop Circuit Ignition switch ON 31
B0001-1A  Wire harness and connector
Resistance Below Engine running
Threshold  SRS control module assembly
Front Airbag Driver

B0001-1C Loop Circuit Voltage
Out of Range
Front Airbag Driver
Loop Circuit
B0001-1B
Resistance Above
Threshold
CAUTION
When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and
1 Check driver side airbag
a. Turn ignition switch to LOCK, disconnect negative battery cable and wait for at least 90 seconds.
b. Disconnect driver side airbag connector, and install new main airbag to coil spring connector I-031.
c. Reconnect negative battery cable and wait for a few seconds.
d. Turn ignition switch ON and wait for at least 90 seconds.
e. Use X-431 3G diagnostic tester to clear DTCs.
f. Turn ignition switch to LOCK.
g. Turn ignition switch ON and wait for at least 90 seconds.
h. Use X-431 3G diagnostic tester to check if there is still DTC output.
WARNING
Never measure driver side airbag directly, otherwise it may cause serious personal injury due to accidental
deployment of airbag.
OK Replace driver side airbag

NG
Use circuit diagram as a guide to perform the following procedures:

 Turn ignition switch to LOCK, disconnect negative battery cable and wait for at least 90 seconds.
 Disconnect main airbag and coil spring connector I-031 and SRS control moduel assembly connector I-
020.
31
 Check if related connector terminal contact pins are in good condition.
NG Repair or replace instrument panel wire

harnessand connector
OK
3 Check driver side airbag control circuit
 Disconnect the SRS control module assembly connector I-020.
 Disconnect connector I-031 between coil spring and main airbag.
 Connect negative battery cable and wait for a few seconds.
 Using a digital multimeter, check for continuity between SRS control module assembly connector I-020 and
coil spring to check for a short circuit in system circuit according to table below.
a. Check for continuity between main airbag and coil spring.
Check for Open
Specified
Multimeter Connection + -
Condition
I-020 (4) - I-031 (9) Continuity
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
I-020 (3) - I-031 (1) Continuity 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
NG Replace coil spring I-020
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
I-031 RA13T310010
RM1A370500
OK
Replace main airbag assembly

DTC B0010-11 Front Airbag Passenger Loop Circuit Short to Ground
DTC B0010-12 Front Airbag Passenger Loop Circuit Short to Battery
Front Airbag Passenger Loop Circuit Resistance Below

DTC B0010-1A
Threshold
Front Airbag Passenger Loop Circuit Resistance Above

DTC B0010-1B
Threshold
31
Belt Pretensioner Front Driver Loop Circuit Short to
DTC B0010-1C
Battery

FRONT
PASSENGER
AIRBAG
I-017
31 1 2
VW
5 6
SRS CONTROL
MODULE
I-020
2 1
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-020
Gr I-017
BYG
EA13T310030

DTC Detection
Condition
Front Airbag
B0010-11 Passenger Loop
Front Airbag
B0010-12 Passenger Loop
Front Airbag
Passenger Loop  Front passenger airbag assembly
B0010-1A
Circuit Resistance
Ignition switch ON
 Wire harness and connector 31
Engine running
Below Threshold  SRS control module assembly
Belt Pretensioner Front
B0010-1C Driver Loop Circuit
Short to Battery
Front Airbag
Passenger Loop
B0010-1B
Circuit Resistance
Above Threshold
CAUTION
1 Check front passenger airbag assembly
b. Disconnect front passenger airbag connector, and connect new front passenger airbag (I-017) to
connector I-020.
NO Replace front passenger airbag
YES

 Disconnect front passenger airbag connector I-017 and SRS control module assembly connector I-020.



OK
3 Check front passenger airbag control circuit

31
a. Turn ignition switch to LOCK, disconnect negative battery
cable and wait for at least 90 seconds.
b. Disconnect the SRS control module assembly connector
I-020.
c. Disconnect the front passenger airbag connector I-017.
d. Connect negative battery cable and wait for a few
seconds.
f. Using a digital multimeter, measure voltage between front
passenger airbag connector I-022 and body ground to
check for a short circuit to power supply according to
table below.
Standard Voltage
Condition
+ -
I-017(2) - Body
Ignition switch ON Below 1 V
ground 2 1
I-017(1) - Body
ground
g. Turn ignition switch to LOCK, disconnect negative battery

cable and wait for at least 90 seconds. I-017
h. Using a digital multimeter, check for continuity between

front passenger airbag connector I-017 and body ground
to check for a short circuit to ground according to table
below.
RA13T310020
RM1A370500

Standard Condition
Condition
+ -
I-017(2) - Always Continuity
I-017(1) 2 1
I-017(1) - Body Always No continuity

ground
I-017(2) - Body Always No continuity
ground I-017
i. Release activation prevention mechanism built into SRS 31

control module assembly connector I-020.
j. Using a digital multimeter, check for continuity between
terminal of front passenger airbag connector I-017 and
SRS control module assembly connector I-020 according RA13T310030
RM1A370500
to table below.
Standard Condition
Condition
+ -
I-017(1) - Always Continuity
I-020(5)
I-017(2) - Always Continuity 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-020(6)
I-020
OK Replace SRS control module assembly
2 1
NG Replace instrument panel wire harness
and connector
I-017 RA13T310040
RM1A370500

Buckle Switch Front Passenger (BLFP) Circuit Short to

DTC B1231-12
Battery
Buckle Switch Front Passenger (BLFP) Circuit Voltage

DTC B1231-1C
Outof Range
PDM (Passenger Detection Mat) Switch Circuit Short to

DTC B1232-12
Battery
31 PDM (Passenger Detection Mat) Switch Circuit Voltage

DTC B1232-1C
Outof Range

31
SRS CONTROL
MODULE
I-020
20
Gr
I-002
9 B-019
Gr
1
FRONT
PASSENGER
SEAT BELT
SWITCH
2 B-027
B
B-025
1 2
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 B-027
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 B
I-020 10 9 8 7 6 5 4 3 2 1 I-002
Gr W
20 19 18 17 16 15 14 13 12 11
EA13T310040

Self-diagnosis Detection Logic
DTC Detection
Condition
Buckle Switch Front
B1231-12 Passenger (BLFP)
Buckle Switch Front
Passenger (BLFP)
B1231-1C
Circuit Voltage Out of
Front passenger seat  Front passenger seat belt switch
Range
31 PDM
belt buckle short to
(Passenger power supply
 Wire harness and connector
B1232-12 Detection Mat) Switch
PDM (Passenger
Detection Mat) Switch
B1232-1C
Range
HINT:
1 Check front passenger seat belt switch
b. Disconnect front passenger seat belt switch connector, and connect new front passenger seat belt switch
to connector B-027.
e. Use X-431 3G diagnostic tester to check if there is still DTC output.
NO Replace front passenger seat belt switch
YES

 Disconnect front passenger seat belt switch connector B-027 and SRS control module assembly
connector I-020.
NG Repair or replace airbag wire harness and

connector

OK
3 Check front passenger seat belt switch controlcircuit

I-020.
c. Disconnect the front passenger seat belt switch
connector B-027.
d. Connect negative battery cable and wait for a few
31
seconds.
f. Using a digital multimeter, measure voltage between front
passenger seat belt switch connector B-027 and body
ground to check for a short circuit to power supply
Standard Voltage
Condition
+ -
B-027 (1) - Body
ground
1 2
g. Turn ignition switch to LOCK, disconnect negative battery
cable and wait for at least 90 seconds. B-027

front passenger seat belt switch connector B-027 and
body ground to check for a short circuit to ground
RA13T310050
RM1A370500
Standard Condition
Condition
+ -
B-027 (2) - Body
ground
1 2
i. Using a digital multimeter, check for continuity between
terminals of connectors B-026 and I-020 according to B-027
table below.
RA13T310060
RM1A370500

Standard Condition
Condition 1 2
B-027
+ -
B-027 (1) – I-002
Always Continuity
(9)
10 9 8 7 6 5 4 3 2 1
I-020 (20) – I-002
Always Continuity
(9) 20 19 18 17 16 15 14 13 12 11
I-002

31 NG Repair or replace airbag wire harness and 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
connector 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-020
RA13T310070
RM1A370500

PDM (Passenger Detection Mat) Switch Circuit Short to

DTC B1232-12
Battery
PDM (Passenger Detection Mat) Switch Circuit Voltage

DTC B1232-1C
Outof Range
31

31
SRS CONTROL
MODULE
I-020
LW 25
I-002
20 B-019
LW
1
PASSENGER
DETECTION
SENSOR
B-026
2
B
B-025
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1 2
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
B-026
W
I-020
Gr
10 9 8 7 6 5 4 3 2 1 I-002
W
20 19 18 17 16 15 14 13 12 11
EA13T310050

DTC Detection
Condition
PDM (Passenger
B1232-12 Detection Mat) Switch
 Front passenger seat belt reminder
Circuit Short to Battery Front passenger seat
sensor
PDM (Passenger sensor short to power  Wire harness or connector
Detection Mat) Switch supply
B1232-1C  SRS control module assembly
Range
31
HINT:
1 Check front passenger seat belt remindersensor
b. Disconnect front passenger seat belt reminder sensor connector, and connect new front passenger seat
belt reminder sensor to connector I-002.
NO Replace front passenger seat belt

reminder sensor
YES

 Disconnect front passenger seat belt reminder sensor connector B-026 and SRS control module assembly
connector I-020.
NG Repair or replace airbag wire harness and

connector
OK

3 Check front passenger seat belt remindersensor control circuit
b. Disconnect the SRS control module assembly connector I-020.
c. Disconnect the front passenger seat belt reminder sensor connector B-026.
d. Connect negative battery cable and wait for a few seconds.
f. Using a digital multimeter, measure voltage between front passenger seat belt reminder sensor connector
B-026 and body ground to check for a short circuit to power supply according to table below.
31 Standard Voltage
Condition
+ -
B-026 (2) - Body
ground
g. Turn ignition switch to LOCK, disconnect negative battery 1 2

B-026
front passenger seat belt reminder sensor connector B-
026 and body ground to check for a short circuit to
ground according to table below.
RA13T310071
RM1A370500
Standard Voltage
Condition
+ -
B-026 (2) - Body
ground
i. Using a digital multimeter, check for continuity between 1 2
terminals of connectors B-026 and I-020 according to

B-026
table below.
RA13T310080
RM1A370500

Standard Voltage
Condition
Connection Condition B-026
+ -
I-020 (25) - I-002
Always Continuity
(20)
10 9 8 7 6 5 4 3 2 1
B-026 (1) - I-002
Always Continuity 20 19 18 17 16 15 14 13 12 11
(20)
I-002
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 31
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-020
RA13T310090
RM1A370500
NG

DTC B1250-16 Battery Voltage Circuit Voltage Below Threshold
DTC B1250-17 Battery Voltage Circuit Voltage Above Threshold
31

IGNITION SWITCH
ON OR START
IP FUSE AND
RF05 RELAY BOX
10A I-032
15
31
R 1
SRS CONTROL
MODULE
I-020
16
B
I-021
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-020
Gr
EA13T310060

DTC Detection
Condition
Battery Voltage Circuit
B1250-16 Voltage Below  Module supply  Battery
Threshold voltage low  Charging system
Battery Voltage Circuit  Module supply  Wire harness and connector
B1250-17 Voltage Above voltage high  SRS control module assembly
Threshold
HINT:
31  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and
a. Measure battery voltage with a digital multimeter.

NG Check charging system (See page 16-6).
OK
Check wire harness and connector (SRS controlmodule assembly – instrument panel fuse
2 and relay box)

 Disconnect the SRS control module assembly connector I-020.
 Disconnect the instrument panel fuse and relay box wire harness connector I-032.

OK
3 Check wire harness and connector (SRS controlmodule assembly - battery)
c. Connect negative battery cable and wait for a few seconds.
d. Turn ignition switch to ON.
e. Using a digital multimeter, measure power supply voltage of SRS control module assembly connector I-
020 to check if power supply circuit is normal according to table below.

Standard Voltage
Condition
+ -
I-020 (1) - Body
ground
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
NG Repair or replace instrument panel wire 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-020
31
RA13T310100
RM1A370500
OK
4 Check wire harness and connector (SRS controlmodule assembly - body ground)
c. Using a digital multimeter, check ground circuit of SRS control module assembly connector I-020 to check
if system ground circuit is normal according to table below.
Standard Condition
Condition
+ -
I-020 (16) - Body
Always Continuity
ground
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
NG Repair or replace airbag wire harness and 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
connector
I-020
RA13T310110
OK

5 Reconfirm DTCs
a. Reconnect SRS control module assembly connector I-020 securely.

b. Reconnect instrument panel fuse and relay box wire harness connector I-032 securely.
c. Connect the negative battery cable.
e. Use X-431 3G diagnostic tester (the latest software) to record and clear DTCs stored in supplemental
restraint system.
f. Turn ignition switch to LOCK and wait for a few seconds.
31 g. Turn ignition switch to ON.
h. Using X-431 3G diagnostic tester, read DTCs stored in supplemental restraint system again.
i. Check if the same DTCs are still output.
YES Replace SRS control module assembly

DTC B1251-49 Electronic Control Unit (ECU), Internal Electronic Failure
DTC B1240-96 ICM Airbag Lamp Failed
DTC U0073-88 CAN Bus Off
DTC U0121-87 Lost Communication with BSM
DTC U0129-86 Vehicle Speed Status from BSM

31
DTC U0140-87 Lost Communication with BCM
DTC U0155-87 Lost Communication with ICM
DTC U1300-55 Software Configuration Error
DTC U1400-87 Lost Communication of ABM

TO CAN
SYSTEM
31
G
Y
2 17
CAN1-L CAN1-H
SRS CONTROL
MODULE
I-020
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-020
Gr
EA13T310080

DTC Detection
Condition
Electronic Control Unit
B1251-49 (ECU), Internal
Electronic Failure
Vehicle Speed Status
U0129-86
from BSM
Lost Communication
U0140-87
with BCM  Engine control module
B1240-96
ICM Airbag Lamp  ABS/ESP control module 31
Failed  Body control module
ON
Lost Communication  Wire harness and connector
U0155-87
with ICM  SRS control module
Lost Communication of  Instrument Cluster
U1300-55
ABM
Lost Communication of
U1400-87
ABM
Lost Communication
U0121-87
with BSM
Use circuit diagram as a guide to perform the following

procedures:
+ -
I-020.
c. Using a digital multimeter, measure resistance between
pins 2 and 17 of SRS control module assembly connector
I-020. Standard resistance is 60 Ω. 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
Standard Resistance
Multimeter Specified I-020

Condition
I-020 (2) - I-020
Ignition switch ON 60 Ω
(17)
RA13T310130
RM1A370500
NG Check other CAN network control circuits

2 Reconfirm DTCs

b. Disconnect the negative battery cable and wait for at least 90 seconds.
e. Use X-431 3G diagnostic tester (the latest software) to record and clear DTCs stored in supplemental
restraint system.
f. Turn ignition switch to LOCK and wait for a few seconds.
31 g. Turn ignition switch to ON, and then select Read Code.
OK Malfunction has been repaired and

system operatesnormally

ON-VEHICLE SERVICE
Driver Airbag Assembly
1. Check the driver airbag assembly (vehicle hasn't been involved in a collision with airbags not deployed).
a. Perform diagnosis system inspection.
b. Perform visual inspection with the driver airbag assembly installed on vehicle:
 Check for cuts, cracks or discoloration on outer surface and grooved portion of driver airbag
assembly. 31
 If any defect above is found, replace driver airbag assembly with a new one.
MODE SET
1 2
0 3
A/C
RA13T310140
1
2
3
4
5
2. Check the driver airbag assembly (vehicle had been involved in a collision with airbag not deployed).
b. Perform visual inspection with driver airbag assembly removed from vehicle:
 Check for cuts, cracks or discoloration on outer surface and grooved portion of driver airbag
assembly.
 Check wire harnesses for cuts and cracks, and if connectors are chipped.
 Check steering wheel for deformation.
CAUTION
Be sure to follow correct procedures to remove and install driver airbag assembly.
RA13T310150
HINT:
 If driver airbag assembly contact plate is deformed, never repair it. Always replace driver airbag assembly
with a new one.

 There should not be any contact between driver airbag assembly and steering wheel, and keep an uniform
clearance all around, when installing new driver airbag assembly onto steering wheel.
31 RA13T310160
 Handle airbag and airbag control module assembly carefully, and never tap or strike them fiercely.
 Removal, inspection and installation of airbag system must meet relevant requirements and
specifications, and never perform operation casually.
 Removed airbag should be kept properly with face up. Store the airbag in a place with enough spare
space to prevent accidental airbag deployment.

WARNING
Wait at least 90 seconds after disconnecting the negative battery cable to disable supplementary restraint
system.
5. Remove the driver airbag assembly.

a. Position the front wheels straight ahead.
b. Using a flat tip screwdriver wrapped with protective tape, push driver airbag assembly snap springs
(arrow) from service hole on both sides of steering wheel.
MODE SET
1 2
0 3
A/C
1 3 5
2 4 R
RA13T310170
c. Disengage driver airbag assembly from steering wheel, and support driver airbag assembly stably by
hands.
d. Disconnect driver airbag assembly wire harness connector (1) and horn wire harness connector (2).

e. Remove the driver airbag assembly.
2
1
RA13T310180
CAUTION 31
 DO NOT damage the airbag wire harness when handling airbag wire harness connector.
WARNING
DO NOT pull the airbag wire harness when removing driver airbag assembly.
f. Remove the driver airbag assembly.
Installation
 Installation is in the reverse order of removal.
CAUTION
 Be sure to install snap springs in place during installation.

normally.
Disposal
Always dispose of airbag together with vehicle which is equipped with supplemental restraint system.
Otherwise, the airbag will be in chemical and physical hazard. Failure to handle it properly will cause personal
injury. Do not dispose of airbag by oneself, and always contact the professional service department to perform
disposal.

Spiral Cable
Removal
WARNING
restraint system.
31
3. Position the front wheels straight ahead.
6. Remove the spiral cable.
a. Disconnect spiral cable wire harness connector
(arrow) and angle sensor connector (1) (if equipped).
RA13T310190
b. Detach fixing claws (arrow) between spiral cable and

combination switch assembly.
RA13T310200
c. Detach angle sensor fixing claws and separate angle

sensor (1) and spiral cable (2).
RA13T310210

Inspection
1. Check the spiral cable.
a. Check that there are no scratches or cracks on connectors, and/or no cracks, dents or chipping on the
cable.
b. If there are scratches, cracks, dents or cuts on connectors or spiral cable, replace the spiral cable with
a new one.
HINT:
When installing charcoal canister breather pipe, be careful to
align the white mark (1) on charcoal canister breather pipe
with the side seam (2) of activated charcoal canister
assembly.
31
RA13T310220
Installation
HINT:
 Always install spiral cable correctly according to matchmarks on spiral cable and steering column (fully
turn spiral cable to one direction slowly, then turn it to the other direction until yellow ball appears in
transparent neutral window and aligns with arrow mark), otherwise spiral cable may be damaged.
RA13T310230
CAUTION

 DO NOT rotate the spiral cable over specified turns to prevent it from breaking.
 Be sure to install fixing claws in place when installing spiral cable.
normally.

Front Passenger Airbag Assembly

1. Check the front passenger airbag assembly (vehicle has been involved in a collision with airbag not
deployed).
b. Perform visual inspection with front passenger airbag assembly removed from vehicle:
 Check for cuts, cracks or wear on front passenger airbag assembly.
 Check for cracks or other damage on connector.
 Check instrument panel or instrument panel crossmember assembly for deformation or damage. If
31 any defect above is found, replace the front passenger airbag assembly with a new one.
WARNING
 Be sure to follow correct procedures to remove and install front passenger airbag assembly.
RA13T310240
Removal
CAUTION
 Handle airbag and airbag control module assembly carefully, and never tap or strike them fiercely.
 Removal, inspection and installation of airbag system must meet relevant requirements and
specifications, and never perform operation casually.
 Removed airbag should be kept properly with face up. Store the airbag in a place with enough spare
space to prevent accidental airbag deployment.

WARNING
restraint system.

4. Remove the front passenger airbag assembly.

a. Remove 2 coupling bolts (arrow) between front passenger airbag assembly and instrument panel
crossmember assembly. (Tightening torque: 10 ± 2 N·m)
31
RA13T310250
b. Disconnect the front passenger airbag assembly wire harness connector (arrow).
WARNING
 DO NOT damage airbag assembly wire harness when handling airbag assembly wire harness
connector.
RA13T310260
c. Remove the instrument panel assembly (See page 46-11).

d. Using a flat tip screwdriver wrapped with protective tape, slightly pry fixing claws (arrow) around front
passenger airbag assembly mounting bracket to separate it from instrument panel assembly.
RA13T310270
e. Remove the front passenger airbag assembly.
Installation

CAUTION
 Before installing tightening bolts, always make sure that airbag wire harness is not hold down or stuck.
Adjust if necessary and install it in place.
 Make sure to tighten fixing bolts to specified torques during installation.
 When installing front passenger airbag assembly, first slide the hook on one side into locating hole in
airbag box, and then press in hook on the other side firmly, making sure that hooks on both sides enter
the corresponding locating holes correctly.
 Always keep vehicle power off during installation. It is forbidden to install the front passenger airbag
assembly with vehicle power on.
31  During installation of instrument panel assembly, if installation cannot proceed due to contact of front
passenger airbag assembly bracket and instrument panel crossmember assembly, hold the airbag
slightly at opening of glove box assembly to install it in place.
normally.
Disposal
Always dispose of airbag assembly together with vehicle that is equipped with supplemental restraint system.
Otherwise, the airbag will be in chemical and physical hazard. Failure to handle it properly will cause personal
injury. Do not dispose of airbag by oneself, and always contact the professional service department to perform
disposal.

SEAT BELT
GENERAL INFORMATION 32-3 Front Seat Belt Buckle Assembly 32-11
Tool 32-5 Height Adjuster Assembly 32-13
Circuit Diagram 32-6 Removal 32-13
Installation 32-13
Rear Seat Belt Assembly 32-15
Seat Belt Inspection 32-7
Removal 32-15
ON-VEHICLE SERVICE 32-8 Inspection 32-16 32
Front Seat Belt Assembly 32-8 Installation 32-16
Removal 32-8 Double Buckle Assembly 32-17

32

32 - SEAT BELT
GENERAL INFORMATION
SEAT BELT
Description
3
32
1
×2
RA13T320001
1 - Height Adjuster Assembly 2 - B-pillar Upper Protector Assembly

3 - B-pillar Upper Belt Fixing Bolt Cap 4 - B-pillar Lower Protector Assembly
5 - Front Seat Belt Assembly 6 - Seat Belt Lower Bolt Protective Cap
7 - Front Seat Belt Buckle Assembly -

32 - SEAT BELT
32
2
4
3
5
RA13T320002
1 - C-pillar Upper Protector Assembly 2 - Rear Speaker Cover Assembly

3 - Back Door Rear Left Wheel House Assembly 4 - C-pillar Lower Protector Assembly
5 - Rear Seat Belt Assembly 6 - Double Buckle Lock Assembly
7 - Double Buckle Lock Assembly Ⅰ -

32 - SEAT BELT
CAUTION
 Front seat belt assembly is a 3 point type belt with limiter and pretensioner, and driver side seat belt
buckle assembly is a device with unfastened alarm function. Driver side seat belt is equipped with seat
belt reminder light which only works with ignition switch ON. If driver or front passenger seat belt is
unfastened, the reminder light will flash continuously. When vehicle speed exceeds 20 km/h, the buzzer
will sound to inform driver and front passenger to fasten their seat belts. The seat belt reminder light will
go off immediately if seat belt is fastened.
 Rear seat belt assembly is 3 point belt.
Operation
In the event of a collision, the seat belt retractor starts to work. The seat belt is locked securely and cannot be
32
pulled out from retractor freely, so that the passenger will be restricted to seat to prevent head and chest from
hitting the steering wheel, instrument panel, windshield or front seat, which can reduce the risk of second
collision.
Specifications

Front Seat Belt Assembly Fixing Bolt 50 ± 5
Front Seat Belt Assembly Fixing Screw 7±1
Seat Belt Buckle Assembly Fixing Nut 50 ± 5
Height Adjuster Assembly Fixing Bolt 23 ± 3.5
Rear Seat Belt Assembly Fixing Bolt 50 ± 5
Rear Seat Belt Assembly Fixing Screw 7±1
Center Seat Belt Assembly Fixing Bolt 50 ± 5
Center Seat Belt Assembly Fixing Screw 7±1
Double Buckle Assembly Fixing Bolt 50 ± 5
Tool
General Tool
Digital Multimeter
RCH0000002

32 - SEAT BELT
Circuit Diagram
Seat Belt System

ON OR START
IP FUSE AND
RF10 RF01 RELAY BOX
10A 10A I-032
33 7
32
RY
R
11 13
INSTRUMENT
CLUSTER
I-011
19 3
W
I-001
13 B-017
W
I-005
1
DRIVER
SEAT
BELT
SWITCH
2 B-013
B
B-012
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 1 2
18 17 16 15 14 13 12 11 10
B-013
B
I-001
I-011 W
L
EA13T320010

32 - SEAT BELT
DIAGNOSIS & TESTING

Seat Belt Inspection
1. When pulling seat belt downward slowly by hand, the seat belt should be pulled out smoothly from
retractor and can return back after releasing. If result is not as specified, replace the seat belt assembly.
Seat belt should be locked automatically as it is pulled out quickly. If not, replace the seat belt.
2. Check seat belt for cuts, wear and looseness. If damaged, replace the seat belt assembly.
3. Check seat belt for overstretch (e.g. after an accident). If damaged, replace the seat belt assembly or
related components.
4. Fasten and release seat belt and seat belt buckle repeatedly to check the engagement between them. If
those conditions (difficult operation, excessive sliding resistance and seizing, etc.) occur, replace the seat
belt assembly or seat belt buckle assembly. 32
WARNING
 Seat belt system should be checked regularly to reduce the possibility and serious level of injury caused
by accidents.
 When checking impacted vehicle, be sure to check seat belt system to reduce the possibility and serious
level of injury caused by accidents.

32 - SEAT BELT
ON-VEHICLE SERVICE
Front Seat Belt Assembly
Removal
HINT:
CAUTION
32  Be sure to wear safety equipment to prevent accidents, when removing front seat belt assembly.
 Appropriate force should be applied, when removing front seat belt assembly. Be careful not to operate
roughly.
 DO NOT scratch interior, when removing front seat belt assembly.

3. Remove the left B-pillar lower protector assembly (See page 50-17).
a. Using a screwdriver wrapped with protective tape, pry
off front seat belt assembly lower bolt protective cap
(arrow).
RA13T320010
b. Remove fixing bolt (arrow) from lower part of front

seat belt assembly.
RA13T320020
c. Remove the left B-pillar upper protector assembly (See page 50-18).

32 - SEAT BELT
d. Remove fixing bolt (arrow) from upper part of front

seat belt assembly.
RA13T320030
e. Remove 2 fixing screws (arrow) from guide ring of front seat belt assembly.
f. Remove seat belt guide ring (1) from slot. 32
1
RA13T320040
g. Remove fixing bolt (1) from front seat belt retractor.

3
h. Remove fixing screw (2) from front seat belt retractor. 2
i. Remove the front left seat belt assembly (3).

1
RA13T320050
Inspection
1. If result is not as specified, replace the seat belt assembly.
Installation
Inspect the front seat belt retractor.
HINT:
DO NOT disassemble the front seat belt retractor.
 When the inclination of front seat belt retractor is 15° or
less, check that front seat belt can be pulled out from
front seat belt retractor. When the inclination of front seat o
45
belt retractor is over 45°, check that the front seat belt
locks.
Unlock
Retractor
Lock
RA13T320060

32 - SEAT BELT
CAUTION
 Keep seat belt assembly clean without oil attached and check seat belt assembly for damage, when
installing front seat belt assembly.
 Be sure to tighten all fixing bolts and fixing screws according to specified torque, when installing front
seat belt assembly.
32

32 - SEAT BELT
Front Seat Belt Buckle Assembly

1. Inspect the front seat belt buckle assembly.
a. Disconnect the front seat belt buckle connector
(arrow).
32
RA13T320070
b. Using a digital multimeter, measure resistance

between terminals 1 and 2 of front seat belt buckle
assembly connector.
Under normal condition, the measured resistance
should be ∞ Ω, (no continuity) when the front seat belt
assembly is fastened and the measured resistance is
less than 0 Ω, (continuity) when the front seat belt
assembly is unfastened.
If result is not as specified, replace front seat belt
buckle assembly.
2 1
RA13T320080
Removal
HINT:
 Use same procedures for front passenger seat belt buckle assembly and driver seat belt buckle assembly.
 Procedures listed below are for driver seat belt buckle assembly.
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing front seat belt buckle assembly.
 DO NOT scratch interior, when removing the front seat belt buckle assembly.
 DO NOT damage wire harness and connector, when removing the front seat belt buckle assembly.

3. Remove the front seat assembly (See page 47-7).

32 - SEAT BELT
4. Remove the driver seat belt buckle assembly.

a. Disengage clips (arrow) from lower side wire harness
connector of seat belt buckle.
RA13T320090
b. Remove fixing nut (1) from seat belt buckle assembly,

and remove driver seat belt buckle assembly (2).
32
RA13T320100
Installation
CAUTION
 Be sure to tighten all fixing bolts according to specified torque, when installing front seat belt buckle
assembly.
 Install connectors in place, when installing front seat belt buckle assembly.

32 - SEAT BELT
Height Adjuster Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing height adjuster assembly.
 Appropriate force should be applied, when removing height adjuster assembly. Be careful not to operate
roughly.
 DO NOT scratch interior, when removing height adjuster assembly.
32

4. Remove the left B-pillar upper protector assembly (See page 50-18).
5. Remove the height adjuster assembly.
a. Remove fixing bolt (arrow) from upper part of front
seat belt assembly.
RA13T320030
b. Remove fixing bolt (arrow) from height adjuster assembly.

c. Remove height adjuster assembly (1) from dowel pin.
RA13T320120
Installation

32 - SEAT BELT
CAUTION
 Be sure to tighten all fixing bolts according to specified torque, when installing height adjuster assembly.
32

32 - SEAT BELT
Rear Seat Belt Assembly

Removal
HINT:
 Use same procedures for right, center and left sides.
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing rear seat belt assembly.
 Appropriate force should be applied, when removing rear seat belt assembly. Be careful not to operate
roughly.
32
 DO NOT scratch interior, when removing rear seat belt assembly.

3. Remove the rear seat cushion assembly (See page 47-15).
5. Remove the rear left seat belt assembly.
a. Remove fixing bolt (arrow) from lower part of rear seat
belt assembly.
RA13T320130
b. Remove the C-pillar lower protector assembly (See page 50-20).

c. Remove seat belt fixing bolt (arrow) from C-pillar
upper protector.
RA13T320131
d. Remove the rear left speaker cover assembly (See page 50-20).
e. Remove the C-pillar upper protector assembly (See page 50-21).
f. Remove the rear left back door left wheel house assembly (See page 50-32).

32 - SEAT BELT
g. Remove fixing bolt from rear left seat belt retractor.

RA13T320132
h. Remove the rear left seat belt assembly.
Inspection
32 Check the rear seat belt retractor.
CAUTION
DO NOT disassemble the rear seat belt retractor.
HINT:
Unlock
When the inclination of rear seat belt retractor is 15° or less,
check that rear seat belt can be pulled out from rear seat belt
retractor. When the inclination of rear seat belt retractor is
over 45°, check that rear seat belt locks.
45
o
Retractor
Lock
RA13T320140
If result is not as specified, replace the rear seat belt assembly.
Installation
CAUTION
 Keep seat belt assembly clean without oil attached and check seat belt assembly for damage, when
installing rear seat belt assembly.
 Be sure to tighten all fixing bolts and fixing screws according to specified torque, when installing rear seat
belt assembly.

32 - SEAT BELT
Double Buckle Assembly

Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing double buckle
assembly.
 DO NOT scratch interior, when removing double buckle assembly.

4. Remove the double buckle assembly.
a. Remove 2 fixing bolts (arrow) from double buckle
assembly, and remove double buckle assembly (1).
RA13T320160
Installation
CAUTION
Be sure to tighten all fixing bolts according to specified torque, when installing double buckle assembly.

- MEMO -

ENGINE IMMOBILIZER
GENERAL INFORMATION 33-3 B1300 33-16
Description 33-3 B1301 33-16
Components Introduction 33-3 B1302 33-16
Operation 33-4 B1303 33-16
Specifications 33-4 B1304 33-16
Torque Specifications 33-4 B1305 33-16
Tools 33-5 B1306 33-16
Special Tool 33-5 U0100 33-16
General Tools 33-5 U0101 33-16
Engine Immobilizer System Match 33-6 B1307 33-16
Engine Immobilizer System Match 33-7 U0073 33-16
33
DIAGNOSIS & TESTING 33-12 Transponder 33-22
Diagnosis Tools 33-12 Installation 33-23
X-431 3G Diagnostic Tester 33-12 Immobilizer Control Module (BCM) 33-24
Digital Multimeter 33-12 Removal 33-24
Diagnostic Help 33-13 Installation 33-25
Intermittent DTC Troubleshooting 33-13 Anti-theft Coil 33-26
Diagnostic Trouble Code (DTC) 
Chart 33-15

33

33 - ENGINE IMMOBILIZER
GENERAL INFORMATION
ENGINE IMMOBILIZER
Description
Immobilizer system consists of key assembly (including transponder), immobilizer coil, BCM and engine
control module (ECM). BCM is the main body, which realizes communication with transponder and engine
management system. When key is inserted into ignition switch, if BCM and transponder are certificated
successfully at specified time, engine control module sends a signal to engine so as to start vehicle.
Components Introduction
1. Body Control Module
 Main function of immobilizer control is realized in BCM, only engine immobilizer function of BCM is
described in this section for convenience of narrative. IMMO is used to refer to immobilizer function,
and hardware of IMMO is BCM. This is an electronic control module which includes microprocessor and
various semiconductor elements; it stores authentication algorithm with transponder and ECM as well 33
as necessary date for normal system operation and after-sale diagnostic service, such as key
information, match information and trouble codes, etc. It controls realization mechanism of immobilizer
function, works with each component in harmony and transfers command and data.
2. Transponder and immobilizer coil
 Transponder exists in each key of vehicle, and it is a passive device, that is, no batteries are
needed.During system operation, this component completes crypto certification of IMMO together with
immobilizer coil.Effective transmission distance for transponder information is 2 cm to 3 cm.
 Immobilizer coil is installed on ignition switch and connects with BCM through wire harness, to provide
energy for signal transmission between BCM and transponder.
3. Engine Control Module (ECM)
 Engine control module is service supplier of system, realizes authentication algorithm with IMMO,
stores matching information, and sends certification request when power is on.

Operation
1. After key is inserted into ignition switch and turned from OFF to ON, IMMO enters wireless certification
status and outputs energy and data to transponder through immobilizer coil, ECM also sends certification
request to IMMO.
2. IMMO may not response immediately after receiving certification request from ECM, but response to ECM
until IMMO and transponder certification completes.
3. After receiving correct wireless signal, transponder performs crypto certification with IMMO.If certification
is successful, IMMO will response crypto certification from ECM; if certification fails, it will response
nothing.
4. After receiving response from IMMO, ECM performs crypto certification again, if certification is successful,
ECM allows to ignite; if certification fails, ECM does not start engine.
33
IMMO EMS
Transponder Algorithm 2 (sk,PIN)

Algorithm 1 (sk) VIN
Algorithm 1 (sk)
Algorithm 2 (sk,PIN)
KeyID
KeyID VIN
RA13T330900
Specifications

Instrument Panel Relay Box Fixing Bolt 0.7 ± 0.2
BCM Fixing Bolt 0.7 ± 0.2
Wireless Key Coupling Screw 0.7 ± 0.2

Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tools
33
Digital Multimeter
RCH0000002

Engine Immobilizer System Match

CAUTION
 Never reset any control module during operation (unless under guidance of after-sale service
department). If version of PC diagnostic tester must be 3.31 or higher, version of X-431 must be 56.80 or
higher. When wrong security codes are input continuously, turn ignition switch to ON and input it again
after waiting for a specified time.
 It is necessary to turn on ignition switch and wait for 10 seconds to enter again when entering wrong
security code twice continuously. If wrong security code is entered again after 10 seconds, wrong
numbers cannot be accumulated.
For example: if entering wrong security code twice continuously, but wrong security code is entered again
after 10 seconds, internal counter will not record the current number and keep original number. If turning off
ignition switch without waiting specified time, waiting time will be reset to 0 and recount, so be sure to wait
and turn ignition switch to ON.
33 Waiting Time for Continuously Inputting Wrong Code
Number for Inputting Wrong Number for Inputting Wrong

Waiting Time
Code Code
0 0 0s
1 1 10 s
2 2 10 min
3 3 20 min
4 4 40 min
5 5 80 min
6 6 160 min
7 7 320 min
8 8 640 min
9 9 1280 min
10 10 1280 min
> 10 10 1280 min

Engine Immobilizer System Match

Match engine immobilizer system after ECM replacement
1. Connect X-431 3G diagnostic tester (the latest software)
1.
to Data Link Connector (DLC), and make it communicate

with vehicle electronic module through data network.
Menu
ENG
Then select corresponding model (A13T) from X-431 3G ABS
diagnostic tester (the latest software) to enter the system SRS
and select "IMMO" system. BCM
ICM
PEPS
IMMO
AT
RA13T330400
a. Please select [After sale function] on SELECT

FUNCTION screen
SELECT FUNCTION
Read fault code

33
Erase fault code
Read data stream
Write data
After sale function
RA13T330410
b. Please select [Programming ECM] on After sale

function screen
After sale function
Match all the systems
Programming ECM
Programming IMMO(learn SK from EMS)
Programming IMMO(learn SK from TCU)
Reprogramming ECM
Reprogramming IMMO
Key match
Erase keys
RA13T330420
c. Please input a VIN with 17 digits

Input
Please input a VIN with 17 digits.
XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
Q W E R T Y U I O P [ ] \
A S D F G H J K L ; ‘ ENTER
Z X C V B N M , . / lt rt
` Tab Caps Space Ins Del
OK Cancel
RA13T330430

d. Please select [Write VIN succeeded] on Write VIN

screen
Write VIN
Write VIN Succeeded !!
OK
RA13T330440
e. When "Please enter a PIN with 8 digits" is displayed

on Input screen, input PIN code and click "OK"
Input
Please enter a PIN with 8 digits.
33 XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RA13T330450
f. When "Please enter again" is displayed on Input

screen, input PIN code and click "OK".
Input
Please enter again.
XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RA13T330460
g. When "Succeeded to program ECM" is displayed on

Programing ECM screen, click "OK".
Programming ECM
h. ECM programing is complete.
Succeeded to program ECM!
OK
RA13T330470
2. Replacement of BCM matching immobilizer system

Connect X-431 3G diagnostic tester (the latest software)
to Data Link Connector (DLC), and make it communicate
with vehicle electronic module through data network. ENG
Menu
Then select corresponding model (A13T) from X-431 3G ABS
and select "IMMO" system BCM
ICM
PEPS
IMMO
AT
RA13T330480

a. Please select [After sale function] on SELECT

FUNCTION screen
SELECT FUNCTION
Read fault code
Erase fault code
Read data stream
Write data
After sale function
RA13T330490
b. Please select [Programming IMMO (learn SK from

EMS)] on After sale function screen
After sale function
Programming ECM
33
Reprogramming ECM
Reprogramming IMMO
Key match
Erase keys
RA13T330500
c. Please input a VIN with 17 digits.

Input
XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RA13T330430
d. When "Please enter a PIN with 8 digits" is displayed

on Input screen, input PIN code and click "OK".
Input
XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RA13T330450
e. When "Please enter again" is displayed on Input

screen, input PIN code and click "OK".
Input
Please enter again.
XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RA13T330460

f. When "Succeeded to program IMMO" is displayed on

Programming IMMO (learn SK from EMS) screen,
click "OK".
Succeeded to program IMMO!
OK
RA13T330540
CAUTION
After matching is complete, it is necessary to turn off ignition switch, disconnect diagnostic tester and wait
about 10 seconds, turn on ignition switch and wait for about 10 seconds and then turn on ignition switch and
33 wait for about 10 seconds to ensure that system is certificated successfully. After ECM is replaced, it is
necessary to perform "Add the old keys" and "Key learning" for original key.

Circuit Diagram
IGNITION SWITCH
ON OR START
IP FUSE
RF01 AND
10A RELAY BOX
I-032
7
RY
33
RY
B
3
B-012
IMMOBILIZER COIL
I-026
1 2 TO CAN
B
B
Gr
SYSTEM
B
RW
G
Y
Y
I-006
B17 B4 C3 C4 B16 B3 B15 B2

CAN1-H CAN1-L CAN2-H CAN2-L
BCM(B/C/E) I-034 B-020
D2 D3 D4 D5 D6 D7 D8
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 3 2 1
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 B-020
B
D9 D: D21 D22 D23 D24 D25
I-034 I-026
W W
EA13T330010

DIAGNOSIS & TESTING

HINT:

Wire harness or connector 55-35
Anti-theft Coil 55-44
Engine has been started ECM 16-9
33 Key transponder 33-22
IMMO (BCM) 46-18
Diagnostic tester cannot communicate with
Diagnostic Interface -
immobilizer system
IMMO (BCM) 46-18
Diagnostic tester cannot communicate with
Diagnostic Interface -
immobilizer system
ECM 16-9
Anti-theft Coil 55-44
Key cannot be matched
Key assembly 33-22
IMMO (BCM) 46-18
Diagnosis Tools
When connecting X-431 3G diagnostic tester:
 Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC) for communication
with vehicle.
 DLC is located at the driver side instrument panel crossmember.
 DLC uses a trapezoidal design which can hold 16 terminals.
Digital Multimeter
When using digital multimeter:
 Troubleshoot electrical malfunctions and wire harness system.
 Look for basic fault.
 Measure voltage, current and resistance.

Diagnostic Help
7. Check and clean all immobilizer system grounds related to the latest DTC.
supply circuit applied to the DTC.
Intermittent DTC Troubleshooting 33

 Look for the data that has changed or the DTC to reset during the wiggle test.
 Inspect the mounting areas of Engine Control Module (ECM), Body Control Module (BCM) wire harness or
wire harness connector and so on for damage, foreign matter, etc. that will cause incorrect signals.
Ground Inspection
(rust) and oxidation may increase load resistance. This situation will seriously affect the normal operation of
circuit. Check the ground points as follows:

Diagnosis Procedure
HINT:
Use following procedures to troubleshoot the constant speed cruise system.
1 1 Vehicle brought to workshop
NEXT
If voltage is below 11 V, recharge or replace battery before proceeding to next step.
33
NEXT
NEXT
DTC
occurs
No DTC For history DTC, go to step 7
NEXT
5 Problem repair (no DTC), then go to step8
NEXT
NEXT
NEXT

NEXT
NEXT
10 End
Diagnostic Trouble Code (DTC) Chart 33

DTC Code DTC Definition
B1300 Internal Control Module EEPROM Error
B1301 Immobilizer and ECM Authentication Failed
B1302 VIN Not Programmed
B1303 The Antenna Communication is Disturbed
B1304 None Transponder was Detected
B1305 Immobilizer has None Key was Storage
B1306 Security Code was not Programmed
U0100 Lost Communication With ECM Authentication Frame
U0101 Lost Communication With TCU Authentication Frame
U0073 Control Module Communication Bus Off
B1307 Immobilizer and Transponder Authentication Failed

DTC B1300 Internal Control Module EEPROM Error
DTC B1301 Immobilizer and ECM Authentication Failed
DTC B1302 VIN Not Programmed
DTC B1303 The Antenna Communication is Disturbed
DTC B1304 None Transponder was Detected
DTC B1305 Immobilizer has None Key was Storage
33 DTC B1306 Security Code was not Programmed
DTC U0100 Lost Communication With ECM Authentication Frame
DTC U0101 Lost Communication With TCU Authentication Frame
DTC B1307 Immobilizer and Transponder Authentication Failed
DTC U0073 Control Module Communication Bus Off
DTC Detection
Condition
Internal Control
B1300 Module EEPROM Ignition switch ON IMMO, key assembly, IMMO
Error
Immobilizer and ECM Wire harness connector, immobilizer coil,
B1301 Ignition switch ON
Authentication Failed key assembly, ECM, IMMO, CAN
Wire harness connector, immobilizer coil,
B1302 VIN Not Programmed Ignition switch ON
key assembly, ECM, IMMO, CAN
The Antenna
B1303 Communication is Ignition switch ON Wire harness connector, CAN, IMMO
Disturbed
None Transponder Wireless key assembly, wire harness
was Detected connector, immobilizer coil, IMMO, CAN
Immobilizer has None Wireless key assembly, wire harness
Key was Storage connector, immobilizer coil, IMMO
Security Code was not Immobilizer coil, wireless key assembly,
Programmed meter, IMMO
Lost Communication
Immobilizer coil, wire harness connector,
U0100 With ECM Ignition switch ON
ECM, IMMO, CAN
Authentication Frame

DTC Detection
Condition
Lost Communication
Immobilizer coil, wire harness connector,
U0101 With TCU Ignition switch ON
TCU, IMMO, CAN
Authentication Frame
Control Module
U0073 Communication Bus Ignition switch ON Wire harness connector, IMMO, CAN
Off
Immobilizer and
Wire harness connector,IMMO, CAN,
B1307 Transponder Ignition switch ON
Immobilizer coil
Authentication Failed

Confirm that battery voltage is between 11 V and 14 V before performing the following procedures.
 Turn ignition switch to LOCK. 33
 Connect X-431 3G diagnostic tester to Data Link Connector (DLC) - the latest software.
 If datastream is not detected, the malfunction is current. Go to diagnosis procedure - Step 1.
 If datastream is detected, the malfunction is current.
CAUTION
Diagnosis Procedure
1 Check key assembly
a. Check key assembly (a)Connect diagnostic tester to malfunctioning vehicle, turn ignition switch to ON and
read key status using diagnostic tester.Read transponder programming status and transponder ID position
in engine immobilizer system.
b. If response status of transponder is "unprogrammed", enter "Add new keys" operation procedure;
c. If response status of transponder is "programmed" and transponder ID is not in engine immobilizer system,
enter "Add the old keys" operation procedure;
d. If response status of transponder is "programmed" and transponder ID is in engine immobilizer system,
and SK in key is different from SK in IMMO, replace transponder and enter "Add new keys" operation
procedure.
e. If response status of transponder is "unprogrammed" and transponder ID is in engine immobilizer system,
and SK in key is same as SK in IMMO, continue to troubleshoot.
NG Replace key assembly
OK

2 Reconfirm DTCs

b. Use X-431 3G diagnostic tester (the latest software) to record and clear DTCs stored in engine immobilizer
system.
c. Turn ignition switch to LOCK and wait for a few seconds.
e. Use X-431 3G diagnostic tester (the latest software) to read DTCs stored in engine immobilizer system
again.
f. Read DTCs.
Result Proceed to
33 B1300 B1301 B1302 B1303 B1304 B1305 B1306

NG
U0100 U0101 U0073 B1307
No DTC is output OK
NG Go to step 3
OK System is normal
NEXT
3 Check immobilizer coil
a. Check coil appearance for obvious damage.

b. Remove immobilizer coil from malfunctioning vehicle, then install it to a new vehicle and perform test.
c. Check the system operation.
NG Replace immobilizer coil
OK
4 Check IMMO
a. Turn ignition switch to ON.Connect X-431 to enter diagnostic IMMO status of engine immobilizer system.
b. Read IMMO electronic tag, trouble code, data flow, and print these information using diagnostic tester; if
communication cannot be established, fill information such as trouble description etc. into trouble feedback
table, and then proceed to CAN network troubleshooting.
NG Replace IMMO and BCM with new ones

and rematchwith diagnostic tester
OK

5 Check engine control module
a. Turn ignition switch to ON.Connect X-431 to enter diagnostic ECM status of engine management system.
b. Read ECM electronic tag, trouble codes, data flow, and print these information using diagnostic tester.If
communication cannot be established, fill information such as trouble description etc. into trouble feedback
table, and then proceed to CAN network troubleshooting.
NG Replace ECM with a new one and rematch

it withdiagnostic tester
OK
6 Check wire harness connectors of entire vehicle

33
c. Disconnect BCM connector I–034 and immobilizer coil
connector I-026.
BCM connector I-034 and immobilizer coil connector I-
026 according to the table below.
Normal Condition
Condition
+ -
I-034 (B4) - I- Always Continuity
026(1)
e. Check engagement and disengagement between B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
immobilizer coil I-026 (2) and ground B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
I-034
3 2 1
I-026
RA13T330020

Normal Condition
Digital Specified
Condition
Multimeter Condition
+ -
I-026(2) - Ground Always No continuity
f. Check CAN network for problems.

3 2 1
g. Using a digital multimeter, measure the resistance of
I-026
IMMO connector CAN network according to table below.
33
RA13T330030
Normal Condition
Digital Specified
Condition
+ -
I-034 (B15) - I- Always 60 Ω
034(B2)
I-034 (B16) - I- Always 60 Ω
034(B3)
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
h. Check power supply voltage B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
i. Using a digital multimeter, measure voltage between I-034

immobilizer coil connector I-026(3) and body ground.
RA13T330040
Normal Condition
Digital Specified
Condition
Multimeter Condition V
+ -
I-026 (3) - Ground Ignition switch ON 11 V or higher
3 2 1
I-026
RA13T330050

NG Repair or replace fuse, wire harness

connector
OK System is normal
33

ON-VEHICLE SERVICE
Transponder
HINT:
As transponder in key is an electronic part of high accuracy, pay attention to followings during service:
 Do not throw or hit key, which may cause severe impact;
 Do not put key in high temperature (90°C or more) for a long time;
 Do not put key in water or other fluid;
 Do not put key in strong magnetic field or electromagnetic field.
CAUTION
33  DO NOT push the terminals with your hands, when removing wireless key.
 Make sure battery positive and negative are installed correctly, when removing wireless key cover.
 DO NOT pry up battery forcibly, after removing wireless key cover. Otherwise, terminals may be
damaged.
 DO NOT touch battery with wet hands, after removing wireless key cover. Otherwise, water may cause
rust.
 DO NOT touch or move any components inside transmitter, after removing wireless key cover.Failure to
do so may interfere with proper operation.
Removal
1. Remove the transponder.
off the wireless key cover as shown in illustration.
RA13T370330
b. Remove 3 screws (arrow), separate wireless key

covers (1) and chip (2). 1
2
RA13T370340

c. Disengage claw from battery holder, and remove the

battery in direction of arrow.
RA13T370350
d. Remove the transponder (1).
1 33
RA13T330130
Installation
CAUTION
 Check that wireless key and transponder can operates properly, after installing transponder.

Immobilizer Control Module (BCM)

Removal
3. Remove the BCM assembly.
off clips from instrument panel left end cover
assembly, and remove instrument panel left end cover
assembly (1).
33
RA13T330140
b. Open small cover plate on instrument panel lower left

storage box assembly in the direction of arrow as
RA13T330150
c. Remove 2 screws (arrow) on diagnostic connector,

loosen diagnostic connector.

RA13T330160
d. Remove 2 screws (arrow) on left protector and bolt

(arrow)
RA13T330170

e. Using a screwdriver wrapped with protective tape, pry

off clips from instrument panel lower left protector
assembly, and remove instrument panel lower left
protector assembly.
RA13T330180
f. Remove 2 bolts (arrow) and move away fuse relay

box.
33
RA13T330190
g. Disconnect all connectors from BCM and remove 3

bolts (arrow).
RA13T330200
h. Remove the BCM.
Installation
HINT:
Be sure to perform match operation so that replaced BCM can operate properly on original vehicle.Make sure
input VIN code and PIN code are correct during operation. After replacing BCM, perform "Add the old keys"
operation for original key, then it can be available.

Anti-theft Coil
Removal
4. Remove the immobilizer coil.
a. Disconnect the immobilizer coil connector (1).
1
33
RA13T330210
b. Using a screwdriver wrapped with protective tape, pry

off connection between immobilizer coil and ignition
switch.
RA13T330220
Installation

GENERAL INFORMATION 34-3 Digital Multimeter 34-7
Description 34-3 Diagnostic Help 34-8
Operation 34-3 Intermittent DTC Troubleshooting 34-8
Operation Method 34-3 Ground Inspection 34-8
Specifications 34-4 Diagnosis Procedure 34-9
Tools 34-4
Constant Speed Cruise 
DIAGNOSIS & TESTING 34-7 Control Switch 34-11
Diagnosis Tools 34-7 Inspection 34-12
X-431 3G Diagnostic Tester 34-7 Installation 34-13
34

34

34 - CONSTANT SPEED CRUISE SYSTEM
GENERAL INFORMATION
Description
Turn on the constant speed cruise control switch after vehicle reaches a certain speed. The set vehicle speed
can be maintained by constant speed cruise control, without accelerator depressed. Cruise control system
consists of the following components:
 Constant speed cruise control switch (multi-function switch)
 Instrument cluster (ICM)
 Body Control Module (BCM)
 Engine Control Module (ECM)
 Transmission Control Module (TCM)
 ABS Control Module
 Accelerator Pedal
 Brake Switch
 Clutch Switch 34
Do not use cruise control under following conditions. Otherwise, it may result in a loss of vehicle control and
cause an accident, resulting in serious injury or even death.
 In traffic congestion areas.
 On roads with sharp bends.
 On winding roads.
 On wet and slippery roads, such as those covered with rain, ice or snow.
 On steep hills. Vehicle speed may be higher (or lower) than the set speed.
Operation
Engine Control Module (ECM) receives resistance signal from constant speed cruise control switch (multi-
function switch), and turns on indicator on instrument panel via CAN net driver.
ECM determines whether to enter or exit cruise mode according to vehicle speed signal, brake pedal signal,
clutch signal, acceleration or deceleration signal and actual operations. After entering cruise mode, ECM
controls throttle valve opening angle to keep vehicle speed within a set range.
Operation Method
1. With ignition switch ON, press ON button of cruise to illuminate and blink the cruise indicator on instrument
cluster (a normal cruise mode condition); When vehicle is driving at approximately between 40 km and 130
km/h, press SET/- button of cruise, and vehicle will drive at constant cruise speed as pressed (Do not put
your foot on acceleration pedal at this time, as cruise system automatically adjust throttle valve opening
angle). Meanwhile cruise indicator on the instrument cluster remains on , it indicates the vehicle enters
cruise mode; If cruise indicator on the instrument cluster remains blink, it has not entered cruise mode, and
attempt to enter cruise mode by peforming procedure again (If it still fails, repair any problem in cruise
system).
2. Under cruise mode, depress the acceleration pedal (cruise indicator remains on during this procedure) to
increase vehicle speed, and release acceleration pedal to automatically resume vehicle to speed cruise
condition before acceleration pedal is depressed. (Note: Vehicle speed is increased only when depressed
acceleration pedal opening angle is greater than the one corresponding to cruise torque).
3. Under cruise mode, depress the acceleration pedal (cruise indicator remains on during this procedure) to
increase vehicle speed, and press SET/- button of cruise while releasing acceleration pedal, then vehicle
is driving at a new cruise speed.
4. Under cruise mode, each time RES/+ button is pressed briefly (less than 0.5 s) (cruise indicator remains
on when pressing), vehicle speed will increase by 2 km/h; Under cruise mode, each time RES/+ button is
pressed firmly (more than 0.5 s) (cruise indicator remains on when depressing), vehicle speed will

increase continuously. When releasing RES/+ button, vehicle stops accelertating and vehicle speed as
releasing RES/+ button will be kept (It is recommended not to press and hold RES/+ button, as it may
increase vehicle speed continuously which may lead to driving hazard).
5. Under cruise mode, each time SET/- button is pressed briefly (less than 0.5 s) (cruise indicator remains on
when depressing), vehicle speed will decrease by 2 km/h; Under cruise mode, each time SET/- button is
pressed firmly (more than 0.5 s)(cruise indicator remains on when depressing), vehicle speed will
decrease continuously. When releasing SET/- button, vehicle stops decelerating and cruise at vehicle
speed while releasing SET/- button. (Note: Press and hold SET/- button to coast with accelerator
undepressed and without braking function. Depress brake pedal when braking is necessary).
6. Under cruise mode, when depressing brake pedal or clutch pedal, cruise indicator on the instrument
cluster blinks (a normal cruise mode condition), and vehicle speed decreases. When vehicle speed is
above 40 km/h, release brake pedal or clutch pedal and press SET/- button, and then vehicle resets cruise
mode and cruise indicator on the instrument cluster remains on.
7. Depress brake pedal under cruise mode and cruise indicator on instrument cluster blinks, which indicates
pre cruise mode. If cruise button is no longer operated, vehicle will keep pre cruise mode, and driver can
operate with normal driving regulations.
8. Cruise mode cannot be entered if malfunction that affects cruise safety of vehicle.
34
9. When cruise main switch is in OFF position, cruise system of vehicle is turned off and cruise cannot be set.
Specifications

Ground Wire Harness Fixing Screw 0.7 ± 0.2
"Steering Wheel Quick Button Trim Cover Fixing
0.7 ± 0.2
Screw"
Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Constant Speed Cruise System (Page 1 of 2)
BATTERY
ENGINE
86 30 COMPARTMENT
ECM
EF26 EF22 EF37 FUSE AND
MAIN
10A 10A 10A RELAY BOX
RELAY
E-067
85 87
75 20 115
RG
RG
RG
R
A54 A42 A55 A56

ECM(B/A)
E-001
34
CAN L1 CAN H1 E-041
A3 A29 A52 A53 A23 A11
RB
RY
G
Y
7 16 E-030
I-036
RB
RY
3 4
B
CLOCK
ON/OFF Cruise SW input
Cruise SW ground1
SPRING
I-031
2000
680
TO CAN
SET/+
SET/-
SYSTEM
E-043
E-001 E-041
B B
9 8 7 6 5 4 3 2 1 I-036 8 7 6 5 4 3 2 1 I-031
B W
18 17 16 15 14 13 12 11 10 16 15 14 13 12 11 10 9
EA13T340010

Constant Speed Cruise System (Page 1 of 2)
BRAKE SWITCH I-013 ELECTRONIC THROTTLE E-008 ELECTRONIC ACCELERATOR PEDAL I-012
6 4 5 3 1 2
3 5 2 1 6 4
WR
3 2
GY
LW
YR
LY
Br
BR
RGr
RBr
L
RG
RB
RY
RL
I-036
9 3 10 6 4 5
E-030
I-018 I-036
34
WR
GY
LW
YR
1 12
LY
E-054 E-030
Br
BR
L
LY
A17 A5 B52 B51 B30 B18 B31 B6 A32 A13 A40 A30 A1 A28 A21
ECM(B/A)
E-001
E-041
E-001 E-041
B B
2 4 6
9 8 7 6 5 4 3 2 1 1 2 3 4 1
1 3 5 4 2
1 2 3 4 5 6
18 17 16 15 14 13 12 11 10 5 6 7 8 9 10 3
I-018 I-013
I-036 E-008 I-012 W B
B B B
EA13T340020

DIAGNOSIS & TESTING

HINT:

Constant speed cruise control switch 34-11
Vehicle speed cannot be set (cruise control
indicator turns off)
Engine Control Module (ECM) -
Constant speed cruise control switch 34-11
34
Brake switch -
Vehicle speed cannot be set (cruise control
ABS -
indicator turns on)
Clutch switch (for MT model) -
Body Control Module (BCM) -
Engine Control Module (ECM) -
Diagnosis Tools
with vehicle.
 DLC is located on instrument panel lower left protector.
Digital Multimeter

Diagnostic Help
6. Visually check related wire harness and connector.
7. Check and clean all CD system grounds related to the latest DTC.
8. Check and clean all Engine Control Module (ECM) ground points related to current DTC.

34  If malfunction is intermittent, perform the followings:
 If possible, try to duplicate the conditions under which the DTC was set.
 Look for the data that has changed or the DTC to reset during the wiggle test.
 Inspect the mounting areas of audio system, wire harness or wire harness connector and so on for
damage, foreign matter, etc. that will cause incorrect signals.
 Remove the No Disc DVD from the malfunctioning vehicle and install it to a new vehicle and perform a
test.If this DTC cannot be cleared, there is malfunction in the No Disc DVD. If DTC can be cleared, reinstall
the No Disc DVD to original vehicle.
Ground Inspection

Diagnosis Procedure
HINT:
HINT:Use following procedures to troubleshoot the audio system.
1 1 Vehicle brought to workshop
NEXT
NEXT 34
NEXT
Output
Go to step 5
DTC
No DTC
Go to next step
is output
NEXT
5 Problem repair (no DTC), then go to step 8
NEXT
NEXT
NEXT

NEXT
NEXT
10 End
34

ON-VEHICLE SERVICE
Constant Speed Cruise Control Switch
Removal
HINT:
Constant speed cruise switch is located on the multi-function switch.
WARNING
 Be sure to read the precautions for SRS airbag before removing steering wheel quick button (See page
31-4).
CAUTION
34
 Be sure to wear necessary safety equipment to prevent accidents when removing constant speed cruise
control switch.
 DO NOT damage clips on steering wheel quick button trim cover when removing constant speed cruise
control switch.

4. Remove the steering wheel quick button.
a. Disconnect the steering wheel quick button connector
(arrow).
RA13T340130
b. Pry off steering wheel trim frame (arrow) with a

screwdriver wrapped with tape.
RA13T340140

c. Using a screwdriver wrapped with protective tape, pry

off the claws (arrow) on steering wheel quick button,
and remove the fixing screw (1) from ground wire
harness.
RA13T340150
d. Press the steering wheel quick button.
FF
/O
ON
VOL
MO
OE
+
S/
RE
-
T/
SE
34
RA13T340160
Inspection
1. Inspect the constant speed cruise control switch.
a. Inspect the constant speed cruise control switch for damage. the wire harness if necessary.
b. Inspect the constant speed cruise control switch connector for damage or poor terminal connection.
the wire harness if necessary.
c. Using digital multimeter, check for continuity between
the terminals of constant speed cruise control switch
according to the table below. + -
1 2 3 4
5 6 7 8
Tester Specified
Condition
FF
/O
ON
Terminal 1 -
VOL
MO
OE
+
S/
RE
RES/+ 2 kΩ
-
T/
SE
Terminal 2
Terminal 1 -
SET/- 680 Ω RA13T340170
Terminal 2
Terminal 1 -
OFF/ON Continuity
Terminal 2
If result is not as specified, replace steering wheel

quick button.
2. Check if connectors are damaged. the wire harness if necessary.
3. Check if the No Disc DVD housing is deformed or damaged. the wire harness if necessary.

Installation
CAUTION
 Operate carefully to prevent damage to other components, when installing the constant speed cruise
switch.
 Install each connector into place when installing constant speed cruise switch.
 Tighten fixing screw to the specified torque when installing constant speed cruise switch.
 Check steering wheel quick button for proper operation, after installing constant speed cruise switch.
34

- MEMO -

LIGHTING SYSTEM
Light Position Diagram 35-3 Installation 35-81
System Assembly Diagram 35-5 Adjustment Switch Assembly 35-82
Circuit Diagram 35-8 Warning Light Switch 35-84
Removal 35-84
Installation 35-84
Back-up Light Switch Assembly 35-85
Removal 35-85
Inspection 35-85
Installation 35-86
System Diagnostic 35-26
Front Dome Light Assembly 35-87
Removal 35-87 35
Inspection 35-87
B1001-11 35-31
Installation 35-88
B1001-13 35-31
Headlight Assembly 35-89
B1002-11 35-37
Removal 35-89
B1002-13 35-37
Installation 35-89
B1005-11 35-43
Adjustment 35-90
B1005-13 35-43
Daytime Running Light Assembly 35-92
B1008-11 35-49
Removal 35-92
B1008-13 35-49
Installation 35-92
B1008-71 35-49
Rear Combination Light Assembly 35-93
B101E-11 35-55
Removal 35-93
B101E-13 35-55
Installation 35-93
B101F-11 35-55
Rear Fog Light 35-94
B101F-13 35-55
Removal 35-94
B1035-11 35-60
Installation 35-94
B1035-13 35-60
High Mounted Stop Light Assembly 35-94
B1036-11 35-60
Removal 35-94
B1036-13 35-60
Installation 35-94
Front Dome Light Diagnosis 35-66
License Plate Light Assembly 35-95
Luggage Compartment Light 
Removal 35-95
Diagnosis 35-70
Installation 35-95
Headlight Diagnosis 35-74
Luggage Compartment Light 
ON-VEHICLE SERVICE 35-79 Assembly 35-96
Combination Light Switch Assembly 35-79 Removal 35-96

35

35 - LIGHTING SYSTEM
GENERAL INFORMATION
LIGHTING SYSTEM
Light Position Diagram
2
1
35
5
7 6
10
8
9
11
12
13
RA13T350010

1 - Headlight High Beam 2 - Headlight Low Beam

3 - Interior Front Dome Light 4 - Side Turn Signal Light
5 - Front Turn Signal Light 6 - Daytime Running Light
7 - Front Position Light 8 - High Mounted Stop Light
9 - Back-up Light 10 - Stop Light
11 - Rear Turn Signal Light 12 - License Plate Light
13 - Rear Fog Light
35

System Assembly Diagram
4
35
RA13T350020
1 - Combination Light Switch 2 - Body Control Module (BCM)

3 - Headlight Leveling Switch 4 - Instrument Panel Fuse and Relay Box
5 - Interior Front Dome Light Switch 6 - Engine Compartment Fuse and Relay Box

Description
Lighting system on this model consists of vehicle lighting device and light signal device, which are used for
normal operation of vehicle to ensure safety when driving at night or in fog.
Lighting system consists of headlight assembly (including low beam light, high beam light, front position light
and turn signal light), side turn signal light, front dome light, daytime running light, rear combination light
assembly (including turn signal light, rear position light/brake light), rear fog light, back-up light, license plate
light, high mounted stop light and luggage compartment light. Headlight assembly and rear combination light
assembly use semi-closed structure for easy inspection and repair.
Specifications
Bulb Specifications
Bulb Name Nominal Light Source (Model/Type)

Headlight (Low Beam) H7
Headlight (High Beam) H1
Front Position Light Light Guide
35 Front Turn Signal Light PY21W
Stop Light P21W
Rear Fog Light P21W
License Plate Light LED
High Mounted Stop Light LED
Rear Position Light LED
Rear Turn Signal Light PY21W
Back-up Light W16W
Side Turn Signal Light LED
Daytime Running Light LED

Headlight Assembly Fixing Bolt 5.0 ± 0.5
Rear Combination Light Assembly Fixing Nut 3.5 ± 0.5
Front Dome Light Assembly Fixing Screw 2.5 ± 0.5
High Mounted Stop Light Fixing Nut 2.5 ± 0.5
Daytime Running Light 1.5 ± 0.5
Rear Fog Light and Retro-reflector 1.5 ± 0.5

Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
35
RCH0000002

Circuit Diagram
High/Low Beam Light (Page 1 of 2)
BATTERY
EF22
10A
30 86 30 86 ENGINE
LOW HIGH
COMPARTMENT
BEAM BEAM
FUSE AND
RELAY RELAY
RELAY BOX
87 85 87 85 E-067
EF33 EF03 EF34 EF04

15A 10A 15A 10A
35 87 16 35 88 36 8
RW
Lg
RY
Y
Y
Sb
B
Y
Y
Sb
Sb
1 7 9 1 7 9
LEFT RIGHT
LEFT RIGHT
HEADLIGHT HEADLIGHT
COMBINATION COMBINATION
M ADJUSTMENT
HEADLIGHT M ADJUSTMENT
HEADLIGHT
MOTOR E-061 MOTOR E-049
E-060 E-050
3 2 5 3 2 5
Br
Br
B
Br
C
B
E-066 E-059
2 4 6 8 10 2 4 6 8 10
2 3 4 E-050 2 3 4 E-060 E-061 E-049
B 1 3 5 7 9 1 3 5 7 9
B B B
EA13T350010

High/Low Beam Light (Page 2 of 2)
IGNITION SWITCH
ON OR START
IP FUSE
BCM(A/B) B-022 I-034 AND
RF07
RELAY BOX
10A
I-032
A18 A43 B23 A45 B12
19
RY
RW
L
ILLUMINATION
B-024 17 B-019
4 5 I-002
P
E-053
BrW
B
RW
RY
2 4 6
35
LOW HI HEADLIGHT
LY
A HEADLIGHT ADJUSTMENT
PARK BEAM FLASH BEAM
COMBINATION SWITCH
SWITCH
220
150
220
150
I-007
I-030
B
3 5
8 9
Br
B
V
I-005
I-036
2
E-030
Br
$ $ $ $ $ $ $ $ $ $ $ $ $
$ $ $ $ $ $ $ $ $ $ $ $ $ B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034
B-022 B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 B
B
$ $ $ $ $ $ $ $ $ $ $ $ $
B-019
$ $ $ $ $ $ $ $ $ $ $ $ $
W
8 7 6 5 4 3 2 1 B-024
16 15 14 13 12 11 10 9
W
9 8 7 6 5 4 3 2 1
I-036 2 1
I-007
18 17 16 15 14 13 12 11 10
B
W
6 5 4 3
1 2 3 4 5
I-030
6 7 8 9 10 B
EA13T350020

Turn Signal Light (Page 1 of 2)

BATTERY
ON OR START ON OR ACC
ENGINE
IP FUSE
COMPARTMENT
SB02 SB04 EF23 EF21 EF16 EF18 RF01 RF26 AND
FUSE AND
30A 30A 15A 15A 15A 15A 10A 10A RELAY BOX
RELAY BOX
I-032
E-067
106 108 72 70 65 67 7 55
RY
RG
RY
G
R
RL
E-026 3 2 E-053
B-015 11 12 14 B-024
Gr
RG
RY
G
R
C7 C10 C2 C1 E20 D9 B17 B5
35 BCM(A/B/C/D/E) B-022 I-034 B-020 E-033 B-021
A45 A46 B11 B14

B
17 B-019
G
I-002 YR
L
B
HEADLIGHT 5 6
RIGHT LEFT B-017
COMBINATION 16
SWITCH I-001
330
150
INTEGRATED
I-030 SWITCH
I-023
G
10
B2 B3 B4 B5 B6 B7 B8 B9 B: B21 B22 B23 B24

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034 1 2 3 4 5
B25 B26 B27 B28 B29 B2: B31 B32 B33 B34 B35 B36 B37
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
6 7 8 9 10
B-022
B
B38 B39 B3: B41 B42 B43 B44 B45 B46 B47 B48 B49 B4:
D2 D3 D4 D5 D6 D7 D8
B51 B52 B53 B54 B55 B56 B57 B58 B59 B5: B61 B62 B63 I-030
B-020 B
B
D9 D: D21 D22 D23 D24 D25
F2 F3 F4 F5 F6 F7 F8 F9 F:
B-021
E2 E3 E4 E5 E6 9 8 7 6 5 4 3 2
F21 F22 F23 F24 F25 F26 F27 F28 F29 F2: F31 B E-033
W 27 26 25 24 23 22 21 :
E7 E8 E9 E: E21 E22 E23
E-026
W
2 3 4 5 6 7 8 9 2 3 4 5 6 7 8 9 : 21
8 7 6 5 4 3 2 1 2 3 4 5 6 7 8 9 :
: 21 22 23 24 25 26 27 22 23 24 25 26 27 28 29 2: 31
21 22 23 24 25 26 27 28 29
16 15 14 13 12 11 10 9
E-053 B-019
W W
I-023 B-017
B W EA13T350030

Turn Signal Light (Page 2 of 2)
BCM(E) B-021
E4 E5
LW
P
LW
LW
LW
P
4
4
21 B-016 REAR 1 B-015 B-023 6 B-015
13 REAR
F-005 TURN LEFT H-008
E-026 TURN RIGHT E-026
SIGNAL TAIL
SIGNAL TAIL
LIGHT LIGHT
P
LW
LW
P
LIGHT LIGHT
B-003
1 B-031
4 1 4 1 1
TURN
POWER
REAR LEFT TURN TURN
POWER
REAR RIGHT
TURN
35
VIEW COMBINATION VIEW COMBINATION
SIGNAL SIGNAL SIGNAL SIGNAL
MIRROR HEADLIGHT MIRROR HEADLIGHT
LIGHT LIGHT LIGHT LIGHT
MOTOR E-061 MOTOR E-049
5 F-003 2 5 H-005 2
B
B
B
F-004 B-006 E-066 H-007 B-032 E-059
F2 F3 F4 F5 F6 F7 F8 F9 F:
B-021 2 3 4 5 6 7 8 9 : 21 22 23 24 B-016
F21 F22 F23 F24 F25 F26 F27 F28 F29 F2: F31 B 25 26 27 28 29 2: 31 32 33 34 35 36 37 W
4 3 2 4 3 2
: 9 8 7 6 5 4 3 2
B-003 2 3 4 5 6 7 8 9 B-015 B-023
7 6 5 7 6 5 B-031
B B : 21 22 23 24 25 26 27 W 29 28 27 26 25 24 23 22 21 W
7 6 5 G.114 7 6 5 I.116 3 5 7 9 21 3 5 7 9 21
E-061 E-049
4 3 2 X 4 3 2 X 2 4 6 8 : 2 4 6 8 : B
B
EA13T350040

Fog Light (Page 1 of 2)

BATTERY ON OR START ON OR ACC
ENGINE
IP FUSE
COMPARTMENT
RF01 RF26 AND
SB02 SB04 EF23 EF21 EF16 EF18 FUSE AND
10A 10A RELAY BOX
RELAY BOX
30A 30A 15A 15A 15A 15A I-032
E-067
7 55
106 108 72 70 65 67
RG
RY
G
R
RY
R
RL
35 E-026
B-015 11 12 14
3 2 E-053
B-024
Gr
RG
RY
G
R
C7 C10 C2 C1 E20 D9 B17 B5
BCM(B/C/D/E) I-034 B-020 E-033 B-021
9 8 7 6 5 4 3 2 E-026 2 3 4 5 6 7 8 9 E-053
27 26 25 24 23 22 21 : W : 21 22 23 24 25 26 27
W
D2 D3 D4 D5 D6 D7 D8
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034
B-020
B B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
D9 D: D21 D22 D23 D24 D25
F2 F3 F4 F5 F6 F7 F8 F9 F:
E2 E3 E4 E5 E6
B-021 E-033
F21 F22 F23 F24 F25 F26 F27 F28 F29 F2: F31 B W
E7 E8 E9 E: E21 E22 E23
EA13T350050

Fog Light (Page 2 of 2)
BCM(A/B/E) B-022 I-034 B-021
A45 B7 E17
G
B
B-007
1 J-001
17 B-019
I-002 W
G
B
2 35
OFF
G
G
1 1
2 2 2 2
HEADLIGHT REAR LEFT REAR RIGHT
3 3 COMBINATION FOG LIGHT FOG LIGHT
SWITCH J-002
FRONT FOG
J-008
REAR FOG
I-030 1 1
B
B
3
6 J-001
B-007
B-006
B2 B3 B4 B5 B6 B7 B8 B9 B: B21 B22 B23 B24 J-002

2 3
Gr
B25 B26 B27 B28 B29 B2: B31 B32 B33 B34 B35 B36 B37 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 J-008
I-034
B-022 B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W Gr
B
B38 B39 B3: B41 B42 B43 B44 B45 B46 B47 B48 B49 B4:
B51 B52 B53 B54 B55 B56 B57 B58 B59 B5: B61 B62 B63
2 3 4 5 6 7 8 9 : 21 8 7 6 5 4 3 2
25 24 23 22 21 : 9
22 23 24 25 26 27 28 29 2: 31
B-019
F2 F3 F4 F5 F6 F7 F8 F9 F:
W
B-021
B
F21 F22 F23 F24 F25 F26 F27 F28 F29 F2: F31
B-007
W
1 2 3 4 5
I-030
6 7 8 9 10 B
EA13T350060

Position Light (Page 1 of 2)

ENGINE
IP FUSE
COMPARTMENT
RF01 RF26 AND
10A 10A RELAY BOX
RELAY BOX
30A 30A 15A 15A 15A 15A I-032
E-067
7 55
106 108 72 70 65 67
RG
RY
G
R
RY
R
RL
35 E-026
B-015 11 12 14
3 2 E-053
B-024
Gr
RG
RY
G
R
C7 C10 C2 C1 E20 D9 B17 B5
BCM(B/C/D/E) I-034 B-020 E-033 B-021
9 8 7 6 5 4 3 2 E-026 2 3 4 5 6 7 8 9 E-053
27 26 25 24 23 22 21 : W : 21 22 23 24 25 26 27
W
D2 D3 D4 D5 D6 D7 D8
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034
B-020
B B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
D9 D: D21 D22 D23 D24 D25
F2 F3 F4 F5 F6 F7 F8 F9 F:
E2 E3 E4 E5 E6
B-021 E-033
F21 F22 F23 F24 F25 F26 F27 F28 F29 F2: F31 B W
E7 E8 E9 E: E21 E22 E23
EA13T350070

Position Light (Page 2 of 2)
BCM(A/B/E) B-022 I-034 B-021
B23 A45 E9 E7
TO LICENSE PLATE LIGHTS
BrW
B
GrB
17 B-019 2 B-015
I-002 E-026
BrW
B
35
2
LOW
LY
PARK BEAM HEADLIGHT

BrW
BrW
GrB
GrB
COMBINATION
SWITCH
220
150
I-030
3 3 RIGHT 3 3
LEFT
COMBINATION COMBINATION REAR LEFT REAR RIGHT
8
HEADLIGHT HEADLIGHT TAIL LIGHT TAIL LIGHT
E-061 E-049 B-003 B-031
2 2 1 1
B
B
E-066 E-059 B-006 B-032
B2 B3 B4 B5 B6 B7 B8 B9 B: B21 B22 B23 B24 3 2 1

B25 B26 B27 B28 B29 B2: B31 B32 B33 B34 B35 B36 B37 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034 6 5 4
B-022 B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
B
B38 B39 B3: B41 B42 B43 B44 B45 B46 B47 B48 B49 B4:
B51 B52 B53 B54 B55 B56 B57 B58 B59 B5: B61 B62 B63
2 3 4 5 6 7 8 9 : 21 1 2 3 4 5 6 7 8 B-003
22 23 24 25 26 27 28 29 2: 31 9 10 11 12 13 14 15 16 W
3 2 1
B-019 B-015
F2 F3 F4 F5 F6 F7 F8 F9 F:
W W
6 5 4
B-021
B
F21 F22 F23 F24 F25 F26 F27 F28 F29 F2: F31
2 4 6 8 10
1 2 3 4 5
I-030 1 3 5 7 9
6 7 8 9 10 B B-031
W
E-061 E-049
B B EA13T350080

License Plate Light

ENGINE
IP FUSE
COMPARTMENT
RF01 RF26 AND
10A 10A RELAY BOX
RELAY BOX
30A 30A 15A 15A 15A 15A I-032
E-067
7 55
106 108 72 70 65 67
RG
RY
G
R
RY
R
RL
E-026 3 2 E-053
B-015 11 12 14 B-024
RG
RY
Gr
G
R
C7 C10 C2 C1 E20 D9 B17 B5
35 BCM(B/C/D/E) I-034 B-020 E-033 B-021
E9
BrW
TO FRONT POSITION LIGHTS
B-007
7 J-001
BrW
BrW
1 1
LEFT LICENSE RIGHT LICENSE
PLATE LIGHT PLATE LIGHT
J-004 J-006
2 2
B
J-001
6
B-007
B
B-006
D2 D3 D4 D5 D6 D7 D8
9 8 7 6 5 4 3 2 2 3 4 5 6 7 8 9 E-053
E-026
27 26 25 24 23 22 21 : W : 21 22 23 24 25 26 27
W B-020
B
D9 D: D21 D22 D23 D24 D25
F2 F3 F4 F5 F6 F7 F8 F9 F: J-004
E2 E3 E4 E5 E6
E-033 1 2 B
B-021 J-006
W
F21 F22 F23 F24 F25 F26 F27 F28 F29 F2: F31 B E7 E8 E9 E: E21 E22 E23 B
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 1 2 3 4 5 6 7

I-034 J-001
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W 8 9 10 11 12 13 14 W
EA13T350090

Back-up Light
BATTERY
EF28
10A
ENGINE
COMPARTMENT
30 86 FUSE AND
REVERSE
LAMP RELAY BOX
RELAY E-067
87 85
26 28
RB
RW
8 E-053
B-024
13
E-026
35
RB
B-015
A31
RW
BCM(A) B-022
A38
RW
RW
W
B-015
4
5 5 E-026
REAR LEFT REAR RIGHT
BACK-UP TAIL LIGHT BACK-UP TAIL LIGHT
W
LIGHT B-003 LIGHT B-031 1

1 1 BACK-UP
LIGHT
B
SWITCH
E-040
2
B-006 B-032
B
E-066
3 2 1
8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 E-053
E-026 6 5 4 B-003 B-031
16 15 14 13 12 11 10 9 W 9 10 11 12 13 14 15 16
W W W
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
1 2 E-040
B-022
B
B
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
EA13T350100

Brake Light
BATTERY
ENGINE
COMPARTMENT
EF24 FUSE AND
15A RELAY BOX
E-067
73
RB
11 E-030
I-036
RB
1
BRAKE
SWITCH
I-013
3
L
35
I-018
1 E-054
L
E-032
1 B-014
L
L
3 B-001
L
T-001
RB
2 2 1
HIGH
REAR RIGHT REAR LEFT MOUNTED
TAIL LIGHT TAIL LIGHT STOP LIGHT
B-031 B-003 T-002
2
1 1
B
T-001
1 B-001
B
B
B
B
B-032 B-006
1 2 3 4 5 6 7 8 9 1 2 3 4
9 8 7 6 5 4 3 2 1 5 4 3 2 1
10 11 12 13 14 15 16 17 18 5 6 7 8 9 10 10 9 8 7 6
18 17 16 15 14 13 12 11 10
I-018
W E-032
E-030 W
B
B-001
3 2 1 3 2 1 W
1
B-003 B-031 I-013
6 5 4 W
6 5 4
W 1 2 T-002 4 2
B
W 3
EA13T350110

Ignition Illumination
BATTERY
R
ENGINE
COMPARTMENT IP FUSE
RF15 AND
FUSE AND
7.5A RELAY BOX
SB02 SB04 EF23 EF21 EF16 EF18 MF05 RELAY BOX
I-032
30A 30A 15A 15A 15A 15A 40A E-067
E-028
E-063 40
106 108 72 70 65 67
L
RG
RY
G
R
R
2 4
JIGGLE
SWITCH
35
I-027
1 3
E-026 3 2 E-053
B-015 11 12 14 B-024
GR
Y
BY
I-001
5 7
B-017
RG
RY
G
R
GR
Y
C7 C10 C2 C1 E20 D9 B18 E16 A27
BCM(A/B/C/D/E) B-022 I-034 B-020 E-033 B-021
D2 D3 D4 D5 D6 D7 D8
9 8 7 6 5 4 3 2 2 3 4 5 6 7 8 9 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
27 26 25 24 23 22 21 : : 21 22 23 24 25 26 27 D9 D: D21 D22 D23 D24 D25 B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
E-026 I-034
W E-053 B-020 W
W B
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
F2 F3 F4 F5 F6 F7 F8 F9 F:
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
B-021
B-022
F21 F22 F23 F24 F25 F26 F27 F28 F29 F2: F31 B
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 B
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
1 2 3 4 5 6 7 8 9 E2 E3 E4 E5 E6
B-017
10 11 12 13 14 15 16 17 18 E-033 1 2 I-027
W
E7 E8 E9 E: E21 E22 E23 W W
3 4
EA13T350120

Dome Light
BATTERY
ENGINE
COMPARTMENT
FUSE AND
RELAY BOX
SB02 SB04 EF23 EF21 EF16 EF18
E-067
30A 30A 15A 15A 15A 15A
E-063
106 108 72 70 65 67
FRONT
ROOM
LIGHT
RG
RY
G
R
R
C-003
OFF
35 2 6 1
B
Y
GR
2
E-026 3 2 E-053
11 12 14 C-001
B-015 B-024 C-001
6 7 I-003
B
I-003
I-005
Y
TO TRUNK LIGHT
RG
RY
G
R
& KEY HOLE LIGHT

I-001
5 7
B-017
GR
Y
C7 C10 C2 C1 E20 D9 E16 A27
BCM(A/C/D/E) B-022 B-020 E-033 B-021
D2 D3 D4 D5 D6 D7 D8
9 8 7 6 5 4 3 2 2 3 4 5 6 7 8 9 E-053 B-020
E-026
27 26 25 24 23 22 21 : W : 21 22 23 24 25 26 27
W B
D9 D: D21 D22 D23 D24 D25
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13

F2 F3 F4 F5 F6 F7 F8 F9 F:
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
B-021
B-022
F21 F22 F23 F24 F25 F26 F27 F28 F29 F2: F31 B
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 B
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
E2 E3 E4 E5 E6
1 2 3 4 5 6 7 8 9
1 2 3
1 2 3 4 5 10 11 12 13 14 15 16 17 18 E7 E8 E9 E: E21 E22 E23
4 5 6
6 7 8 9 10
C-003 E-033
I-003 W B-017
W
W W
EA13T350130

Daytime Running Light

ENGINE
IP FUSE
COMPARTMENT
FUSE AND
RELAY BOX
I-032
E-067
106 108 72 70 65 67 7 55
RY
RG
RY
G
R
RL
E-026 3 2 E-053
B-015 11 12 14 B-024
RG
RY
Gr
G
R
C7 C10 C2 C1 E20 D9 B17 B5
BCM(B/C/D/E) I-034 B-020 E-033 B-021

35
E14 E15
W
V
B-015 B-024
3 1
E-026 E-053
W
V
2 2
LEFT DAYTIME RIGHT DAYTIME
RUNNING LIGHT RUNNING LIGHT
E-062 E-058
1 1
B
E-066 E-059
D2 D3 D4 D5 D6 D7 D8
9 8 7 6 5 4 3 2 E-026 2 3 4 5 6 7 8 9 E-053
27 26 25 24 23 22 21 : W W B-020
: 21 22 23 24 25 26 27 B
D9 D: D21 D22 D23 D24 D25
F2 F3 F4 F5 F6 F7 F8 F9 F:
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034
B-021
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
F21 F22 F23 F24 F25 F26 F27 F28 F29 F2: F31 B
E2 E3 E4 E5 E6 1 2 E-058 1 2 E-062
E-033 8 7 6 5 4 3 2 1 B-024 B B
W 16 15 14 13 12 11 10 9
W
E7 E8 E9 E: E21 E22 E23
EA13T350140

Luggage Compartment Light
BATTERY
ENGINE
COMPARTMENT
FUSE AND
SB02 SB04 EF23 EF21 EF16 EF18 RELAY BOX
30A 30A 15A 15A 15A 15A E-067
106 108 72 70 65 67
RG
RY
G
R
35 E-026 3 2 E-053
B
B-015 11 12 14 B-024
1
LUGGAGE
COMPARTMENT B-012
LIGHT
B-005
B
RG
RY
G
R
2
GR
Y
C7 C10 C2 C1 E20 D9 E16 A28 C3 C4
BCM(A/C/D/E) B-022 B-020 E-033 B-021
9 8 7 6 5 4 3 2 E-026 2 3 4 5 6 7 8 9 E-053
27 26 25 24 23 22 21 : W : 21 22 23 24 25 26 27
W
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13

F2 F3 F4 F5 F6 F7 F8 F9 F:
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
B-021
B-022
F21 F22 F23 F24 F25 F26 F27 F28 F29 F2: F31 B
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 B
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
E2 E3 E4 E5 E6 D2 D3 D4 D5 D6 D7 D8
E-033 B-020 B-005
2 1
W B B
E7 E8 E9 E: E21 E22 E23
D9 D: D21 D22 D23 D24 D25
EA13T350150

DIAGNOSIS & TESTING

HINT:
Position Light, Low Beam Light and High Beam Light

Fuse 55-30
Low beam light does not come on (one
Headlight bulb —
side)
Fuse 55-30
Headlight bulb —
Low beam lights do not come on (both Combination light switch assembly 35-80 35
sides) Low beam relay 55-30
Wire harness or connector
Body Control Module (BCM)
Fuse 55-30
High beam light does not come on (one Headlight bulb —

side) Wire harness or connector 55-34
Headlight assembly 35-74
Fuse 55-30
Headlight bulb —
Combination light switch assembly —
High beam lights do not come on (both
High beam relay —
sides)
Headlight assembly —
Position light bulbs (all) 35-45
Position lights do not come on (both Wire harness or connector —

sides) Combination light switch assembly 35-80
Position light does not come on (one Position light bulb

side) Wire harness or connector

Daytime Running Light

Daytime running light 35-58
Daytime running light does not come on Wire harness or connector
Rear Fog Light

Rear fog light bulb —
Combination light switch assembly 35-80
Rear fog light does not come on
Turn Signal Light and Hazard Warning Light

35
Light bulb 35-33
Wire harness or connector —
Hazard warning light and turn signal
Hazard warning light switch
light do not come on
Combination light switch assembly
Hazard warning light does not come on Hazard warning light switch
(turn signal light is normal) Wire harness or connector
Turn signal light does not come on Combination light switch assembly
(hazard warning light is normal) Wire harness or connector
License Plate Light

License plate light bulb
Combination light switch assembly —
License plate light does not come on
Luggage Compartment Light

Luggage compartment light bulb 35-70
Luggage compartment light does not
come on

Brake Light

Fuse
Brake light bulb 35-63
Brake lights do not come on (all)
Brake light switch
Brake light bulb
Only one brake light does not come on
Front Dome Light

Front dome light bulb 35-87
Front dome light does not come on
Front dome light assembly
35
Back-up Light

Fuse 55-30
Relay 55-30
Back-up lights do not come on (all) Back-up light bulb
Back-up light switch

Confirm that battery voltage is higher than 12 V before performing following procedures.
 Use X-431 3G diagnostic tester to record and clear DTCs stored in lighting system.
 Turn ignition switch to ON and then select Read Code.


 Wiggle related wire harnesses and connectors and observe if signal is interrupted in related circuit.
 If possible, try to duplicate conditions under which DTC was set.
 Check for broken, bent, protruded or corroded terminals.
 Inspect wheel speed sensors and mounting areas for damage, foreign matter, etc. that will cause incorrect
signals.
 Refer to any Technical Bulletin that may apply to malfunction.
Ground Inspection
35 Ground points are very important to the proper operation of circuits. Ground points are often exposed to
moisture, dirt and other corrosive environments. Corrosion (rust) can increase resistance which will change
the way in which a circuit works.
Circuits are very sensitive to proper grounding. A loose or corroded ground can affect the control circuit.
Check the ground points as follows:
System Diagnostic
1. Description
a. Lighting system data and Diagnostic Trouble Codes (DTCs) can be read from Data Link Connector
(DLC) of vehicle. When system seems to be malfunctioning, use X-431 3G diagnostic tester to check
for a malfunction and perform repairs.
2. Check battery voltage
a. Standard voltage:
11 to 14 V
DTC Check/Clear
1. Check for DTCs
b. Turn ignition switch to ON, and turn X-431 3G diagnostic tester on.
c. Select following menu items to read the current malfunctions: A13T / BCM / DTC / Read Current DTC.
d. Read DTCs by following indications on tester screen.
2. Clear DTCs

c. Select following menu items: A13T / BCM / Clear DTC.
d. Clear DTCs by following indications on tester screen.
Data List/Active Test
1. Read data list
HINT:
Using X-431 3G diagnostic tester to read Data List allows values or states of switches, sensors, actuators
and other items to be read without removing any parts. This non-intrusive inspection can be very useful
because intermittent problems or signals may be discovered before parts or wiring is disturbed. Reading
the Data List information early in troubleshooting is one way to save diagnostic time.
CAUTION
 In the table below, values listed under "Normal Condition" are reference values. Do not depend solely on
these reference values, when deciding whether a part is faulty or not.

35
c. Select following menu items: A13T / BCM / Data stream / Input status (Light).
d. Read Data List according to the tester display.
Tester Display Measurement Item/Range Normal Condition

Left turn signal On: Active
Left Hand Turn Light Left turn signal/On or Off
Left turn signal Off: Inactive
Right turn signal On: Active
Right Hand Turn Light Right turn signal/On or Off
Right turn signal Off: Inactive
Front fog light signal On: Active
Front Fog Light Front fog light signal/On or Off
Front fog light signal Off: Inactive
Rear fog light signal On: Active
Rear Fog Light Rear fog light signal/On or Off
Rear fog light signal Off: Inactive
Position light signal On: Active
Position Light Position light signal/On or Off
Position light signal Off: Inactive
Low beam light signal On: Active
Low Beam Low beam light signal/On or Off
Low beam light signal Off: Inactive
High beam light signal On: Active
High Beam High beam light signal/On or Off High beam light signal Off:
Inactive
Hazard warning light signal On:
Hazard warning light signal/On or Active
Hazard
Off Hazard warning light signal Off:
Inactive
Overtaking light signal On: Active
Flash Overtaking light signal/On or Off Overtaking light signal Off:
Inactive

2. Perform active test

HINT:
Use X-431 3G diagnostic tester to perform Active Tests allows items to be tested without removing any
parts. This non-intrusive functional inspection can be very useful because intermittent problems may be
discovered before parts or wiring is disturbed. Perform the Active Test early in troubleshooting is one way
to save diagnostic time. Data List information can be displayed when performing Active Test.
c. Select following menu items: A13T / BCM / Actuation Test.
d. Perform Active Test according to the tester display.
Tester Display Control Range

Left Hand Turn Light Active/Inactive
Right Hand Turn Light Active/Inactive
Position Light Active/Inactive
35 Low Beam Active/Inactive

High Beam Active/Inactive
Front Fog Light Active/Inactive
Rear Fog Light Active/Inactive
Daytime Running Light Active/Inactive
Dome Lamp Active/Inactive
Security Indicator Active/Inactive
Hazard Active/Inactive
Trunk Lamp Active/Inactive
Diagnosis Procedure
HINT:
Perform troubleshooting according to the procedures below.
NEXT
NEXT

DTC
occurs
NEXT
4 Diagnostic Trouble Code (DTC) Chart
NEXT
5 Circuit inspection
35
NEXT
6 Repair or replace
NEXT
7 Clear DTCs (current DTC and history DTC)
NEXT
DTC
Go to step 4
output
No DTC
Go to next step
output
NEXT
9 Conduct test and confirm malfunction has been repaired
NEXT
10 End


DTC DTC Definition
B1001-11 Left Side Turn Lamp Control Circuit
B1001-13 Left Side Turn Lamp Control Circuit
B1002-11 Right Side Turn Lamp Control Circuit
B1002-13 Right Side Turn Lamp Control Circuit
B1003-11 Left Park Light output Control Circuit
B1003-13 Left Park Light output Control Circuit
B1004-11 Right Park Light output Control Circuit
B1004-13 Right Park Light output Control Circuit
B1005-11 Front Park Light output Control Circuit
B1005-13 Front Park Light output Control Circuit
B1006-11 Rear Park Light output Control Circuit
35
B1006-13 Rear Park Light output Control Circuit
B1008-11 Rear Fog Control Circuit
B101E-11 L-DRL Control Circuit
B101F-11 R-DRL Control Circuit
B1035-11 Brake Light Control Circuit
B1035-13 Brake Light Control Circuit
B1036-11 H-Brake Light Control Circuit
B1036-13 H-Brake Light Control Circuit

DTC B1001-11 Left Side Turn Lamp Control Circuit
DTC B1001-13 Left Side Turn Lamp Control Circuit
35


IP FUSE
RF01 RF26 AND
10A 10A RELAY BOX
I-032
7 55
RY
RL
Gr
B17 B5
BCM(A/B/C/D/E) B-022 I-034 B-020 E-033 B-021
E4 A45 A46
B
LW
17 B-019
G
I-002
B
2
LW
LW
LW
35 4 RIGHT LEFT HEADLIGHT

16 B-017
21 B-016 REAR 1 B-015 COMBINATION
SWITCH I-001
F-005 TURN LEFT
330
150
E-026
SIGNAL TAIL I-030
LIGHT LIGHT
LW
LW
B-003
G
1 10
4 1
POWER
REAR LEFT TURN
TURN
VIEW COMBINATION SIGNAL
SIGNAL
MIRROR HEADLIGHT LIGHT
LIGHT
MOTOR E-061
5 F-003 2
B
B
F-004 B-006 E-066
$ $ $ $ $ $ $ $ $ $ $ $ $
( ( ( ( ( ( ( ( ( $ $ $ $ $ $ $ $ $ $ $ $ $
B-021
( ( ( ( ( ( ( ( ( ( (
B $ $ $ $ $ $ $ $ $ $ $ $ $
$ $ $ $ $ $ $ $ $ $ $ $ $
B-022
B

B-003

B
B-023 ( ( ( ( ( ( ( ( (
W B-021
B
( ( ( ( ( ( ( ( ( ( (
1 2 3 4 5
) 6 7 8 9 10
:

I-030 E-061
B B
EA13T350160

DTC Detection
Condition
Left Side Turn Lamp  Light bulb
B1001-11
Control Circuit  Wire harness or connector
Ignition switch ON
Left Side Turn Lamp  Turn signal light switch
B1001-13
Control Circuit  BCM
CAUTION
Diagnosis Procedure
1 Check left turn signal light bulb

35
c. Remove left turn signal light bulb, and check if left turn signal light bulb filament is blown.
NG Replace left turn signal light bulb
OK
2 Check connector and wire harness

c. Check the left turn signal light ground points F-004, B-006 and B-066.
d. Disconnect body controller connectors B-021 and B-022, turn signal light switch connector I-030, front left
turn signal light connector E-061, rear left turn signal light connector B-003 and side turn signal light
connector F-003.
NG Repair or replace related connector or

wire harness
OK

3 Check supply voltage of left turn signal light

3 2 1
c. Disconnect the turn signal light bulb connectors F-003, B- 6 5 4 B-003
003 and E-061. V
+ -
e. Turn ignition switch to ON, and turn combination light
switch to ON position of left turn signal light.
6 5 4
f. Using a digital multimeter, measure turn signal light bulb F-003
3 2 1
connectors F-003, B-003 and E-061 to check supply
voltage and ground of turn signal light according to table
below.
Standard Condition
2 4 6 8 10
E-061
Multimeter Specified 1 3 5 7 9
Condition
35 Connection Condition
RA13T350530
RM1A370500
F-003 (4) - F-003 Changes between
Ignition switch ON
(5) 0 to 12 V
B-003 (4) - B-003 Changes between
Ignition switch ON
(1) 0 to 12 V
E-061 (1) - E-061 Changes between
Ignition switch ON
(2) 0 to 12 V
OK Replace corresponding turn signal light

bulb
NG
4 Check turn signal light wire harness and connector


c. Disconnect the body controller connector B-021.

d. Disconnect the turn signal light connectors F-003, B-003 + -
and E-061.
e. Using a digital multimeter, measure resistance between
F-003
connector B-021 and turn signal light connectors F-003, B-003
B-003 and E-061 to check for short or open circuit ( ( ( ( ( ( ( ( (

Standard Condition ( ( ( ( ( ( ( ( ( ( (
Condition B-021

B-021 (E4) - F- E-061
Always Continuity
003 (4) RA13T350540
RM1A370500

Condition
B-021 (E4) - B-
Always Continuity
003 (4)
B-021 (E4) - E-
Always Continuity
061 (1)
f. Using a digital multimeter, measure resistance between

turn signal light connectors F-003, B-003, E-061 and
ground to check for short or open circuit according to
table below.


Condition
Connection Condition F-003
F-003 (5) - Body

Always Continuity
ground
E-061
B-003 (1) - Body
Always Continuity

35
ground
E-061 (2) - Body
Always Continuity
ground
B-003
RA13T350550
RM1A370500
wire harness
OK
5 Check turn signal light switch and wire harness connector

d. Disconnect the turn signal light switch connector I-030. + -
1 2 3 4 5
e. Using a digital multimeter, measure resistance between 6 7 8 9 10
connector B-022 and turn signal light connector I-030 to
check for short or open circuit according to table below.
I-030
Standard Condition
Multimeter Specified A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13

Condition
Connection Condition A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
B-022 (A45) - I-
Always Continuity
030 (2) A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022 (A46) - I-
Always Continuity B-022
030 (10) RA13T350560
RM1A370500
B-022 (A45) - B-
022 (A46)

f. Remove the turn signal light switch.

g. Using a digital multimeter, check turn signal light switch
for damage according to table below.
Condition
1 2 3 4 5
Combination light
I-030 (2) - I-030 6 7 8 9 10
switch is moved to 150 Ω
(10)
LEFT position
I-030
Combination light
I-030 (2) - I-030
switch does not No continuity
(10)
operate
NG Replace combination light switch, and

RA13T350570
RM1A370500
repair or replace related connector or wire
harness
35
OK
6 Reconfirm DTCs

c. Check if same DTC is output or same problem symptom
occurs.
YES
Replace BCM control module assembly

DTC B1002-11 Right Side Turn Lamp Control Circuit
DTC B1002-13 Right Side Turn Lamp Control Circuit
35


IP FUSE
RF01 RF26 AND
10A 10A RELAY BOX
I-032
7 55
RY
RL
Gr
B17 B5
BCM(A/B/C/D/E) B-022 I-034 B-020 E-033 B-021
E5 A45 A46
B
P
17 B-019
G
I-002
P
B
2
35 B-023
4
REAR 6 B-015 LEFT HEADLIGHT
13 H-008 RIGHT 16 B-017
TURN RIGHT E-026 COMBINATION
SWITCH I-001
SIGNAL TAIL
330
150
I-030
P
P
LIGHT LIGHT
B-031
1
G
4 1 10
POWER
REAR RIGHT
TURN TURN
VIEW COMBINATION
SIGNAL SIGNAL
MIRROR HEADLIGHT
LIGHT LIGHT
MOTOR E-049
5 H-005 2
B
H-007 B-032 E-059
$ $ $ $ $ $ $ $ $ $ $ $ $
( ( ( ( ( ( ( ( ( $ $ $ $ $ $ $ $ $ $ $ $ $
B-021
( ( ( ( ( ( ( ( ( ( (
B $ $ $ $ $ $ $ $ $ $ $ $ $
$ $ $ $ $ $ $ $ $ $ $ $ $
B-022
B

B-023
B-031 W
E-049 B
B
( ( ( ( ( ( ( ( (
1 2 3 4 5
+ ( ( ( ( ( ( ( ( ( ( (
6 7 8 9 10
:
I-030 B-021
B B
EA13T350170

DTC Detection
Condition
Right Side Turn Lamp  Wire harness or connector
B1002-11
Control Circuit  Light bulb
Ignition switch ON
Right Side Turn Lamp  Turn signal light switch
B1002-13
Control Circuit  BCM
CAUTION
Diagnosis Procedure
1 Check right turn signal light bulb

35
c. Remove right turn signal light bulb, and check if right turn signal light bulb filament is blown.
NG Replace right turn signal light bulb
OK

c. Check the right turn signal light ground points F-004, B-006 and B-066.
d. Disconnect body controller connectors B-021 and B-022, turn signal light switch connector I-030, front right
turn signal light connector E-049, rear right turn signal light connector B-031 and side turn signal light
connector H-005.

wire harness
OK

3 Check supply voltage of right turn signal light

c. Disconnect the turn signal light bulb connectors H-005,
B-031 and E-049. V
+ - 2 4 6 8 10
d. Connect the negative battery cable. 1 3 5 7 9
e. Turn ignition switch to ON, and turn combination light E-049

switch to ON position of right turn signal light.
f. Using a digital multimeter, measure turn signal light bulb
connectors H-005, B-031 and E-049 to check supply
3 2 1
voltage and ground of turn signal light according to table 6 5 4
below. 3 2 1 6 5 4
Standard Condition
H-005
Multimeter Specified B-031
Condition
35 Connection Condition
RA13T350580
RM1A370500
H-005 (4) - H-005 Changes between
Ignition switch ON
(5) 0 to 12 V
B-031 (4) - B-031 Changes between
Ignition switch ON
(1) 0 to 12 V
E-049 (1) - E-049 Changes between
Ignition switch ON
(2) 0 to 12 V
OK Replace corresponding turn signal light

bulb
NG
4 Check turn signal light wire harness and connector


d. Disconnect the turn signal light connectors H-005, B-031 + -
and E-049.

H-005
connector B-021 and turn signal light connectors H-005,

B-031 and E-049 to check for short or open circuit
according to table below. E-049 B-031
Standard Condition
( ( ( ( ( ( ( ( (
Condition ( ( ( ( (
Connection Condition ( ( ( ( ( (
B-021 (E5) - H-
Always Continuity
005 (4) B-021
RA13T350590
RM1A370500

Condition
B-021 (E5) - B-
Always Continuity
031 (4)
B-021 (E5) - E-
Always Continuity
049 (1)

turn signal light connectors H-005, B-031, E-049 and
ground to check for short or open circuit according to
table below. 6 5 4
3 2 1
Condition H-005
3 2 1
H-005 (5) - Body
Always Continuity 6 5 4
ground 2 4 6 8 10
1 3 5 7 9
B-031 (1) - Body
Always Continuity 35
ground E-049
B-031
E-049 (2) - Body
Always Continuity
ground
RA13T350600
RM1A370500
wire harness
OK
5 Check turn signal light switch and wire harness connector

d. Disconnect the turn signal light switch connector I-030. + -
1 2 3 4 5
connector B-022 and turn signal light connector I-030 to
check for short or open circuit according to table below.
I-030
Standard Condition

Condition
B-022 (A45) - I-
Always Continuity
030 (2) A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022 (A46) - I-
030 (10) RA13T350610
RM1A370500
B-022 (A45) - B-
022 (A46)

f. Using a digital multimeter, check turn signal light switch

for damage according to table below.
Standard Condition
+ -
Condition
Combination light
I-030 (2) - I-030 1 2 3 4 5
switch is moved to 330 Ω
(10) 6 7 8 9 10
RIGHT position
Combination light
I-030 (2) - I-030 I-030
(10)
operate
NG Replace combination light switch, and

repair or replace related connector or wire
harness RA13T350620
RM1A370500
35 OK
6 Reconfirm DTCs

occurs.
YES

DTC B1005-11 Front Park Light output Control Circuit
DTC B1005-13 Front Park Light output Control Circuit
35


IP FUSE
RF01 RF26 AND
10A 10A RELAY BOX
I-032
7 55
RY
RL
Gr
B17 B5
BCM(A/B/E) B-022 I-034 B-021
B23 A45 E9
35
BrW
B
B-007
7 J-001
17 B-019 2 B-015
I-002 E-026 BrW
BrW
BrW
B
1 1
LEFT LICENSE RIGHT LICENSE
2 PLATE LIGHT PLATE LIGHT
LOW
LY
J-004 J-006
PARK BEAM HEADLIGHT
BrW
BrW
COMBINATION 2 2
SWITCH
B
B
220
150
I-030
3 3 RIGHT
LEFT
8 COMBINATION COMBINATION J-001
HEADLIGHT HEADLIGHT 6
B-007
E-061 E-049
2 2
B
B
E-066 E-059 B-006
$ $ $ $ $ $ $ $ $ $ $ $ $

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034
$ $ $ $ $ $ $ $ $ $ $ $ $
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
B-022
B
$ $ $ $ $ $ $ $ $ $ $ $ $
1 2 3 4 5 6 7 8 2 4 6 8 10
$ $ $ $ $ $ $ $ $ $ $ $ $
9 10 11 12 13 14 15 16 1 3 5 7 9

E-061 E-049
B-015
B B
W
B-019
W
( ( ( ( ( ( ( ( (
1 2
1 2 3 4 5 1 2 3 4 5 6 7
J-004
( ( ( ( ( ( ( ( ( ( ( 6 7 8 9 10 8 9 10 11 12 13 14
B
J-006
B J-001
I-030 W
B-021
B EA13T350180
B

DTC Detection
Condition
Front Park Light output
B1005-11  Wire harness or connector
Control Circuit
Ignition switch ON  Light bulb
Front Park Light output
B1005-13  BCM
Control Circuit
CAUTION
Diagnosis Procedure
1 Check front small light bulb

35
c. Remove front small light bulb, and check if bulb filament is blown.
NG Replace front small light bulb
OK

c. Check the front small light ground points E-066 and E-059.
d. Disconnect the body controller connectors B-021 and B-020.

wire harness
OK

3 Check supply voltage of front small light

c. Disconnect the front small light bulb connectors E-061
and E-049. V
+ -
d. Connect the negative battery cable. 2 4 6 8 10
e. Turn ignition switch to ON and turn on the small light 1 3 5 7 9
switch.
E-049
f. Using a digital multimeter, measure front small light bulb
connectors E-061 and E-049 to check supply voltage and
ground of small light according to table below.
Standard Condition 2 4 6 8 10
1 3 5 7 9
Condition E-061
35 E-061 (3) - E-061 RA13T350630
RM1A370500
Always 12 V
(2)
E-049 (3) - E-049
Always 12 V
(2)
OK Replace corresponding front small light

bulb
NG
4 Check front small light wire harness and connector


d. Disconnect the small light connectors E-061 and E-049. + -
e. Using a digital multimeter, measure resistance between E-061
connector B-021 and small light connectors E-061 and E-

049 to check for short or open circuit according to table
( ( ( ( ( ( ( ( (
below.
Standard Condition ( ( ( ( ( ( ( ( ( ( (
Condition B-021

B-021 (E9) - E-
Always Continuity
E-049
061 (3)
B-021 (E9) - E- RA13T350640
RM1A370500
Always Continuity
049 (3)


small light connectors E-061, E-049 and ground to check
for short or open circuit according to table below.
Standard Condition
+ -
Condition E-061
E-061 (2) - Body
Always Continuity
ground

E-049 (2) - Body
Always Continuity
ground E-049
E-061 (3) - Body

ground
E-049 (3) - Body
ground RA13T350650
RM1A370500

wire harness 35
OK
5 Check combination light switch

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
c. Disconnect the body controller connectors B-022 and I- B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
034. + - I-034
d. Disconnect the combination light switch connector I-030.

connectors B-022, I-034 and combination light switch 6 7 8 9 10
connector I-030 to check for short or open circuit

according to table below. I-030
Standard Condition A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
Condition
B-022 (A45) - I- A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
Always Continuity
030 (2) B-022 RA13T350660
RM1A370500
I-034 (B23) - I-030
Always Continuity
(8)

f. Remove the combination light switch.

g. Using a digital multimeter, measure combination light
switch according to table below.
Condition
1 2 3 4 5
Combination light 6 7 8 9 10
I-030 (2) - I-030 switch is turned to
220 Ω
(8) ON position of
I-030
small light
Combination light
I-030 (2) - I-030
(8)
operate
RA13T350670
RM1A370500
NG Replace combination light switch, or
repair or replace wire harness connector
35
OK
6 Reconfirm DTCs

occurs.
YES

DTC B1008-11 Rear Fog Control Circuit
35


IP FUSE
RF01 RF26 AND
10A 10A RELAY BOX
I-032
7 55
RY
RL
Gr
B17 B5
BCM(A/B/E) B-022 I-034 B-021
A45 B7 E17
G
B
B-007
35 17 B-019
1 J-001
I-002
W
G
B
2
G
G
OFF

2 2
REAR LEFT REAR RIGHT
HEADLIGHT FOG LIGHT FOG LIGHT
COMBINATION J-002 J-008
SWITCH 1 1
FRONT FOG
REAR FOG
I-030
B
3 6 J-001
B-007
B-006
$ $ $ $ $ $ $ $ $ $ $ $ $ J-002

Gr
$ $ $ $ $ $ $ $ $ $ $ $ $ B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 J-008
I-034
B-022 B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W Gr
B
$ $ $ $ $ $ $ $ $ $ $ $ $
$ $ $ $ $ $ $ $ $ $ $ $ $

B-019
( ( ( ( ( ( ( ( (
W
B-021
B
( ( ( ( ( ( ( ( ( ( (
B-007
W
1 2 3 4 5
I-030
6 7 8 9 10 B
EA13T350190

DTC Detection
Condition
Rear Fog Control
B1008-11
Circuit  Wire harness or connector
Rear Fog Control  Fog light bulb
B1008-13 Ignition switch ON
Circuit  Combination light switch
Rear Fog Control  BCM
B1008-71
Circuit
CAUTION
Diagnosis Procedure
35
1 Check rear fog light bulb

c. Remove rear fog light bulb, and check if bulb filament is blown.
NG Replace rear fog light bulb
OK

c. Check the rear fog light ground point B-006.
d. Disconnect the body controller connectors B-021, B-022 and I-034.
e. Disconnect the rear fog light connectors J-002 and J-008.
f. Check if wire harnesses are worn, pierced, pinched or partially broken.
g. Check for broken, bent, protruded or corroded terminals.
h. Check if terminal contact pins of related connectors are in good condition.

wire harness
OK

3 Check supply voltage of rear fog light

c. Disconnect the rear fog light bulb connectors J-002 and
J-008. V
+ -
e. Turn ignition switch to ON and turn on the fog light switch.
f. Using a digital multimeter, measure rear fog light bulb
1 2
connectors J-002 and J-008 to check supply voltage and
J-002
ground of fog light according to table below.
J-008
Standard Condition
Condition
J-002 (8) - J-002
35 (1)
Always 12 V
RA13T350680
RM1A370500
J-008 (2) - J-008

Always 12 V
(1)
OK Replace corresponding rear fog light bulb
NG
4 Check rear fog light wire harness and connector

d. Disconnect the fog light connectors J-002 and J-008. + -
1 2
e. Using a digital multimeter, measure resistance between J-002
connector B-021 and rear fog light connectors J-002 and J-008
J-008 to check for short or open circuit according to table
below.
Standard Condition
E1 E2 E3 E4 E5 E6 E7 E8 E9
Condition E10 E11 E12 E13 E14 E15 E16 E17 E18 E19 E20
B-021 (E17) - J-
002 (2)
B-021 (E17) - J- RA13T350690
RM1A370500
Always Continuity
008 (2)


fog light connectors J-002, J-008 and ground to check for
short or open circuit according to table below.
Standard Condition
+ -
Condition
Connection Condition J-002
J-008
J-002 (1) - Body
Always Continuity
ground
J-008 (1) - Body
Always Continuity
ground
J-002 (2) - Body
ground
J-008 (2) - Body
ground RA13T350700
RM1A370500

wire harness 35
OK
5 Check combination light switch and wire harness connector

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
c. Disconnect the body controller connectors B-022 and I- B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
034. + - I-034
d. Disconnect the combination light switch connector I-030.

connectors B-022, I-034 and combination light switch 6 7 8 9 10
connector I-030 to check for short or open circuit

according to table below. I-030
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
Condition
B-022 (A45) - I- A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
Always Continuity
030 (2) B-022 RA13T350710
RM1A370500
I-034 (B7) - I-030
Always Continuity
(3)

f. Using a digital multimeter, measure combination light

Standard Condition
+ -
Condition
Combination light
1 2 3 4 5
I-030 (2) - I-030 switch is turned to
Continuity 6 7 8 9 10
(3) ON position of
rear fog light
I-030
Combination light
I-030 (2) - I-030
(3)
operate
NG Replace combination light switch, or

repair or replace wire harness connector RA13T350720
RM1A370500
35 OK
6 Reconfirm DTCs

occurs.
YES

DTC B101E-11 L-DRL Control Circuit
DTC B101E-13 L-DRL Control Circuit
DTC B101F-11 R-DRL Control Circuit
DTC B101F-13 R-DRL Control Circuit
35


ENGINE
IP FUSE
COMPARTMENT
FUSE AND
RELAY BOX
I-032
E-067
106 108 72 70 65 67 7 55
RY
RG
RY
G
R
RL
E-026 3 2 E-053
B-015 11 12 14 B-024
RG
RY
Gr
G
R
C7 C10 C2 C1 E20 D9 B17 B5
BCM(B/C/D/E) I-034 B-020 E-033 B-021
35
E14 E15
W
V
B-015 B-024
3 1
E-026 E-053
W
V
2 2
LEFT DAYTIME RIGHT DAYTIME
RUNNING LIGHT RUNNING LIGHT
E-062 E-058
1 1
B
E-066 E-059
& & & & & & &

E-026 E-053
W W B-020
B
& & & & & & &
( ( ( ( ( ( ( ( (
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034
B-021
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
( ( ( ( ( ( ( ( ( ( (
B
' ' ' ' ' 1 2 E-058 1 2 E-062

E-033 8 7 6 5 4 3 2 1 B-024 B B
W 16 15 14 13 12 11 10 9
W
' ' ' ' ' ' '
EA13T350200

DTC Detection
Condition
 Daytime running light
 BCM
CAUTION
Diagnosis Procedure
1 Check connector and wire harness 35

c. Check the daytime running light ground points E-062 and E-058.
d. Disconnect the body controller connector B-021.
e. Disconnect the daytime running light connectors E-062 and E-058.

wire harness
OK

2 Check supply voltage of daytime running light

c. Disconnect the daytime running light connectors E-062
and E-058. V
+ -
e. Start the vehicle.
f. Using a digital multimeter, measure daytime running light
connectors E-062 and E-058 to check supply voltage and 1 2
ground of daytime running light according to table below. E-062

Standard Condition E-058
Condition
E-062 (2) - E-062
35 (1)
Always 12 V
RA13T350730
RM1A370500
E-058 (2) - E-058

Always 12 V
(1)
OK Replace corresponding daytime running

light
NG
3 Check daytime running light wire harness and connector

d. Disconnect the daytime running light connectors E-062 + -
and E-058. 1 2
E-062
e. Using a digital multimeter, measure resistance between E-058
connector B-021 and daytime running light connectors E-
062 and E-058 to check for short or open circuit
Standard Condition E1 E2 E3 E4 E5 E6 E7 E8 E9
Multimeter Specified E10 E11 E12 E13 E14 E15 E16 E17 E18 E19 E20
Condition
B-021 (E15) - E- B-021
Always Continuity
058 (2) RA13T350740
RM1A370500
B-021 (E14) - E-
Always Continuity
062 (2)

f. Disconnect the daytime running light connectors E-062

and E-058.
g. Using a digital multimeter, measure resistance between
daytime running light connectors E-062, E-058 and
ground to check for short or open circuit according to + -
table below.
1 2
Standard Condition
E-062
E-058
Condition
E-062 (1) - Body
Always Continuity
ground
E-058 (1) - Body
Always Continuity
ground
E-062 (2) - Body
Always No continuity RA13T350750
RM1A370500
ground
E-058 (2) - Body
ground
Always No continuity 35

wire harness
OK
4 Reconfirm DTCs

occurs.
YES

DTC B1035-11 Brake Light Control Circuit
DTC B1035-13 Brake Light Control Circuit
DTC B1036-11 H-Brake Light Control Circuit
DTC B1036-13 H-Brake Light Control Circuit
35

BATTERY
ENGINE
COMPARTMENT
EF24 FUSE AND
15A RELAY BOX
E-067
73
RB
11 E-030
I-036
RB
1
BRAKE
SWITCH
I-013
L I-018
1 E-054
35
L
E-032
1 B-014
L
L
3 B-001
L
RB T-001
2 2 1
HIGH
REAR RIGHT REAR LEFT MOUNTED
TAIL LIGHT TAIL LIGHT STOP LIGHT
B-031 B-003 T-002
2
1 1
B
T-001
1 B-001
B
B
B
B
B-032 B-006
1 2 3 4 5 6 7 8 9 1 2 3 4
9 8 7 6 5 4 3 2 1 5 4 3 2 1
10 11 12 13 14 15 16 17 18 5 6 7 8 9 10 10 9 8 7 6
18 17 16 15 14 13 12 11 10
I-018
W E-032
E-030 W
B
B-001
3 2 1 3 2 1 W
1
B-003 B-031 I-013
6 5 4 W
6 5 4
W 1 2 T-002 4 2
B
W 3
EA13T350210

DTC Detection
Condition
Brake Light Control
B1035-11
Circuit
 Brake light
Brake Light Control
B1035-13  Wire harness or connector
Circuit
Ignition switch LOCK  Fuse
H-Brake Light Control
B1036-11  Brake light switch
Circuit
 BCM
H-Brake Light Control
B1036-13
Circuit
CAUTION
35
Diagnosis Procedure
1 Check fuse

c. Remove fuse EF24 (15A) from engine compartment fuse and relay box.
NG Replace fuse EF24 (15A)
OK

c. Check the brake light ground points B-006 and B-032.
d. Disconnect the brake light switch connector I-013.
e. Disconnect the brake light connectors B-031, B-003 and T-002.

wire harness
OK

3 Check supply voltage of brake light

3 2 1
c. Disconnect the brake light bulb connectors B-031, B-003 B-031
V 6 5 4
and T-002. + -
e. Depress the brake pedal.
f. Using a digital multimeter, measure brake light bulb
3 2 1
connectors B-031, B-003 and T-002 to check supply B-003
voltage and ground of brake light according to table 6 5 4
below.
Standard Condition
Condition 1 2 T-002
B-031 (1) - B-031 RA13T350760
RM1A370500
35
Always 12 V
(2)
B-003 (2) - B-003
Always 12 V
(1)
T-002 (1) - T-002
Always 12 V
(2)
OK Replace corresponding brake light bulb
NG
4 Check brake light wire harness and connector


c. Disconnect the brake light switch connector I-013. B-031

d. Disconnect the brake light bulb connectors B-031, B-003 + -
and T-002.
connector I-013 and brake light connectors B-031, B-003
and T-002 to check for short or open circuit according to
table below.
B-003
Standard Condition
1
Condition 3
1 2 T-002 I-013
I-013 (3) - B-031
Always Continuity
(2) RA13T350770
RM1A370500
I-013 (3) - B-003
Always Continuity
(2)

Condition
I-013 (3) - T-002
Always Continuity
(1)

wire harness
OK
5 Check brake light switch and wire harness connector

c. Disconnect the brake light switch connector I-013.
V
35
+ -
e. Using a digital multimeter, measure voltage between 1

connector I-013 and body ground to check for short or 4 2
3
open circuit according to table below. I-013
Standard Condition
Condition
I-013 (1) - Body
Always 12 V
ground
RA13T350780
RM1A370500
f. Remove the brake light switch.

g. Using a digital multimeter, measure brake light switch + - 3
Standard Condition
4 2
Brake pedal 1
Terminal 1 -
depressed (switch Continuity
pin released)
Brake pedal
Terminal 2 -
depressed (switch No continuity
Terminal 4
pin released)
Brake pedal
Terminal 1 -
Terminal 3
pin pushed)
Brake pedal
Terminal 2 -
released (switch Continuity
Terminal 4
pin pushed)

NG Replace brake light switch, or repair or

replace wire harness connector
OK
System operates normally
35

Front Dome Light Diagnosis
BATTERY
ENGINE
COMPARTMENT
FUSE AND
RELAY BOX
E-067
30A 30A 15A 15A 15A 15A
E-063
106 108 72 70 65 67
FRONT
ROOM
LIGHT
RG
RY
G
R
R
C-003
OFF
35 2 6 1
B
Y
GR
2
E-026 3 2 E-053
11 12 14 C-001
B-015 B-024 C-001
6 7 I-003
B
I-003
I-005
Y
TO TRUNK LIGHT
RG
RY
G
R
R
B
& KEY HOLE LIGHT

I-001
5 7
B
B-012 B-017
GR
Y
C3 C4 C7 C10 C2 C1 E20 D9 E16 A27
BCM(A/C/D/E) B-022 B-020 E-033 B-021
& & & & & & &

E-053 B-020
E-026
W
W B
& & & & & & &
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13

( ( ( ( ( ( ( ( (
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
B-021
B-022
( ( ( ( ( ( ( ( ( ( (
B
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 B
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
' ' ' ' '

1 2 3 4 5 6 7 8 9
1 2 3
1 2 3 4 5 10 11 12 13 14 15 16 17 18 ' ' ' ' ' ' '
4 5 6
6 7 8 9 10
C-003 E-033
I-003 W B-017
W
W W
EA13T350220

Problem Symptom Detection Condition Possible Cause

Dome light does not operate Ignition switch ON  Dome light
 BCM
CAUTION
Diagnosis Procedure
1 Check fuse

35
c. Remove front dome light bulb, and check if bulb filament is blown.
NG Replace damaged dome light bulb
OK
2 Check ground point, connector and wire harness
a. Check body controller connector B-012 and dome light ground point I-005 (See page 35-26).
b. Disconnect the body controller connectors B-021 and B-022.
c. Disconnect the front dome light connector C-003.

wire harness
OK

3 Check supply voltage of dome light
a. Disconnect the negative battery cable.

b. Disconnect the dome light connector C-003.
V
d. Using a digital multimeter, measure dome light connector + -
C-003 to check supply voltage and ground of dome light
Standard Condition
1 2 3
Condition
Connection Condition C-003
C-003 (1) - C-003

Always 12 V
(2)
C-003 (2) - C-003
Always 12 V
(6)
35 RA13T350800
RM1A370500
OK Replace corresponding dome light bulb
NG
4 Check dome light wire harness and connector

b. Disconnect the negative battery cable. 1 2 3 C-003
c. Disconnect the dome light connector C-003. 4 5 6
d. Disconnect the body controller connectors B-021 and B- + -

022.
e. Using a digital multimeter, measure resistance between ( ( ( ( ( ( ( ( (
dome light connector C-003 and body controller

connectors B-021 and B-022 to check for short or open ( ( ( ( ( ( ( ( ( ( (
circuit according to table below.

Standard Condition B-021
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
Condition
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
C-003 (2) - B-021
Always Continuity A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
(E16) RA13T350810
B-022
C-003 (6) - B-022
Always Continuity
(A27)
C-003 (1) - Body
Always Continuity
ground

wire harness

OK
5 Check dome light switch

c. Remove the dome light assembly.
d. Using a digital multimeter, measure dome light assembly + -
to check for damage according to table below.
Standard Condition
1 2 3
Condition
C-003
C-003 (6) - C-003 Dome light switch
Continuity
(1) in DOOR position
C-003 (6) - C-003
(2)
Dome light switch
ON
Continuity 35
NG Repair or replace dome light assembly RA13T350820

RM1A370500
OK
6 Replace BCM
a. Replace the BCM.

b. Connect related wire harness connectors.
OK

Luggage Compartment Light Diagnosis
BATTERY
ENGINE
COMPARTMENT
FUSE AND
SB02 SB04 EF23 EF21 EF16 EF18 RELAY BOX
30A 30A 15A 15A 15A 15A E-067
106 108 72 70 65 67
RG
RY
G
R
35 E-026 E-053
3 2
B
B-015 11 12 14 B-024
1
LUGGAGE
COMPARTMENT B-012
LIGHT
B-005
B
RG
RY
G
R
2
GR
Y
C7 C10 C2 C1 E20 D9 E16 A28 C3 C4
BCM(A/C/D/E) B-022 B-020 E-033 B-021
E-026 E-053
W
W
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13

( ( ( ( ( ( ( ( (
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
B-021
B-022
( ( ( ( ( ( ( ( ( ( (
B
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 B
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
' ' ' ' ' & & & & & & &
E-033 B-020 B-005
2 1
W B B
' ' ' ' ' ' '
& & & & & & &
EA13T350230


Luggage compartment light does
Ignition switch ON  Luggage compartment light
not operate
 BCM
CAUTION
Diagnosis Procedure
1 Check fuse

35
c. Remove luggage compartment light bulb, and check if bulb filament is blown.
NG Replace damaged luggage compartment

light bulb
OK
a. Disconnect the body controller connectors B-021 and B-022.

b. Disconnect the front luggage compartment light connector B-005.
c. Check if wire harnesses are worn, pierced, pinched or partially broken.
d. Check for broken, bent, protruded or corroded terminals.
e. Check if terminal contact pins of related connectors are in good condition.

wire harness
OK

3 Check supply voltage of luggage compartment light

b. Disconnect the luggage compartment light connector B-
005.
c. Connect the negative battery cable. V
+ -
d. Using a digital multimeter, measure luggage
compartment light connector B-005 to check supply
voltage of luggage compartment light according to table
below. 2 1
Standard Condition B-005
Condition
B-005 (1) - B-005
Back door opened 12 V
(2)
35 RA13T350830
RM1A370500
OK Replace corresponding luggage
compartment light bulb
NG
4 Check luggage compartment light wire harness and connector

2 1
c. Disconnect the luggage compartment light connector B-
005. B-005
+ -
d. Disconnect the body controller connectors B-021 and B-
022. ( ( ( ( ( ( ( ( (

luggage compartment light connector B-005 and body ( ( ( ( ( ( ( ( ( ( (
controller connectors B-021 and B-022 to check for short

or open circuit according to table below. B-021
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
Condition
B-005 (1) - B-021 A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
RM1A370500
(E16) B-022
B-005 (2) - B-022

Always Continuity
(A28)

wire harness

OK
5 Replace BCM
a. Replace the BCM.

b. Connect related wire harness connectors.
d. Check operation of luggage compartment light.
OK
35

Headlight Diagnosis
BATTERY
EF22
10A
30 86 30 86 ENGINE
LOW HIGH
COMPARTMENT
BEAM BEAM
FUSE AND
RELAY RELAY
RELAY BOX
87 85 87 85 E-067
EF33 EF03 EF34 EF04

15A 10A 15A 10A
87 16 35 88 36 8
RW
Lg
RY
Y
Y
Sb
35
RY
RW
B-024
9 5 4 E-053
RW
RY
Y
Sb
7 A43 A18 7 9
BCM(A/B) B-022 I-034
B23 A45 B12

B
5 LEFT 5 RIGHT
COMBINATION 17 B-019 COMBINATION
HEADLIGHT I-002 HEADLIGHT
E-061 E-049
HEADLIGHT COMBINATION
B
2 SWITCH I-030
B
LOW HI
LY
PARK BEAM FLASH BEAM

220
150
220
150
E-066 E-059
8 9
V
1 2 3 4 5 2 4 6 8 10 2 4 6 8 10
8 7 6 5 4 3 2 1 B-024 I-030 E-061
1 3 5 7
E-049
16 15 14 13 12 11 10 9
W 6 7 8 9 10 B 9 B 1 3 5 7 9
B
$ $ $ $ $ $ $ $ $ $ $ $ $
$ $ $ $ $ $ $ $ $ $ $ $ $
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
$ $ $ $ $ $ $ $ $ $ $ $ $
I-034
B-019 $ $ $ $ $ $ $ $ $ $ $ $ $ B
W
B-022 EA13T350240
B


Low beam light does not operate  Low beam light relay
High beam light does not operate  High beam light relay
 BCM
Light on one side does not operate
 Fuse
Ignition switch ON  Low beam control circuit short
to power supply
High beam and low beam lights do  Low beam control circuit short
not operate to power supply
 High beam control circuit short
to power supply
 High beam control circuit open
CAUTION
35
Malfunction Confirmation Procedure

Diagnosis Procedure
1 Check low beam light bulb and high beam light bulb

c. Remove left headlight bulb, and check if bulb filament is blown.
d. Remove right headlight bulb, and check if bulb filament is blown.
NG Replace headlight bulb
OK
2 Check fuse and relay
a. Remove fuses EF33 (15A), EF03 (10A), EF34 (15A) and EF03 (10A) from engine compartment fuse and
relay box.
b. Remove low beam light relay and high beam light relay from engine compartment fuse and relay box.
c. Check fuse and relay for blown and damage.
NG Repair or replace damaged fuse and relay
OK

a. Check the headlight ground points E-066 and E-059.

b. Disconnect body controller connectors I-034 and B-022 and engine compartment fuse and relay box
connector.
c. Disconnect the combination light switch connector I-030.

wire harness
OK
35 4 Check supply voltage of headlight

b. Disconnect the headlight connectors E-061 and E-049.
d. Turn on the headlight. V
+ -
2 4 6 8 10
e. Using a digital multimeter, measure headlight connectors
1 3 5 7 9
E-061 and E-049 to check supply voltage and ground of
headlight according to table below. E-061
Standard Condition
Condition 2 4 6 8 10
1 3 5 7 9
E-061 (7) - E-061

Always 12 V
(5) E-049
E-061 (9) - E-061

Always 12 V
(5) RA13T350850
RM1A370500
E-049 (9) - E-049

Always 12 V
(5)
E-049 (7) - E-049
Always 12 V
(5)
OK Replace corresponding headlight bulb
NG

5 Check headlight wire harness and connector

c. Disconnect the headlight connectors E-061 and E-049.
E-061
d. Using a digital multimeter, measure resistance between + - E-049
headlight connectors E-061, E-049 and engine
compartment fuse and relay box to check for short or
open circuit according to table below.
Standard Condition
Condition
EF34 15A
EF33 15A
E-061 (7) - EF33
Always Continuity
EF04 10A
EF03 10A
(15A)
E-061 (9) - EF03
(10A)
Always Continuity
RA13T350860
35
E-049 (7) - EF34
Always Continuity
(15A)
E-049 (9) - EF04
Always Continuity
(10A)

wire harness
OK
6 Check BCM wire harness and connector

d. Using a digital multimeter, measure resistance between + -
body controller connector B-022 and engine
compartment fuse and relay box to check for short or
open circuit according to table below.
85
86
85
86
Standard Condition
30 87
30 87

Condition
B-022 (A18) -
High beam relay Always Continuity A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
(85) A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022
B-022 (A43) - Low
beam relay (85)


wire harness
OK
7 Check combination light switch and connector

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
c. Disconnect the combination light switch connector I-030. B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
d. Disconnect the body controller connectors B-022 and I- + - I-034

034.
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
e. Using a digital multimeter, measure resistance between A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
combination light switch connector I-030 and body
controller connectors B-022 and I-034 to check for short
or open circuit according to table below. A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
35 Standard Condition
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022
Condition
Connection Condition 1 2 3 4 5
I-030
6 7 8 9 10
I-030 (2) - B-022
Always Continuity
(A45) RA13T350880
I-030 (8) - I-034
Always Continuity
(B23)
I-030 (9) - I-034
Always Continuity
(B12)
f. Remove the combination light switch.

g. Using a digital multimeter, measure resistance of
combination light switch to check for damage (See page
35-80).
NG Replace combination light switch
OK
8 Reconfirm DTCs

b. Start engine and turn on headlight.
c. Check if same DTC is output or same problem symptom occurs.
YES

ON-VEHICLE SERVICE
Combination Light Switch Assembly
Removal
3. Remove the driver airbag.
4. Remove the steering wheel (See page 28-8).
6. Remove the combination switch assembly.
a. Disconnect combination light switch connector (1) and
wiper switch connector (2).
35
1
2
RA13T350030
b. Loosen combination switch clamp, pull combination

switch outward, disconnect connection between
combination switch and steering column and remove
combination switch.
RA13T350040
c. Loosen combination switch clamp, pull combination

switch outward, disconnect connection between
combination switch and steering column and remove
combination switch.
RA13T350050

Inspection
1. Check the combination light switch.
a. Using ohm band of digital multimeter, measure
resistance between terminals as shown in table.
+ -
Combination light switch assembly (position light/low
beam light/high beam light switch)
6 7 8 9 10
Condition
Terminal 8 -
Always No continuity RA13T350060
Terminal 2
Terminal 8 -
Always 220 Ω
Terminal 2
Terminal 8 -
Always 150 Ω
Terminal 2
35 Terminal 9 -
Always 150 Ω
Terminal 2
Terminal 9 -
Always 330 Ω
Terminal 2
b. Using ohm band of digital multimeter, check for

continuity between terminals as shown in table.
+ -
Combination light switch assembly (daytime running
light/rear fog light switch)
6 7 8 9 10

Terminal 5 - Switch in front fog
Continuity RA13T350060
Terminal 2 light position
Terminal 3 - Switch in rear fog
Continuity
Terminal 2 light position
Terminal 5 -
Switch OFF No continuity
Terminal 2
Terminal 3 -
Switch OFF No continuity
Terminal 2
If result is not as specified, replace combination light

switch assembly.
c. Using ohm band of digital multimeter, measure
resistance between terminals as shown in table.
+ -
Combination light switch assembly (turn signal light
switch)
6 7 8 9 10

Terminal 10 - Switch in left turn
150 Ω RA13T350060
Terminal 2 position


Terminal 10 - Switch in right
150 Ω
Terminal 2 turn position
If result is not as specified, replace combination light

switch assembly.
Installation
CAUTION

normally.
35

Adjustment Switch Assembly

Removal
3. Remove the adjustment switch assembly.
both ends of adjustment switch to remove it.
- 3
2
RA13T350070
35 b. Disconnect adjustment switch wire harness connector

(arrow), and remove adjustment switch assembly.
RA13T350080
Inspection
1. Check the headlight leveling switch.
a. Check resistance of headlight leveling switch.
3
4
Multimeter Specified 5
Condition
Resistance value
Terminal 3 -
increases
Terminal 5
gradually
Turn headlight
Resistance value RA13T350090
Terminal 5 - leveling switch
decreases
Terminal 6 (level 0 to level 3)
gradually
Terminal 5 - Resistance value
Terminal 6 does not change
If result is not as specified, replace adjustment switch

assembly.

b. Check the headlight leveling front backlight

illumination. + -
3
5
Multimeter Switch Specified 6
Battery positive
(+) - Terminal 4 Backlight comes
Always
Battery negative on RA13T350100
(-) - Terminal 3
If result is not as specified, replace adjustment switch

assembly.
Installation
35

Warning Light Switch

Removal
3. Remove the A/C control panel assembly (See page 30-30).
4. Remove the warning light switch.
a. Disconnect warning light switch wire harness
connector (1) and A/C control panel connector (2).
2
35 RA13T350110
b. Remove the A/C control panel assembly.
Installation

Back-up Light Switch Assembly

Removal
WARNING
 Be sure to wear necessary safety equipment to prevent accidents, when removing back-up light switch.
 Check if safety lock of lift is locked when repairing or inspecting lifted vehicle.

4. Remove the back-up light switch assembly.
a. Disconnect the back-up light switch assembly wire
b. Remove the back-up light switch assembly (1). 35
RA13T350140
HINT:
Transmission oil may flow out when removing back-up light switch assembly. Use a container to collect the
oil.
 Drained transmission oil should be collected with a recovering tool.
Inspection
1. Check the back-up light switch assembly.
a. Using ohm band of digital multimeter, check for
continuity between terminals of back-up light switch
+ -
assembly as shown in table.
Standard Condition
1 2
Condition
Terminal 1 -
Switch pushed Continuity
Terminal 2
RA13T350150
Terminal 1 -
Switch released No continuity
Terminal 2

Installation
1. Apply thread locker to threads of back-up light switch assembly, and clean transmission oil on the area
between transmission and back-up light switch assembly, before installing back-up light switch assembly.
Then install back-up light switch assembly securely.
2. Check if transmission oil level is in proper position after installation.
a. If oil level is not in proper position, it is necessary to fill transmission oil to specified position (fill oil until
it flows out of retaining plug).
35

Front Dome Light Assembly

Removal
3. Remove the front dome light assembly.
tape, remove front dome light assembly cover.
RA13T350160
b. Remove 2 fixing screws (arrow) from front dome light

assembly.
35
RA13T350170
c. Disconnect front dome light assembly wire harness

connector (arrow), and remove front dome light
assembly.
RA13T350180
Inspection
1. Check the front dome light assembly.
a. Measure front dome light assembly as shown in table.
1 2 3
4 5 6
Condition
Battery positive
(+) - Terminal 2 Dome light switch Dome light comes
Battery negative in DOOR position on
(-) - Terminal 6
RA13T350190

Condition
Battery positive
(+) - Terminal 2 Dome light switch Dome light comes
Battery negative ON on
(-) - Terminal 1
If result is not as specified, replace front dome light

assembly.
Installation
35

Headlight Assembly
Removal
HINT:
Removal procedures listed below are for left side.
4. Remove the headlight assembly.
a. Remove 2 fixing bolts from upper part of headlight
assembly.
35
RA13T350200
b. Remove 1 fixing bolt (arrow) from front bumper left

mounting bracket, and 1 fixing bolt (arrow) on front
part.
RA13T350210
c. Disconnect headlight assembly wire harness

connectors (arrow), and remove headlight assembly.
RA13T350220
Installation

CAUTION
 When installing headlight assembly, make sure headlight assembly is well fitted with hood, front wing
and front bumper. Adjust as necessary.
Adjustment
1. Preparations:
a. Tire inflation pressure comes up to standard.
b. Vehicle is unloaded (besides spare tire and tool kit, it is generally specified to include the weight of
driver).
c. Park vehicle on a level ground or a workplace.
d. Keep lens surface of headlight assembly free from dirt.
e. Check if power supply operates normally and bulbs are installed correctly.
Headlight beam can be adjusted up and down, left and right by using headlight leveling switch or adjustment
area at the rear of headlight. Always perform adjustment according to the international standard.
35
No. Item Standard
Up and down offset of left/right low beam
1 570 - 630 mm
light
2 High beam light intensity > 30000 cd
2. Headlight leveling can be adjusted according to number of passengers and loading condition. There are 4
adjustment bands to be selected on headlight leveling knob: 0, 1, 2 and 3.
Turn up: Raise headlight beam.
Turn down: Lower headlight beam.
Adjust light according to table below.
Passenger and Luggage Loading Condition

Knob Position
Occupant Luggage Loading
Driver None 0
Driver + Front Passenger None 0
Full Occupied None 1
Full Occupied Full luggage loading 2
Driver Full luggage loading 3
3
2
1
O
RA13T350230

CAUTION
 Whether headlight leveling is correct or not will directly affects driving safety. Be sure to adjust the beam
with special tool according to related specification.
3. Manual headlight leveling: headlight leveling can be changed by adjusting the following areas manually as
Adjustment method for left headlight
a. Low beam up/down adjustment
When rotating inner hexagon wrench clockwise, the 1
beam moves downward;
When rotating inner hexagon wrench
counterclockwise, the beam moves upward.
b. Low beam left/right adjustment
When rotating inner hexagon wrench clockwise, the
beam moves to right; 35
counterclockwise, the beam moves to left.
2
RA13T350240
c. High beam up/down adjustment

When rotating inner hexagon wrench clockwise, the 1
beam moves downward;
counterclockwise, the beam moves upward.
d. High beam left/right adjustment
When rotating inner hexagon wrench clockwise, the
beam moves to right;
counterclockwise, the beam moves to left.
2
RA13T350250

Daytime Running Light Assembly

Removal
HINT:
3. Raise vehicle on a lift.
5. Remove the daytime running light assembly.
a. Disconnect the daytime running light assembly wire
harness connector.
b. Remove 3 fixing screws (arrow) from daytime running
light assembly.
35
RA13T350270
c. Remove daytime running light assembly from back side of front bumper mounting hole.
Installation

Rear Combination Light Assembly

Removal
HINT:
Use same procedures for rear right and rear left sides.
Procedures listed below are for rear left side.
3. Remove the rear combination light assembly.
a. Remove 3 fixing screws from upper part of rear left
combination light.
35
RA13T350280
b. Remove 1 rear left combination light fixing nut from

interior, and then remove rear combination light
connector.
RA13T350290
c. Remove the rear left combination light assembly.
Installation
CAUTION
 When installing rear combination light assembly, make sure rear combination light assembly is well fitted
with rear bumper. Adjust as necessary.

Rear Fog Light

Removal
HINT:
Use same procedures for rear fog light and back-up light.
Procedures listed below are for rear fog light.
3. Remove the rear bumper assembly (See page 49-21).
4. Remove the rear fog light assembly.
a. Disconnect the daytime running light assembly wire
harness connector.
35
RA13T350320
b. Remove 4 fixing bolts (arrow) from rear fog light

assembly, and then remove rear fog light.
RA13T350330
Installation
High Mounted Stop Light Assembly

Removal
4. Remove the high mounted stop light assembly (See page 49-32).
Installation

License Plate Light Assembly

Removal
HINT:
4. Remove the license plate light assembly.
a. Remove the license plate light wire harness
connector.
35
RA13T350340
b. Press clip on license plate light to lower right direction

to detach license plate light from license plate light
protector, and then remove license plate light
assembly.
RA13T350350
Installation

Luggage Compartment Light Assembly

Removal
3. Remove the luggage compartment light assembly.
a. Open the luggage compartment door.
up one end of luggage compartment light.
35 RA13T350370
c. Disconnect the luggage compartment light assembly

wire harness connector (arrow).
RA13T350380
d. Remove the luggage compartment light assembly.
Installation

WIPER AND WASHER
Description 36-3 Front Washer Nozzle Assembly 36-34
Tool 36-4 Inspection 36-34
Rear Wiper Arm Assembly 36-36
Removal 36-36
Installation 36-37
Diagnosis Tools 36-8
Rear Wiper Motor Assembly 36-38
Removal 36-38
Chart 36-10
Inspection 36-39
B1014-71 36-11
Installation 36-39
B1015-71 36-11
Rear Washer Nozzle Assembly 36-40
B1017-71 36-11
Removal 36-40
B1016-71 36-20
Inspection 36-40
B1009-71 36-20
Installation 36-41
ON-VEHICLE SERVICE 36-27 Washer Pump Assembly 36-42
36
Wiper Switch Assembly 36-27 Removal 36-42
Inspection 36-28 Inspection 36-43
Installation 36-28 Washer Fluid Reservoir Assembly 36-44
Front Wiper Arm Assembly 36-29 Removal 36-44
Removal 36-29 Inspection 36-45
Front Wiper Motor Assembly 36-31 Washer Line Assembly 36-46

36

36 - WIPER AND WASHER
GENERAL INFORMATION
WIPER AND WASHER
Description
3 1
2
4
×3
36
10
9
11
12
14
13
15
20
19 18 ×3
×2
17 16
RA13T360010

1 - Rear Wiper Arm Trim Cap 2 - Rear Wiper Arm Assembly

3 - Rear Wiper Arm Blade 4 - Rear Washer Nozzle Assembly
5 - Grommet 6 - Rear Wiper Motor Assembly
7 - Washer Line Assembly 8 - Main Wiper Arm
9 - BladeMain Wiper Arm Assembly 10 - Sub Wiper Arm Blade
11 - Sub Wiper Arm Assembly 12 - Front Washer Nozzle Assembly
13 - Front Wiper Arm Trim Cap 14 - Front Windshield Lower Support Assembly
15 - Wiper Link Rod 16 - Front Wiper Motor Assembly
17 - Guide Pipe Assembly 18 - Washer Fluid Reservoir Assembly
19 - Washer Pump 20 - Washer Line Assembly
Wiper and washer equipment, controlled by wiper switch assembly, is important for cleaning the front
windshield. It only operates when ignition switch is ON. Driver operates control lever of wiper switch
assembly, to control all operations of wiper and washer system.
Specifications
36

Front Wiper Arm Assembly Fixing Nut 18 ± 1
Wiper Motor and Link Rod Assembly Fixing Bolt 9±1
Front Wiper Motor Assembly Fixing Nut 18 ± 1
Rear Wiper Arm Assembly Fixing Nut 10 ± 1
Rear Wiper Motor Assembly Fixing Bolt 10 ± 1
Washer Fluid Reservoir Assembly Fixing Bolt 10 ± 1
Tool
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Wiper and Washer Systems (Page 1 of 2)
ENGINE
COMPARTMENT IP FUSE
FUSE AND RF01 RF26 AND
RELAY BOX RELAY BOX
30A 30A 15A 15A 15A 15A 10A 10A
E-067 I-032
7 55
106 108 72 70 65 67
RG
RY
G
R
RY
R
RL
E-026 3 2 E-053
B-015 11 12 14 B-024
Gr
RG
RY
G
R
C7 C10 C2 C1 E20 D9 B17 B5
BCM(A/B/C/D/E) B-022 I-034 B-020 E-033 B-021
B8 B22 B19 B21 B24 B20 A45
36
B
17 B-019
Lg
WR
YW
VW
YR
P
I-002
B
1 2 9 7 10 4 3
MIST
OFF OFF
WIPER
INT
WIPER
LO WIPER/WASH AND
(AUTO RETURN) WASHER
HI
WIPER/WASH SWITCH
MIST (AUTO RETURN) 3000 1000 332 0 I-029
OFF
OFF
INT
LO WIPER
HI WIPER/WASH(AUTO RETURN)
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 F2 F3 F4 F5 F6 F7 F8 F9 F:
B-022 B-021
B B
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 F21 F22 F23 F24 F25 F26 F27 F28 F29 F2: F31
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
2 3 4 5 6 7 8 9 D2 D3 D4 D5 D6 D7 D8
9 8 7 6 5 4 3 2 E2 E3 E4 E5 E6
27 26 25 24 23 22 21 : : 21 22 23 24 25 26 27 E-033
D9 D: D21 D22 D23 D24 D25 E7 E8 E9 E: E21 E22 E23 W
E-026
W E-053
W B-020
B
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 I-002
W I-029 W
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
10 9 8 7 6 B 20 19 18 17 16 15 14 13 12 11
EA13T360010

Wiper and Washer Systems (Page 2 of 2)
BATTERY
EF29
25A
ENGINE
30 86 30 86 COMPARTMENT
LOW HIGH
FUSE AND
WIPER WIPER
RELAY BOX
RELAY RELAY
E-067
87 85 87 85
140 32 62 141 63
B
RB
R
2 4
LOW
GY
YB
WIPER REAR
E-066 HIGH MOTOR WIPER
M E-031 M MOTOR
T-004
36 3 1
B
WASHER 3 1 2
LW
YR
M MOTOR
G
B
E-066 E-057
T-001
1 2 1 6 5 B-001
E-032
7 8 6
G
B-014
YR
B-006
YB
B
LW
GY
YB
B-014 3
E-032 G
A42 A30 A24 D5 D12 D10 A26
BCM(A/D) B-022 E-033
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 E2 E3 E4 E5 E6
B-022 E-033
B E7 E8 E9 E: E21 E22 E23 W
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
5 4 3 2 1
5 4 3 2 1
10 9 8 7 6 1 2 1 2 3
1 2 3 4 5 6 7 8 9
E-031
10 11 12 13 14 15 16 17 18
B
T-004
E-057 W
Gr
B-014
W
B-001
W
EA13T360020

DIAGNOSIS & TESTING

HINT:

Fuse 55-30
Wiper switch assembly 36-27
Both front wiper and washer systems do
Washer pump 36-42
not operate
BCM 46-18
Front wiper system does not operate in LO Front wiper motor assembly 36-31
or HI BCM 46-18
36
Wiper switch assembly -
Front wiper motor assembly 36-31
Front wiper system does not operate in INT
BCM 46-18
Fuse 55-30
Wiper switch assembly -
Front wiper system does not operate Front wiper motor assembly 36-31
BCM 46-18
Front wiper motor assembly 36-31
Front wiper arm and blade do not return to
original position when front wiper switch is BCM 46-18
off
Fuse 55-30
Both rear wiper and washer systems do not Rear wiper motor assembly 36-38
operate Washer pump 36-42
BCM 46-18


Fuse 55-30
Rear wiper system does not operate Rear wiper motor assembly 36-38
BCM 46-18
Rear washer nozzle assembly 36-40
Rear washer system does not operate Washer pump 36-42
BCM 46-18
Diagnosis Tools
36 When connecting X-431 3G diagnostic tester:
with vehicle.
 DLC is located at driver side lower left protector.
Digital Multimeter
 Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC), and make it
 Use X-431 3G diagnostic tester to record and clear DTCs stored in Body Control Module (BCM).
 If no DTC is detected, malfunction indicated by DTC is intermittent. Please refer to Intermittent DTC
Troubleshooting.


 Inspect mounting areas of wiper motor assembly, wire harness or wire harness connector and so on for
 Check and clean all wire harness connectors and grounds related to DTC.
 Remove Body Control Module (BCM) from malfunctioning vehicle, then install it to a new vehicle and
perform a test. If DTC cannot be cleared, Body Control Module (BCM) is malfunctioning. If DTC can be
cleared, reinstall Body Control Module (BCM) to original vehicle.
power supply circuit applied to DTC.
Ground Inspection
(rust) and oxidation may increase load resistance. This situation will seriously affect normal operation of
36
Diagnosis Procedure
HINT:
Use following procedures to troubleshoot the wiper and washer systems.
NEXT
NEXT
NEXT
DTC
occurs

NEXT
NEXT
NEXT
NEXT
36
NEXT
NEXT
10 End

B1014-71 Front Wiper Low Speed Control Circuit
B1015-71 Front Wiper High Speed Control Circuit
B1016-71 Rear Washer Control Circuit
B1017-71 Front Washer Control Circuit
B1009-71 Rear Wiper Control Circuit

DTC B1014-71 Front Wiper Low Speed Control Circuit
DTC B1015-71 Front Wiper High Speed Control Circuit
DTC B1017-71 Front Washer Control Circuit

DTC Detection Warning Light

DTC Code DTC Definition Possible Cause
Condition Condition
Front Wiper Low  Front wiper motor
B1014-71
Speed Control Circuit assembly
Front Wiper High Relay
B1015-71
Speed Control Circuit  Wiper switch
assembly
Ignition switch ON ON
 Washer pump
Front Washer Control  Wire harness or
B1017-71 connector
Circuit
 Body Control 36
Module (BCM)

BATTERY
EF29
25A
ENGINE
30 86 30 86 COMPARTMENT
LOW HIGH
FUSE AND
WIPER WIPER
RELAY BOX
RELAY RELAY
E-067
87 85 87 85
140 32 62 141 63
B
RB
R
2 4
LOW
GY
YB
WIPER
E-066 HIGH MOTOR
M E-031
3 1
B
36 WASHER
LW
M MOTOR
E-066 E-057
1 2
E-032
B-014 7 8 6
YB
B
LW
GY
YB
A42 A30 A24 D5 D12
BCM(A/D) B-022 E-033
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 ' ' ' ' '
B-022 E-033
B ' ' ' ' ' ' ' W
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
5 4 3 2 1
1 2
E-031
B
E-057
Gr
EA13T360030

CAUTION
Diagnosis Procedure
1 Check if front wiper motor assemblies operate
a. Check the wiper motor fuse.
NG Replace fuse
OK
2 Check wiper switch assembly
a. Remove wiper switch assembly from malfunctioning vehicle, and install it to a new vehicle and perform a 36
test.
NG Replace wiper switch assembly
OK
3 Check front wiper motor assembly
a. Remove front wiper motor assembly from malfunctioning vehicle, and install it to a new vehicle and
perform a test.
NG Replace front wiper motor assembly
OK
4 Check washer pump
a. Remove washer pump from malfunctioning vehicle, and install it to a new vehicle and perform a test.
NG Replace washer pump
OK
5 Check switch connector and BCM connector

c. Disconnect switch connector I-029 and BCM connector I-034.


switch connector I-029 and BCM connector I-034
Multimeter Specified + -
Condition
I-029 (1) - I-034 Always Continuity B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
(B8) B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
I-034
I-029 (2) - I-034 Always Continuity
(B22)
I-029 (10) - I-034 Always Continuity 5 4 3 2 1
(B24) 10 9 8 7 6
I-029
(B20)
e. Disconnect switch connector I-029 and wire harness RA13T360330

connector I-002.
switch connector I-029 and wire harness connector I-002
36 according to table below.
Condition
10 9 8 7 6 5 4 3 2 1
(17) 20 19 18 17 16 15 14 13 12 11
I-002
g. Disconnect BCM connector B-022 and wire harness
connector B-019.
5 4 3 2 1
10 9 8 7 6
I-029
RA13T360340

BCM connector B-022 and wire harness connector B-019
Condition
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
B-022 (A45) - Always Continuity A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
B-019 (17)
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
NG Repair or replace body wire harness and A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
connector B-022
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
B-019
RA13T360350

OK
6 Check front wiper motor connector and enginecompartment fuse and relay box connector

c. Disconnect front wiper motor connector E-031 and
engine compartment fuse and relay box connector E-
067.
front wiper motor connector E-031 and engine
compartment fuse and relay box connector E-067
according to table below. 5 4 3 2 1
+ - E-031
Condition
30
87
E-031 (2) - E-067 Always Continuity 86 85
(141)
E-031 (4) - E-067 Always Continuity 36
(63)
e. Check BCM connector B-022 and wire harness

connector B-014.
RA13T360360

Condition 1 2 3 4 5 6 7 8 9
Connection Condition 10 11 12 13 14 15 16 17 18
B-022 (A24) - Always Continuity

B-014 (6) B-014
g. Disconnect front wiper motor connector E-031 and wire

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
harness connector E-032.
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022
RA13T360370


front wiper motor connector E-031 and wire harness
connector E-032 according to table below.
Condition
E-031 (3) - E-032 Always Continuity 5 4 3 2 1
(6) E-031
i. Disconnect front wiper motor connector E-031 and

ground point E-066.
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
E-032
RA13T360380

front wiper motor connector E-031 and ground point E-
36
Condition
E-031 (1) - E-066 Always Continuity 5 4 3 2 1
E-031

wire harnessand connector
RA13T360390
OK
7 Check BCM connector and engine compartmentfuse and relay box connector

c. Check BCM connector B-022 and wire harness
connector B-014.


Condition 1 2 3 4 5 6 7 8 9
B-022 (A30) - B- Always Continuity

014 (8) B-014
B-022 (A42) - B- Always Continuity

014 (7) A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
e. Disconnect engine compartment fuse and relay box
connector E-067 and wire harness connector E-032. A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022
RA13T360400

engine compartment fuse and relay box connector E-067
and wire harness connector E-032 according to table 9 8 7 6 5 4 3 2 1
below. 18 17 16 15 14 13 12 11 10 36
+ -
E-032
Condition
30
87
E-067 (62) - E- Always Continuity 86 85
032 (8)
E-067 (32) - E- Always Continuity
032 (7)
g. Disconnect the front wiper motor connector E-067.
RA13T360410

front wiper motor connector E-067 and ground point E-
066 according to table below. 85
30 87
86
Condition
E-067 (140) - E- Always Continuity
066

wire harnessand connector
RA13T360420

OK
8 Check washer motor connector and BCM connector

c. Disconnect washer motor connector E-057 and BCM connector E-033.
washer motor connector E-057 and BCM connector E-
Condition 1 2
E-057 (1) - E-033 Always Continuity E-057
(D5)
E-057 (2) - E-033 Always Continuity
(D12) ' ' ' ' '
36 ' ' ' ' ' ' '

connector
E-033
RA13T360430
OK
9 Reconfirm DTCs
a. Connect all connectors.

b. Connect the negative battery cable.
c. Turn ignition switch to ON.
d. Use X-431 3G diagnostic tester (the latest software) to record and clear DTCs stored in Body Control
Module (BCM).
e. Turn ignition switch to LOCK and wait for a few seconds.
f. Turn ignition switch to ON.
g. Use X-431 3G diagnostic tester (the latest software) to read DTCs stored in Body Control Module (BCM)
again.
h. Read DTCs.
Result Proceed to
DTCs B1014-71, B1015-71, B1017-7 are output NG
No DTC is output OK
NG Replace Body Control Module (BCM)

OK
System is normal
36

DTC B1016-71 Rear Washer Control Circuit
DTC B1009-71 Rear Wiper Control Circuit

DTC Detection
Condition
Rear Washer Control  Wiper switch assembly
B1017-71
Circuit  Washer pump
Rear Wiper Control
B1009-71  Body Control Module (BCM)
Circuit
 Rear wiper motor assembly
36

REAR
WIPER
M MOTOR
T-004
WASHER 3 1 2
YR
M MOTOR
G
B
E-057
T-001
1 2 1 6 5 B-001
G
36
YR
B-006
YB
B-014 3
E-032
G
D5 D12 D10 A26
BCM(A/D) B-022 E-033
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 ' ' ' ' '
B-022 E-033
B ' ' ' ' ' ' ' W
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
5 4 3 2 1
10 9 8 7 6 1 2 1 2 3
T-004
E-057 W
Gr
B-001
W
EA13T360040

CAUTION
Diagnosis Procedure
1 Check if rear wiper motor assemblies operate
a. Check the wiper motor fuse.
NG Replace fuse
OK
2 Check wiper switch assembly
36 a. Remove wiper switch assembly from malfunctioning vehicle, and install it to a new vehicle and perform a
test.
NG Replace wiper switch assembly
OK
3 Check washer pump
a. Remove washer pump from malfunctioning vehicle, and install it to a new vehicle and perform a test.
NG Replace washer pump
OK
4 Check rear wiper motor assembly
a. Remove rear wiper motor assembly from malfunctioning vehicle, and install it to a new vehicle and perform
a test.
NG Replace rear wiper motor assembly
OK
5 Check switch connector and BCM connector

c. Disconnect switch connector I-029 and BCM connectors I-034 and B-022.


switch connector I-029 and BCM connector I-034, and
continuity between switch connector I-029 and BCM 5 4 3 2 1
connector B-022 according to the table below. 10 9 8 7 6
+ -
I-029
Condition
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
I-029 (9) - I-034 Always Continuity B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
(B19) I-034

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
(B21)
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
I-029 (3) - B-022 Always Continuity
(A45) A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
NG Repair or replace body wire harness and B-022

connector RA13T360431
OK
36
6 Check rear wiper motor connector and BCM connector

c. Disconnect rear wiper motor connector T-004 and wire harness connector T-001.
rear wiper motor connector T-004 and wire harness
connector T-001 according to table below.
Condition 1 2 3 4 5
6 7 8 9 10
T-004 (2) - T-001 Always Continuity

(5) T-001

(6)
T-004 (3) - T-001 Always Continuity 1 2 3
(1)
T-004
e. Disconnect the wire harness connector B-001.
RA13T360432


wire harness connector B-001 and ground point B-006
Multimeter Specified + - 5 4 3 2 1
Condition
B-001 (1) - B-006 Always Continuity
g. Disconnect wire harness connector B-001 and BCM

connector B-022. B-001
RA13T360440

wire harness connector B-001 and BCM connector B-022
36
5 4 3 2 1
10 9 8 7 6
Condition
(A26) B-001
i. Disconnect wire harness connectors B-001 and B-014.

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022
RA13T360450

wire harness connectors B-001 and B-014 according to
table below.
5 4 3 2 1
10 9 8 7 6
Condition
(3)
B-001
k. Disconnect wire harness connector E-032 and BCM

connector E-033.
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B-014
RA13T360460

l. Using a digital multimeter, check for continuity between

wire harness connector E-032 and BCM connector E-033
Condition 9 8 7 6 5 4 3 2 1

(D10)
NG Repair or replace wire harness or ' ' ' ' '

connector
' ' ' ' ' ' '
E-033
RA13T360470
OK
36
7 Check washer motor connector and BCM connector

c. Disconnect washer motor connector E-057 and BCM
connector E-033.
washer motor connector E-057 and BCM connector E-
Condition 1 2
(D5)
E-057 (2) - E-033 Always Continuity
(D12) ' ' ' ' '
' ' ' ' ' ' '

connector
E-033
RA13T360430
OK
8 Reconfirm DTCs


d. Use X-431 3G diagnostic tester (the latest software) to record and clear DTCs stored in Body Control
Module (BCM).
g. Use X-431 3G diagnostic tester (the latest software) to read DTCs stored in Body Control Module (BCM)
again.
h. Read DTCs.
Result Proceed to
DTCs B1016-71, B1009-71 are output NG
No DTC is output OK
OK
System is normal
36

ON-VEHICLE SERVICE
Wiper Switch Assembly
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing wiper switch assembly.
 Appropriate force should be applied when removing wiper switch assembly. Be careful not to operate
roughly.
 Try to prevent interior and body paint surface from being scratched, when removing wiper switch
assembly.

4. Remove the wiper switch assembly.
36
a. Disconnect the wiper switch assembly connector
(arrow).
MIST
OFF
INT
PULL LO
HI
RA13T360020
b. Using a screwdriver wrapped with protective tape,

press claws on wiper switch assembly and remove
VOL
wiper switch assembly by gently sliding it outward.
ON
INT
OFF
MISTF
OF
INT
PULL LO
HI
AIRBAG
SRS
RA13T360030

Inspection
1. Check the wiper switch assembly.
a. Using a digital multimeter, check for continuity
between terminals of wiper switch assembly
+ -
AR
RE
1 2 3 4 5
Terminal 1 -
MIST Continuity 6 7 8 9 10
Terminal 3
Terminal 2 -
INT Continuity RA13T360040
Terminal 3
Terminal 1 -
LO Continuity
Terminal 3
Terminal 1, 2 -
HI Continuity
Terminal 3
Terminal 3 -
Rear wiper ON Continuity
Terminal 7
36 Terminal 3 -
FRONT WASHER Continuity
Terminal 4
Terminal 3, 7 -
REAR WASHER Continuity
Terminal 9
If result is not as specified, replace wiper switch

assembly.
Installation
CAUTION
 Always operate carefully to prevent components from being damaged, when installing wiper switch
assembly.
 Install connectors in place, when installing wiper switch assembly.
 Check wiper switch for proper operation, after installing wiper switch assembly.

Front Wiper Arm Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing front wiper arm assembly.
 Appropriate force should be applied when removing front wiper arm assembly. Be careful not to operate
roughly.
 Try to prevent front windshield assembly from being scratched, when removing front wiper arm
assembly.

3. Remove the front wiper arm blade.
a. Raise front wiper arm assembly in direction of arrow
36
RA13T360050
b. Pull out front wiper arm blade from front wiper arm
assembly in direction of arrow as shown in illustration.
SH
B
RA13T360060
4. Remove the front wiper arm assembly.

a. Using a screwdriver wrapped with protective tape,
remove front wiper arm trim caps (1). 1
b. Remove 2 fixing nuts (arrow) from front wiper arm
assembly, and remove front wiper arm assembly.
RA13T360070

Installation
CAUTION
 Always operate carefully to prevent other components from being damaged, when installing front wiper
arm assembly.
 Be sure to tighten fixing nuts to specified torque, when installing front wiper arm assembly.
 Check front wiper arm assembly for proper operation, after installing front wiper arm assembly.
HINT:
 Always adjust front wiper arm assembly to a proper
position during installation.
 Pay attention to locating points on front windshield
assembly during installation. Wiper arm blade should be
pressed against locating points as shown in illustration.
36 RA13T360080

Front Wiper Motor Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing front wiper motor assembly.
 Appropriate force should be applied when removing front wiper motor assembly. Be careful not to
operate roughly.
 Try to prevent body paint surface from being scratched, when removing front wiper motor assembly.

3. Remove the front wiper arm assembly (See page 36-29).
4. Remove the front windshield lower support assembly (See page 49-29).
5. Remove the wiper motor and link rod assembly.
a. Disconnect connector (1) from wiper motor and link
rod assembly. 36
1
b. Remove 3 fixing bolts (arrow) from wiper motor and
link rod assembly.
RA13T360090
c. Remove the wiper motor and link rod assembly.

6. Remove the front wiper motor assembly.
a. Remove fixing nut (1) from front wiper motor
assembly.
b. Remove 3 fixing bolts (arrow) from front wiper motor
assembly.
1
RA13T360100
c. Separate front wiper motor assembly from wiper link rod.

Inspection
1. Check the front wiper motor assembly.
a. Check the LO operation.
Measurement Condition Specified Condition

Battery negative (-) → Terminal 1
Motor running at low speed (LO)
Battery positive (+) → Terminal 2
If result is not as specified, replace front wiper motor assembly.

b. Check the HI operation.

Motor running at high speed (HI)
If result is not as specified, replace front wiper motor assembly.

c. Check the auto reset function.
+ -
36  Connect positive (+) battery lead to terminal 2 or 4,
and negative (-) battery lead to terminal 1. When
motor is running at low speed (LO) or high speed
(HI), disconnect battery positive (+) to stop front
wiper motor at any position other than the original
position.
 Connect terminals 2 and 3 with a lead, connect 1 2 3 4 5
another lead extending from center to positive (+)
battery lead, and connect negative (-) battery lead RA13T360110
to terminal 1 to run motor to the original position at
low speed (LO).
 Check if front wiper motor assembly can stop
automatically after running to the original position.
OK: Motor stops automatically after running to the
original position, which indicates that motor can
reset automatically. If result is not as specified,
replace front wiper motor assembly.
2. Check the wiper link rod.
a. Check pivot (1) for looseness or falling off, link rod (2)
for deformation or breakage, and shaft sleeve (3) for
seizure. Replace wiper link rod if necessary. 3
2
RA13T360120

Installation
CAUTION
 Always operate carefully to prevent other components from being damaged, when installing front wiper
motor assembly.
 Adjust and make sure wiper motor and link rod is at original position, before installing front wiper motor
assembly, otherwise, wiper system cannot operate normally.
 Install connector in place and tighten fixing bolts and nuts to specified torque, when installing front wiper
motor assembly.
 Check wiper system for proper operation, after installing front wiper motor assembly.
36

Front Washer Nozzle Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing front washer nozzle assembly.
 Appropriate force should be applied when removing front washer nozzle assembly. Be careful not to
operate roughly.

4. Remove the front washer nozzle assembly.
a. Loosen front washer nozzle assembly in direction of
arrow as shown in illustration.
36
RA13T360130
b. Remove the front washer nozzle assembly.
Inspection
1. Check the front washer nozzle assembly.
a. Check front washer nozzle for blockage, deformation
or damage. Replace front washer nozzle if necessary.
RA13T360140

Installation
CAUTION
 Always operate carefully to prevent components from being damaged, when installing front washer
nozzle assembly.
 Install washer line joints in place, when installing front washer nozzle assembly.
 Check front washer nozzle for proper operation, after installing front washer nozzle assembly.
36

Rear Wiper Arm Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing rear wiper arm assembly.
 Appropriate force should be applied when removing rear wiper arm assembly. Be careful not to operate
roughly.
 Try to prevent rear windshield assembly from being scratched, when removing rear wiper arm assembly.

3. Remove the rear wiper arm blade.
a. Raise rear wiper arm assembly in direction of arrow
36
RA13T360150
b. Pull out rear wiper arm blade from rear wiper arm
assembly in direction of arrow as shown in illustration.
RA13T360160
4. Remove the rear wiper arm assembly.

a. Remove the rear wiper arm trim cap (1).
b. Remove fixing nut (arrow) from rear wiper arm
assembly.
1
RA13T360170
c. Remove the rear wiper arm assembly.

Installation
CAUTION
 Always operate carefully to prevent other components from being damaged, when installing rear wiper
arm assembly.
 Be sure to tighten fixing nuts to specified torque, when installing rear wiper arm assembly.
 Check rear wiper arm assembly for proper operation, after installing rear wiper arm assembly.
36

Rear Wiper Motor Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing rear wiper motor assembly.
 Appropriate force should be applied when removing rear wiper motor assembly. Be careful not to operate
roughly.
 Try to prevent body paint surface from being scratched, when removing rear wiper motor assembly.

3. Remove the rear wiper arm assembly (See page 36-36).
4. Remove the back door protector assembly (See page 48-40).
5. Remove the rear wiper motor assembly.
a. Disconnect the rear wiper motor assembly connector
36 (1).
b. Remove 3 fixing bolts (arrow) from rear wiper motor
1
assembly.
RA13T360180
c. Remove the rear wiper motor assembly.

d. Using a screwdriver wrapped with protective tape, pry
out the grommet (arrow).
RA13T360190

Inspection
1. Check the rear wiper motor assembly.
a. Check operation of rear wiper motor assembly.

Motor runs normally
If result is not as specified, replace rear wiper motor assembly.

b. Check the auto reset function.
+ -
 Connect positive (+) battery lead to terminal 3, and
negative (-) battery lead to terminal 1. When motor
is running, disconnect battery positive (+) to stop 1 2 3
rear wiper motor at any position other than the

auto stop position.
 Connect positive (+) battery lead to terminal 3 and
negative (-) battery lead to terminal 2 to make the
motor run again.
 Check that motor can reset automatically. RA13T360200
36
OK: Motor can reset automatically.
If result is not as specified, replace rear wiper
motor assembly.
2. Check grommet for deterioration, deformation or damage. Replace grommet with a new one if necessary.
Installation
CAUTION
 Always operate carefully to prevent other components from being damaged, when installing rear wiper
motor assembly.
 Tighten fixing bolts to specified torque, when installing rear wiper motor assembly.
 Check wiper system for proper operation, after installing rear wiper motor assembly.

Rear Washer Nozzle Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing rear washer nozzle assembly.
 Appropriate force should be applied when removing rear washer nozzle assembly. Be careful not to
operate roughly.

3. Remove the back door protector assembly (See page 48-40).
4. Remove the rear spoiler assembly (See page 49-32).
5. Remove the rear washer nozzle assembly.
a. Disconnect joint (arrow) between washer line and rear
washer nozzle.
36
RA13T360210
b. Press claws (arrow) on rear washer nozzle assembly

as shown in illustration, and remove rear washer
nozzle assembly.
RA13T360220
Inspection
1. Check the rear washer nozzle assembly.
a. Check rear washer nozzle assembly for blockage,
deformation or damage. Replace rear washer nozzle
if necessary.
RA13T360230

Installation
CAUTION
 Always operate carefully to prevent components from being damaged, when installing rear washer
nozzle assembly.
 Install washer line joints in place, when installing rear washer nozzle assembly.
 Check rear washer nozzle for proper operation, after installing rear washer nozzle assembly.
36

Washer Pump Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing washer pump assembly.
 Appropriate force should be applied when removing washer pump assembly. Be careful not to operate
roughly.
 Try to prevent body paint surface from being scratched, when removing washer pump assembly.

3. Remove the wing (See page 49-15).
4. Remove front and rear washer pump assemblies.
CAUTION
36
Put a container under washer pump to collect washer fluid, before removing washer pump assembly.
a. Disconnect front and rear washer pump connectors

(1).
b. Disconnect joint (2) between front washer line and
washer pump and joint (3) between rear washer line 1
and washer pump.
2 3
RA13T360240
c. Using a screwdriver wrapped with protective tape,

remove the washer pump assembly (arrow).
RA13T360250

Installation
CAUTION
 Always operate carefully to prevent components from being damaged, when installing washer pump
assembly.
 Install washer line joint in place, when installing washer pump assembly.
 Check washer system for proper operation, after installing washer pump assembly.
Inspection
1. Check the washer pump assembly.
a. Fill washer fluid reservoir assembly with washer fluid.
b. Connect positive (+) battery lead to terminal 1 of
washer pump and negative (-) battery lead to terminal
2.
c. Check that washer fluid flows out of washer pump.
36
2 1
OK: Washer fluid flows out of washer pump.

If result is not as specified, replace washer pump
assembly.
RA13T360260

Washer Fluid Reservoir Assembly

Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing washer fluid reservoir
assembly.
 Appropriate force should be applied when removing washer fluid reservoir assembly. Be careful not to
operate roughly.
 Try to prevent body paint surface from being scratched, when removing washer fluid reservoir assembly.

3. Remove the guide pipe assembly.
a. Remove fixing bolt (arrow) from guide pipe assembly.
36
RA13T360270
b. Remove guide pipe assembly from washer fluid reservoir assembly.

5. Remove the washer fluid reservoir assembly.
a. Disconnect front and rear washer pump connectors
(1). 1
b. Disconnect joints (2) between front and rear washer
lines and washer pumps.
c. Remove 3 wire harness clips (arrow), and move away
wire harness.
RA13T360280
d. Remove fixing nut (arrow), fixing bolt (1) and washer

fluid reservoir assembly.
1
RA13T360290

Inspection
1. Check the washer fluid reservoir assembly.
a. Check washer fluid reservoir assembly for leakage,
deformation or damage. Replace washer fluid
reservoir assembly if necessary.
b. Check internal and external sides of washer fluid
reservoir for dirt. Remove dirt or replace washer fluid
reservoir assembly if necessary.
c. Check grommet for damage. Replace if necessary.
RA13T360300
Installation
CAUTION
 Always operate carefully to prevent components from being damaged, when installing washer fluid
reservoir assembly. 36
 Tighten fixing bolts to specified torque, when installing washer fluid reservoir assembly.
 Install washer line joint in place, when installing washer fluid reservoir assembly.

Washer Line Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing washer line assembly.
 Appropriate force should be applied when removing washer line assembly. Be careful not to operate
roughly.
 Try to prevent body paint surface from being scratched, when removing washer line assembly.

5. Remove the washer line assembly.
a. Disconnect joint (1) between washer line and front
36 washer pump.
b. Remove washer line fixing clip (arrow) from vehicle.
RA13T360310
c. Remove the washer line assembly.
Installation
CAUTION
 Always operate carefully to prevent components from being damaged, when installing washer line
assembly.
 Install washer line joint in place, when installing washer line assembly.
 Check washer system for proper operation, after installing washer line assembly.

DOOR LOCK
Description 37-3 Front Door Lock Assembly 37-39
Front Door Key Cylinder Assembly 37-41
Removal 37-41
Installation 37-42
Front Door Lock Striker Assembly 37-43
Removal 37-43
Installation 37-43
Rear Door Lock Assembly 37-44
Removal 37-44
All Doors Lock/Unlock Functions do 
Inspection 37-44
not Operate 37-17
Installation 37-45
Only Driver Side Door Lock/Unlock 
Function does not Operate 37-21 Rear Door Lock Striker Assembly 37-46
Only Front Passenger Side Door  Removal 37-46
Lock/Unlock Function does not  Installation 37-46 37
Operate 37-24 Back Door Lock Assembly 37-47
Only Rear Left Door Lock/Unlock  Removal 37-47
Function does not Operate 37-27 Inspection 37-47
Only Rear Right Door Lock/Unlock  Installation 37-47
Function does not Operate 37-30 Back Door Lock Striker Assembly 37-48
Only Wireless Control Function  Removal 37-48
does not Operate 37-33
Installation 37-48
B1024-71 37-34
Wireless Key 37-49
Engine Hood Lock Assembly 37-38 Installation 37-49
Removal 37-38

37

37 - DOOR LOCK
GENERAL INFORMATION
DOOR LOCK
Description
2
5
37
RA13T370010
1 - Engine Hood Lock Assembly 2 - Front Right Door Lock Assembly

3 - Rear Right Door Lock Assembly 4 - Back Door Lock Assembly
5 - Rear Left Door Lock Assembly 6 - Front Left Door Lock Assembly
1. Central lock and unlock operation

a. Lock and unlock operation via wireless key.
 Turn key to OFF position;
 All four doors are closed;
 Lock command is received from wireless key.
The vehicle performs central lock operation, while left and right turn signal lights blink once and horn
briefly sounds once.
 Any of doors is not closed;
 Key is in a position other than ACC or ON;
The vehicle performs a central lock operation, and then performs central unlock operation, while turn
signal lights blink twice.
 All of the four doors are closed;
 Engine hood or back door is not closed;
 Key is in a position other than ACC and ON;

37 - DOOR LOCK

The vehicle performs central lock operation, and turn signal lights blink twice; If the engine hood and
luggage compartment door are closed at this time, the vehicle will enter into fortifying mode.
As long as unlock command is received from wireless key, the vehicle performs central unlock
operation once and left and right turn signal lights blink twice.
b. Lock and unlock operation via central lock.
 Press central lock switch with all of the four doors closed to perform lock command;
 Press central unlock switch to perform unlock command;
 Press central lock switch with any of the doors not closed, first perform lock command and then
unlock command;
c. Auto unlock
 Turn key to OFF position with vehicle locked and vehicle speed 0, to preform auto unlock operation.
2. Wireless key operation
a. Lock button on wireless key
 Key is in OFF position or is removed;
 All of the four doors, engine hood and back door are closed;
 Lock command is received from wireless key;
The vehicle performs central lock operation, turn signal lights blink once, horn briefly sounds once and
vehicle is locked successfully.
 Turn key to OFF position or remove it;
37
 One or more doors are not closed;
Doors unlock once after locking, turn signal lights blink twice, horn does not sound, and vehicle does
not enter fortifying mode successfully.
b. Unlock button on wireless key
 Press unlock button on wireless key to perform central unlock operation, and turn signal lights blink
twice.
c. Back door opener switch on wireless key
 Turn key to OFF position, and all of the four doors, engine hood and back door close; The back door
opens when back door opening button is long pressed.
3. Anti-theft management
a. Fortifying mode
 Key is not in IGN ON/ACC position;
 All of the four doors, engine hood and back door are closed;
b. Fortifying failure mode
 If lock command is received from wireless key with any door open, turn signal lights blink once and
then illuminate once, and central lock operation is first performed and then unlock operation is
performed.
 Turn key to OFF position;
 Any of doors is not closed;
Doors unlock once after locking, turn signal lights blink twice, horn does not sound, and vehicle does
not enter fortifying mode successfully.
c. Press lock button on wireless key with key in OFF position and engine hood/back door not closed, the
vehicle performs central lock operation, and turn signal lights blink twice while horn does not sound.

37 - DOOR LOCK
4. Fortifying deactivation mode

a. When unlock command is received from wireless key, the vehicle exits fortifying mode, and turn signal
lights illuminate twice at the same time.
b. With vehicle in fortifying mode, turn key to ON position and then start engine, then exit the fortifying
mode after engine is started.
5. Back door opening mode
a. In fortifying mode, long press back door opener switch on wireless key to open the back door by using
back door outside switch. At this time, the turn signal lights illuminate twice and anti-theft horn does not
sound.
6. Alarm mode
a. In fortifying mode, if any of the following conditions occur:
 Engine hood is opened illegally (this function is not provided on China model);
 Back door is opened illegally;
 Any door is opened illegally;
The vehicle enters alarm mode, and anti-theft horn sounds while turn signal lights illuminate; the alarm
will continue for a cycle and one trigger source may cause alarm to be triggered for up to 3 cycles.
b. If the opened door/engine hood/back door is closed when alarm sounds, the alarm will stop after this
cycle is ended.
7. Alarm deactivation mode
a. If unlock command is received from wireless key when vehicle is in alarm mode, the alarm deactivates 37
and sound and light alarms stop.
8. Re-fortifying mode
a. When unlock button is pressed with key removed, all doors, engine hood and back door closed and
vehicle in fortifying mode, four doors will be locked and vehicle will enter fortifying mode again after 30
seconds if no further operations (opening door, engine hood and back door) are performed, the central
lock operation is performed again, and turn signal lights blink once while horn sounds once.
b. Back door opening
 In central lock status, long press back door opener switch on wireless key to open the back door by
using back door switch.
 In central unlock status, the back door can be opened using back door outside handle.
 In fortifying mode, back door outside switch is disabled.
c. Door status
 When any of doors, engine hood or back door is opened, the corresponding display will be shown
on the instrument cluster display.
d. Collision unlock: collision unlock function is enabled when following conditions are met:
 Key is in ON position;
 BCM receives a collision signal sent from analog ABM;
After collision unlock function is enabled, BCM performs unlock operation once and then performs once
again after 1 second, while dome light (with dome light at DOOR position) and hazard warning light
come on and then go off after 15 minutes.
Dome light and hazard warning light function can be turned off immediately by performing following
operations within 15 minutes after collision occurs: Turn key to OFF from ON position, and then back to
ON again.
Central lock function is disabled after collision occurs, but central unlock function can be performed.
Central lock function resumes by performing following operations: Turn key to OFF from ON position.
9. Wireless key match
If wireless key is lost, damaged, or Body Control Module (BCM) is replaced, the wireless key needs to be
matched again. Detailed operation procedures are as follows:

37 - DOOR LOCK
a. Connect X-431 3G diagnostic tester (the latest

software) to Data Link Connector (DLC), and make it Menu
communicate with vehicle electronic module through ENG
data network. Then select corresponding model ABS
(A13T) on X-431 3G diagnostic tester (the latest

SRS
BCM
software) to enter the system and select "BCM" ICM
system. TPMS
APM
RA13T370400
b. Please select [special function] on SELECT

FUNCTION screen. SELECT FUNCTION
Read fault code
Erase fault code
Read data stream
System information
Action Test
write data
special function
RA13T370410
c. Please select [Key learning] on special function

37 screen. special function
Key learning
Shipping Mode
Fault code set
Communication control
RA13T370420
d. Hazard warning light flashes once when

"Communicating, please wait …"displays on Communication Information
Communication information screen. Please press and

hold any button on wireless key for more than 1
second and release it until hazard waning light flashes
once. Communicating,please wait...
RA13T370430
e. When "Routine Complete" is displayed on Key

Learning screen, click "OK". Key Learning
Routine Complete
OK
RA13T370440
f. Key match is completed.

37 - DOOR LOCK
10.Wireless key
a. Door lock/unlock control via wireless key.
 Wireless key lock: With all doors fully closed, press lock button on wireless key, all doors will be
locked while turn signal lights blink once. Security indicator will also blink normally to indicate that
system is in armed state, and body anti-theft system is started. With any door open or not fully
closed, press lock button on wireless key, all doors are unlocked immediately after performing lock
operation while turn signal lights blink twice to remind driver that vehicle is not fortified.
b. Wireless key unlock: Press unlock button on wireless key, all doors will unlock while turn signal lights
blink twice, body anti-theft system is deactivated and security indicator turns off. After unlocking doors
with wireless key, open any door within 30 seconds. If no door is opened within 30 seconds, doors will
be locked again automatically.
Vehicle security system has 7 modes:
1. Fortifying mode
a. It will enter fortifying mode when following conditions are met:
 Key is removed.
 All doors, engine hood and back door are closed.
 All doors are locked by lock button on wireless key.
b. When vehicle is in fortifying mode, following opeartions will occur:
 Turn signal lights blink once to indicate that vehicle is in fortifying state.
 In fortifying mode, if no door is opened within 30 seconds after unlocking doors by wireless key, the
doors will lock again automatically. 37
2. Fortifying failure mode
a. System will enter fortifying failure mode under following conditions:
 If any door, engine hood or back door is not fully closed.
b. When vehicle is in fortifying mode, following conditions occur:
 Turn signal lights blink twice. If all doors are not fully closed, the central door lock performs "doors
lock and then unlock" regardless of the engine hood and back door conditions.
 If all doors are fully closed without engine hood/back door fully closed, the doors will be locked.
3. Fortifying deactivation mode
a. In fortifying mode, fortifying will be deactivated if either of following conditions occurs:
 Press unlock button on wireless key.
 Press back door button on wireless key for more than 1.5 seconds.
 Open doors with key.
b. Fortifying deactivation mode (unlock doors using wireless key, open doors with mechanical key or
press back door button) features any of followings:
 All doors are unlocked.
 Turn signal lights slowly blink twice and anti-theft indicator stops blinking.
4. Refortifying mode
a. It will enter refortifying mode when following conditions are met:
 Fortifying will be deactivated by using wireless key button after entering fortifying mode.
 Conditions of all doors, engine hood and back door do not change.
 If key is not in ignition key cylinder or ignition switch is in any position other than ACC or ON, system
will enter refortifying mode after 30 seconds.
b. Refortifying mode features any of followings:
 All doors are locked, turn signal lights do not blink, which indicate that system enters refortifying
mode.

37 - DOOR LOCK
5. Alarm mode
a. When vehicle is in fortifying mode, alarm will be triggered if any of following conditions occurs:
 Manually open any door, engine hood or back door.
 Ignition switch ON
b. When vehicle is in alarm mode, the following condition occurs:
 After alarm is triggered, turn signal lights will blink for 30 seconds. Blinking will occur again after an
interval of 5 seconds. This process will repeat for 3 times. If all doors/engine hood are fully closed or
ignition switch is turned OFF in this process, all doors will be locked again automatically after
completing the current blinking for turn signal lights and 5 seconds have elapsed. At this time, body
anti-theft system will be restarted.
6. Alarm deactivation mode
a. Following operations will deactivate alarm mode:
 Press unlock button on wireless key.
 Open doors with key.
 Press back door button on wireless key for more than 1.5 seconds.
7. Back door opening mode
a. In fortifying mode, if back door opening button on wireless key is pressed for 1.5 seconds, the back
door is unlocked and turn signal lights blink twice. After an interval of 1 second, system enters back
door opening mode.
 Opening of back door does not trigger alarm mode.
37  After back door is closed, system enters fortifying mode again without any sound or light feedback.
 If lock button on wireless key is pressed with back door open, system enters fortifying failure mode.
If unlock button on wireless key is pressed, system enters fortifying deactivation mode.
 If all doors and engine hood are opened, system will enter alarm mode, regardless of whether back
door is closed.
Specifications

Engine Hood Lock Assembly Fixing Nut 9±1
Front Door Lock Assembly Fixing Screw 5±1
Front Door Key Cylinder Assembly Fixing Screw 7±1
Front Door Lock Striker Assembly Fixing Screw 23 ± 1
Rear Door Lock Assembly Fixing Screw 5±1
Rear Door Lock Striker Assembly Fixing Screw 23 ± 1
Back Door Lock Assembly Fixing Screw 9±1
Front Door Outside Handle Fixing Screw 1.5

37 - DOOR LOCK
Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002 37

37 - DOOR LOCK
Circuit Diagram
Power Door Lock System (Page 1 of 3)

ENGINE
COMPARTMENT IP FUSE
RELAY BOX RELAY BOX
30A 30A 15A 15A 15A 15A 10A 10A
E-067 I-032
7 55
106 108 72 70 65 67
RG
RY
G
R
RY
R
RL
E-026 3 2 E-053
B-015 11 12 14 B-024
Gr
RG
RY
G
R
C7 C10 C2 C1 E20 D9 B17 B5
BCM(A/B/C/D/E) B-022 I-034 B-020 E-033 B-021
A45 A49 A50 A35 D4 A48
RW
GR
LY
B
E-032
B-016 2
13 1 2 B-014
YB
Br
F-005
RW
37
GR
LY
4 B-001
7 8
T-001
Br
YB
RW
GR
GR
LY
LY
1 3 2
BACK
1 2 BACK
FRONT DOOR
LEFT
3 1
CENTER
DOOR M LOCK
SWITCH
POWER CONTROL T-005 MOTOR
LOCK UNLOCK LOCK T-006
WINDOW
F-007 2
B
SWITCH 1
F-001 2 B
11
B
T-001
B
1 B-001
B
F-004 B-006
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
B-022 B-021
B B
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
2 3 4 5 6 7 8 9 D2 D3 D4 D5 D6 D7 D8
9 8 7 6 5 4 3 2 E2 E3 E4 E5 E6
27 26 25 24 23 22 21 : : 21 22 23 24 25 26 27 E-033
D9 D: D21 D22 D23 D24 D25 E7 E8 E9 E: E21 E22 E23 W
E-026
W E-053
W B-020
B
1 2 3 4 5 6 7 8 9 10 11 12 13 9 8 7 6 5 4 3 2 1
3 2 1
14 15 16 17 18 19 20 21 22 23 24 25 26 18 17 16 15 14 13 12 11 10 T-001
1 2 3 4 5
1 2 T-005 F-007 W
E-032 B B 6 7 8 9 10
B-016
W W
8 7 6 5 4 3 2 1
1 2 3 4 T-006 F-001 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
16 15 14 13 12 11 10 9 I-034
B Y B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W EA13T370010

37 - DOOR LOCK
BCM(A/E) B-022 B-021
A23 A37 A10 A12 A52 E6
GW
YR
W
Y
V
12 B-016 B-023 B-011 B-028 B-015
3 H-008 2 2 9 10
F-005 L-005 R-005 E-026
YR
W
GW
Y
V
P
1 1 1 1 2 1
FRONT FRONT REAR REAR
LEFT RIGHT LEFT RIGHT HOOD SIREN
DOOR DOOR DOOR DOOR CONTACT E-044
CONTACT CONTACT CONTACT CONTACT SWITCH
SWITCH
F-009
SWITCH
H-002
SWITCH
L-001
SWITCH
R-001
E-046
2 37
2 2 2 2 1
B
B
B
B
L-005 R-005
1 B-011 1 B-028
B
B
B
F-004 H-007 B-012 B-025 E-066
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
B-022 B-021
B B
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 2 1
B-016 B-023 B-015
1 2 3 4 5 6 7 8 9 10 11 12 13
W 18 17 16 15 14 13 12 11 10 W 9 10 11 12 13 14 15 16 W
14 15 16 17 18 19 20 21 22 23 24 25 26
L-001 R-001
B B
5 4 3 2 1 5 4 3 2 1
B-011 B-028 2 1 1 2
1 2 3
10 9 8 7 6 W 10 9 8 7 6 W
E-044 E-046
F-009 H-002 B B
B B
EA13T370020

37 - DOOR LOCK
BCM(D) E-033
D3 D2
P
L
E-032
B-014 5 4
P
L
P
L
P
P
L
B-016 15 14 B-023 B-011 3 4 B-028 3 4
F-005 H-008 2 1 L-005 R-005
37
P
P
L
L
L
3 1 1 3 3 1 1 3
DOOR LOCK DOOR LOCK DOOR LOCK DOOR LOCK
M MOTOR M MOTOR M MOTOR M MOTOR
F-008 H-001 L-002 R-002
E2 E3 E4 E5 E6 9 8 7 6 5 4 3 2 1
E-032 1 2 3 4 5 6 7 8 9 10 11 12 13 B-016
E-033
W W
W 18 17 16 15 14 13 12 11 10 14 15 16 17 18 19 20 21 22 23 24 25 26
E7 E8 E9 E: E21 E22 E23
9 8 7 6 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1
B-023 B-011 B-028
18 17 16 15 14 13 12 11 10 W 10 9 8 7 6 W 10 9 8 7 6 W
1 2 3 F-008 H-001 L-002 R-002

B B B B
EA13T370030

37 - DOOR LOCK
DIAGNOSIS & TESTING

HINT:
Power Door Lock Control System:

Body Control Module (BCM) fuse 55-44
Power door unlock/lock switch
55-47
button
All doors lock/unlock functions do Front left door lock assembly 55-47
not operate
Other door lock assemblies 55-44
Body Control Module (BCM) 55-44
Power door unlock/lock switch
button
55-46 37
Only driver side door lock/unlock Front left door lock assembly 55-47
function does not operate
Front right door lock assembly 55-47
Only front passenger side door
lock/unlock function does not Wire harness or connector 55-44
operate
Rear left door lock assembly 55-48
Only rear left door lock/unlock
Rear right door lock assembly 55-49
Only rear right door lock/unlock
Back door lock assembly 55-50
Only back door open/close

37 - DOOR LOCK
Wireless Door Lock Control System:

Wireless key battery 37-49
Only wireless control function Anti-theft match 37-5

does not operate Wire harness or connector 55-44
Turn signal light 37-49
Only no answer-back
Diagnosis Tools
1. When connecting X-431 3G diagnostic tester:
a. Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC) for
communication with vehicle.
b. DLC is located at driver side instrument panel crossmember.
c. DLC uses a trapezoidal design which can hold 16 terminals.
37 Digital Multimeter
2. When using digital multimeter:
a. Troubleshoot electrical malfunctions and wire harness system.
b. Look for basic fault.
c. Measure voltage, current and resistance.

 Use X-431 3G diagnostic tester to record and clear DTCs stored in power door lock control system.

 Look for data that has changed or reset DTC during wiggle test.

37 - DOOR LOCK
 Inspect airbag components and mounting areas for damage, foreign matter, etc. that will cause incorrect
signals.
Ground Inspection
Ground inspection are very important to normal operation of electrical appliances and circuits. Ground points
are often exposed to moisture, dirt and other corrosive environments. Corrosion (rust) can increase resistance
which will change the way in which a circuit works.
Electrical control circuits are very sensitive to proper grounding. A loose or corroded ground can affect the
electrical control circuit. Operations to check ground points are as follows:
1. Remove the ground nut.
3. Clean as necessary to ensure good contact.
4. Reinstall ground nut securely.
wire harnesses are clean, securely fastened and can provide a good ground path.
37
Diagnosis Procedure
HINT:
Use following procedures to troubleshoot the power door lock control system.
NEXT
NEXT
NEXT
DTC
occurs

37 - DOOR LOCK
NO
DTC
NEXT
NEXT
NEXT
37
NEXT
NEXT
10 End

37 - DOOR LOCK
All Doors Lock/Unlock Functions do not Operate

ENGINE
COMPARTMENT IP FUSE
RELAY BOX RELAY BOX
30A 30A 15A 15A 15A 15A 10A 10A
E-067 I-032
7 55
106 108 72 RG 70 65 67
RY
G
R
RY
R
RL
E-026 3 2 E-053
B-015 11 12 14 B-024
Gr
RG
RY
G
R
C7 C10 C2 C1 E20 D9 B17 B5
BCM(A/B/C/D/E) B-022 I-034 B-020 E-033 B-021
D3 D2
P
L
E-032
B-014 5 4
P
L
37
P
L
P
B-016 15 14 B-028 3 4
F-005 R-005
P
P
L
L
3 1 1 3
FRONT LEFT REAR RIGHT
DOOR LOCK DOOR LOCK
M MOTOR M MOTOR
F-008 R-002
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 ( ( ( ( ( ( ( ( (
B-022 B-021
B B
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 ( ( ( ( ( ( ( ( ( ( (
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
& & & & & & &

' ' ' ' '

E-033
W
& & & & & & & ' ' ' ' ' ' '
E-026
W E-053 B-020
W B
9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 13 F-008 R-002 E-032
1 2 3
B B 18 17 16 15 14 13 12 11 10 W
14 15 16 17 18 19 20 21 22 23 24 25 26
B-016 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034

W B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
EA13T370040

37 - DOOR LOCK
1 Check fuse

c. Using a digital multimeter, check fuses SB02 (30A), SB04 (30A), EF23 (15A), EF21 (15A), EF16 (15A) and
EF18 (15A).
NG Replace power supply and ignition switch

fuse
OK
Use circuit diagram as a guide to perform the following

inspection procedures:
37
+ -
c. Disconnect BCM connector E-033(D3) and front left door ' ' ' ' '
lock motor connector F-008 (3).

' ' ' ' ' ' '
Normal Condition
E-033
Digital Specified
Condition
E-033 (D3) -
Ignition switch ON Continuity
F-008 (3) 1 2 3
F-008
RA13T370011
RM1A370500
d. check for continuity between body wire harness

connector B-032 (5) and front left door lock motor
connector F-008(3).
Normal Condition
+ -
Digital Specified
Condition 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
B-032 (5) - F-008

Ignition switch ON Continuity E-032
(3)
1 2 3
F-008
RA13T370013
RM1A370500

37 - DOOR LOCK
e. Check for continuity between connectors E-033 (D3) and

E-032 (5).
Normal Condition
+ -
Digital Specified
Condition
Multimeter Condition 9 8 7 6 5 4 3 2 1
B-032 (5) - E-033 18 17 16 15 14 13 12 11 10

(D3) E-032
f. Check for continuity between BCM and rear right door

lock.
' ' ' ' '
' ' ' ' ' ' '
E-033
RA13T370017
RM1A370500
g. Using a digital multimeter, check for continuity between

connector E-033 (D2) and rear right door lock connector
R-002.
Normal Condition
+ -
Digital Specified
37
Condition 1 2 3
R-002
E-033 (D2) -
R-002 (3)
' ' ' ' '
' ' ' ' ' ' '
E-033
RA13T370016
RM1A370500

body connector E-032 (4) and rear right door lock
connector R-002 (3).
Normal Condition
+ -
Digital Specified
Condition 1 2 3
R-002
E-032 (4) - R-002
(3)
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
E-032
RA13T370014
RM1A370500

37 - DOOR LOCK
i. Using a digital multimeter, check for continuity between

connectors E-033 (D2) and E-032 (4).
Normal Condition
+ -
Digital Specified
Condition
Multimeter Condition 9 8 7 6 5 4 3 2 1
E-032 (4) - E-033 18 17 16 15 14 13 12 11 10

(D2) E-032
NG Repair or replace wire harness connector

' ' ' ' '
OK Replace BCM assembly

' ' ' ' ' ' '
E-033
RA13T370015
RM1A370500
37

37 - DOOR LOCK
Only Driver Side Door Lock/Unlock Function does not Operate

IP FUSE
RF01 RF26 AND
10A 10A RELAY BOX
I-032
7 55
RY
RL
Gr
B17 B5
BCM(D) E-033
D3 D2 A23
P
W
E-032
B-014 5 4
12 B-016
F-005
37
P
1
B-016 15 14 FRONT
F-005 LEFT
DOOR
CONTACT
P
SWITCH
F-009
3 1 2
FRONT LEFT
B
DOOR LOCK
M MOTOR
F-008
F-004
' ' ' ' ' 9 8 7 6 5 4 3 2 1

E-032 1 2 3 4 5 6 7 8 9 10 11 12 13 B-016
E-033
W W
W 18 17 16 15 14 13 12 11 10 14 15 16 17 18 19 20 21 22 23 24 25 26
' ' ' ' ' ' '
1 2 3 F-008 2 1 5 4 3 2 1
B B-028
10 9 8 7 6 W
F-009
B
EA13T370050

37 - DOOR LOCK
Problem causes:
 Power door unlock/lock switch button
 Front left door lock assembly
Service method:
CAUTION
1 Check wire harness connector

c. Disconnect the front left door fastener connector F-008.
37 connectors B-016 and F-008.
Normal Condition
+ -
Digital Specified
Condition
1 2 3 4 5 6 7 8 9 10 11 12 13
B-016 (15) -
Always Continuity 14 15 16 17 18 19 20 21 22 23 24 25 26
F-008 (3)
B-016 (14) - B-016
Always Continuity
F-008 (1)
NG Repair or replace front left door wire 1 2 3
harnessand connector F-008
OK
RA13T370021
RM1A370500
2 Check front left door fastener

c. Remove front left door fastener and perform test after
replacing with a new one.
NG Repair or replace front left door fastener

37 - DOOR LOCK
3 Check front left door lock control switch

c. Check for continuity between BCM connector B-022 and
front left door lock control switch connector F-009.
Normal Condition
+ -
Digital Specified
Condition
Multimeter Condition 2 1
B-022 (A23) -
Always Continuity
F-009 (1)
F-009
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022
37
RA13T370041
RM1A370500
d. Check for continuity between front left door lock control

switch connector F-009 and body ground.
Normal Condition
+ -
Digital Specified
Condition
2 1
F–009 (1) - F-004 Always Continuity
F-009
NG Repair or replace front left door lock
controlswitch
OK Replace BCM
F-004
RA13T370042
RM1A370500

37 - DOOR LOCK
Only Front Passenger Side Door Lock/Unlock Function does not

Operate
IP FUSE
RF01 RF26 AND
10A 10A RELAY BOX
I-032
7 55
RY
RL
Gr
B17 B5
BCM(D) E-033
D3 D2 A37
P
YR
E-032
B-014 5 4
37
12 B-023
H-006
P
YR
1
B-023 2 1 FRONT
F-008 RIGHT
DOOR
CONTACT
P
SWITCH
H-002
3 1 2
FRONT RIGHT
B
DOOR LOCK
M MOTOR
H-001
H-007
' ' ' ' ' 9 8 7 6 5 4 3 2 1

9 8 7 6 5 4 3 2 1
E-032 B-023
E-033
W 18 17 16 15 14 13 12 11 10 W
W 18 17 16 15 14 13 12 11 10
' ' ' ' ' ' '
1 2 3 H-001 2 1 5 4 3 2 1
B B-028
10 9 8 7 6 W
F-002
B
EA13T370060

37 - DOOR LOCK
Problem causes:
 Front right door lock assembly
Service method:
CAUTION

c. Disconnect the front right door fastener connector H-001.
connectors B-023 and H-001. 37
Normal Condition
+ -
Digital Specified
Condition
9 8 7 6 5 4 3 2 1
B-023 (2) - H-001
Always Continuity 18 17 16 15 14 13 12 11 10
(1)
B-023
B-023 (1) - H-001
Always Continuity
(3)
1 2 3
H-001
RA13T370023
RM1A370500

37 - DOOR LOCK

BCM connector B-022 and front right door lock control
switch.
Normal Condition
+ -
2 1
Digital Specified
Condition
H-002
B-022 (A37) - H-
Always Continuity
002 (1)
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022
RA13T370044
RM1A370500

front right door lock control switch and ground.
Normal Condition
+ -
37 Digital
Condition
Specified 2 1
H-002 (2) - H-007 Always Continuity
H-002
NG Repair or replace front right door wire

OK
H-007
RA13T370045
RM1A370500
2 Check front right door fastener

c. Remove front right door fastener and perform test after replacing with a new one.
NG Repair or replace front right door fastener

37 - DOOR LOCK
Only Rear Left Door Lock/Unlock Function does not Operate

IP FUSE
RF01 RF26 AND
10A 10A RELAY BOX
I-032
7 55
RY
RL
Gr
B17 B5
BCM(D) E-033
D3 D2 A10
P
P
E-032
B-014 5 4
2 B-011
L-005
37
P
1
B-011 3 4 REAR
L-005 LEFT
DOOR
CONTACT
P
SWITCH
L-001
3 1 2
B
REAR LEFT B-011

1
DOOR LOCK L-005
M MOTOR
B
F-008
F-004
' ' ' ' ' 9 8 7 6 5 4 3 2 1

E-033 E-032
W 18 17 16 15 14 13 12 11 10 W
' ' ' ' ' ' '
5 4 3 2 1
B-011
10 9 8 7 6 W
1 2 3 L-002 2 1
B
F-009
B
EA13T370070

37 - DOOR LOCK
Problem causes:
 Rear left door lock assembly
Service method:
CAUTION

c. Disconnect the rear left door fastener connector L-002.
37 connectors B-011 and L-002.
Normal Condition
5 4 3 2 1
+ -
Digital Specified 10 9 8 7 6
Condition
B-011 (3) - L-002
Always Continuity
(3)
B-011 (4) - L-002 B-011
Always Continuity
(1)
1 2 3
L-002
RA13T370024
RM1A370500

37 - DOOR LOCK

BCM connector B-022 and rear left door lock control
switch connector L-001.
Normal Condition
+ -
Digital Specified 2 1
Condition
Multimeter Condition L-001
B-022 (A10) -
Always Continuity
L-001 (1)
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022
RA13T370051
RM1A370500

rear left door lock control switch connector L-001 and
body ground.
Normal Condition
+ -
37
Digital Specified
Condition 2 1
L-001
L-001 (1) - B-012 Always Continuity
NG Repair or replace rear left door wire

B-012
OK
RA13T370052
RM1A370500
2 Check rear left door fastener

c. Remove rear left door fastener and perform test after replacing with a new one.
NG Repair or replace rear left door fastener

37 - DOOR LOCK
Only Rear Right Door Lock/Unlock Function does not Operate

IP FUSE
RF01 RF26 AND
10A 10A RELAY BOX
I-032
7 55
RY
RL
Gr
B17 B5
BCM(D) E-033
A12 D3 D2
L
V
E-032
B-028 B-014 5 4
2
R-005
37
V
L
P
1
REAR
RIGHT B-028 3 4
DOOR R-005
CONTACT
SWITCH
R-001
2
P
B
R-005
1 B-028 1 3
REAR RIGHT
B
DOOR LOCK
M MOTOR
R-002
B-025
' ' ' ' ' 9 8 7 6 5 4 3 2 1 5 4 3 2 1

E-033 E-032 B-028
10 9 8 7 6 W
W 18 17 16 15 14 13 12 11 10 W
' ' ' ' ' ' '
2 1
1 2 3 R-002
B R-001
B
EA13T370080

37 - DOOR LOCK
Problem causes:
 Rear right door lock assembly
Service method:
CAUTION

c. Disconnect the rear right door fastener connector R-002.
connectors B-028 and R–002. 37
Normal Condition
+ -
Digital Specified 5 4 3 2 1
Condition
Multimeter Condition 10 9 8 7 6
B-028 (3) - R-002

Always Continuity
(1)
B-028 (4) - R-002 B-028
Always Continuity
(3)
1 2 3
R-002
RA13T370025
RM1A370500

37 - DOOR LOCK

BCM connector B-022 and rear right door lock control
switch connector R-001.
Normal Condition
+ -
Digital Specified 2 1
Condition
Multimeter Condition R-001
B-022 (A12) -
Always Continuity
R-001 (1)
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022
RA13T370055
RM1A370500

rear right door lock control switch connector R-001 and
body ground.
Digital Specified + -
37 Multimeter
Condition
Condition
2 1
R-001 (2) - B-025 Always Continuity
R-001
NG Repair or replace rear right door wire

OK
B-025
RA13T370056
RM1A370500
2 Check rear right door fastener

c. Remove rear right door fastener and perform test after replacing with a new one.
NG Repair or replace rear right door fastener

37 - DOOR LOCK
Only Wireless Control Function does not Operate

Problem causes:
 Wireless key battery
 Anti-theft match (See page 37-5)
 Wire harness connector (See page 37-5)
Service method:
CAUTION
1 Check if LED indicator in wireless key comeson
NG Replace key battery
OK System is normal
37

37 - DOOR LOCK
DTC B1024-71 Trunk Lock Control Circuit

IP FUSE
RF01 RF26 AND
10A 10A RELAY BOX
I-032
7 55
RY
RL
Gr B17 B5
BCM(A/B/C/D/E) B-022 I-034 B-020 E-033 B-021
A35 D4 A48
E-032 RW2
B-014
YB
Br
RW
37 4 7 8
B-001
T-001
Br
YB
RW
1 3 2
BACK
BACK
DOOR
DOOR M LOCK
SWITCH
T-005 MOTOR
T-006
2
B
1
B
T-001
1 B-001
B
B-006
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 ( ( ( ( ( ( ( ( (
B-022 B-021
B B
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 ( ( ( ( ( ( ( ( ( ( (
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
& & & & & & &

' ' ' ' '
1 2 3 4 E-033
1 2 T-005 & & & & & & & ' ' ' ' ' ' ' W
B
T-006
B B-020
B
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 1 2 3 4 5 T-001

9 8 7 6 5 4 3 2 1
W
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 6 7 8 9 10
18 17 16 15 14 13 12 11 10
I-034
E-032 W
W EA13T370090

37 - DOOR LOCK
DTC Detection
Condition
 Back door lock assembly Wire
Trunk Lock Control
B1024-71 Ignition switch ON harness connector Body Control
Circuit Relay Stuck
Module (BCM)
CAUTION
1 Check back door lock assembly
a. Check the back door lock assembly (See page 55-50).
NG Replace back door lock assembly
OK Replace BCM
37
2 Check instrument panel wire harness and connector

c. Disconnect body connector B-022 and back door fasterer
connector T-006. + -
1 2 3 4
Normal Condition
T-006
Condition
B-022 (A48) - A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
Always Continuity
T-006 (2) A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022
RA13T370028
RM1A370500

37 - DOOR LOCK
d. Check for continuity between connectors B-022 and 

T-001.
Normal Condition
+ -
Condition
B-022 (A48) -
Always Continuity T-001
T-001 (8)
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022
RA13T370029
RM1A370500
e. Check for continuity between BCM connector B-022 and

back door lock switch connector T-005.
Normal Condition
+ -
37 Multimeter
Condition
Specified
B-022 (A35) - T-005

Always Continuity
T–005 (1)
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022
RA13T370031
RM1A370500
f. Check for continuity between BCM connector E-033 and

door lock motor connector T-006.
Normal Condition
+ -
Condition
E-033 (D4) -
T-006 (3)
' ' ' ' '
' ' ' ' ' ' '
E-033
RA13T370033
RM1A370500

37 - DOOR LOCK
g. Check for grounding condition of back door lock switch

connector T-005 and door lock motor connector T-006.
Normal Condition
+ -
Condition
T-006 (1) -
Ground
T-005 (2) -
Always Continuity
Ground
OK Malfunction has been repaired, and 1 2
system operatesnormally
T-005
RA13T370034
RM1A370500
37

37 - DOOR LOCK
ON-VEHICLE SERVICE
Engine Hood Lock Assembly
Removal
HINT:
 Be sure to wear necessary safety equipment to prevent
accidents, when removing engine hood lock assembly.
 Try to prevent body paint surface from being scratched,
when removing engine hood lock assembly.
RA13T370110
1. Remove the engine hood lock assembly.

a. Remove 3 fixing bolts (arrow) from engine hood lock
assembly. (Tightening torque: 9 ± 1 N·m)
37
RA13T370120
b. Disengage engine hood cable assembly from slot and remove engine hood lock assembly.
Installation
CAUTION
 Check if engine hood operates properly, after installing engine hood lock assembly.

37 - DOOR LOCK
Front Door Lock Assembly

Removal
HINT:
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing front door lock
assembly.
 Try to prevent interior and body paint from being scratched, when removing front door lock assembly.

3. Remove the front left door inner protector assembly (See page 48-17).
4. Remove the front left door protective film assembly (See page 48-19).
5. Remove the front left door glass rear guide rail assembly (See page 48-19).
6. Remove the front left door lock assembly.
37
a. Disconnect connector (arrow) from front door lock
assembly.
RA13T370130

37 - DOOR LOCK
b. Disengage front door outside handle cable from slot of

front door handle base.
c. Disengage clip (1) from front door inside handle cable.
RA13T370140
d. Remove 3 fixing screws (arrow) from front door lock

assembly, and remove front door lock assembly.
37
RA13T370150
Inspection
1. Check the front door lock assembly (fastener assembly).
a. Apply battery voltage to terminals of front door lock
-
assembly (fastener assembly) connector and check if +
front door lock assembly operates normally according

to table below.

1 2
Battery positive (+) -
Terminal 1 Battery negative Lock
(-) - Terminal 2
RA13T370160
Terminal 2 Battery negative Unlock
(-) - Terminal 1
If result is not as specified, replace front door lock assembly.
Installation
HINT:
 Check if connector is installed correctly, when installing front door lock assembly.
 Install clips and cables in place, when installing front door lock assembly.
 Check if front door lock operates properly, after installing front door lock assembly.

37 - DOOR LOCK
Front Door Key Cylinder Assembly

Removal
HINT:
 Be sure to wear necessary safety equipment to prevent accidents, when removing front door key cylinder
assembly.
 Try to prevent body paint surface from being scratched, when removing front door key cylinder assembly.
5. Remove the front left door key cylinder assembly.
a. Remove the front door outside handle protective
cover block cover (arrow).
37
RA13T370170
b. Loosen 1 fixing screw (arrow) from front door key

cylinder assembly, and remove front door key cylinder 1
assembly and front door handle protective cover (1). 
HINT:
It is unnecessary to remove fixing screw from front
door key cylinder assembly, because fixing screw is
integrated with front door handle base.
RA13T370180
c. Disengage clip (arrow) from front door key cylinder

lever, and remove front door key cylinder lever (1).
RA13T370190

37 - DOOR LOCK
d. Using a screwdriver wrapped with protective tape,

disengage claws (arrow) and separate front door
handle protective cover (1) from front door key 1
cylinder assembly (2).
2
RA13T370200
Installation
CAUTION
 Install clip on the lever in place, when installing front door key cylinder assembly.
 Check if front door key cylinder operates properly, after installing front door key cylinder assembly.
37

37 - DOOR LOCK
Front Door Lock Striker Assembly

Removal
HINT:
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing front door lock striker
assembly.
 Try to prevent body paint surface from being scratched, when removing front door lock striker assembly.
1. Remove the front left door lock striker assembly.

a. Remove 2 fixing screws (arrow) from front door lock
striker assembly, and remove front left door lock
striker assembly (1). 
1
37
RA13T370210
Installation

37 - DOOR LOCK
Rear Door Lock Assembly

Removal
HINT:
3. Remove the rear left door protective film assembly (See page 48-29).
4. Remove the rear left door lock assembly.
a. Disconnect connector from rear door lock assembly.
b. Disengage rear door outside handle cable from slot of
rear door handle base.
c. Disengage clips from rear door inside handle cable.
37
RA13T370230
d. Remove 3 fixing screws (arrow) and rear door lock

assembly. 
RA13T370240
Inspection
1. Check the rear door lock assembly (fastener assembly).
a. Apply battery voltage to terminals of rear door lock
-
assembly (fastener assembly) connector and check +
operation of rear door lock assembly according to

table below.
Measurement Condition Condition

Battery positive (+) - 1 2
Terminal 1 Battery negative Lock
(-) - Terminal 2
RA13T370250

37 - DOOR LOCK

Terminal 2 Battery negative Unlock
(-) - Terminal 1
Installation
CAUTION
 Check if connector is installed correctly, when installing rear door lock assembly.
 Install cable in place, when installing rear door lock assembly.
 Check if rear door lock operates properly, after installing rear door lock assembly.
37

37 - DOOR LOCK
Rear Door Lock Striker Assembly

Removal
HINT:
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing rear door lock striker.
 Try to prevent body paint surface from being scratched, when removing rear door lock striker.
1. Remove the rear left door lock striker assembly.

a. Remove 2 fixing screws (arrow) from rear door lock
striker, and remove rear left door lock striker assembly
(1). (Tightening torque: 23 ± 1 N·m)
37 1
RA13T370260
Installation

37 - DOOR LOCK
Back Door Lock Assembly

Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing back door lock
assembly.
 Try to prevent interior and body paint from being scratched, when removing back door lock assembly.

3. Remove the back door trim board assembly (See page 48-36).
4. Remove the back door lock assembly.
a. Disconnect connector (1) from back door lock
assembly. 2
b. Remove 2 fixing screws (arrow) from back door lock
assembly, and remove back door lock assembly (2). 
37
1
RA13T370270
Inspection
1. Check the back door lock assembly.
between terminals of back door lock assembly
+ -
1 2 3
Terminal 1 - Terminal 2 Lock
Terminal 1 - Terminal 3 Unlock
If result is not as specified, replace back door lock

assembly. RA13T370280
Installation
CAUTION
 Check if connector is installed correctly, when installing back door lock assembly.
 Check if back door lock operates properly, after installing back door lock assembly.

37 - DOOR LOCK
Back Door Lock Striker Assembly

Removal
HINT:
 Be sure to wear necessary safety equipment to prevent accidents, when removing back door lock striker
assembly.
 Try to prevent body paint surface from being scratched, when removing back door lock striker assembly.
1. Remove the back door lock striker protector assembly.
a. Remove back doorsill pressure plate assembly and
then remove 3 fixing screws (arrow) from back doorsill
pressure plate.
RA13T370300

up 4 clips on pressure plate assembly.
37
RA13T370310
2. Remove the back door lock striker assembly.

a. Remove 2 fixing screws (arrow) from back door lock
striker assembly, and remove back door lock striker
assembly (1). 
RA13T370320
Installation

37 - DOOR LOCK
Wireless Key
Removal
CAUTION
 DO NOT push terminals with your hands, when removing wireless key cover.
 Make sure battery positive and negative are installed correctly, when removing wireless key cover.
 DO NOT pry up battery forcibly, after removing wireless key cover. Otherwise, terminals may be
damaged.
 DO NOT touch battery with wet hands, after removing wireless key cover. Otherwise, water may cause
rust.
 DO NOT touch or move any components inside transmitter, after removing wireless key cover. Failure to
do so may interfere with proper operation.
1. Remove the wireless key.

out wireless key cover as shown in illustration.
37
RA13T370330
b. Separate wireless key covers (1) and chip (2).

1
2
RA13T370340
c. Disengage claws (arrow) from battery holder, and

remove battery holder in direction of arrow.
RA13T370350
Installation

37 - DOOR LOCK
CAUTION
 Check that wireless key operates properly, after installing wireless key.
37

INSTRUMENT CLUSTER
GENERAL INFORMATION 38-3 B1100-16 38-14
Description 38-3 B1100-17 38-14
Operation 38-4 B1101-11 38-18
Specification 38-4 B1101-15 38-18
Tools 38-4 B1103-00 38-23
Circuit Diagram 38-5 U0151-87 38-23
Instrument Cluster Terminal List 38-7 B1104-41 38-27
U0100-87 38-29
U0101-87 38-33
U0129-87 38-37
U0140-87 38-41
U0245-87 38-45
Ground Inspection 38-11 ON-VEHICLE SERVICE 38-49
Diagnosis Procedure 38-11 Instrument Cluster 38-49
Diagnostic Trouble Code (DTC) Chart 38-13 Removal 38-49
B1100-13 38-14 Installation 38-50
38

38

38 - INSTRUMENT CLUSTER
GENERAL INFORMATION
INSTRUMENT CLUSTER
Description
Instrument Cluster
27 1 2 3 4 5 6 7 8 9 10 11 12 13
26
25 180 200 220 8

00:04 7
160
0.0 km 6
140 H F 14
24 + -
EPC 5
120
15
23 100 4
C E
80 240km
3
60
40 20 0 km/h x1000rpm 0 1 2
38
22 21 20 19 18 17 16
RA13T380010
1 - Left Turn Signal Indicator 2 - Low Beam Indicator

3 - High Coolant Temperature Warning Light 4 - Coolant Temperature
5 - Clock 6 - Fuel Level
7 - Low Fuel Level Warning Light 8 - Front Passenger Seat Belt Reminder Light (if
equipped)
9 - Right Turn Signal Indicator 10 - Transmission Malfunction Warning Light (for
CVT Model)
11 - Brake System Malfunction Indicator 12 - ABS Warning Light
13 - Brake System Malfunction Indicator 14 - Tachometer
15 - Low Tire Pressure and Tire Pressure System 16 - Driver Seat Belt Reminder Light
Malfunction Indicator (if equipped)
17 - ESP OFF Indicator (if equipped) 18 - ESP System Malfunction Indicator (if equipped)
19 - Parking Brake Indicator 20 - Low Engine Oil Pressure Warning Light
21 - Engine Malfunction Warning Light 22 - EPC Warning Light
23 - Speedometer 24 - Charging Warning Light/Intelligent Alternator
Malfunction Warning Light
25 - Cruise Indicator (if equipped) 26 - Position Indicator
27 - Rear Fog Indicator

This vehicle is equipped with pointer type instrument cluster. Instrument cluster is a highly integrated
electronic instrument display system and mainly consists of engine coolant temperature gauge, tachometer,
fuel gauge, speedometer, multi-information display and warning indication symbols. Multi-information display
mainly displays vehicle information, which contains following items: clock, trip mileage, total mileage and
instantaneous fuel consumption.
Operation
Instrument cluster is located above the upper left of instrument panel assembly, and is used to monitor and
display operation status of each system and component in vehicle. Instrument cluster receives signals from
each sensor and switch, and displays operation status of each system using meters, multi-information display,
indicators and warning lights. It also reminds and informs driver by flashing lights and sounding buzzer. As a
result, it helps driver to eliminate possible troubles in time, thus avoiding malfunctions or accidents efficiently.
Specification

Instrument Cluster Fixing Screw 1.5 ± 0.5
Tools
Special Tool
38
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Instrument Cluster (Page 1 of 2)

ON OR START
IP FUSE AND
RF10 RF01 RELAY BOX
10A 10A I-032
33 7
TO CAN
SYSTEM
RY
R
ILLUMINTION
G
Y
Br
11 13 29 30 12
CAN2-L CAN2-H
INSTRUMENT
CLUSTER
I-011
38
31 16 7 3 4
WG
ILLUMINTION
WR
Br
Br
L
I-035
2 E-029
2 4
I-003
WG
3 C-001
6 ECO
10 E-035
SWITCH
Br
E-007
I-010
WG
1 3
CLOCK SPRING 5
I-031
B
ALTERNATOR SUNROOF
E-017 MODULE
C-002 I-005 I-005
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
I-011
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 6 5 4 3 2 1
L
16 15 14 13 12 11 10 9
12 11 10 9 8 7
I-031
W E-035
B
1 2 3 4 5
1 2 3 4 5 6 7 8 4 3 2 1
1 2 3 4 5 6 1 2 3
6 7 8 9 10
8 7 6 5
9 10 11 12 13 14 15 16
E-017
C-002 I-010 B
I-035 I-003
W W W
W EA13T380010

Instrument Cluster (Page 2 of 2)
INSTRUMENT
CLUSTER
I-011
9 26 5 21 19 18
WR
LW
LY
W
G
L
I-036 I-035 I-002 I-001
13 7 8 13 12
E-030 3 E-029 B-019 B-017
LY
G
L
9 5 E-035
E-007 1 FUEL PUMP
LW
W
MOTOR &
FUEL LEVEL
LY
G
SENSOR
1 2 B-008 1 DRIVER 1
2
OIL BRAKE FLUID PARKING
SEAT
PRESSURE LEVEL BRAKE
BELT
WR
SWITCH SENSOR SWITCH

SWITCH
38 E-016
1
E-004
2
B-013 B-018
B
E-005 B-012
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
12 11 10 9 8 7
I-036
I-011 B E-035
L B
1 2 3 4 5 6 7 8 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
9 10 11 12 13 14 15 16 18 17 16 15 14 13 12 11 10 20 19 18 17 16 15 14 13 12 11
I-035 I-002
W I-001 W
W
1 1 2 1
1 2 1 2 3 4
B-013 B-018
E-004 E-016 B-008 B W
B EA13T380020
B B

Instrument Cluster Terminal List

Instrument cluster

1 - 17 -
2 - 18 Parking Brake Switch Signal
3 Ground 19 Seat Belt Unfasten
4 ECO Switch (Reserve) 20 -
5 Fuel Level Sensor Ground 21 Fuel Level Sensor Signal
6 - 22 -
7 Vehicle Speed Output 23 -
8 - 24 -
9 Oil Pressure Warning 25 -
10 - 26 Brake Fluid Level Signal
11 Battery Power Supply 27 -
12 Backlight Illumination Input 28 -
13 Ignition Switch Power Supply 29 CAN2-L
14 - 30 CAN2-H 38
15 - 31 Adjustment Button Signal Input
16 Charging System Indication 32 -

DIAGNOSIS & TESTING

HINT:

Fuse 38-15
Entire instrument cluster does not operate Instrument cluster 38-49
Wheel speed 25-95
Vehicle speed display abnormal Wire harness or connector 55-42
Wire harness and connector 55-42
Tachometer abnormal
38 Engine Control Module (ECM) 06-245
Fuel level sensor 08-14
Fuel gauge abnormal Wire harness or connector 55-42
Position light switch (combination light
35-79
switch)
Position indicator abnormal Wire harness or connector 55-42

Turn signal light switch (combination light
35-28
switch)
Turn signal indicator abnormal
High beam switch (combination light
35-82
switch)
High beam indicator abnormal Wire harness or connector 55-42



Rear fog light switch (combination light
35-82
switch)
Rear fog indicator abnormal Wire harness or connector 55-42

Alternator 16-4
Charging system warning light abnormal Wire harness or connector 55-42
Engine oil level 13-7
Low engine oil pressure warning light Oil pressure switch 13-14
abnormal Wire harness or connector 55-42
ABS control unit assembly 25-90
ABS warning light abnormal CAN line or connector 53-7
Fuel amount in tank 08-12 38
Fuel level sensor 08-14
Low fuel level warning light abnormal
Coolant level 12-10
Extremely high engine coolant temperature -
Coolant temperature warning light Coolant temperature sensor 12-10

abnormal Wire harness or connector 55-42
Engine Control Module (ECM) 06-245
CAN line or connector 53-7
Engine malfunction warning light abnormal Engine Control Module (ECM) 06-245
SRS warning light abnormal Airbag control module (SRS) 31-45
Driver seat belt buckle switch 32-8
Driver seat belt reminder light abnormal Wire harness or connector 55-42


Front passenger seat belt buckle switch 31-50
Front passenger seat belt reminder light
abnormal (if equipped)
Low brake fluid level -
Brake system warning light abnormal Parking brake switch 27-10
Cruise switch (multi-function switch) 34-11
Cruise indicator (if equipped) abnormal Wire harness or connector 55-42
Transmission Control Unit (TCU) 18-89
Transmission malfunction warning light
abnormal
Low or high tire pressure (tire pressure is
Low tire pressure warning light (if not within specified range) 24-7
equipped) abnormal
38 CAN line or connector 53-7

Engine immobilizer system warning light (if
Engine Control Module (ECM) 06-245
equipped) abnormal
Diagnosis Tools
with vehicle.
 DLC is located on instrument panel lower left protector.
Digital Multimeter
Diagnostic Help

7. Check and clean all instrument cluster system grounds related to the latest DTC.

 Look for data that has changed or the DTC to reset during the wiggle test.
 Inspect mounting areas of instrument cluster, wire harness or wire harness connector and so on for
 Check and clean all wire harness connectors and grounding parts related to current DTC.
 Remove instrument cluster from malfunctioning vehicle, and install it to a new vehicle and perform a test. If
DTC cannot be cleared, instrument cluster may be malfunctioning. If DTC can be cleared, reinstall
instrument cluster to original vehicle.
 If multiple trouble codes were set, refer to circuit diagrams to look for any common ground circuit or power
38
Ground Inspection
Diagnosis Procedure
HINT:
HINT: Use following procedures to troubleshoot the instrument cluster system.
NEXT

NEXT
NEXT
DTC
occurs
NO
DTC
NEXT

38
NEXT
NEXT
NEXT
NEXT
10 End


B1100-13 Power Supply Fault
B1101-11 ICM Fuel System Fault
B1101-15 ICM Fuel System Fault
B1103-00 Airbag Warning Light Fault
B1104-41 EEPROM Checksum Error
B110A-00 Wheel Button Fault
B110C-11 ICM Fuel Master Detect Circuit Fault
B110C-13 ICM Fuel Master Detect Circuit Fault
B110D-11 ICM Fuel Assistant Detect Circuit Fault
U0100-87 Lost Communication with Engine Control System Module
U0101-87 Lost Communication with Transmission Control Unit
U0129-87 Lost Communication with Brake System Control Module
U0131-87 Lost Communication with Electronic Power Steering Module 38
U0140-87 Lost Communication with Body Control Module
U0151-87 Lost Communication with Air Bag Module
U0164-87 Lost Communication with Climate Module
U0214-87 Lost Communication with Passive Entry Passive Start Unit
U0128-87 Lost Communication with Electric Park Brake
U0245-87 Lost Communication with Radio Receiver Module
U0127-87 Lost Communication with Tire Pressure Monitor Module
U0141-87 Lost Communication with RADAR

DTC B1100-13 Power Supply Fault

ON OR START
IP FUSE AND
RF10 RF01 RELAY BOX
10A 10A I-032
33 7
RY
R
38
11 13
INSTRUMENT
CLUSTER
I-011
3
B
I-005
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I-011
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 L
EA13T380030

DTC Detection
Condition
B1100-13 Power Supply Fault  Charging system
B1100-16 Power Supply Fault  Fuse
Ignition switch ON
 Instrument cluster

Confirm that battery voltage is between 11 and 14 V before performing following procedures.
 Using X-431 3G diagnostic tester, record and clear DTCs stored in instrument cluster control system.
CAUTION
 When performing circuit diagnosis and test, always refer to circuit diagram for specific circuit and 38
Diagnosis Procedure
OK
OK
3 Check fuse
a. Unplug fuses RF10 (10A), RF01 (10A) from instrument panel fuse and relay box.
NG Replace fuse

OK
4 Check instrument panel wire harness and connector

c. Disconnect the instrument panel wire harness connectors
I-032 and I-011.
body wire harness connector I-032 and instrument panel
wire harness connector I-011 according to table below.
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
Condition
Connection Condition I-011
I-032 (33) - I-011

Always Continuity
(11)
I-032 (07) - I-011
6 7 8 9
2
Always Continuity 10 11 12 13 22 23 24 25 26 27
(13)
3
1 4
14 15 16 17 28
5 24
25 29
18 19 20 21
e. Connect the instrument panel wire harness connector  32 33

36 37 38 39 40 41 42 43 44
I-032.
34 35
45 46 47 48
38 f. Connect the negative battery cable. 49 50 51 53 55
58
56
59
57
60
g. Turn ignition switch to ON.

I-032
RA13T380011
h. Using a digital multimeter, measure voltage between

instrument panel wire harness connector I-011 and body
ground according to table below to check if system power
supply control circuit is normal.
V
+ -
Condition
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
I-011 (11) - Body
Ignition switch ON 11 to 14 V 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
ground
I-011 (13) - Body
Ignition switch ON 11 to 14 V I-011
ground

RA13T380020
OK
5 Reconfirm DTCs


d. Use X-431 3G diagnostic tester (the latest software) to record and clear DTCs stored in instrument cluster
control system.
g. Use X-431 3G diagnostic tester (the latest software) to read DTCs stored in instrument cluster control
system again.
NG Replace instrument cluster
OK
System is normal
38

DTC B1101-11 ICM Fuel System Fault
DTC B1101-15 ICM Fuel System Fault
38


ON OR START
IP FUSE AND
RF10 RF01 RELAY BOX
10A 10A I-032
33 7
RY
R
11 13
INSTRUMENT
CLUSTER
I-011
5 21 3
WR
B
L
I-002
7 8
B-019 I-005 38
L
1 FUEL PUMP
MOTOR &
FUEL LEVEL
SENSOR
2 B-008
WR
10 9 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I-011 20 19 18 17 16 15 14 13 12 11
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 L
I-002
W
1 2 3 4
B-008
B
EA13T380040

DTC Detection
Condition
B1101-11 ICM Fuel System Fault  Fuel level sensor
ICM Fuel System Fault Ignition switch ON  Instrument cluster
B1101-15

CAUTION
38 component information.
Diagnosis Procedure
1 Check fuel level sensor wire harness andconnector

c. Disconnect fuel level sensor and fuel pump assembly connector B-008.
d. Check wire harness, connector and terminal for deformation, bend or damage.
NG Repair or replace fuel level sensor wire

OK
2 Check fuel level sensor
a. Connect the negative battery cable.

c. Read the remaining fuel amount segments from fuel
gauge in instrument cluster.
d. Turn ignition switch to LOCK.
e. Disconnect the negative battery cable.

f. Disconnect fuel level sensor and fuel pump assembly

connector B-008.
g. Using a digital multimeter, measure resistance between
fuel level sensor terminals 1 and 2.
h. Check if fuel level sensor is normal according to the
correspondence between oil amount segments and
standard resistance of fuel level sensor shown in table + -
below.
5 4 3 2 1
Fuel Level Multimeter

Specification (Ω)
Indictor Connection
Terminal 1 -
E 177 ± 5
Terminal 2
RA13T380030
Terminal 1 -
1/4 125 ± 4
Terminal 2
Terminal 1 -
1/4 93 ± 4
Terminal 2
Terminal 1 -
3/4 62 ± 3
Terminal 2
Terminal 1 -
F 20 ± 3
Terminal 2
NG Replace fuel pump assembly

38
OK
3 Check body wire harness and connector

c. Disconnect body wire harness connector B-008 and
instrument panel wire harness connector I-011.
body wire harness connectors B-008 and I-011 according
to table below.
Condition
B-008 (01) - I-011
Always Continuity 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
(21) 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
B-008 (02) - I-011

Always Continuity
(05) I-011
NG Repair or replace body wire harness and

connector 1 2 3 4
B-008
RA13T380040

OK
4 Reconfirm DTCs

control system.
g. Use X-431 3G diagnostic tester (the latest software) to read DTCs stored in instrument cluster system
again.
OK
System is normal
38

DTC B1103-00 Airbag Warning Light Fault
DTC U0151-87 Lost Communication with Air Bag Module
BCM (B)
I-034
CAN2-H CAN2-L
CAN1-L CAN1-H
CAN1-L CAN1-H
CAN1-L CAN1-H
INSTRUMENT 29 Y B2 B3 Y 2 SRS CONTROL
CLUSTER
MODULE
I-011 30 G B15 B16 G 17
I-020
38
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I-011 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I-020
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 L 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 Gr
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034

B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
EA13T530050

DTC Detection
Condition
Airbag Warning Light
B1103-00  Airbag system
Fault
Lost Communication
U0151-87  Instrument cluster
with Air Bag Module

CAUTION
38  When performing circuit diagnosis and test, always refer to circuit diagram for specific circuit and
Diagnosis Procedure
1 Check airbag
a. Remove airbag from malfunctioning vehicle and install it to a new vehicle and perform a test.
b. Connect all connectors.
c. Connect the negative battery cable, and turn ignition switch to ON.
d. Check the operation of airbag.
NG Replace airbag
OK
2 Check airbag control module (SRS)
a. Remove airbag control module (SRS) from malfunctioning vehicle, and install it to a new vehicle and
perform a test.
d. Check the operation of airbag control module (SRS).
NG Replace airbag control module (SRS)

OK
3 Check connector and terminal

c. Disconnect the airbag control module (SRS) connector I-020.
NG Repair or replace connector and terminal
OK
4 Check CAN line (instrument cluster - BCM)

I-011 and I-034.
instrument panel wire harness connectors I-029 and  38
I-011 according to table below.
Condition
I-034 (B2) - I-011
(29) 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-034 (B15) -
Always Continuity
I-011 (30) I-011
NG Repair or replace CAN line B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12

B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
I-034
RA13T380050
OK
5 Check CAN line (BCM - airbag control module(SRS))

I-034 and I-020.


instrument panel wire harness connectors I-020 and 
Multimeter Specified + - B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12

Condition
Connection Condition B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
I-034
I-034 (B3) - I-020
Always Continuity
(02)
I-034 (B16) -
Always Continuity
I-020 (17) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17

I-020
RA13T380090
OK
6 Reconfirm DTCs

38 b. Connect the negative battery cable.
control system.
again.
OK
System is normal

DTC B1104-41 EEPROM Checksum Error
DTC Detection
Condition
EEPROM Checksum
B1104-41 Ignition switch ON  Instrument cluster
Error

CAUTION 38
Diagnosis Procedure
1 Reconfirm DTCs
a. Use X-431 3G diagnostic tester (the latest software) to clear DTCs stored in instrument cluster control
system.
b. Turn ignition switch to LOCK and wait for a few seconds.
d. Use X-431 3G diagnostic tester (the latest software) to read DTCs stored in instrument cluster control
system again.
e. Read DTCs.
Result Proceed to
DTC B1104-41 is output NG
No DTC is output OK
OK

2 Check airbag control module (SRS)
a. Remove airbag control module (SRS) from malfunctioning vehicle, and install it to a new vehicle and
perform a test.
d. Check the operation of airbag control module (SRS).
NG Replace airbag control module (SRS)
OK

c. Disconnect the airbag control module (SRS) connector I-020.
38
OK
System is normal

Lost Communication with Engine Control System

DTC U0100-87
Module
BCM (B)
I-034
CAN2-H CAN2-L
CAN1-L CAN1-H
CAN1-L CAN1-H
CAN1-L CAN1-H
INSTRUMENT 29 Y B2 B3 Y A23
CLUSTER ECM(A)
I-011 30 G B15 B16 G A11 E-041
38
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37 E-041
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
B
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
I-011
L
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034

B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
EA13T530060

DTC Detection
Condition
Lost Communication  Engine Control Module (ECM)
U0100-87 with Engine Control Ignition switch ON  Instrument cluster
System Module
 CAN communication

CAUTION
Diagnosis Procedure
1 Check Engine Control Module (ECM)
a. Remove Engine Control Module (ECM) from malfunctioning vehicle, and install it to a new vehicle and
perform a test.
d. Check the operation of Engine Control Module (ECM).
NG Check operation of Engine Control

Module (ECM)
OK

c. Disconnect the Engine Control Module (ECM) connector E-041.

OK

I-011 and I-034.
Condition
I-034 (B2) - I-011
(29) 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-034 (B15) -
Always Continuity
I-011 (30) I-011

B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
I-034
38
RA13T380050
OK
4 Check CAN line (BCM - ECM)

c. Disconnect instrument panel wire harness connector 
I-034 and engine compartment wire harness connector
E-041.


instrument panel wire harness connector I-034 and
engine compartment wire harness connector E-041 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
according to table below. B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
+ - I-034
Condition
I-034 (B16) -
Always Continuity
E-041 (A11) A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37

I-034 (B3) -
Always Continuity A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
E-041 (A23) A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041 RA13T380060
OK
5 Reconfirm DTCs

control system.
again.
h. Read DTCs.
Result Proceed to
DTC B1104-41 is output NG
No DTC is output OK
OK
System is normal

DTC U0101-87 Lost Communication with Transmission Control Unit
BCM (B)
I-034
CAN2-H CAN2-L
CAN1-L CAN1-H
CAN1-L CAN1-H
CAN1-L CAN1-H
INSTRUMENT 29 Y B2 B3 Y 31
CLUSTER TCU
I-011 30 G B15 B16 G 32 E-069
38
1 2 3 4 5 6 7 8 9 10 41 42
11 12 13 14 15 16 17 18 19 20 43 44
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 E-069
21 22 23 24 25 26 27 28 29 30 45 46 B
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
31 32 33 34 35 36 37 38 39 40 47 48
I-011
L
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034

B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
EA13T380070

DTC Detection
Condition
Lost Communication  Transmission Control Unit (TCU)
U0101-87 with Transmission Ignition switch ON  Instrument cluster
Control Unit

CAUTION
Diagnosis Procedure
1 Check Transmission Control Unit (TCU)
a. Remove Transmission Control Unit (TCU) from malfunctioning vehicle, and install it to a new vehicle and
perform a test.
d. Check the operation of Transmission Control Unit (TCU).
NG Replace Transmission Control Unit (TCU)
OK

c. Disconnect the Transmission Control Unit (TCU) connector E-069.

OK

I-011 and I-034.
Condition
I-034 (B2) - I-011
(29) 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-034 (B15) -
Always Continuity
I-011 (30) I-011

B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
I-034
38
RA13T380050
OK
4 Check CAN line (BCM - TCU)

E-069.


instrument panel wire harness connectors I-034 and
engine compartment wire harness connector E-069
according to table below. B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
+ - B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
Multimeter Specified I-034

Condition
I-034 (B16) -
Always Continuity
E-069 (32) 1 2 3 4 5 6 7 8 9 10 41 42
I-034 (B16) - 11 12 13 14 15 16 17 18 19 20 43 44
Always Continuity
E-069 (31) 21 22 23 24 25 26 27 28 29 30 45 46
31 32 33 34 35 36 37 38 39 40 47 48
NG Repair or replace CAN line E-069
RA13T380070
OK
5 Reconfirm DTCs

control system.
again.
h. Read DTCs.
Result Proceed to
DTC U0101-87 is output NG
No DTC is output OK
OK
System is normal

DTC U0129-87 Lost Communication with Brake System Control Module
BCM (B)
I-034
CAN2-H CAN2-L
CAN1-L CAN1-H
CAN1-L CAN1-H
CAN1-L CAN1-H
INSTRUMENT 29 Y B2 B3 Y 2
CLUSTER ESP
I-011 30 G B15 B16 G 14 E-051
38
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
E-051
I-011 B
L
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034

B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
EA13T380080

DTC Detection
Condition
Lost Communication  Brake control module (ABS)
U0129-87 with Brake System Ignition switch ON  Instrument cluster
Control Module

CAUTION
Diagnosis Procedure
1 Check brake control module (ABS)
a. Remove brake control module (ABS) from malfunctioning vehicle, and install it to a new vehicle and
perform a test.
d. Check the operation of brake control module (ABS).
NG Replace brake control module (ABS)
OK

c. Disconnect the brake control module (ABS) connector E-051.

OK
3 Check CAN line (instrument cluster - ABS)

I-011 and I-034.
Condition
I-034 (B2) - I-011
(29) 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-034 (B15) -
Always Continuity
I-011 (30) I-011

B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
I-034
38
RA13T380050
OK
4 Check CAN line (BCM - ABS)

E-051.


instrument panel wire harness connector I-034 and
engine compartment wire harness connector E-051
+ - B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
Multimeter Specified B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
Condition
Connection Condition I-034
I-034 (B16) -
Always Continuity
E-051 (14)
I-034 (B3) -
Always Continuity 12 11 10 9 8 7 6 5 4 3 2
E-051 (02)
13 1
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-051
RA13T380080
OK
5 Reconfirm DTCs

control system.
again.
h. Read DTCs.
Result Proceed to
No DTC is output OK
OK
System is normal

DTC U0140-87 Lost Communication with Body Control Module
CAN2-H CAN2-L
CAN1-L CAN1-H
INSTRUMENT 29 Y B2
CLUSTER BCM (B)
I-011 30 G B15 I-034
38
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
I-011
L
EA13T380090

DTC Detection
Condition
Lost Communication  Body Control Module (BCM)
U0140-87 with Body Control Ignition switch ON  CAN communication
Module

CAUTION
Diagnosis Procedure
1 Check Body Control Module (BCM)
a. Remove Body Control Module (BCM) from malfunctioning vehicle, and install it to a new vehicle and
perform a test.
d. Check the operation of Body Control Module (BCM).
NG Replace Body Control Module ( BCM)
OK

c. Disconnect the Body Control Module (BCM) connector I-034.

OK

I-011 and I-034.
Condition
I-034 (B2) - I-011
(29) 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-034 (B15) -
Always Continuity
I-011 (30) I-011

B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
I-034
38
RA13T380050
OK
4 Reconfirm DTCs

control system.
again.
h. Read DTCs.
Result Proceed to
No DTC is output OK

OK
System is normal
38

DTC U0245-87 Lost Communication with Radio Receiver Module
CAN2-L CAN2-H
CAN2-H CAN2-L
RADAR 5 G 30 INSTRUMENT
CONTROL
MODULE 13 Y 29
CLUSTER 38
I-011
B-004
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I-011
1 2 3 4 5 6 7 8 B-004 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 L
9 10 11 12 13 14 15 16 W
EA13T380110

DTC Detection
Condition
Lost Communication  Audio module
U0245-87 with Radio Receiver Ignition switch ON  CAN communication
Module

CAUTION
Diagnosis Procedure
1 Check audio module (AUDIO)
a. Remove audio module (AUDIO) from malfunctioning vehicle, and install it to a new vehicle and perform a
test.
d. Check the operation of audio module (AUDIO).
NG Replace audio module (AUDIO)
OK

c. Disconnect the audio module (AUDIO) connector I-016.

OK
3 Check CAN line (instrument cluster - AUDIO)

I-011 and I-016.
Condition
I-016 (C1) - I-011
(30) 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-016 (C7) - I-011

Always Continuity
(29)
I-011

C6 C5 C4 C3 C2 C1
C12 C11 C10 C9 C8 C7 38

I-016
RA13T380100
OK
4 Reconfirm DTCs

control system.
again.
h. Read DTCs.
Result Proceed to
No DTC is output OK

OK
System is normal
38

ON-VEHICLE SERVICE
Instrument Cluster
Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing instrument cluster.
 Operate carefully to prevent components from being damaged, when removing instrument cluster.
 DO NOT scratch interior and body paint, when removing instrument cluster.

3. Remove the instrument cluster.
a. Remove fixing screw (arrow) from lower part of
combination switch cover.
38
RA13T380120
b. Remove combination switch upper cover (1) and

instrument panel trim frame assembly (2).
2
RA13T380130
c. Remove 4 fixing screws (arrow) from lower part of

instrument cluster.
RA13T380140

d. Remove 1 instrument cluster connector (arrow).
RA13T380150
Installation
CAUTION
 When installing instrument cluster, be sure to align instrument cluster positioning hole with instrument
panel dowel pin, and clamp clips in place.
 When installing instrument cluster, be sure to install connector in place.
 When installing instrument cluster, be sure to tighten fixing screws in place.
 Operate carefully to prevent other components from being damaged, when installing instrument cluster.
38

AUDIO SYSTEM
Description 39-3 No Disc DVD 39-33
Tool 39-4 Inspection 39-34
Door Speaker 39-35
Removal 39-35
Inspection 39-36
Installation 39-36
Rear Speaker 39-37
Removal 39-37
Inspection 39-38
Installation 39-38
Chart 39-12 Antenna Assembly 
(w/ antenna amplifier) 39-39
B1800-16 39-13
Removal 39-39
B1800-17 39-13
Inspection 39-39
B1810-00 39-19
Installation 39-39
B1811-00 39-21
Multi-function Interface 39-40
B1812-00 39-23
Removal 39-40
B1814-00 39-26
Installation 39-40
B1830-04 39-30
Steering Wheel Quick Button 
39
B1831-04 39-30
(if equipped) 39-41
B1832-04 39-30
Removal 39-41
B1833-04 39-30
Inspection 39-42
B1834-04 39-30
Installation 39-43
B1835-04 39-30

39

39 - AUDIO SYSTEM
GENERAL INFORMATION
AUDIO SYSTEM
Description
MO
OE
SET
0 1
2
3
3
4
A/C
1
3
5
2
4
R
4 39
5 6
RA13T390010
1 - Steering Wheel Quick Button (If Equipped) 2 - No Disc CD Control Panel

3 - Multi-function Interface 4 - Antenna Assembly (w/ Antenna Amplifier)
5 - Rear Right Speaker Assembly 6 - Rear Left Speaker Assembly
7 - Front Left Speaker Assembly 8 - Front Right Speaker Assembly

39 - AUDIO SYSTEM
Audio system mainly consists of No Disc DVD, speakers and antenna.

No Disc DVD mainly consists of No Disc DVD, No Disc DVD control panel and multi-function interface.
This model is equipped with 4 speakers.
Antenna system primarily refers to antenna assembly (w/ antenna amplifier).
Specifications

No Disc CD Fixing Screw 3 ± 0.5
Front Speaker Fixing Screw 2.0 ± 0.5
Rear Speaker Fixing Bolt 2.0 ± 0.5
Rear Left Speaker Cover Assembly Fixing Bolt 2.5 ± 0.5
Tool
Special Tool
ཽ⪔⊳䖜
39
RCH0000001
General Tool
Digital Multimeter
RCH0000002

39 - AUDIO SYSTEM
Circuit Diagram
Audio System (Page 1 of 3)

BATTERY
ON OR ACC ON OR START
IP FUSE AND
RF09 RF26 RF07 RELAY BOX
10A 10A 10A I-032
32 55 19
CAMERA
J-009
4 2 3 1
YR
RL
R
J-001
10 9 11 12 B-007
TO CAN
SYSTEM
39
YR
R
2 1 3 4 B-019
I-002
ILLUMINTION
YR
Br
Y
R
B15 B13 C2 C11 C5 C12 C6 C7 C1 B16

CAN2-L CAN2-H
AUDIO (B/C) I-015 I-016
B9 B10 B11 B12

10 9 8 7 6 5 4 3 2 1 7 6 5 4 3 2 1
B13 B14 B15 B16 14 13 12 11 10 9 8
20 19 18 17 16 15 14 13 12 11
I-015
B I-002
W
C6 C5 C4 C3 C2 C1
3 1 B-007
C12 C11 C10 C9 C8 C7 W
4 2
I-016
L
J-009
B
EA13T390010

39 - AUDIO SYSTEM
AUDIO (A) I-014
A3 A7 A2 A6 A4 A8 A1 A5
Gr
Br
W
G
P
L
I-001
10 11 1 2 3 4 8 9 B-017
Gr
G
V
16 17 B-016 B-023
Br
W
P
F-005 8 9 H-008
Gr
G
1 2 1 2 1 2 1 2
39

DOOR SPEAKER DOOR SPEAKER SPEAKER SPEAKER
F-006 H-006 B-002 B-030
A1 A2 A3 A4
9 8 7 6 5 4 3 2 1
1 1 1 1
A5 A6 A7 A8
18 17 16 15 14 13 12 11 10 2 2 2 2
I-014
Y B-002 B-030 F-006 H-006
I-001
W B B B B
1 2 3 4 5 6 7 8 9 10 11 12 13 9 8 7 6 5 4 3 2 1
14 15 16 17 18 19 20 21 22 23 24 25 26
18 17 16 15 14 13 12 11 10
B-023
B-016 W
W EA13T390020

39 - AUDIO SYSTEM
AUDIO (B) I-015
B9 B10 D1 D2 D3 D4 B14 E1 B12
LY
B
YW
YR
I-003
10
C-001
10 5
CLOCK
SPRING
LY
I-031 I-006
1 2 3 4 1
AP1 Signal
USB
ANTENNA
AMPLIFIER
39
C-004
B9 B10 B11 B12 8 7 6 5 4 3 2 1

1 2 3 4 5 1
B13 B14 B15 B16
16 15 14 13 12 11 10 9 6 7 8 9 10
I-015 C-004
B W
I-031 I-003
W W
EA13T390030

39 - AUDIO SYSTEM
DIAGNOSIS & TESTING

HINT:

Noise source (interference) -
Noise occurs
No Disc DVD control panel
39-33
(malfunction)
No Disc DVD assembly does not No Disc DVD fuse (blown) 55-29
operate No Disc DVD (malfunction) 39-33
Wire harness and connector
-
(malfunction)
System setting (incorrect) -
Speaker assembly 39-35
No sound can be heard from speakers Speaker assembly -
39 No Disc DVD control panel 39-33

Wire harness and connector -
No Disc DVD control panel
39-33
(malfunction)
No Disc CD (malfunction) 39-33
Radio broadcast signal cannot be
Optional equipment (interference) -
received (poor reception)
Antenna assembly (malfunction) 39-39
Wire harness and connector
-
(malfunction)
HINT:
When checking general malfunctions of audio system, perform inspection at spacious area nearby that is free
of obstacles.

39 - AUDIO SYSTEM
Diagnosis Tools
with vehicle.
 DLC is located at the lower protector on left side of insturment panel.
Digital Multimeter
Diagnostic Help
1. Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC), and make it
3. If DTC cannot be cleared, the malfunction is current.
39
7. Check and clean all CD system grounds related to the latest DTC.

 If malfunction is intermittent, perform the followings:
 If possible, try to duplicate the conditions under which the DTC was set.
 Look for the data that has changed or the DTC to be reset during the wiggle test.
 Check the installation of audio system, wire harness or wire harness connector and so on for damage,
foreign matter, etc. that may cause incorrect signals.
 Check and clean all wire harness connectors and grounding parts related to the DTC.
 Remove No Disc DVD from the malfunctioning vehicle and install it to a new vehicle and perform a test.If
the DTC cannot be cleared, No Disc DVD is malfunctioning. If the DTC can be cleared, reinstall the No
Disc DVD to original vehicle.

39 - AUDIO SYSTEM
Ground Inspection
Groundings are very important to entire circuit system, and whether they are normal or not can seriously affect
the entire circuit system. Ground points are often exposed to moisture, dirt and other corrosive environments.
Corrosion (rust) and oxidation may increase load resistance. This situation will seriously affect the normal
operation of circuit.Ground points inspections are as follows:
1. Remove the ground bolt or nut.
Make sure all wire harnesses are clean, securely fastened and can provide a good ground path.
Diagnosis Procedure
HINT:
Use following procedures to troubleshoot the audio system.
NEXT
39 2 Check battery voltage
NEXT
NEXT
DTC
Go to step 5
occurs
NO
Go to next step
DTC
NEXT

39 - AUDIO SYSTEM
NEXT
NEXT
NEXY
NEXT
NEXT 39
10 END

39 - AUDIO SYSTEM

Trouble Type Byte
Description
(Hexadecimal)
B1800-16 Power Supply voltage failure
B1800-17 Power Supply voltage failure
B1810-00 Front Panel Button Failure
B1811-00 Steering Button Failure
B1812-00 Speed signal abnormal
B1813-00 Speakers connected to Amplifier failure
B1814-00 Tuner Antenna abnormal
B1830-04 Amplifier R/W Failure
B1831-04 EEPROM R/W Failure
B1832-04 Tuner IC R/W Failure
B1833-04 PMIC of Main Processor R/W Failure
B1834-04 Voice Recognition IC R/W Failure
B1835-04 Communication Failure between MCU and Main Processor
U0140-87 Lost Communication With BCM
U0155-87 Lost Communication With ICM
39 U0141-87 Lost Communication With RADAR
U0164-87 Lost Communication With CLM
U0129-87 Lost Communication With BSM
U0126-87 Lost Communication With SAM
U0001-00 High Speed CAN Communication Bus
U0127-87 Lost Communication With Tire Pressure Monitor Module

39 - AUDIO SYSTEM
DTC B1800-16 Power Supply voltage failure
DTC B1800-17 Power Supply voltage failure
39

39 - AUDIO SYSTEM

BATTERY
IP FUSE AND
10A 10A 10A I-032
32 55 19
RL
R
39
B15 B13 C2
AUDIO (B/C) I-015 I-016
B9 B10 B11 B12

C6 C5 C4 C3 C2 C1
B13 B14 B15 B16
C12 C11 C10 C9 C8 C7
I-015
B I-016
L
EA13T390040

39 - AUDIO SYSTEM
DTC Detection
Condition
Power Supply voltage  Charging system
B1800-16
failure Ignition switch ON  Fuse
Power Supply voltage Engine running  Ignition switch assembly
B1800-17 failure  Wire harness or connector

Confirm that battery voltage is between 11 V and 14 V before performing following procedures.
 Use X-431 3G diagnostic tester to record and clear DTCs stored in DVD system.
CAUTION
39
Diagnosis Procedure
1 Check battery
OK
OK
3 Check fuse
a. Unplug fuses RF09 (10A), RF26 (10A) and RF07 (10A)

from instrument panel fuse and relay box.
b. Check the resistance of fuses RF09 (10A), RF26 (10A)
and RF07 (10A).

39 - AUDIO SYSTEM
NG Replace fuse
OK
4 Check ignition switch assembly
a. Check the ignition switch assembly (See page 15-12).
OK
5 Check instrument panel wire harness

c. Disconnect the instrument panel wire harness connector
I-015.
f. Using a digital multimeter, measure the voltage between
instrument panel wire harness I-015 and vehicle body
39 according to the table below.
V
Multimeter + -
Specified
Condition
Terminal
B9 B10 B11 B12
I-015 (B15) - B13 B14 B15 B16

Always 11 - 14 V
Body ground I-015
I-015 (B13) -
Always 11 - 14 V
Body ground
g. Turn ignition switch to LOCK.

h. Disconnect the negative battery cable.
i. Connect all connectors.
j. Disconnect the instrument panel wire harness connector RA13T390020
RM1A370500
I-016.
k. Connect the negative battery cable.
l. Turn ignition switch to ON.

39 - AUDIO SYSTEM
m. Using a digital multimeter, measure the voltage between

instrument panel wire harness I-016 and vehicle body
according to the table below.
V
Multimeter + -
Specified
Condition
Terminal C6 C5 C4 C3 C2 C1
I-016 (C2) - Body

Always 11 - 14 V C12 C11 C10 C9 C8 C7
ground I-016
RA13T390030
RM1A370500
n. Using a digital multimeter, check for continuity between

instrument panel fuse and relay box I-032 and instrument
panel connector I-016 according to the table below.
Specified + -
6 7 8 9
2
22 23 24 25 26 27
Condition
10 11 12 13
3
1 4
14 15 16 17 28
5 24
29
I-032 (19) - I-016 (C2) Continuity

25
18 19 20 21
32 33
36 37 38 39 40 41 42 43 44
34 35
39
45 46 47 48
49 50 51 53 55 56 57
58 59 60
I-032
C6 C5 C4 C3 C2 C1
C12 C11 C10 C9 C8 C7
I-016
RA13T390400
RM1A370500
o. Disconnect the instrument panel wire harness I-016.

p. Using a digital multimeter, check for continuity between
instrument panel fuse and relay box I-032 and instrument
panel connector I-015 according to the table below.
6 7 8 9
+ - 2
10 11 12 13 22 23 24 25 26 27
3
Specified
1 4
14 15 16 17 28
5 24
Condition
25 29
18 19 20 21
32 33
36 37 38 39 40 41 42 43 44
I-032 (32) - I-015 (B15) Continuity

34 35
45 46 47 48
I-032 (55) - I-015 (B13) Continuity

49 50 51 53 55 56 57
58 59 60
I-032
harness B9 B10 B11 B12
B13 B14 B15 B16
I-015
RA13T390410
RM1A370500

39 - AUDIO SYSTEM
OK
6 Reconfirm DTCs

d. Use X-431 3G diagnostic tester (the latest software) to
record and clear the DTCs stored in No Disc DVD control
system.
g. Use X-431 3G diagnostic tester (the latest software) to
read the DTC stored in No Disc DVD control system
again.
NG Replace No Disc DVD
OK
System is normal
39

39 - AUDIO SYSTEM
DTC B1810-00 Front Panel Button Failure
DTC Detection
Condition
Front Panel Button
B1810-00 Ignition switch: ON  No Disc DVD control panel
Failure

 Use X-431 3G diagnostic tester to record and clear DTC stored in CD system.
Diagnosis Procedure
1 Check No Disc DVD control panel operation.
a. Remove the No Disc DVD control panel from

39
malfunctioning vehicle and install it to a new vehicle and
perform a test.
c. Connect the negative battery cable, and turn ignition
switch to ON.
d. Check No Disc DVD control panel operation.
NG Repair No Disc DVD control panel
OK
2 Reconfirm DTCs

system.
again.

39 - AUDIO SYSTEM
OK
System is normal
39

39 - AUDIO SYSTEM
DTC B1811-00 Steering Button Failure
DTC Detection
Condition
B1811-00 Steering Button Failure Ignition switch: ON  Steering wheel quick button

Diagnosis Procedure
1 Check steering wheel quick button

39
b. Remove the driver airbag (See page 31-45).
c. Check the steering wheel quick button (See page 39-41).
NG Replace steering wheel quick button
OK
2 Reconfirm DTCs

system.
again.

39 - AUDIO SYSTEM
OK
System is normal
39

39 - AUDIO SYSTEM
DTC B1812-00 Speed signal abnormal
ESP E-051
CAN1-H CAN1-L
14 2
Y
G
E-054
6 5
I-018
B16 B3
CAN1-H CAN1-L
BCM (B)
I-034
CAN2-H CAN2-L
B15 B2
39
Y
G
C1 C7
CAN2-H CAN2-L
AUDIO (C) I-016
C6 C5 C4 C3 C2 C1
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034 I-016
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W C12 C11 C10 C9 C8 C7 L
E-051
12 11 10 9 8 7 6 5 4 3 2 E-054
13 1
B 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 W
10 9 8 7 6 5
38 37 36 35 34 33 32 31 30 29 28 27 26 25
EA13T390050

39 - AUDIO SYSTEM
DTC Detection
Condition
 Vehicle speed sensor
B1812-00 Speed signal abnormal Ignition switch: ON
 CAN bus

CAUTION
39 Diagnosis Procedure
1 Check vehicle speed sensor
a. Check the vehicle speed sensor.
NG Replace vehicle speed sensor
OK
2 Check CAN bus (No Disc DVD - BCM)

c. Disconnect No Disc DVD connector I-016 and BCM
connector I-034.

39 - AUDIO SYSTEM

BCM connector I-034 and No Disc DVD connector I-026
according to the table below.
Specified + -
Condition
I-034 (B2) - I-016 (C7) Continuity
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
I-034 (B15) - I-016 (C1) Continuity B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
I-034
NG Repair or replace CAN bus
C6 C5 C4 C3 C2 C1
C12 C11 C10 C9 C8 C7
I-016
RA13T390420
RM1A370500
OK
3 Check CAN bus (BCM-EPS (ABS))
NG Repair or replace CAN bus
OK 39
4 Reconfirm DTC

system.
again.
OK
System is normal

39 - AUDIO SYSTEM
DTC B1814-00 Tuner Antenna abnormal

BATTERY
IP FUSE AND
10A 10A 10A I-032
32 55 19
RL
R
P
B15 B13 C2
AUDIO (B/C) I-015 I-016
B14 E1 B12
39
LY
I-003
10
C-001
LY
I-006
1
AP1 Signal
ANTENNA
AMPLIFIER
C-004
B9 B10 B11 B12
B13 B14 B15 B16 1
I-015 C-004
B W
1 2 3 4 5
C6 C5 C4 C3 C2 C1 6 7 8 9 10
C12 C11 C10 C9 C8 C7

I-003
I-016 W
L
EA13T390060

39 - AUDIO SYSTEM
DTC Detection
Condition
 Antenna assembly (/ amplifier)
B1812-00 Speed signal abnormal Ignition switch: ON  No Disc DVD
 Wire harness and connector

CAUTION
39
Diagnosis Procedure
1 Check battery
OK
OK
3 Check antenna assembly (w/ amplifier)
a. Remove antenna assembly (w/ amplifier) from

malfunctioning vehicle and install it to a new vehicle and
perform a test.
b. Check radio operation

39 - AUDIO SYSTEM
NG Replace antenna assembly (w/ amplifier)
OK
4 Check ignition switch assembly
a. Check the ignition switch assembly (See page 15-12).
OK
5 Check wire harness and connector betweenradio and antenna

c. Disconnect the instrument panel wire harness connector
I-015.
d. Disconnect the antenna wire harness connector C-004.
instrument panel wire harness I-015 and anntena
connector I-024 according to the table below.
39
Multimeter + -
Specified
Condition
Terminal B9 B10 B11 B12
B13 B14 B15 B16

I-015 (B14) -
Always Continuity I-015
C-004-(AP1)
NG Repair or replace audio antenna wire

harness andconnector 1
C-004
W
RA13T390430
RM1A370500
OK
6 Reconfirm DTC

system.

39 - AUDIO SYSTEM

again.
OK
System is normal
39

39 - AUDIO SYSTEM
DTC B1830-04 Amplifier R/W Failure
DTC B1831-04 EEPROM R/W Failure
DTC B1832-04 Tuner IC R/W Failure
DTC B1833-04 PMIC of Main Processor R/W Failure
DTC B1834-04 Voice Recognition IC R/W Failure
Communication Failure between MCU and Main

DTC B1835-04
Processor
39

39 - AUDIO SYSTEM

BATTERY
IP FUSE AND
10A 10A 10A I-032
32 55 19
RL
R
P
B15 B13 C2
AUDIO (B/C) I-015 I-016
B14 E1 B12
LY
I-003 39
10
C-001
LY
I-006
1
AP1 Signal
ANTENNA
AMPLIFIER
C-004
B9 B10 B11 B12
B13 B14 B15 B16 1
I-015 C-004
B W
1 2 3 4 5
C6 C5 C4 C3 C2 C1 6 7 8 9 10
C12 C11 C10 C9 C8 C7

I-003
I-016 W
L
EA13T390060

39 - AUDIO SYSTEM
DTC Detection
Condition
B1830-04 Amplifier R/W Failure
B1831-04 EEPROM R/W Failure
B1832-04 Tuner IC R/W Failure
PMIC of Main
B1833-04
Processor R/W Failure Ignition switch: ON  No Disc DVD
Voice Recognition IC
B1834-04
R/W Failure
Communication Failure
B1835-04 between MCU and
Main Processor

39  If DTC is detected, malfunction indicated by DTC is current. Go to diagnosis procedure - Step 1.
CAUTION
Diagnosis Procedure
1 Check No Disc DVD
a. Remove No Disc DVD from malfunctioning vehicle and

install it to a new vehicle and perform a test.
d. Check if No Disc DVD operates normally.
OK
System is normal

39 - AUDIO SYSTEM
ON-VEHICLE SERVICE
No Disc DVD
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing No Disc DVD.
 Appropriate force should be applied when removing the No Disc DVD. Be careful not to operate roughly.
 DO NOT scratch interior when removing No Disc DVD.

3. Remove the combination switch lower cover (See page 28-11).
4. Remove the combination switch upper cover (See page 38-49).
5. Remove the instrument cluster trim frame assembly (See page 38-49).
6. Remove center panel assembly with interior crow plate.
39
RA13T390040
7. Remove the No Disc DVD.

a. Remove 4 fixing screws from No Disc DVD.
RA13T390050
b. Disconnect No Disc DVD connector (1), USB

connector (2) and antenna (3).
1
RA13T390060

39 - AUDIO SYSTEM
c. Remove the No Disc DVD.
Inspection
1. Check No Disc DVD connector and terminal for deformation or damage. Replace it if necessary.
2. Check the connector for damage. Replace it if necessary.
3. Check housing of No Disc DVD for deformation or damage. Replace it if necessary.
Installation
Installation procedures are in the reverse order of removal.
CAUTION
 Operate carefully to prevent other components from being damaged when installing No Disc DVD.
 Be sure to tighten fixing screws to the specified torque when installing No Disc DVD.
 Install each connector in place when installing No Disc DVD.
 Check No Disc DVD for proper operation when installing No Disc DVD.
39

39 - AUDIO SYSTEM
Door Speaker
Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing door speaker.
 Appropriate force should be applied when removing the door speaker. Be careful not to operate roughly.
 DO NOT scratch front door inner protector assembly when removing door speaker.

3. Remove front left door speaker.
a. Remove the front left door protector assembly (See page 48-16).
b. Remove 4 screws (arrow) from front left speaker.
39
RA13T390070
c. Disconnect connector (1) from front left door speaker,

remove front left door speaker and protecting film (2).
RA13T390080

39 - AUDIO SYSTEM
Inspection
1. Inspect the door speaker.
a. Using a digital multimeter, measure the resistance of
door speaker as shown in the table.
+ -
Standard Resistance
1
Multimeter Specified 2
Condition
Terminal 1 - Terminal 2 Always Approx. 3.5 Ω
If result is not as specified, replace the door speaker.

RA13T390090
2. Check door speaker vibrating membrane for damage or deformation. Replace it if necessary.
3. Check if there is damaged door speaker connector, bent terminal or poor contact. Replace it if necessary.
Installation
CAUTION
 Operate carefully to prevent other components from being damaged when installing door speaker.
 Be sure to tighten fixing screws to the specified torque when installing door speaker.
 Install connector in place when installing door speaker.
39  Check if woofer operates normally when installing door speaker.

39 - AUDIO SYSTEM
Rear Speaker
Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing rear speaker.
 Appropriate force should be applied when removing the rear speaker. Be careful not to operate roughly.
 DO NOT scratch front door inner protector assembly when removing rear speaker.

3. Remove rear left door speaker.
a. Remove the hatrack assembly (See page 50-10).
b. Turn over luggage compartment left trim cover
assembly (1) partially, remove 2 plastic nuts fixing rear
left speaker cover assebmly (arrow).
39
1
RA13T390180
c. Remove 2 nuts fixing rear left speaker cover assembly

(arrow), and disconnect rear left speaker connector 1
(1).
RA13T390190
d. Remove rear left speaker cover assembly from C column upper protector.
e. Remove 4 fixing screws fixing rear left speaker from
rear left speaker cover assembly.
RA13T390200

39 - AUDIO SYSTEM
Inspection
1. Inspect the rear left speaker.
a. Using a digital multimeter, measure the resistance of
rear left speaker as shown in the table.
+ -
Standard Resistance
1 2
Condition
Terminal 1 - Terminal 2 Always Approx. 6.0 Ω
If result is not as specified, replace the rear left

speaker. RA13T390210
2. Check rear left speaker vibrating membrane for damage or deformation. Replace it if necessary.
3. Check if there is damaged left rear speaker connector, bent terminal or poor contact. Replace it if
necessary.
Installation
CAUTION
 Operate carefully to prevent other components from damage when installing rear left speaker.
 Be sure to tighten fixing screws to the specified torque when installing rear left speaker.
39  Install connector in place when installing rear left speaker.
 Check if woofer operates normally when installing rear left speaker.

39 - AUDIO SYSTEM
Antenna Assembly (w/ antenna amplifier)

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing antenna assembly (w/ antenna
amplifier).
 Appropriate force should be applied when removing the antenna assembly (w/ antenna amplifier). Be
careful not to operate roughly.
 DO NOT scratch interior when removing antenna assembly (w/ antenna amplifier).

3. Remove the ceiling assembly (See page 50-25).
4. Remove the antenna assembly (w/ antenna amplifier).
a. Disconnect antenna (1), connector (2) and connector
(3) from antenna assembly.
2
39
3
RA13T390100
b. Remove the antenna assembly (w/ antenna amplifier).
Inspection
1. Check the antenna assembly.
a. Check the antenna assembly for wear, cracks, deformation or damage. Replace it if necessary.
b. Check antenna assembly for loose connection or disconnection. Replace it if necessary.
c. Check terminals of antenna connector for deformation or bend. Replace it if necessary.
Installation
CAUTION
 Operate careful to prevent damage to other components when installing antenna assembly.
 Install each connector and antenna in place when installing antenna assembly.
 Check audio system for proper operation after installing antenna assembly.

39 - AUDIO SYSTEM
Multi-function Interface
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing multi-function interface.
 Appropriate force should be applied when removing the multi-function interface. Be careful not to operate
roughly.

3. Remove the multi-function interface.
a. Pry out multi-function interface (arrow) with a
A/C
OFF
39 RA13T390110
b. Disconnect multi-function interface connector (arrow),

and remove multi-function interface.
A/C
OFF
RA13T390120
Installation
CAUTION
 Operate carefully to prevent other components from being damaged when installing multi-function
interface.
 Install each connector and antenna in place when installing antenna assembly.
 Check multi-function interface for proper operation after installation.

39 - AUDIO SYSTEM
Steering Wheel Quick Button (if equipped)

Removal
WARNING
 Be sure to read the precautions for SRS airbag before removing steering wheel quick button (See page
31-45).
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing steering wheel quick button.
 Prevent damage to claws on steering wheel quick button trim cover, when removing steering wheel quick
button.

4. Remove the steering wheel quick button.
a. Disconnect the steering wheel quick button connector
(arrow). 39
RA13T390130
b. Pry off steering wheel trim frame (arrow) with a

RA13T390140

39 - AUDIO SYSTEM

off the claws (arrow) on steering wheel quick button,
and remove the fixing screw (1) from ground wire
harness.
RA13T390150
d. Press the steering wheel quick button.
FF
/O
ON
VOL
MO
OE
+
S/
RE
-
T/
SE
RA13T390160
Inspection
1. Check the steering wheel quick button.
a. Check the steering wheel quick button for damage. Replace it if necessary.
39 b. Check the steering wheel quick button connector for damage or poor terminal contact. Replace it if
necessary.
c. Check for continuity between steering wheel quick button connector and audio unit (No Disc CD).
Replace it if necessary.
d. Using a digital multimeter, measure the resistance of
steering wheel quick button according to the value(s)
in the table below. + -
Standard Resistance 1 2 3 4
5 6 7 8

FF
/O
ON
VOL
MO
OE
+
S/
RE
-
T/
SE
Terminal 3 -
MODE Approx. 10 kΩ
Terminal 8
RA13T390170
Terminal 3 -
VOL+ Approx. 1.39 kΩ
Terminal 8
Terminal 3 -
VOL- Approx. 3.62 kΩ
Terminal 8
Terminal 3 -
SEEK (UP) Approx. 0 Ω
Terminal 8
Terminal 3 -
SEEK (DOWN) Approx. 470Ω
Terminal 8
If result is not as specified, replace the steering wheel

quick button.

39 - AUDIO SYSTEM
Installation
CAUTION
 Operate carefully to prevent other components from being damaged when installing steering wheel quick
button.
 Install each connector in place when installing steering wheel quick button.
 Tighten fixing screws to the specified torque, when installing steering wheel quick button.
 Check steering wheel quick button for proper operation after installation.
39

- MEMO -

Description 40-3 Reversing Radar Sensor 40-8
Reversing Radar Normal Alarm  Installation 40-8
Display 40-3 Camera Assembly 40-9
Specification 40-4 Removal 40-9
Circuit Diagram 40-5 Reversing Radar Control Module 
Reversing Radar Control Module  Assembly 40-10
Assembly Terminal List 40-6 Removal 40-10
DIAGNOSIS & TESTING 40-7 Installation 40-10
40

40

40 - REVERSING RADAR SYSTEM
GENERAL INFORMATION
Description
1 2
3
40
RA13T400001
RM1A400010
1 - Instrument Cluster (Built-in Buzzer) 2 - Right Reversing Radar Sensor

3 - Reversing Radar Control Module Assembly 4 - Left Reversing Radar Sensor
5 - Center Left Reversing Radar Sensor -
Operation
Reversing radar system is an auxiliary system, intended to assist driver when reversing, consists of reversing
radar sensor (probe), reversing radar control module assembly and alarm device (instrument cluster built-in
buzzer).Reversing radar system is activated when shift lever is shifted to reverse range. When reversing radar
sensor detects obstacles behind vehicle, instrument cluster built-in buzzer will sound. This can help driver to
eliminate errors due to blind corners and blurred vision, improving the driving safety when reversing.
Reversing Radar Normal Alarm Display

Reversing radar system consists of three reversing radar sensors and one reversing radar control module
assembly.
When ignition switch is ON, shift lever is moved to reverse gear and vehicle is reversing at a speed below 5
km/h, reversing radar is activated. Corresponding measured message will be displayed on multi-information
display and a built-in buzzer will alarm.

The response mode of reversing radar system is buzzer response. Table below shows the correspondence
between buzzer response frequency and actual obstacle distance:
Alarm Type 1st Section 2nd Section 3rd Section 4th Section 5th Section
Pre-warning
Displayed Area Safe Area Amble Area Park Area Park Area
Area
Alarm Distance
＞ 150 95 - 150 65 - 90 40 - 60 ≤ 35
(cm)
1Hz(ON 2 Hz (ON 4Hz (ON
Buzzer Sound No Sound
500ms/OFF 250ms/OFF 125ms/OFF Continuous Sound
Frequency (OFF)
500ms) 250ms) 125ms)
Specification

Fixing Bolt Between Reversing Radar Control
5±1
Module Assembly and Body
Tool
General Tool
40
Digital Multimeter
RCH0000002

Circuit Diagram
Reversing Radar System
IGNITION SWITCH
ON OR START
ENGINE
COMPARTMENT
EF08 FUSE AND
10A RELAY BOX
E-067
40
TO CAN
GW
SYSTEM
E-026
7
B-015
G
Y
R
B
B-006
3 13 5 14 16
CAN2-L CAN2-H
RADAR
CONTROL
MODULE
B-004
7 8 12 11 15
RW
G
Y
L
2 3 5 8 4 B-007 40
J-001
RW
RW
RW
B
B
G
Y
L
1 2 3 1 2 3 1 2 3
LEFT RADAR SENSOR CENTER RADAR SENSOR RIGHT RADAR SENSOR

J-003 J-005 J-007
1 2 3 4 5 6 7 8 2
1 2 3 4 5 6 7 8 7 6 5 4 3 2 1
9 10 11 12 13 14 15 16
9 10 11 12 13 14 15 16 14 13 12 11 10 9 8 1 3
B-015 B-004 J-003 J-005 J-007

W W B B B
B-007
W
EA13T400010

Reversing Radar Control Module Assembly Terminal List

1 - 9 -
2 - 10 -
3 IG Power 11 Sensor Power
4 - 12 Sensor Ground
5 CAN2-H 13 CAN2-L
6 - 14 Ground
7 Left Radar Sensor Signal 15 Right Radar Sensor Signal
8 Center Radar Sensor Signal 16 Ground
40

DIAGNOSIS & TESTING

HINT:

Back-up light switch 35-85
Reversing radar sensor 40-8
Reversing radar system does not
Reversing radar control module 40-10
function (buzzer in instrument
assembly
cluster does not sound)
40

ON-VEHICLE SERVICE
Reversing Radar Sensor
Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing reversing radar
sensor.
 Operate carefully to avoid damage to reversing radar sensor, when removing reversing radar sensor.

4. Remove the reversing radar sensor.
a. Disconnect the reversing radar sensor connectors
(arrow).
40
RA13T400010
b. Press clamping portion on reversing radar sensor in

RA13T400020
c. Remove reversing radar sensor from rear bumper assembly.
Installation
HINT:
 When installing reversing radar sensor, align the boss at end of reversing radar sensor with groove on rear
bumper assembly, and then firmly install reversing radar sensor.

CAUTION
 Install connectors in place, when installing reversing radar sensor.

 Check reversing radar system for proper operation, after installing reversing radar sensor.
Camera Assembly
Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing camera assembly.
 Appropriate force should be applied when removing camera assembly. Be careful not to operate roughly.
1. Turn off all electrical equipment and the ignition switch. Wait until engine cools down.
3. Remove the camera assembly.
up clips on camera assembly.
40
RA13T400030
b. Disconnect camera assembly connector (arrow), and

remove camera assembly (1).
RA13T400040
Installation

Reversing Radar Control Module Assembly

Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing reversing radar
control module assembly.
 Appropriate force should be applied when removing reversing radar control module assembly. Be careful
not to operate roughly.

4. Remove the luggage compartment left wheel house assembly (See page 50-32).
5. Removing the reversing radar control module assembly.
a. Disconnect the reversing radar control module
assembly connector (1).
b. Remove 2 fixing bolts (arrow) between reversing
1
radar control module assembly and body, and remove
reversing radar control module assembly.
40
RA13T400050
Installation
CAUTION
 Tighten fixing bolts to specified torque, when installing reversing radar control module assembly.
 Install connectors in place, when installing reversing radar control module assembly.
 Check reversing radar system for proper operation, after installing reversing radar control module
assembly.

General Information 41-3 Ground Inspection 41-19
Description 41-3 Diagnosis Procedure 41-19
Tire Pressure Monitoring System 41-3
Operation 41-4
Specifications 41-4
C1403-29 41-22
Tools 41-5
C1404-29 41-22
DIAGNOSIS & TESTING 41-6 C1405-29 41-22
Problem Symptoms Table 41-6 C1406-29 41-22
Diagnosis Tool 41-8 C1403-55 41-24
Digital Multimeter 41-8 C1404-55 41-24
Diagnostic Help 41-8 C1405-55 41-24
Intermittent DTC Troubleshooting 41-8 C1406-55 41-24
Precautions for Maintaining Tire  C1403-96 41-26
Pressure Monitoring System 41-9 C1404-96 41-26
C1405-96 41-26
Configuration and Learning of Tire
Pressure Monitoring System 41-11 C1406-96 41-26
C1413-98 41-28
Configurations for Body Control 
Module and Instrument Cluster 41-12 C1414-98 41-28
Tire Pressure Monitoring System  C1415-98 41-28
Enters Sensor Learning Status by  C1416-98 41-28
Operating Diagnostic Tester 41-13 C1417-16 41-31
Tire Pressure Sensor Learning  C1418-16 41-31
Method 41-15 C1419-16 41-31
Learning Process 41-16 C141A-16 41-31 41
Tire Pressure Learning Method for 
Low-frequency Trigger 41-17 ON-VEHICLE SERVICE 41-33
Instrument Cluster Display Image  Tire Pressure Sensor 41-33
with Tire Pressure Sensor Learning Removal of Tire 41-33
Successfully 41-18 Removal of Tire Pressure Sensor 41-35
Learning Status Inspection of  Installation of Tire Pressure Sensor 41-35
Tire Pressure Monitoring System 41-18 Installation of Tire 41-40

41

41 - TIRE PRESSURE MONITORING SYSTEM
General Information
Description
Tire Pressure Monitoring System
3 4
180 200 220
00:04 8 7
160
0.0 km
140 6
+ - H F
EPC 5
120 bar bar
100
C
bar bar 4
E
80 240km
3
60
40 20 0 km/h x1000rpm 0 1 2
LF RF
CAN
RF
1 6
5
41
LR RR
RA13T410010
1 - Rear Left Tire Pressure Sensor 2 - Instrument Cluster

3 - Front Left Tire Pressure Sensor 4 - Front Right Tire Pressure Sensor
5 - Body Control Module 6 - Rear Right Tire Pressure Sensor

3
2
4
6
7
RA13T410020
1 - Screw 2 - Sensor Body

3 - Valve Body 4 - Rubber Nozzle
5 - Valve Core 6 - Valve Cap
Tire Pressure Monitoring System (TPMS) is an active safety device, which can monitor tire pressure and
temperature in real time and display tire pressure on meter.When tire pressure is too low or temperature is too
high, tire pressure monitoring system will warn.
41 Operation
Tire pressure sensor is the transmitting terminal of tire information, body control module is the receiving
terminal of tire information and meter is the display terminal of tire information. Tire pressure sensor is core
component of tire pressure monitoring system. Tire pressure sensor is installed on rim, which collects data
such as pressure, temperature inside tire, and sends these data to body control module via radio-frequency
signal. Frequency of wireless communication between tire pressure sensor and body control module is
433.92 MHz.
Body control module receives radio-frequency signal sent from tire pressure sensor and processes these
data. Body control module processes data of tire pressure sensor, then sends them to meter via CAN bus.
Tire pressure value is displayed on meter via CAN bus signal. When tire pressure is too high or too low, or
temperature is too high, it informs driver of abnormal tire.
Specifications

Body Control Module Fixing Nut 5±1
Tire Pressure Sensor Fixing Nut 8±1

Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002
41

DIAGNOSIS & TESTING

HINT:
Use symptoms table below to help determine cause of problem.Check each suspected area in
sequence.Repair or adjust faulty components, or replace as necessary.
Symptom Suspected Area Troubleshooting See page

Check and inflate tire
Tire pressure < 1.9 bar -
pressure
Low pressure warning Defective tire pressure Replace, perform

41-13
(warning light remains on, sensor function configuration and learning
malfunctioning wheel sign Replace body control
flashes) Body Control Module (BCM)
module and perform sensor 41-15
damage
learning
Tire pressure system set Check and repair -
Tire temperature > 85°C Cool down naturally -
Defective tire pressure Replace, perform
41-13
High temperature warning sensor function configuration and learning
(warning light remains on, Replace body control
wheel sign flashes) Body Control Module (BCM)
module and perform sensor 41-15
damage
learning
41 sensor function configuration and learning
41-13
Sensor configuration and

learning are performed
Perform configuration and
System malfunction warning incorrectly when replacing 41-15
learning
(warning light remains on new wheels (spare tire
after flashing for 75 included)
seconds, tire pressure value
Repair shielded objects
of corresponding wheel
Electromagnetic outside of tire/strong
does not display and wheel -
interference/shielding electromagnetic radio
sign will flash)
interference
Replace -
damage

Symptom Suspected Area Troubleshooting See page

Display status cannot be Vehicle speed is higher than
-
reached 30 km/h for 45 seconds
Replaced tire pressure
sensor is not configured Perform configuration and
All of tire pressure 41-13
correctly, sensor is not learning
information cannot be learned
displayed (all of tire
pressure information for four Replace body control
wheels display as "--") Body Control Module (BCM) module and perform sensor 41-15
learning
Four sensors are not
installed or all of them are Reinstall or replace -
damaged (very rare)
41-13
sensor function configuration and learning
Sensor configuration and
learning are performed
Perform configuration and
incorrectly when replacing 41-13
learning
Some tire pressure new wheels (spare tire
information cannot be included)
displayed (some tire
Repair shielded objects
pressure information
Electromagnetic outside of tire/strong
displays as "--") -
interference/shielding electromagnetic radio
interference
Replace -
damage
Tire pressure system set Check and repair - 41

Diagnosis Tool
with vehicle.
 DLC is located at the driver side instrument panel crossmember.
Digital Multimeter
Diagnostic Help
3. If DTC cannot be cleared, the malfunction is current.
7. Check and clean all system grounds related to the latest DTC.
41 supply circuit applied to DTC.

 Look for changed data or reset DTCs during wiggle test.
 Check mounting areas of instrument cluster, wire harness or wire harness connector and so on for
damage, foreign matter, etc. that may cause incorrect signals.
 Remove instrument cluster from malfunctioning vehicle, then install it to a new vehicle and perform a test.If
DTC cannot be cleared, instrument cluster is malfunctioning.If DTC can be cleared, reinstall instrument
cluster to original vehicle.

Precautions for Maintaining Tire Pressure Monitoring System

1. Effective Conditions for Tire Pressure Monitoring System
No. Necessary Condition

1 IGN-ON
2 Vehicle speed is higher than 30 km/h, and continuous driving time is more than 45 seconds
Tire pressure monitoring system can be started normally only when key is in IGN-ON, vehicle driving speed is
higher than 30 km/h and continuous driving time is more than 45 seconds. When key is not in IGN-ON, body
control module cannot receive radio-frequency signal from tire pressure sensor; when vehicle speed cannot
reach 30 km/h or driving time is short, tire pressure sensor will not send radio-frequency signal.
 When vehicle is stationary and key is turned from IGN-
OFF to IGN-ON, tire pressure and temperature
information cannot be displayed on instrument cluster.
bar bar
bar bar
RA13T410521
 When key is turned to IGN-ON, vehicle driving speed is

higher than 30 km/h and continuous driving time is more
than 45 seconds, four wheel tire and temperature
information will be displayed.
 If there is a significant change in tire pressure, tire 2.1
bar
2.1
bar
pressure sensor will send a radio-frequency signal

suddenly.If key is turned to IGN-ON, tire pressure
41
2.1 2.1
bar bar
monitoring system will process signals sent from tire

pressure monitoring system immediately.
RA13T410522
2. Tire Inflation
Do not inflate tires depending on values displayed from tire pressure monitoring system. Tire pressure
monitoring system can monitor tire pressure and temperature in real time only when vehicle speed is higher
than 30 km/h.If inflating tires using pressure values displayed from tire pressure monitoring system, inflation
value may be higher than tire standard value, which will cause accidents. Do not inflate tires with high tire
temperature, which will cause damage to the tire, even blowouts, resulting in accidents.
3. For Tire Pressure Sensor
 When system is fault or disabled, check tire pressure sensor and judge if it is the tire pressure sensor for
A13T model of Chery Automobile Co., Ltd.If tire pressure sensor of other manufacturers (not for A13T
model of Chery Automobile Co., Ltd.) is used by customer, configuration and learning for tire pressure
sensor cannot be performed and system is abnormal or disabled.
 Tire pressure sensor is integrated with functions of common valve nozzle, and inflation/deflation operation
is the same as common valve nozzle.Alway use genuine sensor fittings, without replacing components
inside of sensor.After maintenance, install genuine waterproof cap of tire pressure sensor properly.Never
reuse a disposed tire pressure sensor components, or it may cause air leakage, resulting in a risk of
danger.When inflating/deflating or tire bead breaking, do not remove the sensor nuts.If tire pressure sensor
nuts are removed when tire pressure is higher than external ambient pressure, there may be a risk of
danger.

 Tire pressure sensor must be assembled with a torque wrench, and tightening torque should be 8 ± 1 N·m.
If torque is smaller, it may cause air leakage, resulting in a risk of danger; if torque is larger, it may damage
tire pressure sensor or related components, resulting in a risk of danger.
4. Tire Pressure Increase
When vehicle is driving normally, heat is generated in the tire due to friction, which will cause tire pressure to
increase.For every 10°C increase in tire temperature, tire pressure will increase by about 0.1 bar.
5. Tire Replacement
If a tire equipped with tire pressure monitoring system is replaced with one without tire pressure sensor, it will
cause a system malfunction warning.If the tire equipped with tire pressure sensor (for A13T model of Chery
Automobile Co., Ltd.) is replaced, but configuration and learning are not performed, system malfunction
warning will still occur. As spare tire for A13T model is not equipped with tire pressure sensor, tire pressure
monitoring system malfunction will also occur when spare tire is used on a vehicle equipped with tire pressure
monitoring system.
When replacing tire, always follow tire pressure Installation specification, to avoid damaging tire pressure
sensor during replacement.For installation and removal of tire, refer to Installation and Removal of Tire
Pressure Sensor section.Never allow tire bead breaker and tire tread to squeeze the sensor.
41

Configuration and Learning of Tire Pressure Monitoring

System
CAUTION
 Perform tire pressure sensor learning after rotating tire and replacing tire pressure sensor.
HINT:
Configuration and learning of tire pressure monitoring system involve with configuration of tire receiver and
instrument cluster and learning of tire pressure sensor.
NEXT
2 Check if it is possible to enter tire pressureinformation screen on instrument cluster
NG Reconfigure body control module and

instrumentcluster
OK
41
3 Perform tire pressure sensor learning
NEXT
4 Test vehicle with a speed higher than 30km/h for 45 seconds
NEXT
5 Check if tire pressure information is displayedcorrectly
NG Reconfigure body control module and

instrumentcluster
OK
6 End

Configurations for Body Control Module and Instrument Cluster

1. Use diagnostic tester to enter write data menu, and click
"Vehicle TPMS Configuration". write data
TPMS Self-Learning
Test Mode
Vehicle TPMS Configuration
RA13T410530
2. If tire pressure display function of instrument cluster is

turned off currently, click "Vehicle TPMS Configuration" to
turn on the function. ON
OFF
RA13T410540
3. Click Test Mode menu to detect if tire pressure display

function of meter is turned on. Test Mode
Routine Start
Routine Stop
41
RA13T410550
4. When clicking "Routine Start" on instrument cluster, tire

pressure malfunction indicator flashes and "Routine Start
Successfully By The Tester" is displayed on diagnostic
tester, which indicates that tire pressure display function
of meter has been turned on successfully.Click "Routine 160
180 200 220
00:04
0.0 km
8 7
Stop" to exit current test mode and tire pressure 140 6

+ - H F
EPC 5
120
malfunction indicator on instrument cluster goes off. 100

C E
4
When "Routine Stopped" is displayed on diagnostic

80 240km
3
60
40 20 0 km/h x1000rpm 0 1 2
tester, return to previous menu.

RA13T410560

Tire Pressure Monitoring System Enters Sensor Learning Status by

Operating Diagnostic Tester
1. Turn ignition switch to ON, select write data menu and
click TPMS Self-Learning. write data
TPMS Self-Learning
Test Mode
RA13T410570
2. Learning screen is shown in illustration, click tire menu

that needs to learn (take front left tire as an example). TPMS-self Learning
FLH TPMS-self Learning
FRH TPMS-self Learning
RLH TPMS-self Learning
RRH TPMS-self Learning
RA13T410580
3. During learning, hint will be displayed on diagnostic

tester. TPMS-self Learning
41
Please rapid deflation of the left front wheel (about 20 seconds)
OK
RA13T410590

CAUTION
 There are two methods for tire pressure sensor learning. One is deflation, another is low-frequency
trigger learning. If low-frequency trigger is used, deflation will not be performed.
4. When clicking "OK" button on diagnostic tester, tire

pressure screen is displayed on instrument cluster and
tire pressure warning light flashes. Perform tire pressure
sensor learning when tire pressure monitoring system 160
180 200 220
00:04 8 7
0.0 km
enters sensor learning status. 120
140 + -
EPC
H
bar bar
F
6
100
C
bar bar 4
E
80 240km
3
60
40 20 0 km/h x1000rpm 0 1 2
bar bar
bar bar
RA13T410600
5. After front left tire pressure sensor learning is successful, tire pressure malfunction indicator on instrument
cluster goes off, front left tire pressure value is displayed and "Procedure is finished" is displayed on
diagnostic tester, which indicates that front left tire pressure sensor learning has been finished.
41

Tire Pressure Sensor Learning Method

1. Precautions
No. Precautions Details

Tire learned on diagnostic tester menu
1 Avoid error learning of tire
must be matched with deflated tire
Only operate one tire every time, and do
2 Avoid error learning of tire not deflate (or inflate) for other tires at this
time
Keep away from vehicles with tire pressure
3 Avoid error learning of tire sensor, avoiding error learning or
interference
If only one tire shall be replaced, other tires should not be replaced and positions should not be changed,
only learn one tire separately.
2. Correction methods for tire pressure monitoring system are as follows:
a. Keep a vehicle speed higher than 30 km/h for about 45 seconds;
b. If tire pressure monitoring system can be operated normally, pressure information of four tires is
displayed;
c. If certain tire pressure information is still not displayed, tire configuration may be incorrect, which needs
to be relearned.
3. Tire Pressure Learning Method for Inflation/Deflation
 With key in IGN-ON, perform quick deflation for tire to be learned (deflation for about 20 seconds) after
entering learning status. At this time, check pressure value of learned tire through instrument cluster,
and learning is successful.If multiple wheels should be learned, one minute interval is required among
each wheel learning.
41

Learning Process
1 Start
NEXT
2 There is enough pressure in tire (full loadedwith pressure recommended)
NEXT
3 Tire pressure monitoring system enters learningstatus by operating diagnostic tester
NEXT
4 Perform tire pressure deflation (for about20 seconds)
NEXT
5 Learned tire pressure value can be displayedon instrument cluster
NEXT
41
6 Learning is successful
NEXT
7 End
CAUTION
 After learning is finished, use tire pressure gauge to inflate tire to standard pressure, then correct tire
pressure monitoring system with vehicle speed more than 25 km/h for 45 seconds.

Tire Pressure Learning Method for Low-frequency Trigger

1. After entering learning status with key in IGN-ON, tire pressure wireless signal will be generated from
sensor directly using low-frequency trigger (inflation/deflation for tire is not needed). After triggering is
finished, pressure value of learned wheel will be displayed on instrument cluster, and learning is
successful.
1 Start
NEXT
2 Ignition key is in IGN-ON
NEXT
3 Tire pressure monitoring system enters learningstatus by operating diagnostic tester
NEXT
4 Trigger tire pressure sensor to be learnedusing low-frequency trigger
NEXT
5 Sensor ID, temperature value and pressurevalue are displayed on low-frequency trigger
41
NEXT
NEXT
7 End
If distance between low-frequency trigger and tire pressure

sensor is less than 10 cm, bring low-frequency trigger
antenna near tire around tire pressure sensor on wheel, and
then press trigger button on low-frequency trigger.After low- <10cm
frequency trigger is triggered successfully, related

information such as learned tire ID, pressure value and
temperature value will be displayed.
C
RA13T410610

CAUTION
Instrument Cluster Display Image with Tire Pressure Sensor Learn-

ing Successfully
After inflation/deflation learning or low-frequency trigger
learning is successful, tire pressure value and temperature
value will be displayed on instrument cluster.
180 200 220

00:04 8 7
160
0.0 km
140 6
+ - H F
EPC 5
120 bar bar
100
C
bar bar 4
E
80 240km
3
60
40 20 0 km/h x1000rpm 0 1 2
RA13T410620
If turn light stops flashing, front left wheel pressure value is 2.2 ± 0.1 bar and temperature value is 11°C, front
left wheel learning is successful.
If tire pressure monitoring system is learning front left wheel, left and right turn lights will stop flashing after
deflation. At this time, one tire pressure sensor is learned successfully by tire pressure monitoring system,
please click "OK" to finish learning on front left wheel.
Learning methods for front right, rear right and rear left tire
pressure sensors are the same as that for front left tire
pressure sensor.If only one tire shall be replaced, other tires
write data
should not be replaced and positions should not be

41 changed, only learn one tire separately.
Tire pressure learning:press the button will stop learning!
OK
RA13T410630
Learning Status Inspection of Tire Pressure Monitoring System

1. After reconfiguring tire pressure monitoring system, use reading function of datastream to perform
inspection for each tire pressure sensor learning status in tire pressure monitoring system (take front left
wheel as an example).
a. Front left sensor ID can be read using diagnostic
tester, if learning status is successful, it indicates that SELECT FUNCTION
body control module is matched with front left sensor Read fault code
successfully.If not, it indicates that the match is not Erase fault code
successful and front left wheel sensor should be Read data stream
relearned. System information
Freeze Frame Data
Special Operation
RA13T410640

2. When vehicle speed is higher than 25 km/h for more than 45 seconds, use diagnostic tester to read
following datastreams:
a. Front left sensor pressure: bar
b. Front left sensor pressure: °C
c. If temperature is not default value and tire pressure is close to the value displayed on instrument
cluster, it indicates that body control module can receive wireless signals from front left tire pressure
sensor.Or it indicates that learning is not successful or tire pressure sensor is fault.
Ground Inspection
Ground points are very important to the proper operation of circuits.Ground points are often exposed to
moisture, dirt and other corrosive environments.Corrosion (rust) may increase load resistance.This situation
may change the way in which a circuit works.
Circuits are very sensitive to proper grounding.A loose or corroded ground can affect the control circuit.Check
the ground points as follows:
6. If several wire harnesses are crimped into one ground terminal, check if they are installed correctly.Make
sure all wire harnesses are clean, securely fastened and providing a good ground path.
Diagnosis Procedure
HINT:
Use following procedures to troubleshoot the instrument cluster system.
41
NEXT
NEXT
NEXT

DTC
occurs
NO
DTC
5 Problem Repair (No DTC)
NEXT
NEXT
7 Problem Repair (No DTC)
NEXT
41 NEXT
NEXT
10

DIAGNOSIS & TESTING

DTC DTC Definition
C1403-29 Front Left Hand Sensor Signal Invalid
C1403-55 Front Left Hand Sensor Not Configured
C1403-96 Front Left Hand Sensor Component Internal Fail
C1404-29 Front Right Hand Sensor Signal Invalid
C1404-55 Front Right Hand Sensor Not Configured
C1404-96 Front Right Hand Sensor Component Internal Fail
C1405-29 Rear Left Hand Sensor Signal Invalid
C1405-55 Rear Left Hand Sensor Not Configured
C1405-96 Rear Left Hand Sensor Component Internal Fail
C1406-29 Rear Right Hand Sensor Signal Invalid
C1406-55 Rear Right Hand Sensor Not Configured
C1406-96 Rear Right Hand Sensor Component Internal Fail
C1413-98 Front Left Hand Tire Temperature Component or System Over Temperature
C1414-98 Front Right Hand Tire Temperature Component or System Over Temperature
C1415-98 Rear Left Hand Tire Temperature Component or System Over Temperature
C1416-98 Rear Right Hand Tire Temperature Component or System Over Temperature
C1413-98 Front Left Hand Tire Temperature Component or System Over Temperature 41
C1414-98 Front Right Hand Tire Temperature Component or System Over Temperature
C1415-98 Rear Left Hand Tire Temperature Component or System Over Temperature
C1416-98 Rear Right Hand Tire Temperature Component or System Over Temperature
C1417-16 Front Left Hand Sensor Voltage, Component or System Low Voltage
C1418-16 Front Right Hand Sensor Voltage, Component or System Low Voltage
C1419-16 Rear Left Hand Sensor Voltage, Component or System Low Voltage
C141A-16 Rear Right Hand Sensor Voltage, Component or System Low Voltage
C1402-44 TPMS EEPROM Access Fail Data Memory Failure

DTC C1403-29 Front Left Hand Sensor Signal Invalid
DTC C1404-29 Front Right Hand Sensor Signal Invalid
DTC C1405-29 Rear Left Hand Sensor Signal Invalid
DTC C1406-29 Rear Right Hand Sensor Signal Invalid
DTC Detection
Condition
Front Left Hand
C1403-29
 No RF signals are sent from tire
Front Right Hand
C1404-29 pressure sensor, or sent signal is too
Sensor Signal Invalid Vehicle speed ＞ 30 weak.
Rear Left Hand Sensor km/h for 45 seconds
C1405-29  Reception of body control module is
Signal Invalid
poor, and no RF signals are received.
Rear Right Hand
C1406-29

CAUTION
Diagnosis Procedure
1 Check power supply voltage of body controlmodule
a. Measure voltage between power supply terminal of body control module and ground with a multimeter.
b. Power supply voltage should be between 11 V and 14 V.
NG Check and repair battery and power

supply system

OK
2 Check body control module ground circuit
a. Check body control module ground for looseness or corrosion.
NG Tighten or replace body control module

groundcircuit.
OK
3 Check configuration of tire pressure monitoringsystem
a. After configuration, drive vehicle with speed higher than 30 km/h for a certain time.
NG Reconfigure tire pressure sensor of

malfunctioningwheel
OK
4 Check body control module of malfunctioningwheel
a. Perform configuration and test after replacement.
NG Replace body control module of

malfunctioningwheel
41
OK
5 Check tire pressure sensor of malfunctioningwheel
a. Perform configuration after replacement.
NG Replace tire pressure sensor of

malfunctioningwheel
OK
6 System detection is normal

DTC C1403-55 Front Left Hand Sensor Not Configured
DTC C1404-55 Front Right Hand Sensor Not Configured
DTC C1405-55 Rear Left Hand Sensor Not Configured
DTC C1406-55 Rear Right Hand Sensor Not Configured
DTC Detection
Condition
Front Left Hand
C1403-55
Sensor Not Configured
Front Right Hand
C1404-55
Sensor Not Configured Vehicle speed ＞ 30  Configure BCM function and learning
Rear Left Hand Sensor km/h for 45 seconds function is not finished.
C1405-55
Not Configured
Rear Right Hand
C1406-55
Sensor Not Configured

CAUTION
Diagnosis Procedure

supply system

OK

groundcircuit.
OK

malfunctioningwheel
OK

malfunctioningwheel
41
OK

malfunctioningwheel
OK

DTC C1403-96 Front Left Hand Sensor Component Internal Fail
DTC C1404-96 Front Right Hand Sensor Component Internal Fail
DTC C1405-96 Rear Left Hand Sensor Component Internal Fail
DTC C1406-96 Rear Right Hand Sensor Component Internal Fail

DTC Detection
Condition
Front Left Hand
C1403-96 Sensor Component
Internal Fail
Front Right Hand
Internal Fail Vehicle speed ＞ 30  Sensor is abnormal, RF data indicates
Rear Left Hand Sensor km/h for 45 seconds that sensor is malfunctioning.
C1405-96 Component Internal
Fail
Rear Right Hand
Internal Fail

41 Confirm that battery voltage is between 11 V and 14 V before performing following procedures.
CAUTION
Diagnosis Procedure


supply system
OK

groundcircuit.
OK

malfunctioningwheel
OK
a. Perform configuration and test after replacement. 41

malfunctioningwheel
OK

malfunctioningwheel
OK

Front Left Hand Tire Temperature Component or System

DTC C1413-98
OverTemperature
Front Right Hand Tire Temperature Component or Sys-

DTC C1414-98
tem OverTemperature
Rear Left Hand Tire Temperature Component or System

DTC C1415-98
OverTemperature
Rear Right Hand Tire Temperature Component or Sys-

DTC C1416-98
tem OverTemperature
DTC Detection
Condition
Front Left Hand Tire
Temperature
C1413-98
Component or System
Over Temperature
Front Right Hand Tire
Temperature
C1414-98
Component or System
Over Temperature Vehicle speed ＞ 30  Sensor is abnormal, RF data indicates
Rear Left Hand Tire km/h for 45 seconds that sensor is malfunctioning.
41 C1415-98
Temperature
Component or System
Over Temperature
Rear Right Hand Tire
Temperature
C1416-98
Component or System
Over Temperature


CAUTION
Diagnosis Procedure

supply system
OK

groundcircuit.
OK
41
a. When temperature of one or more tires is higher than 85°C, system will send a high temperature warning
while driving speed is higher than 30 km/h for a period of time.
b. When high temperature warning occurs, stop vehicle and cool down the tire naturally, or it may cause
accidents.
c. When tire temperature is too high, do not cool it down with cold water, which will cause tire damage,
resulting in accidents.
d. When driving speed is higher than 25 km/h for a period of time and tire temperature is lower than 80°C,
high temperature warning will release automatically.
NG Cool down naturally
OK

malfunctioningwheel

OK

malfunctioningwheel
OK
41

Front Left Hand Sensor Voltage, Component or System

DTC C1417-16
Low Voltage
Front Right Hand Sensor Voltage, Component or System

DTC C1418-16
LowVoltage
Rear Left Hand Sensor Voltage, Component or System

DTC C1419-16
Low Voltage
Rear Right Hand Sensor Voltage, Component or System

DTC C141A-16
Low Voltage
DTC Detection
Condition
Front Left Hand
Sensor Voltage,
C1417-16
Component or System
Low Voltage
Front Right Hand
Sensor Voltage,
C1418-16
Component or System
Low Voltage Vehicle speed ＞ 30  Battery is depleted
km/h for 45 seconds
Rear Left Hand Sensor
C1419-16 Voltage, Component or
System Low Voltage
41
Rear Right Hand
Sensor Voltage,
C141A-16
Component or System
Low Voltage


CAUTION
Diagnosis Procedure

supply system
OK

groundcircuit.
OK
41
3 Check if tire pressure information is displayed
a. If tire pressure information of malfunctioning wheel is still not displayed, it is necessary to replace tire
pressure sensor.
NG Replace tire pressure sensor
OK

malfunctioningwheel
OK

ON-VEHICLE SERVICE
Tire Pressure Sensor
CAUTION
 Avoid dropping the sensor; if tire pressure sensor is dropped from the place with 1 m in height, it is
interpreted as fault in tire pressure sensor.
 Tire pressure sensor must be installed on clean and dry hub.
 Valve cap must be installed on valve, except for inflation, bleeding and pressure inspection, etc.
 During installation and removal, used tools cannot touch with tire pressure sensor, to avoid damage to
the tire pressure sensor.
 Sensor air pressure inlet cannot be covered partially or completely by lubricant or other materials.
 Tire pressure sensor screw cannot be tightened again after it is loosened.
Removal of Tire
1. Remove tire and deflate air in it completely (See page 24-7).
CAUTION
 During tire bead breaking, always follow the operation specification to prevent damage to tire pressure
sensor.
2. Keep one side with tire pressure sensor away from

separation shovel (arrow) for about 30 cm, and put
41
shovel block between rim and tire, then depress pedal to
separate rim and tire.
RA13T410650
3. Turn over tire to keep one side with tire pressure sensor
away from separation shovel (arrow) for about 30 cm,
and put shovel block between rim and tire, then depress
pedal to separate rim and tire.
RA13T410660

4. Lock tire on turnable device, lower replacer head and

keep it away from sensor for 5 - 15 cm.
RA13T410670
5. Use a crowbar to pry out outside tire, and sleeve it to

replacer head, then take away crowbar.
RA13T410680
CAUTION
 Both crowbar and tire cannot touch with sensor.
6. Remove the wheel.
41 a. Rotate wheel, and movable direction of wheel should

be the direction that replacer head is gradually kept
away from tire pressure sensor (rotation arrow), then
remove tire from upper part.
RA13T410690
b. Lift up tire, and pry out tire from lower part using
crowbar.
RA13T410700

c. Lower replacer head and pry out lower tire tread using
crowbar, then sleeve it on replacer head and keep it
away from sensor for 5 - 15 cm (arrow).
5-15
cm
RA13T410710
d. Rotate wheel, and movable direction of wheel should

be the direction that replacer head is gradually kept
away from tire pressure sensor (rotation arrow), then
pry out tire completely.
RA13T410720
Removal of Tire Pressure Sensor

1. Use a proper tool, rotate nut counterclockwise until it
separates from tire pressure sensor completely.
41
RA13T410730
2. Remove tire pressure sensor from wheel hub.
Installation of Tire Pressure Sensor
CAUTION
 Tire pressure sensor must be assembled with a torque wrench, and normal wrench cannot ensure a
torque of 8 ± 1 N·m. If torque is smaller, it may cause air leakage, resulting in a risk of danger; if torque is
larger, it may damage tire pressure sensor or related components, resulting in a risk of danger.
Tire Pressure Sensor Tightening Speed and Assembling Torque List
Tightening Speed Assembling Torque

≤ 30 rpm 8 ± 1 N·m

RA13T410750
1. Adjust plane direction of seal washer cutout.

a. When removing sensor body, first check if seal
washer cutout plane is parallel with polyester plane. If
they are not parallel and there is an angle between
two planes, turn seal washer to make seal washer
cutout plane parallel with polyester plane. A
RA13T410750
b. If seal washer cutout plane is parallel with polyester

plane, it indicates that assembly is qualified.
41
RA13T410760
c. If seal washer cutout plane is not parallel with

polyester plane and there is a large angle between
two planes, it indicates that assembly is not qualified.
RA13T410761

2. Adjust the valve lever position.

a. First, press root of valve lever using middle of thumb
with action force downward along groove direction, so
that root of valve lever enters groove completely;
then, press valve lever using middle of thumb and
press seal washer using tip of thumb with action force
vertically downward along seal washer, so that valve
lever bends with maximum angle, never apply
horizontal action force along seal washer.
RA13T410770
b. If root of valve lever enters groove completely and

valve lever bends with maximum angle, it indicates
that assembly is qualified.
RA13T410780
c. If root of valve lever dose not enter groove completely

and valve lever dose not bend with maximum angle, it
indicates that assembly is not qualified.
41
RA13T410790
d. If valve lever dose not bend with maximum angle, it

RA13T410791
e. If seal washer plane is not perpendicular to valve lever

after action force is applied along horizontal direction
of seal washer, it indicates that assembly is not
qualified.
RA13T410792

3. Insert valve lever of tire pressure sensor into hub and pretightened nut.
a. Support tire pressure sensor using four fingers of left
hand vertically upward, and do not apply horizontal
inward force; hold outer edge of rim using thumb of
left hand with force downward, so that both sides of
sensor housing attaches with rim firmly. Pass valve
lever through rim along center shaft of valve nozzle
hole, with insert direction from internal part of tire
assembly to external part of tire assembly. Tighten nut
clockwise with right hand until tire pressure sensor is
secured firmly.
RA13T410800
b. If valve lever enters groove completely, sensor is

secured completely and firmly and sensor housing
attaches with rim firmly, it indicates that assembly is
qualified.
RA13T410810
c. If pretightened nut is not tightened in place, many

threads exposed from valve lever can be seen and
sensor is not secured, it indicates that assembly is not
qualified.
41
RA13T410811
d. If horizontal inward force is applied and valve lever of

sensor slides out of groove, it indicates that assembly
is not qualified.
RA13T410820
e. If right side of sensor does not attach with rim firmly, it

RA13T410821

f. If left side of sensor attaches with rim firmly, it

indicates that assembly is qualified.
RA13T410830
g. If right side of sensor does not attach with rim firmly, it

RA13T410831
4. Tighten nut firmly.

a. Support bottom of sensor using four fingers of left
hand with action force upward. Hold rim edge using
thumb of left hand with action force downward. Apply
force to make tire pressure sensor attach with rim
firmly, and sensor cannot move during tightening. Axis
of manual torque wrench socket overlaps with axis of
valve lever without an angle. Tighten nut clockwise,
and the tightening is finished when torque reaches 8 ± 41
1 N·m. Nut cannot be tightened again after tightening
is finished.
RA13T410840
b. If valve lever enters groove completely, sensor is

secured completely and firmly and both sides of
sensor housing attach with rim firmly, it indicates that
assembly is qualified.
RA13T410850
c. If valve lever slides out of groove, it indicates that

assembly is not qualified.
RA13T410860

d. If seal washer and seal ring are deformed and

damaged due to excessive torque, it indicates that
assembly is not qualified.
RA13T410870
Installation of Tire
CAUTION
 Always follow operation specification to prevent damage to tire pressure sensor.

 Both crowbar and tire cannot touch with sensor.
 Confirm that distance between intersection and valve lever is proper.
1. Similar to installation of common tire, apply soap water or

glycerin to tire bead along inner circle before you prepare
to install or pack the tire.
41
RA13T410880
2. Put tire on hub and keep intersection between hub and

tire edge away from valve lever for 15 - 20 cm.
RA13T410890
3. Install tire to make sure the distance between intersection

and valve lever is about 20 cm.
20cm
RA13T410900

4. Rotate wheel to install one side of tire into hub. Rotation

direction of wheel (rotation arrow) should be the direction
that makes replacer head get farther and farther away
from sensor.
RA13T410910
5. Put another side of tire in place, so that intersection

between tire edge and hub is away from valve lever for
about 20 cm. Curving arrow indicates rotation direction of 20
cm
wheel.
RA13T410920
6. Rotate wheel to install another side of tire into hub.
41
RA13T410930

- MEMO -

HORN
GENERAL INFORMATION 42-3 Horn Fuse Inspection 42-6
Description 42-3 Horn Relay Inspection 42-7
Specification 42-3
Tool 42-4
Horn 42-8
Removal 42-8
DIAGNOSIS & TESTING 42-6 Inspection 42-8
Problem Symptoms Table 42-6 Installation 42-9
42

42

42 - HORN
GENERAL INFORMATION
HORN
Description
SRS
AIRBAG
42
RA13T420001
RM1A410001
This vehicle is equipped with dual electronic horn (high pitched and low pitched) system.
Horn system consists of the following components:
 Horn: both high pitched horn and low pitched horn are installed on body frame side rail.
 Horn switch: it is installed on steering wheel.
 Horn fuse: it is located in engine compartment fuse and relay box.
 Horn relay: it is located in engine compartment fuse and relay box.
Specification

Horn Bracket Fixing Nut 16 ± 2

42 - HORN
Tool
General Tool
Digital Multimeter
RCH0000002
42

42 - HORN
Circuit Diagram
Horn
BATTERY
EF25 EF22
15A 10A ENGINE
COMPARTMENT
30 86 FUSE AND
HORN RELAY BOX
RELAY E-067
87 85
91 90
P
R
P
R
E-032 15 E-030
9
1 1 B-014 I-036
LOW-PITCHED HIGH-PITCHED
HORN HORN
P
P
E-048 E-047
A44 14
2 2 CLOCK
B
BCM(A) B-022 SPRING

I-031
42
B
E-059
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
9 8 7 6 5 4 3 2 1
B-022 E-032
B 18 17 16 15 14 13 12 11 10 W
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
1 2 3 4 5 6 7 8 9 8 7 6 5 4 3 2 1
E-030 I-031
10 11 12 13 14 15 16 17 18 B W
16 15 14 13 12 11 10 9
1 2 E-047 1 2 E-048
Gr Gr
EA13T420010

42 - HORN
DIAGNOSIS & TESTING

HINT:

Horn fuse (blown) 55-41
High pitched horn (damaged) 42-8
Horn does not sound Horn switch (damaged) 28-8
Spiral cable (damaged) 28-13
Wire harness (short or open) -
Horn Fuse Inspection

1. Identify horn fuse on engine compartment fuse and relay
box.
2. Check the horn fuse.
a. Using a fuse puller, remove horn fuse (15 A).
ERLY11
Horn
relay
b. Check if fuse is blown. Replace if it is blown.
RA13T420020
42
CAUTION
 Use a fuse with the same specification as original fuse to avoid affecting the normal usage of electrical
equipment.

42 - HORN
Horn Relay Inspection

1. Check the horn relay.
+ -
a. Remove horn relay from engine compartment fuse
3
and relay box.
5
b. Check the horn relay.

2 4 1
Multimeter Measurement Specified ERLY11
Horn
relay

When battery
voltage is not
Terminal 3 - RA13T420022
applied between No continuity
Terminal 5
terminal 2 and
terminal 1
When battery
Terminal 3 - voltage is applied
Continuity
Terminal 5 between terminal
2 and terminal 1
If result is not as specified, replace relay.
42

42 - HORN
ON-VEHICLE SERVICE
Horn
Removal
4. Remove the high pitched horn.
a. Disconnect the high pitched horn wire harness
connector (1). 1
b. Remove fixing nut (arrow) from high pitched horn
bracket, and remove high pitched horn.
RA13T420010
5. Remove the low pitched horn.

a. Disconnect the low pitched horn wire harness
connector (1).
1
b. Remove fixing nut (arrow) from low pitched horn
bracket, and remove low pitched horn.
42
RA13T420021
Inspection
1. Check the high pitched horn.
Apply battery voltage to high pitched horn and check
operation of high pitched horn. + -
Condition
Condition Condition 1 2
Battery negative
Always Horn sounds
(-) - Terminal 2
Battery positive
Always Horn sounds
(+) - Terminal 1
RA13T420030
If result is not as specified, replace high pitched horn.

42 - HORN
2. Check the low pitched horn.

Apply battery voltage to low pitched horn and check
operation of low pitched horn. + -
Condition 1 2
Condition Condition
Battery negative Always Horn sounds
(-) - Terminal 2
Battery positive Always Horn sounds
(+) - Terminal 1
RA13T420040
If result is not as specified, replace low pitched horn.

3. Check the wire harness.
Using a digital multimeter, check horn system wire harness for open, short or ground failure. Replace if
necessary.
Installation
CAUTION
 Tighten fixing nuts to specified torque.

 Install connectors in place.
42

- MEMO -

OTHER SYSTEM
GENERAL INFORMATION 43-3 Cigarette Lighter Assembly 43-5
Other System 43-4 USB Interface 43-7
Removal 43-7
Installation 43-7
43

43

43 - OTHER SYSTEM
GENERAL INFORMATION
OTHER SYSTEM
Description
OFF
A\C
OFF
P
R 4
N
D
RA13T430001
1 - USB Interface 2 - Cigarette Lighter Housing

43
3 - Cigarette Lighter Fixing Bush 4 - Cigarette Lighter End
Cigarette lighter assembly is located on the lower center storage box.

43 - OTHER SYSTEM
Circuit Diagram
Other System
IGNITION SEITCH
ACC OR ON
RF28 IP FUSE AND

RELAY BOX
15A I-032
57
RY
2
BACKUP
POWER
SUPPLY
I-024
1
B
43
I-004
I-024
W
EA13T430010

43 - OTHER SYSTEM
ON-VEHICLE SERVICE
Cigarette Lighter Assembly
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing cigarette lighter assembly.
 Appropriate force should be applied, when removing cigarette lighter assembly. Be careful not to operate
roughly.
 Try to prevent lower center storage box assembly from being scratched, when removing cigarette lighter
assembly.

3. Remove the cigarette lighter assembly.
a. Remove cigarette lighter end in direction of arrow as
OFF
A\C
RA13T430010

off cigarette lighter fixing clip (arrow) on instrument
panel. A\C
OFF
43
RA13T430020
c. Disconnect cigarette lighter connector (arrow) and

take out cigarette lighter assembly.
OFF
A\C
OFF
RA13T430030

43 - OTHER SYSTEM
d. Separate cigarette lighter housing and cigarette

lighter fixing bush in direction of arrow as shown in
illustration.
RA13T430040
Installation
HINT:
 When installing cigarette lighter, align the protrusion of
cigarette lighter housing end with the slot on lower center
storage box as shown in illustration, and install cigarette
lighter securely.
RA13T430050
CAUTION
 Check cigarette lighter for proper operation, after installing cigarette lighter assembly.
43

43 - OTHER SYSTEM
USB Interface
Removal
1. Using a screwdriver wrapped with protective tape, pry off
USB interface fixing clips on instrument panel.
OFF
A\C
RA13T430060
2. Disconnect the USB interface (arrow)
OFF
A\C
RA13T430070
Installation
43

- MEMO -

General Information 44-3 Inspection 44-41
Specifications 44-7 Front Door Weather Bar 44-43
Front Door Glass Upper Run 44-44
Installation 44-45
Front Door Glass Assembly 44-46
Diagnosis Tool 44-11
Removal 44-46
Installation 44-46
Front Door Power Glass Regulator 44-47
Removal 44-47
B100C-13 44-16
Inspection 44-47
B100C-71 44-16
Installation 44-48
B100D-13 44-16
Power Glass Regulator Switch 44-49
B100D-71 44-16
Removal 44-49
B1022-71 44-16
Inspection 44-50
B1029-71 44-16
Installation 44-51
B102E-86 44-16
Rear Door Weather Bar 44-52
B100E-13 44-22
Removal 44-52
B100E-71 44-22
Installation 44-53
B100F-13 44-22
Rear Door Glass Assembly 44-54
B100F-71 44-22
Removal 44-54
B1023-71 44-22
Rear Door Glass Upper Run 44-56
B1026-71 44-22
Removal 44-56
B102A-71 44-22
Installation 44-56
B102F-86 44-22
Rear Door Glass Guide Rail Assembly 44-57
B1010-13 44-28
Removal 44-57
B1010-71 44-28
Installation 44-57
B1011-13 44-28
Rear Door Power Glass Regulator 44-58
44
B1011-71 44-28
Removal 44-58
B102B-71 44-28
Inspection 44-58
B1030-86 44-28
Installation 44-59
B1033-71 44-28
Front Windshield Assembly 44-60
B1034-71 44-28
Removal 44-60
B1012-13 44-34
Installation 44-62
B1012-71 44-34
Rear Windshield Assembly 44-66
B1013-13 44-34
Removal 44-66
B1013-71 44-34
Installation 44-68
B1025-71 44-34
B1028-71 44-34 Rear Window Defroster 44-72
B102C-71 44-34 General Information 44-72
B1031-86 44-34 Description 44-72
Front Left Door Glass Regulator Switch 44-40
Diagnosis Tool 44-74
Removal 44-40

Rear Window Defroster Switch 44-77
44

44 - WINDSHIELD/WINDOW GLASS
General Information
Description
1 2 3
4
6
8 7
5
44
RA13T440010

1 - Front Windshield Assembly 2 - Front Left Door Glass Assembly

3 - Rear Left Door Glass Assembly 4 - Rear Left Door Triangular Window Glass
5 - Front Right Door Glass Assembly 6 - Rear Right Door Glass Assembly
7 - Rear Right Door Triangular Window Glass 8 - Rear Windshield Assembly
2
4
44 RA13T440020
1 - Front Right Door Glass Regulator Switch 2 - Rear Right Door Glass Regulator Switch
Assembly Assembly
3 - Front Left Door Glass Regulator Switch Assembly 4 - Rear Left Door Glass Regulator Switch Assembly
5 - Rear Left Door Glass Regulator 6 - Front Left Door Glass Regulator
7 - Rear Right Door Glass Regulator 8 - Front Right Door Glass Regulator
Power window control system controls window glass UP/DOWN function, by operating glass regulating
control switches on door inner protector assembly.Main control devices of this system include: front left door
glass regulator switch (built into driver side door) and glass regulator switches (built into front and rear
passenger side doors).Press front left door glass regulator switch or any glass regulator switch, to transmit
UP/DOWN signal to corresponding power glass regulator motor, thus controlling UP/DOWN operation of
corresponding power window glass.

Main Component Function
Component Description
 Located on front left door inner protector
assembly. It controls operation of front and rear
passenger side glass regulator switches.
Power window lock switch  When power window lock switch is in lock
position, UP/DOWN operation of power window
glass will be possible only with driver side glass
regulator switch.
 Locates on door inner protector assembly.
Power Glass Regulator Switch  Each power glass regulator switch controls UP/
DOWN operation of corresponding power window
glass.
Power glass regulator  Change power window glass position.
System Function
Function Description
Power window glass moves up when glass
Manual UP function regulating control switch is being pulled, and stops
when switch is released.
Power window glass moves down when glass
Manual DOWN function regulating control switch is being pushed and held,
and stops when switch is released.
Power window glass moves down automatically by a
Automatic DOWN function short push of glass regulating control switch.To stop
it partway, push or pull switch again.
Respective power window glass cannot be operated
by all passenger side power window glass regulator
switches when power window lock switch is pushed.
Power window LOCK function
In this case, only driver side power window glass can
be operated.This function can be canceled only
when power window lock switch is pressed again. 44
Operation Inspection
1. Check the power window lock switch.
a. Check that front and rear passenger side power
window glasses cannot be operated by front and rear
passenger power glass regulator switches, when
power window lock switch is pressed.
OK: Operation of front and rear passenger side power
glass regulator switches is impossible.
b. Check that front and rear passenger side power
window glasses can be operated by front and rear
passenger power glass regulator switches, when RA13T440030
power window lock switch is pressed again.

OK: Operation of front and rear passenger side power
glass regulator switches is possible.

2. Check the manual UP/DOWN function.

a. Check that driver side power window glass operates as follows:
OK
Front Left Door Glass

Condition Switch Operation Power Window Glass
Regulator Switch
Pulled UP (close)
Ignition switch ON Driver side
Pushed DOWN (open)
b. Check that power window glasses other than driver side power window glass operate as follows:
OK

Regulator Switch
Pulled UP (close)
Passenger side
Pushed DOWN (open)
Ignition switch ON Pulled UP (close)

Rear left side
Window lock switch OFF Pushed DOWN (open)
Pulled UP (close)
Rear right side
Pushed DOWN (open)
3. Check the remote manual UP/DOWN function.

a. Check that driver side power window glass operates as follows:
OK

Regulator Switch
Fully pulled UP (close)
Ignition switch ON Driver side
Fully pushed DOWN (open)
44 b. Check that power window glasses other than driver side power window glass operate as follows:
OK

Regulator Switch
Pulled UP (close)
Passenger side
Pushed DOWN (open)
Ignition switch ON Pulled UP (close)

Rear left side
Window lock switch OFF Pushed DOWN (open)
Pulled UP (close)
Rear right side
Pushed DOWN (open)

Specifications

Front Door Cover Plate Fixing Screw 1.5 ± 0.5
Front Door Glass Rear Guide Rail Assembly Fixing
7±1
Bolt
Front Door Power Glass Regulator Fixing Bolt 7±1
Front Door Power Glass Regulator Fixing Nut 7±1
Rear Door Cover Plate Fixing Screw 1.5 ± 0.5
Rear Door Glass Front Guide Rail Assembly Fixing
7±1
Bolt
Rear Door Glass Rear Guide Rail Assembly Fixing
7±1
Bolt
Rear Door Power Glass Regulator Fixing Bolt 7±1
Rear Door Power Glass Regulator Fixing Nut 7±1
Center Control Integration Panel Assembly 1.5 ± 0.5
Tools
Special Tool
Interior Crow Plate
RCH0000025 44
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Power Window Control System (Page 1 of 3)

ENGINE
COMPARTMENT IP FUSE
RELAY BOX RELAY BOX
30A 30A 15A 15A 15A 15A 10A 10A
E-067 I-032
7 55
106 108 72 70 65 67
RG
RY
G
R
RY
R
RL
E-026 3 2 E-053
B-015 11 12 14 B-024
Gr
RG
RY
G
R
C7 C10 C2 C1 E20 D9 B17 B5
BCM(B/C/D/E) I-034 B-020 E-033 B-021
C14 C13 C12 C11 C9 C8 C5 C6

R
R
B
B
B-016 B-023 B-011
11 10 6 7 6 5 6 5 B-028
F-005 H-008 L-005 R-005
G
R
R
B
2 1 2 1 2 1 2 1
DOWN
DOWN
DOWN
DOWN
UP
UP
UP
UP
M M M M

POWER WINDOW POWER WINDOW POWER WINDOW POWER WINDOW
44 REGULATOR MOTOR
F-002
REGULATOR MOTOR
H-004
REGULATOR MOTOR
L-003
REGULATOR MOTOR
R-003
2 3 4 5 6 7 8 9 E-053 D2 D3 D4 D5 D6 D7 D8
9 8 7 6 5 4 3 2 E-026 2 1
: 21 22 23 24 25 26 27
W
27 26 25 24 23 22 21 : W B-020
B F-002 H-004
D9 D: D21 D22 D23 D24 D25
Gr Gr
L-003 R-003
F2 F3 F4 F5 F6 F7 F8 F9 F: Gr Gr
B-021 E2 E3 E4 E5 E6
F21 F22 F23 F24 F25 F26 F27 F28 F29 F2: F31 B E-033
W 5 4 3 2 1
E7 E8 E9 E: E21 E22 E23
10 9 8 7 6
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034

B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
5 4 3 2 1
B-011
10 9 8 7 6
W B-028
W
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 B-016
B-023
W
18 17 16 15 14 13 12 11 10 W 14 15 16 17 18 19 20 21 22 23 24 25 26
EA13T440010

BCM(A) B-022
A34 A33 A47 A19 A36 A45 A40

GW
WR
ILLUMINATION
Gr
W
B
P
B-016
6 5 4 3 7 13 8 9
F-005
GW
Gr
W
B
P
WR
B
Br
6 5 4 3 7 11 8 9 13
WINDOW
INHIBIT
FR RL RR
FL WINDOW
WINDOW WINDOW
WINDOW SW
SW SW
SW
12
FRONT LEFT POWER WINDOW SWITCH F-001
B
F-004
44
8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 13 B-016 F-001
W 16 15 14 13 12 11 10 9 Y
14 15 16 17 18 19 20 21 22 23 24 25 26
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
B-022
B
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
EA13T440020

L-004 R-004 H-003

REAR LEFT POWER REAR RIGHT POWER FRONT RIGHT POWER
WINDOW SWITCH WINDOW SWITCH WINDOW SWITCH
4 3 1 2 4 3 1 2 4 3 1 2
YR
GL
LR
Br
Br
Br
B
B
L-005 R-005 5 15 4 H-008
8 1 9 7 B-011 8 1 9 7 B-028 B-023
L
B
B
Br
Br
Br
GL
YR
B
LR
B-012 B-025 H-007
ILLUMINATION
A21 A22 A20
BCM(A) B-022
44
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
9 8 7 6 5 4 3 2 1 R-004
B-022 B-023 1 2 3 4 L
B 18 17 16 15 14 13 12 11 10 W
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
5 4 3 2 1 5 4 3 2 1 1 2 3 4 H-003 1 2 3 4 L-004
B-011 B-028 L L
10 9 8 7 6 10 9 8 7 6
W W
EA13T440030

DIAGNOSIS & TESTING

HINT:

Power supply, fuse 55-30
Driver side glass regulator switch 44-40
Driver/passenger side power
window glass cannot be operated Driver/Passenger side power
44-50
by driver side glass regulator glass regulator
switch
Power supply, fuse 55-30
Passenger side power glass
44-50
Passenger side power window regulator switch
glass cannot be operated by
Passenger side power glass
passenger side glass regulating 44-50
regulator
control switch
Power window glass has Ground 55-44

intermittent problem Wire harness or connector 55-46
Diagnosis Tool
When connecting X-431 3G diagnostic tester: 44
with vehicle.
 DLC is located at driver side instrument panel crossmember.
Digital Multimeter
Diagnostic Help
 Connect X-431 3G Diagnostic tester (the latest software) to Data Link Connector (DLC), and make it
 Confirm that malfunction is current, and carry out diagnostic test and repair procedures.
 If DTC cannot be deleted, the malfunction is current.
 Only use a digital multimeter to measure voltage of electronic system.

 Visually check related wire harness.

 Check and clean all BCM system grounds related to the latest DTC.
 If multiple trouble codes were set, use circuit diagrams and look for any common ground circuit or power
 Look for changed data or reset DTCs during wiggle test.
 Check mounting areas of power window assembly, wire harnesses or wire harness connectors and so on
for damage, foreign matter, etc. that will cause incorrect signals.
perform a test. If DTC cannot be cleared, Body Control Module (BCM) is malfunctioning.If DTC can be
cleared, reinstall Body Control Module (BCM) to original vehicle.
Ground Inspection
Ground points are very important to entire circuit system, which are normal or not can seriously affect the
entire circuit system.Ground points are often exposed to moisture, dirt and other corrosive
environments.Corrosion (rust) and oxidation may increase load resistance. This situation will seriously affect
the normal operation of circuit. Check the ground points as follows:
44 5. Check if add-on accessories interfere with ground circuit.
Diagnosis Procedure
HINT:
Use following procedures to troubleshoot the power glass system.
NEXT


NEXT
NEXT
DTC
occurs
NO
DTC
NEXT
NEXT
NEXT 44
NEXT
10 End


DTC DTC Definition
B100C-13 Front Left Window Up Control Circuit
B100C-71 Front Left Window Up Control Circuit
B100D-13 Front Left Window Down Control Circuit
B100D-71 Front Left Window Down Control Circuit
B100E-13 Front Right Window Up Control Circuit
B100E-71 Front Right Window Up Control Circuit
B100F-13 Front Right Window Down Control Circuit
B100F-71 Front Right Window Down Control Circuit
B1010-13 Rear Left Window Up Control Circuit
B1010-71 Rear Left Window Up Control Circuit
B1011-13 Rear Left Window Down Control Circuit
B1011-71 Rear Left Window Down Control Circuit
B1012-13 Rear Right Window Up Control Circuit
B1012-71 Rear Right Window Up Control Circuit
B1013-13 Rear Right Window Down Control Circuit
B1013-71 Rear Right Window Down Control Circuit
B1021-17 Anti-pinch Module Power Supply
B1021-16 Anti-pinch Module Power Supply
B1022-71 FL Window Button
B1023-71 FR Window Button
B1025-71 RR Window Button
44 B1026-71 Passenger FR Window Button
B1028-71 Passenger RR Window Button Short
B1029-71 FL Window Relay
B102A-71 FR Window Relay
B102B-71 RL Window Relay
B102C-71 RR Window Relay
B102D-96 Anti-pinch Module Controller
B102E-86 FL Window Motor Position Signal
B102F-86 FR Window Motor Position Signal
B1030-86 RL Window Motor Position Signal
B1031-86 RR Window Motor Position Signal
B1032-87 Lost Communication With Anti-pinch Module MCU
B1033-71 RL Window Button

B1034-71 Passenger RL Window Button
44

DTC B100C-13 Front Left Window Up Control Circuit
DTC B100C-71 Front Left Window Up Control Circuit
DTC B100D-13 Front Left Window Down Control Circuit
DTC B100D-71 Front Left Window Down Control Circuit
DTC B1022-71 FL Window Button
DTC B1029-71 FL Window Relay
DTC B102E-86 FL Window Motor Position Signal
44


ENGINE
COMPARTMENT IP FUSE
RELAY BOX RELAY BOX
30A 30A 15A 15A 15A 15A 10A 10A
E-067 I-032
7 55
106 108 72 70 65 67
RG
RY
G
R
RY
R
RL
E-026 3 2 E-053
B-015 11 12 14 B-024
Gr
RG
RY
G
R
C7 C10 C2 C1 E20 D9 B17 B5
BCM(B/C/D/E) I-034 B-020 E-033 B-021
C14 C13 A34 A45 A40
WR
ILLUMINATION
W
B
R
B
B-016
6 13 8 9
F-005
11 10 B-016
WR
W
F-005
Br
R
B
6 8 9 13
2 1
DOWN
UP
M FRONT LEFT POWER

WINDOW SWITCH
FRONT LEFT FL F-001
POWER WINDOW WINDOW
REGULATOR MOTOR SW
F-002
12
B
F-004
E-053 & & & & & & &

44
E-026 2 1

W
W B-020
B F-002
& & & & & & &
Gr
( ( ( ( ( ( ( ( (
' ' ' ' '
B-021 E-033
( ( ( ( ( ( ( ( ( ( (
B W
' ' ' ' ' ' '
8 7 6 5 4 3 2 1
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034 1 2 3 4 5 6 7 8 9 10 11 12 13 B-016 F-001
W 16 15 14 13 12 11 10 9 Y
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W 14 15 16 17 18 19 20 21 22 23 24 25 26
EA13T440050

DTC Detection
Condition
Front Left Window Up
B100C-13
Control Circuit
Front Left Window Up
B100C-71
Control Circuit
Front Left Window  Glass regulating control master switch
B100D-13
Down Control Circuit  Power glass regulator assembly
Ignition switch ON
Front Left Window  Wire harness or connector
B100D-71
Down Control Circuit  Body Control Module (BCM)
B1022-71 FL Window Button
B1029-71 FL Window Relay
FL Window Motor
B102E-86
Position Signal

 Confirm that battery voltage is between 11 V and 14 V before performing following procedures.
 Use X-431 3G diagnostic tester to record and clear DTCs stored in BCM.
CAUTION
44 When performing circuit diagnosis and test, always refer to circuit diagram for specific circuit and

1 Perform Active Test of window system usingX-431 3G diagnostic tester
NG Check BCM, front left door glass regulator

andconnected wire harnesses
OK Read datastream of window system using

X-431 3Gdiagnostic tester
NEXT
2 Read datastream of window system using X-4313G diagnostic tester
NG Check BCM, front left door glass regulator

switchand connected wire harnesses
OK Check front left door glass regulator

switch
NEXT
3 Check front left door glass regulator switch
a. Remove front left door glass regulator switch from

malfunctioning vehicle, then install it to a new vehicle and
perform a test.
c. Connect negative battery cable, and turn ignition switch
to ON.
d. Check operation of front left door glass regulator switch.
NG Replace front left door glass regulator 44

switch
OK Check front left door power glass

regulator
NEXT
4 Check front left door power glass regulator
a. Remove front left door power glass regulator from

perform a test.
to ON.
d. Check operation of front left door power glass regulator.

NG Replace front left door glass regulator
OK Check wire harness and connector
NEXT

c. Disconnect BCM connector B-022.
d. Using a digital multimeter, check for continuity between + -
8 7 6 5 4 3 2 1
BCM connector B-022 and front left door glass regulator 16 15 14 13 12 11 10 9
switch connector F-001 according to table below.
F-001
Normal Condition

Condition
B-022 (A45) - F- Ignition switch

Continuity
001 (8) OFF A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022 (A34) - F- Ignition switch
Continuity
001 (6) OFF B-022
RA13T440040
RM1A370500
e. Turn ignition switch to LOCK and disconnect negative

battery cable.
f. Disconnect BCM connector B-020, front left door glass & & & & & & &
regulator motor connector F-002 and body wire harness

connector B-016. + -
& & & & & & &
g. Using a digital multimeter, check for continuity between

B-020
BCM and front left door glass regulator.
44 Normal Condition
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Condition
B-016
B-020 (C14) - B- Ignition switch
Continuity
016 (11) OFF 8 7 6 5 4 3 2 1
2 1 16 15 14 13 12 11 10 9
B-016 (11) - F- Ignition switch
Continuity
002 (2) OFF F-002 F-001
RA13T440045
RM1A370500
Continuity
016 (10) OFF
Continuity
001 (1) OFF

h. Disconnect the body wire harness connector B-016.

i. Using a digital multimeter, check for continuity among
body wire harness connector B-016, BCM connector B- 1 2 3 4 5 6 7 8 9 10 11 12 13
022 and front left door glass regulator switch connector 14 15 16 17 18 19 20 21 22 23 24 25 26
F-001. + -
B-016
Normal Condition
8 7 6 5 4 3 2 1
Condition 16 15 14 13 12 11 10 9
F-001
B-022 (A34) - B- Ignition switch
Continuity A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
016 (6) OFF
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
B-016 (6) - F-001 Ignition switch

Continuity
(1) OFF A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
B-022 (A45) - B- Ignition switch A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
Continuity
016 (13) OFF B-022
RA13T440046
RM1A370500
Continuity
001 (8) OFF
NG Replace body wire harness
OK Reconfirm DTCs
NEXT
6 Reconfirm DTCs

record and clear DTCs stored in body control system. 44
read DTCs stored in body control system again.
Result Proceed to
B100C-13, B100C-71, B100D-13, B100D-71,
NG
B1022-71, B1029-71 and B102E-86 are output
No DTC is output OK
OK System is normal

DTC B100E-13 Front Right Window Up Control Circuit
DTC B100E-71 Front Right Window Up Control Circuit
DTC B100F-13 Front Right Window Down Control Circuit
DTC B100F-71 Front Right Window Down Control Circuit
DTC B1023-71 FR Window Button
DTC B1026-71 Passenger FR Window Button
DTC B102A-71 FR Window Relay
DTC B102F-86 FR Window Motor Position Signal
44


ENGINE
COMPARTMENT IP FUSE
RELAY BOX RELAY BOX
30A 30A 15A 15A 15A 15A 10A 10A
E-067 I-032
7 55
106 108 72 70 65 67
RG
RY
G
R
RY
R
RL
E-026 3 2 E-053
B-015 11 12 14 B-024
Gr
RG
RY
G
R
C7 C10 C2 C1 E20 D9 B17 B5
BCM(B/C/D/E) I-034 B-020 E-033 B-021
C12 C11 A33 A45 A40 A20

GW
WR
B
LR
Br
B
R
B
B-016 H-007
5 13 8 9 H-008
F-005 4 15 5
B-023 B-023
L
6 7
GW
H-008
B
LR
Br
B
B
WR
R
B
Br
2 1 2 1 3 4
5 11 9 13
DOWN
UP
FRONT RIGHT
POWER WINDOW FR
REGULATOR MOTOR WINDOW
H-004 SW
12
B
FRONT RIGHT POWER

WINDOW SWITCH
FRONT LEFT POWER WINDOW SWITCH F-001 F-004
H-003

E-053 & & & & & & &
2 1
44
E-026 W
W B-020
B F-002 H-004
& & & & & & &
Gr Gr
L-003 R-003
( ( ( ( ( ( ( ( ( Gr Gr
B-021 ' ' ' ' '
( ( ( ( ( ( ( ( ( ( (
B 1 2 3 4 H-003
E-033
L
' ' ' ' ' ' ' W
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13

9 8 7 6 5 4 3 2 1 B-023 B-016
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 1 2 3 4 5 6 7 8 9 10 11 12 13
18 17 16 15 14 13 12 11 10 W W
14 15 16 17 18 19 20 21 22 23 24 25 26
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034
B-022 B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
B EA13T440060

DTC Detection
Condition
B100E-13 Front Right Window
Up Control Circuit
B100E-71 Front Right Window
Up Control Circuit
B100F-13 Front Right Window
Down Control Circuit
 Driver side airbag
B100F-71 Front Right Window Ignition switch ON
Down Control Circuit  Wire harness and connector
Engine running
B1023-71 FR Window Button
B1026-71 Passenger FR Window
Button
B102A-71 FR Window Relay
B102F-86 FR Window Motor
Position Signal

44 CAUTION
When performing circuit diagnosis and test, always refer to circuit diagram for specific circuit and

NG Check BCM, front right door glass

regulator andconnected wire harnesses
OK Check BCM, front right door glass

regulator switchand connected wire
harnesses
NEXT
NG Check BCM, front right door glass

harnesses
OK Check BCM, front right door glass

regulator andconnected wire harnesses
NEXT
3 Check power glass regulator switch
a. Remove front right door glass regulator switch from

perform a test.
to ON.
d. Check operation of power glass regulator switch. 44
NG Replace front right power glass regulator
switch
OK Check front right glass regulator and

regulatorswitch assembly
NEXT
4 Check front right door power glass regulator
a. Remove front right door power glass regulator from

perform a test.
to ON.

d. Check operation of front right door power glass regulator.
NG Replace front right door power glass

regulator
NEXT

c. Disconnect BCM connector B-022, body wire harness 1 2 3 4 5 6 7 8 9 10 11 12 13
connector B-016 and front left door glass regulator switch + -

14 15 16 17 18 19 20 21 22 23 24 25 26
connector F-001.
B-016
d. Using a digital multimeter, check for continuity among
BCM connector B-022, left door glass regulator switch 8 7 6 5 4 3 2 1
connector F-001 and body wire harness connector B-016 16 15 14 13 12 11 10 9
according to table below. F-001
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13

Condition

016 (5) OFF
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52

Continuity B-022
RA13T440048
RM1A370500
(5) OFF
Continuity
016 (13) OFF
Continuity
001 (11) OFF
44 e. Disconnect front right door glass regulator switch

connector H-003, BCM connector B-022 and body wire
harness connector B-023. 9 8 7 6 5 4 3 2 1
f. Using a digital multimeter, check for continuity among 18 17 16 15 14 13 12 11 10
BCM connector B-022, body wire harness connector B- + - B-023

023 and front right glass regulator switch connector H-
1 2 3 4
Multimeter Specified H-003

Condition
Continuity
B-023 (4) - H-003 Ignition switch

(2) OFF
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
Continuity B-022
023 (15) OFF RA13T440051
RM1A370500
B-023 (15) - H- Ignition switch

Continuity
003 (1) OFF

g. Disconnect BCM connector B-020, front right glass

regulator motor connector H-004 and body wire harness
connector B-023.
9 8 7 6 5 4 3 2 1
h. Using a digital multimeter, check for continuity among 18 17 16 15 14 13 12 11 10
BCM connector B-020, front right glass regulator motor + -
B-023
connector H-004 and body wire harness connector B-
023.
& & & & & & &
Condition
Connection Condition & & & & & &
&

Continuity
023 (6) OFF B-020

Continuity
(2) OFF 2 1
B-020 (C11) - B- Ignition switch H-004

Continuity
023 (7) OFF RA13T440053
RM1A370500

Continuity
(1) OFF

connector
OK Reconfirm DTCs
NEXT
6 Reconfirm DTCs

d. Use X-431 3G diagnostic tester (the latest software) to 44
record and clear DTCs stored in body control system.
Result Proceed to
B100E-13, B100E-71, B100F-13, B100F-71、
B1023-71, B1026-71, B102A-71 and B102F-86 are NG
output
No DTC is output OK
OK System is normal

DTC B1010-13 Rear Left Window Up Control Circuit
DTC B1010-71 Rear Left Window Up Control Circuit
DTC B1011-13 Rear Left Window Down Control Circuit
DTC B1011-71 Rear Left Window Down Control Circuit
DTC B102B-71 RL Window Relay
DTC B1030-86 RL Window Motor Position Signal
DTC B1033-71 RL Window Button
DTC B1034-71 Passenger RL Window Button
44


ENGINE
COMPARTMENT IP FUSE
RELAY BOX RELAY BOX
30A 30A 15A 15A 15A 15A 10A 10A
E-067 I-032
7 55
106 108 72 70 65 67
RG
RY
G
R
RY
R
RL
E-026 3 2 E-053
B-015 11 12 14 B-024
Gr
RG
RY
G
R
C7 C10 C2 C1 E20 D9 B17 B5
BCM(B/C/D/E) I-034 B-020 E-033 B-021
C9 C8 A47 A45 A40 A21

WR
B
P
B-016
R
B
4 13 8 9
F-005 B-012
GL
B
B
P
B-011
Br
6 5
B
L-005
WR
B
L-005
Br
R
B
B-011 7 9 1 8
2 1 4 11 9 13
DOWN
GL
Br
B
B
UP
M
2 1 3 4
REAR LEFT RL
POWER WINDOW WINDOW
REGULATOR MOTOR SW REAR LEFT
POWER
L-003 WINDOW
12
SWITCH
B
L-004
FRONT LEFT POWER
F-001 F-004
WINDOW SWITCH
E-026
E-053
W
& & & & & & &
2 1
44
W B-020
B L-003
& & & & & & &
Gr
( ( ( ( ( ( ( ( (
5 4 3 2 1
B-021 ' ' ' ' ' 10 9 8 7 6
( ( ( ( ( ( ( ( ( ( (
B E-033
W
' ' ' ' ' ' '
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13

B-011
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 W
I-034
W 1 2 3 4 5 6 7 8 9 10 11 12 13
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
8 7 6 5 4 3 2 1 1 2 3 4 14 15 16 17 18 19 20 21 22 23 24 25 26
16 15 14 13 12 11 10 9 A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
L-004
L B-022 B-016
F-001
B W EA13T440070
Y

DTC Detection
Condition
Rear Left Window Up
B1010-13
Control Circuit
Rear Left Window Up
B1010-71
Control Circuit
Rear Left Window
B1011-13
Down Control Circuit  Glass regulator switch
Rear Left Window  Power glass regulator assembly
Down Control Circuit  Wire harness or connector
B102B-71 RL Window Relay  Body Control Module (BCM)
RL Window Motor
B1030-86
Position Signal
B1033-71 RL Window Button
Passenger RL Window
B1034-71
Button

44 CAUTION

NG Check BCM, rear left door glass regulator

andconnected wire harnesses
OK Check wire harness connector
NEXT
NG Check BCM, rear left door glass regulator

switchand connected wire harnesses
OK Check power glass regulator switch
NEXT
a. Remove rear left door glass regulator switch from

perform a test.
to ON.
d. Check operation of power glass regulator switch.
NG Replace power glass regulator switch
OK Check rear left door power glass regulator 44
NEXT
4 Check rear left door power glass regulator
a. Remove rear left door power glass regulator from

perform a test.
to ON.
d. Check operation of rear left door power glass regulator.
NG Replace rear left door power glass

regulator

NEXT

c. Disconnect BCM connector B-022, body wire harness 1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
connector B-016 and front left door glass regulator switch + -
connector F-001.
B-016
BCM connector B-022, body wire harness connector B- A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
016 and front left door glass regulator switch connector A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
F-001.
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
Condition

Continuity
016 (4) OFF 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Continuity F-001
RA13T440055
RM1A370500
(4) OFF
Continuity
016 (13) OFF
Continuity
001 (11) OFF
e. Disconnect BCM connector B-022, body wire harness

connector B-011 and rear left door glass regulator switch
connector L-004.
f. Using a digital multimeter, check for continuity among 5 4 3 2 1
BCM connector B-022, body wire harness connector B- + - 10 9 8 7 6
011 and rear left door glass regulator switch connector L-

44
1 2 3 4
004.
L-004
Multimeter Specified B-011

Condition
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
011 (7) OFF
B-011 (7) - L-004 Ignition switch
B-022 (A45) - B- Ignition switch B-022

Continuity
011 (9) OFF RA13T440057
RM1A370500

Continuity
(1) OFF

g. Disconnect BCM connector B-020, body wire harness

connector B-011 and rear left door glass regulator
connector L-003.
h. Using a digital multimeter, check for continuity among 5 4 3 2 1
BCM connector B-020, body wire harness connector B- + - 10 9 8 7 6
011 and rear left door glass regulator connector L-003.

2 1
Condition L-003

Continuity
011 (6) OFF & & & & & & &

Continuity
(2) OFF & & & & & & &

Continuity
011 (5) OFF B-020
RA13T440059
RM1A370500
Continuity
(1) OFF

connector
OK Reconfirm DTCs
NEXT
6 Reconfirm DTCs

record and clear DTCs stored in body control system. 44
Result Proceed to
B1010-13, B1010-71, B1011-13, B1011-71, B102B-
NG
71, B1030-86, B1033-71 and B1034-71 are output
No DTC is output OK
OK System is normal

DTC B1012-13 Rear Right Window Up Control Circuit
DTC B1012-71 Rear Right Window Up Control Circuit
DTC B1013-13 Rear Right Window Down Control Circuit
DTC B1013-71 Rear Right Window Down Control Circuit
DTC B1025-71 RR Window Button
DTC B1028-71 Passenger RR Window Button Short
DTC B102C-71 RR Window Relay
DTC B1031-86 RR Window Motor Position Signal
44


ENGINE
COMPARTMENT IP FUSE
RELAY BOX RELAY BOX
30A 30A 15A 15A 15A 15A 10A 10A
E-067 I-032
7 55
106 108 72 70 65 67
RG
RY
G
R
RY
R
RL
E-026 3 2 E-053
B-015 11 12 14 B-024
Gr
RG
RY
G
R
R
C7 C10 C2 C1 E20 D9 B17 B5
BCM(B/C/D/E) I-034 B-020 E-033 B-021
C5 C6 A19 A45 WR A40 A22

B
V
B-025
B-016
R
B
3 13 8 9
Br
F-005
YR
B
V
6 5 B-028
R-005
R-005 7 9 1 8
B-028
WR
B
Br
G
YR
Br
B
B
2 1 3 11 8 9 13
2 1 3 4
DOWN
UP
REAR RIGHT RR
POWER WINDOW WINDOW
REGULATOR MOTOR SW
R-003
12
REAR RIGHT POWER
B
WINDOW SWITCH
FRONT LEFT POWER WINDOW SWITCH F-001 R-004
F-004
E-026
E-053
W
& & & & & & &
2 1 44
W B-020
B R-003
& & & & & & &
Gr
( ( ( ( ( ( ( ( (
5 4 3 2 1
B-021 ' ' ' ' '
10 9 8 7 6
( ( ( ( ( ( ( ( ( ( (
B E-033
W
' ' ' ' ' ' '
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 1 2 3 4
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 R-004 B-028
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
L W
I-034
W 8 7 6 5 4 3 2 1
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
16 15 14 13 12 11 10 9
B-016 A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
1 2 3 4 5 6 7 8 9 10 11 12 13
W F-001
14 15 16 17 18 19 20 21 22 23 24 25 26 B-022 Y
B EA13T440080

DTC Detection
Condition
Rear Right Window Up
B1012-13
Control Circuit
Rear Right Window Up
B1012-71
Control Circuit
Rear Right Window
B1013-13
Down Control Circuit  Glass regulator switch
Rear Right Window  Power glass regulator assembly
Down Control Circuit  Wire harness or connector
B1025-71 RR Window Button  Body Control Module (BCM)
Passenger RR
B1028-71
Window Button Short
B102C-71 RR Window Relay
RR Window Motor
B1031-86
Position Signal

44  If DTC is not detected, malfunction indicated by DTC is intermittent (See page 44-18).
CAUTION
NG Check BCM, rear right door glass

harnesses
OK Read datastream of window system using

X-431 3Gdiagnostic tester

NEXT
NG Check BCM, rear right door glass

regulating switchand connected wire
harnesses
OK Check power glass regulator switch
NEXT
a. Remove rear right door glass regulator switch from

perform a test.
to ON.
d. Check operation of power glass regulator switch.
NG Replace power glass regulator switch
OK Check rear right door power glass

regulator
NEXT
4 Check rear right door power glass regulator

44
a. Remove rear right door power glass regulator from
perform a test.
to ON.
d. Check operation of rear right door power glass regulator.
NG Replace rear right door power glass

regulator
NEXT


c. Disconnect BCM connector B-022, front left door glass 1 2 3 4 5 6 7 8 9 10 11 12 13
regulator switch connector F-001 and body wire harness + -

14 15 16 17 18 19 20 21 22 23 24 25 26
connector B-016.
B-016
BCM connector B-022, front left door glass regulator 8 7 6 5 4 3 2 1
switch connector F-001 and body wire harness connector 16 15 14 13 12 11 10 9
B-016. F-001
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13

Condition A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
016 (3) OFF
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52

Continuity B-022
RA13T440061
RM1A370500
(3) OFF
Continuity
016 (13) OFF
Continuity
001 (11) OFF
e. Disconnect BCM connector B-022, body wire harness

connector B-028 and rear right door glass regulator
switch connector R-004. 5 4 3 2 1
B-028
10 9 8 7 6
f. Using a digital multimeter, check for continuity among
BCM connector B-022, body wire harness connector B- + -
028 and rear right door glass regulator switch connector

R-004.
44 Connection
Condition
Condition R-004

Continuity
B-028 (7) - R-004 Ignition switch

Continuity
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
Continuity
028 (9) OFF B-022 RA13T440063

Continuity
(1) OFF

g. Disconnect BCM connector B-020, body wire harness

connector B-028 and rear right glass regulator motor
connector R-003. 5 4 3 2 1
10 9 8 7 6 B-028
h. Using a digital multimeter, check for continuity among
BCM connector B-020, body wire harness connector B- + -
028 and rear right glass regulator motor connector R-

003.
& & & & & & &

Condition
& & & & & & &
Continuity
028 (6) OFF B-020

Continuity
(2) OFF 2 1

Continuity R-003
028 (5) OFF RA13T440065

Continuity
(1) OFF

connector
OK Reconfirm DTCs
NEXT
6 Reconfirm DTCs

d. Use X-431 3G diagnostic tester (the latest software) to 44
record and clear DTCs stored in body control system.
Result Proceed to
B1012-13, B1012-71, B1013-13, B1013-71, B1025-
NG
71, B1028-71, B102C-71 and B1031-86 are output
No DTC is output OK
OK System is normal

ON-VEHICLE SERVICE
Front Left Door Glass Regulator Switch
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing front left door glass regulator
switch.
 Appropriate force should be applied when removing front left door glass regulator switch. Be careful not
to operate roughly.
 Try to prevent front door inner protector assembly from being scratched, when removing front left door
glass regulator switch.

3. Remove the front left door glass regulator switch.
up front left door glass regulator switch assembly.
44
RA13T440200
b. Disconnect the front left door glass regulator switch

connector (1).
c. Remove the front left door glass regulator switch
assembly (2).
RA13T440210


detach claws (arrow) from front left door glass
regulator switch assembly and remove front left door
glass regulator switch.
RA13T440220
Inspection
1. Check the front left door glass regulator switch.
between terminals of front left door glass regulator
+ -
1 2 3 4 5 6 7 8
9 10111213141516
Component
UP 3000 Ω
Front left 6-8
door glass OFF No continuity
regulator DOWN 332 Ω RA13T440230
switch 6-8
OFF No continuity
UP 3000 Ω
Front right 5 - 11
regulator DOWN 332 Ω
switch 5 - 11
OFF No continuity
UP 3000 Ω
Rear left door 4 - 11
glass OFF No continuity
regulator
switch 4 - 11
DOWN 332 Ω 44
OFF No continuity
UP 3000 Ω
Rear right 3 -11
switch 3 -11
OFF No continuity
Power Pushed Continuity

window lock 7 - 11 Pushed
switch No continuity
again
If result is not as specified, replace front left door glass regulator switch.

Installation
 Installation is in the reverse order of removal.
CAUTION
 Check if connector is installed in place, when installing front left door glass regulator switch.
 Check if front left door glass regulator switch can be operated normally after installation.
44

Front Door Weather Bar

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing front door weather bars.
 Appropriate force should be applied when removing front door weather bars. Be careful not to operate
roughly.
 Try to prevent body paint surface from being scratched, when removing front door weather bars.

3. Remove the front left door outer weather bar.
a. Remove the outside rear view mirror assembly (See page 45-9).
b. Using an interior crow plate, remove front door outer
weather bar (1) from trough in direction of arrow as
44
RA13T440260
Installation

Front Door Glass Upper Run

HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing front door glass assembly.
 Appropriate force should be applied when removing front door glass assembly. Be careful not to operate
roughly.

4. Remove the left outside rear view mirror assembly (See page 45-9).
5. Remove the front left door outer weather bar (See page 44-43).
6. Loosen and remove front left door glass upper run.
a. Lower front door glass assembly and pull lower part
(arrow) of front door glass upper run out from trough.
44
RA13T440262
b. Remove 2 fixing screws (arrow) and front left door

cover plate. (Tightening torque: 1.5 ± 0.5 N·m)
RA13T440265

c. Remove front left door glass upper run (1) from trough
in direction of arrow as shown in illustration.
RA13T440268
Installation
44

Front Door Glass Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing front door glass assembly.
 Appropriate force should be applied when removing front door glass assembly. Be careful not to operate
roughly.
 Prevent window glass from dropping which will cause damage, when removing front door glass
assembly.

6. Remove the front left door outer weather bar (See page 44-43).
7. Remove the front left door glass assembly.
a. Raise front door glass assembly to a proper position.
b. Using a "TORX" driver, remove 2 fixing screws (arrow)
from glass. (Tightening torque: 1.5 ± 0.5 N·m)
44
RA13T440270
Installation

Front Door Power Glass Regulator

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing front door power glass regulator.
 Appropriate force should be applied when removing front door power glass regulator. Be careful not to
operate roughly.

5. Remove the front left door glass assembly (See page 48-19).
6. Remove the front left door power glass regulator.
a. Disconnect connector (1) from front left door power
glass regulator.
b. Remove 5 fixing nuts (arrow) from front left door
power glass regulator assembly, and remove front left
door power glass regulator assembly. (Tightening
torque: 7 ± 1 N·m)
44
RA13T440280
Inspection
1. Check the front door power glass regulator.
a. Apply battery voltage to terminals of front door power
glass regulator motor connector, and check operation + -
of front door power glass regulator motor according to

1 2
table below.
Battery positive Battery negative Specified

(+) (-) Condition
2 1 UP smoothly
1 2 DOWN smoothly
RA13T440290
If result is not as specified, replace front door power glass regulator.

Installation
CAUTION
 After installing front left door power glass regulator is installed, make sure that window glass can go up
and down smoothly and freely without any vibration, chattering or shock loading, etc.
44

Power Glass Regulator Switch

Removal
HINT:
 Use same procedures for front right, rear right and rear left sides.
 Procedures listed below are for rear left side.
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing power glass regulator switch.
 Appropriate force should be applied when removing power glass regulator switch. Be careful not to
operate roughly.
 Try to prevent door inner protector assembly from being scratched, when removing power glass
regulator switch.

3. Remove the rear left power glass regulator switch.
off rear left power glass regulator switch assembly (1).
b. Disconnect the rear left power glass regulator switch
connector.
44
RA13T440300
c. Remove the rear left power glass regulator switch

assembly (1).
RA13T440310


detach 4 claws (arrow) from rear left power glass
regulator switch and remove rear left power glass
regulator switch.
RA13T440320
Inspection
1. Check the power glass regulator switch.
between terminals of power glass regulator switch

Component
UP 3000 Ω
Front right 2-1
switch 2-1
OFF No continuity
UP 3000 Ω
Rear left door 2-1
glass OFF No continuity
switch 2-1
OFF No continuity
UP 3000 Ω
Rear right 2-1
44 regulator
switch 2-1
DOWN 330 Ω
OFF No continuity
If result is not as specified, replace power glass regulator

switch.
2. Check the power glass regulator switch illumination light
(for rear left door side).
a. Apply battery voltage to terminals of power glass
regulator switch connector, and check operation of
+ -
power glass regulator switch according to table below.
1 2 3 4
(+) (-) Condition
4 3 Backlight ON
b. If result is not as specified, replace power glass

regulator switch. RA13T440330

Installation
CAUTION
 Check if connector is installed in place, when installing power glass regulator switch.
 Check if power glass regulator switch can be operated normally after installation.
44

Rear Door Weather Bar

Removal
HINT:
 Be sure to wear safety equipment to prevent accidents, when removing rear door weather bars.
 Appropriate force should be applied when removing rear door weather bars. Be careful not to operate
roughly.
3. Remove the rear left door outer weather bar.
a. Using an interior crow plate, pry up and move away
rear door glass inner triangular trim board (1) in
RA13T440340
b. As shown in illustration, remove bolt from inner part of

triangular trim board, pry up and move away outer
triangular trim board (1).
44
RA13T440350

c. Remove the rear left door outer weather bar (1)

upward.
RA13T440360
Installation
44

Rear Door Glass Assembly

Removal
HINT:
3. Remove the rear left door inner protector assembly (See page 48-17).
4. Remove the rear left door metal bracket (See page 48-29).
6. Remove the rear door weather bar (See page 44-52).
7. Remove the rear left door glass run.
a. Lower rear door glass assembly to a proper position,
and pull rear left door glass run (1) out from trough.
RA13T440370
8. Remove the rear left door glass assembly.
44 CAUTION
 Prevent window glass from dropping and becoming damaged, when removing rear door glass assembly.
a. Remove 2 fixing screws (arrow) from rear left door

cover plate, and remove rear left door cover
plate.(Tightening torque: 1.5 ± 0.5 N·m)
b. Raise rear door glass assembly to a proper position.
RA13T440380

c. Using a "TORX" driver, remove 2 fixing screws from

glass, and remove rear left door glass
assembly.(Tightening torque: 1.5 ± 0.5 N m)
RA13T440390
Installation
CAUTION
 Prevent window glass from dropping which will cause damage, when installing rear door glass assembly.
44

Rear Door Glass Upper Run

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing rear door glass upper run.
 Appropriate force should be applied when removing rear door glass upper run. Be careful not to operate
roughly.

3. Remove the rear left door weather bar (See page 44-54).
4. Remove the rear door glass assembly (See page 44-54).
5. Remove the rear door triangular window glass assembly.
6. Remove the rear door glass upper run.
a. Remove fixing clips from rear left door glass upper
run, and remove rear left door glass upper run (1).
44
RA13T440400
Installation

Rear Door Glass Guide Rail Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing rear door glass guide rail
assembly.
 Appropriate force should be applied when removing rear door glass guide rail assembly. Be careful not to
operate roughly.

6. Remove the rear left door glass front guide rail assembly.
a. Remove 2 fixing bolts (arrow) from rear left door glass
front guide rail assembly, and remove rear left door
glass front guide rail assembly. 
44
RA13T440410
Installation
CAUTION
 After installing window glass regulating system, make sure that window glass can go up and down
smoothly and freely without any vibration, chattering or shock loading, etc.

Rear Door Power Glass Regulator

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing rear door power glass regulator.
 Appropriate force should be applied when removing rear door power glass regulator. Be careful not to
operate roughly.

6. Remove the rear left door glass assembly (See page 44-54).
7. Remove the rear left door power glass regulator.
a. Disconnect connector (arrow) from rear left door
power glass regulator.
b. Remove 5 fixing bolts (arrow) from rear left door
power glass regulator. 
44
RA13T440420
Inspection
1. Check the rear door power glass regulator.
a. Apply battery voltage to terminals of rear door power
-
glass regulator motor connector, and check operation +
of rear door power glass regulator motor according to

table below. 1 2

(+) (-) Condition
2 1 UP smoothly
1 2 DOWN smoothly
RA13T440430

If result is not as specified, replace rear door power glass regulator assembly.
Installation
CAUTION
 After installing rear door power glass regulator, make sure that window glass can go up and down
smoothly and freely without any vibration, chattering or shock loading, etc.
44

Front Windshield Assembly

Removal
3. Remove the roof assembly (See page 51-9).
 It is not necessary to completely remove roof assembly. Lower front part of roof assembly, so that front
windshield assembly can be removed.
4. Remove the inside rear view mirror assembly (See page 45-13).
5. Remove the wiper arm assembly (See page 36-29).
7. Remove the front windshield weatherstrip.
8. Remove the front windshield assembly.
a. Using a knife, cut off the adhesive.
Cut
RA13T440440
CAUTION
 Try to prevent body paint surface from being scratched. when cutting off the adhesive.
b. Apply protective tape to outer surface of body to prevent scratches.
44 CAUTION
 To prevent instrument panel upper body assembly from being scratched, place a plastic sheet between
piano wire and instrument panel upper body assembly.
c. Pass a piano wire through seam between body and front windshield assembly.

d. Tie wooden blocks or similar objects to both piano wire ends, cut off adhesive by pulling piano wire
around front windshield assembly, and remove front windshield assembly.
CAUTION
 When removing front windshield assembly, an assistant is needed.

 When removing front windshield assembly, prevent it from dropping.
 Leave as much adhesive on the body as possible when cutting off the adhesive.
 When separating front windshield assembly from vehicle, be careful not to damage body paint, interior
and exterior ornaments.
9. Clean the vehicle body.

a. Using a knife, cut off any excess adhesive on contact
surface of vehicle body as shown in illustration.
RA13T440450
CAUTION
 Leave as much adhesive on the body as possible, when cutting off the adhesive.
b. Clean contact surface of vehicle body with cleaner.
44
Adhesive
RA13T440460
CAUTION
 Even if all adhesive has been removed, cleaning of vehicle would be necessary.

10.Clean the removed glass.
CAUTION
 DO NOT touch the glass after cleaning it.

 Even if a new glass is used, it is necessary to clean it with glass cleaner.
a. Using a scraper, remove adhesive sticking to glass.

b. Clean outer edges of glass with cleaner.
RA13T440470
Installation
1. Position the front windshield assembly.
a. Align positioning blocks with metal plate installation
holes of body.
b. Check if whole contact surface of glass edge is
perfectly even.
c. Place matchmarks on front windshield assembly and
body at positions shown in illustration.
RA13T440480
2. Apply a coat of primer M to contact surface of vehicle body.

44
CAUTION
 Allow primer to dry for at least 3 minutes.

 DO NOT apply primer to the adhesive.
 DO NOT apply too much primer.
 DO NOT keep any opened primer M for later use.
a. Using a brush, apply a coat of primer M to contact

surface of vehicle body. Primer M Primer M
b. Width of primer is 13 to 15 mm.
Primer M Adhesive
RA13T440490

3. Clean contact surface of front windshield assembly.
CAUTION
 DO NOT touch the glass surface after cleaning it.
a. Remove any residue on contact surface of front

windshield assembly with a clean, lint-free cloth
soaked with cleaner.
RA13T440500
4. Apply a coat of primer G to contact surface of front windshield assembly.
CAUTION

 DO NOT keep any opened primer G for later use.
a. Using a brush, apply a coat of primer G to glass edge and contact surface.
b. Wipe off any excess primer with a clean cloth before drying.
c. Width of primer is 13 to 15 mm.
Primer G 13-15 mm 44
RA13T440510
5. Install the front windshield weatherstrip.

6. Mix the adhesive.
CAUTION
 Adhesive should be mixed thoroughly within 5 minutes.
a. Using a solvent, thoroughly clean mixing board and scraper.

b. Using a scraper, thoroughly mix 500 g main adhesive

and 75 g hardener on mixing board.
RA13T440520
7. Apply the adhesive.

a. Cut off tip of cartridge nozzle and add adhesive.
b. Install cartridge to sealer gun.
c. Apply adhesive evenly to front windshield assembly
Adhesive width: 8 mm
Adhesive height: 12 mm
8 mm
12 mm
RA13T440530
8. Install the front windshield assembly.
CAUTION
 Check that lower/upper clearance and right/left clearance of front windshield assembly are uniform, to
ensure good fitting with weatherstrips all around.
a. Align matchmarks on glass and vehicle body, and

44 gently press in glass along edge.
RA13T440540
b. Using a scraper, uniformly apply adhesive to glass edge.

c. Remove any excess or spilled adhesive with a

scraper.
Adhesive
RA13T440550
d. Apply tape all the way around, and do not remove them until adhesive hardens.
9. Check and repair sealing of glass.
a. Check glass for leakage after adhesive has completely hardened.
b. If it leaks, seal leaks by adding adhesive.
10.Install the front windshield lower support assembly.
11. Install the wiper arm assembly.
12.Install the inside rear view mirror assembly.
13.Install the roof assembly.
14.Connect the negative battery cable.
44

Rear Windshield Assembly

Removal
HINT:
 It is not necessary to completely remove the roof assembly. Lower the rear part of roof assembly, so
that rear windshield assembly can be removed.
5. Remove the defroster wire harness assembly.
a. Remove the defroster connector (arrow).
RA13T440560
6. Remove the rear windshield weatherstrip.

7. Remove the rear windshield assembly.
a. Using a knife, cut off the adhesive.
Cut
44
RA13T440440
CAUTION
b. Apply protective tape to outer surface of body to prevent scratches.

c. Pass a piano wire through seam between body and rear windshield assembly.

d. Tie wooden blocks or similar objects to both piano

wire ends, cut off adhesive by pulling piano wire
around rear windshield assembly, and remove rear
windshield assembly.
RA13T440580
CAUTION
 When removing rear windshield assembly, an assistant is needed.

 When removing rear windshield assembly, prevent it from dropping.
 Leave as much adhesive on the body as possible when cutting off the adhesive.
 When separating rear windshield assembly from vehicle, be careful not to damage body paint, interior
and exterior ornaments.
8. Clean the vehicle body.

a. Using a knife, cut off any excess adhesive on contact
surface of vehicle body as shown in illustration.
Adhesive
RA13T440460
CAUTION
44
 Leave as much adhesive on the body as possible, when cutting off the adhesive.
b. Clean contact surface of vehicle body with cleaner.
CAUTION
 Even if all adhesive has been removed, cleaning of vehicle would be necessary.

9. Clean the removed glass.
CAUTION
 DO NOT touch the glass after cleaning it.

 Even if a new glass is used, it is necessary to clean it with glass cleaner.
a. Using a scraper, remove adhesive sticking to glass.

b. Clean outer edges of glass with glass cleaner.
RA13T440470
Installation
1. Position the rear windshield assembly.
a. Align positioning blocks with metal plate installation holes of body.
b. Check if whole contact surface of glass edge is perfectly even.
c. Place matchmarks on rear windshield assembly and
body at positions shown in illustration.
44
RA13T440610
d. Remove the rear windshield assembly.

2. Apply a coat of primer M to contact surface of vehicle body.
CAUTION

 DO NOT keep any opened primer M for later use.
a. Using a brush, apply a coat of primer M to contact

surface of vehicle body.
10 9 8 7 6 5 4 3 2 1
+ -
20 19 18 17 16 15 14 13 12 11
I-002
W
1
5 4 3 2 1
10 9 8 7 6
T-008
T-007 B-001
RA13T440620
b. Width of primer is 13 to 15 mm.

3. Clean contact surface of rear windshield.
CAUTION
 DO NOT touch the surface of rear windshield after cleaning it.

44
a. Remove any residue on contact surface of rear

windshield with a clean, lint-free cloth soaked with
cleaner.
RA13T440500

4. Apply a coat of primer G to contact surface of rear windshield assembly.
CAUTION

 DO NOT keep any opened primer G for later use.
a. Using a brush, apply a coat of primer G to glass edge

and contact surface.
Primer G 13-15 mm
RA13T440510
b. Wipe off any excess primer with a clean cloth before drying.
c. Width of primer is 13 to 15 mm.
5. Install the rear windshield weatherstrip.
6. Mix the adhesive.
a. Using a solvent, thoroughly clean mixing board and
scraper.
b. Using a scraper, thoroughly mix 500 g main adhesive
and 75 g hardener on mixing board.
44
RA13T440520
7. Apply the adhesive.

a. Cut off tip of cartridge nozzle and add adhesive.
b. Install cartridge to sealer gun.
c. Apply adhesive evenly to rear windshield assembly as
Adhesive width: 8 mm
Adhesive height: 12 mm
8 mm
12 mm
RA13T440530

8. Install the rear windshield assembly.
CAUTION
 Check that lower/upper clearance and right/left clearance of rear windshield assembly are uniform, to
ensure good fitting with weatherstrips all around.
a. Align matchmarks on glass and vehicle body, and

gently press in glass along edge.
Matchmarks
RA13T440670
b. Using a scraper, uniformly apply adhesive to glass edge.

c. Remove any excess or spilled adhesive with a
scraper.
Adhesive
RA13T440550
d. Apply tape all the way around, and do not remove them until adhesive hardens.
9. Check and repair sealing of glass.
a. Check glass for leakage after adhesive has completely hardened.
b. If it leaks, seal leaks by adding adhesive. 44
10.Install the tonneau cover assembly.
11. Connect the negative battery cable.

Rear Window Defroster

General Information
Description
RA13T440610
When rear window defroster switch is turned on, rear window defroster wire is heated to remove fog, frost or
water vapor on rear windshield, thus realizing a clear view.To turn on rear window defroster, turn ignition
switch to ON and press rear window defroster switch. Then rear window defroster starts operating and
indicator on rear window defroster switch turns on. Press rear window defroster switch again to stop rear
window defroster. Also, the indicator turns off.
Circuit Diagram
Rear Window Defroster System
44

BATTERY
R
ENGINE
COMPARTMENT
MF05 FUSE AND
RELAY BOX RF24 RF15
40A
E-067 30A 7.5A
E-063 IP FUSE
30 86 AND
RELAY BOX
R DEFROST I-032
RELAY E-028
87 85
R 28 25
GR
I-002
18
B-019
R
I-001
2 B-001 18
B-017
T-001
GR
R
1 T-003
T-007 A29
R
BCM(A) B-022
1
DEFROSTER
T-008
T-009
1
B
T-010
5 4 3 2 1
44
9 8 7 6 5 4 3 2 1
I-001 10 9 8 7 6 5 4 3 2 1 I-002 10 9 8 7 6
B-001
18 17 16 15 14 13 12 11 10 W W W
20 19 18 17 16 15 14 13 12 11
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13

1 T-008 T-009 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
B B
B-022
B
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
1 T-007
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
W
EA13T440040


Fuse 44-75
Rear window defroster switch is Rear Window Defroster Switch 44-77

turned on but does not operate Rear window defroster wire 55-50
Rear window defroster has Ground 55-44

intermittent problem Wire harness or connector 55-44
Diagnosis Tool
Digital Multimeter
HINT:
Diagnostic Help
Ground Inspection
Ground points are very important to entire circuit system, which are normal or not can seriously affect the
entire circuit system.Ground points are often exposed to moisture, dirt and other corrosive
environments.Corrosion (rust) and oxidation may increase load resistance.This situation will seriously affect
the normal operation of circuit.Check the ground points as follows:
44 1. Remove ground bolt or nut.
6. If several wire harnesses are crimped into one ground terminal, check if they are installed correctly.Make
Diagnosis Procedure
HINT:
 Use following procedures to troubleshoot the rear window defroster control system.
NEXT

Standard voltage: 11 to 14 V If voltage is below 11 V,

recharge or replace the battery before proceeding to next
step.
NEXT
NEXT
NEXT
NEXT
6 End
CAUTION
44
1 Check fuse and relay

b. Using voltage band of digital multimeter, check if fuses
RF24(30A) and RF15(7.5A) are normal.
NG Replace fuse


c. Disconnect body connector B-001, instrument panel wire
10 9 8 7 6 5 4 3 2 1
harness connector I-002 and rear window defroster + -
connector T-008. 20 19 18 17 16 15 14 13 12 11
d. Using a digital multimeter, check for continuity among I-002

W
body connector B-001, instrument panel wire harness
connectors I-002, T-007 and rear window defroster
connector T-008.
1
5 4 3 2 1
Condition T-008
I-002 (18) - B-001 Always Continuity 1
(2)
T-007 B-001
B-001 (2) - T-007 Always Continuity
RA13T440620
(1)
(1)
Always Continuity
e. Disconnect instrument panel wire harness connector I-

001 and BCM connector B-022.
instrument panel wire harness connector I-001 and BCM
connector B-022.
Condition
I-001 (18) - B-022 Always Continuity 18 17 16 15 14 13 12 11 10
44 (A29)
I-001
NG Repair or replace body wire harness,

instrumentpanel wire harness and A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
connector. A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
OK System is normal A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52
B-022
RA13T440630
NEXT
End

Rear Window Defroster Switch

Removal
HINT:
 Rear window defroster switch is installed on center control integration panel assembly, and cannot be
disassembled.
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing rear window defroster switch.
 Appropriate force should be applied when removing rear window defroster switch. Be careful not to
operate roughly.
 When removing rear window defroster switch, prevent interior from being scratched.

3. Remove the lower center storage box assembly (See page 39-33).
4. Remove the center control integration panel assembly (See page 39-33).
Installation
CAUTION
 Install the connector in place when installing rear window defroster switch.
 Always operate carefully to prevent components from being damaged, when installing rear window
defroster switch.

44

- MEMO -

REAR VIEW MIRROR
Description 45-3 Inspection 45-10
Specification 45-4 Installation 45-10
Tool 45-4 Outside Rear View Mirror Lens 
Circuit Diagram 45-5 Assembly 45-11
Removal 45-11
DIAGNOSIS & TESTING 45-6 Inspection 45-12
Problem Symptoms Table 45-6 Installation 45-12
Diagnosis Tool 45-6 Inside Rear View Mirror Assembly 45-13
Diagnostic Help 45-6 Removal 45-13
Intermittent DTC Troubleshooting 45-6 Installation 45-13
Ground Inspection 45-7 Outside Rear View Mirror Adjustment 
Diagnosis Procedure 45-7 Switch 45-14
Outside Rear View Mirror Assembly 45-9 Inspection 45-15
Installation 45-16
45

45

45 - REAR VIEW MIRROR
GENERAL INFORMATION
REAR VIEW MIRROR
Description
RA13T450001
1 - Left Outside Rear View Mirror Assembly 2 - Inside Rear View Mirror Assembly
3 - Right Outside Rear View Mirror Assembly 4 - Outside Rear View Mirror Adjustment Switch
Assembly
This vehicle is equipped with power outside rear view mirror assembly and inside rear view mirror assembly.
Power outside rear view mirror assembly: driver can control the rotation of motor by operating outside rear 45
view mirror adjustment switch in vehicle, thus adjusting mirror surface to achieve a required visual angle.
Outside rear view mirror adjustment switch is located on front left door inner protector assembly. With ignition
switch ON, press outside rear view mirror switch to "L" or "R" position to select left or right outside rear view
mirror assembly to be adjusted, and then press rear view mirror button (up, down, left or right) to achieve a
required visual angle. It is necessary to adjust inside rear view mirror assembly manually to desired direction.
When driving at night, required rear view mirror assembly angle can be adjusted by pulling back glare-
resistant rod to reduce glare.

Specification

Outside Rear View Mirror Assembly Fixing Bolt 6±1
Tool
General Tool
Digital Multimeter
RCH0000002
45

Circuit Diagram
Power Rear View Mirror Control System (Page 1 of 1)
IGNITION SWITCH
BATTERY
ON OR ACC
R
ENGINE
COMPARTMENT
IP FUSE RF24 RF15 FUSE AND
AND MF05
30A 7.5A RELAY BOX
RELAY 40A
BOX 30 86 E-067
I-032 E-063
RF26 DEFROST
E-028 RF18
RELAY
10A 10A
87 85
55 43 25
B
RY
RL
GR
I-006 3 7
I-001
18
TO REAR B-017
DEFROSTER
GR
SWITCH
S3 S4 S5
S1 S2 A29
REAR VIEW MIRROR
ADJUSTMENT SWITCH BCM(A)
L O R L O R I-008 B-022
5 4 1 6 2
GW
RW
Br
W
I-002
13 12 10 14 11 19 B-019
GW
RW
Br
W
B-016 18 20 19 B-023
F-005 10 12 11 H-008
GW
RW
RW
Br
W
2 3 1 2 3 1
POWER POWER
REAR REAR
VIEW 1-,3+,L 1-,3+,L VIEW
MIRROR
MOTOR 1-,2+,U 1-,2+,U
MIRROR
MOTOR 45
F-003 H-005
6 5 6 5
RY
RY
B
F-005 14 H-008
22 F-004 H-007
B-016 B-023
10 9 8 7 6 5 4 3 2 1 I-002 9 8 7 6 5 4 3 2 1 B-023
9 8 7 6 5 4 3 2 1
I-001 W W
18 17 16 15 14 13 12 11 10
18 17 16 15 14 13 12 11 10 W 20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7 8 9 10 11 12 13 B-016 6 5 4
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 W
14 15 16 17 18 19 20 21 22 23 24 25 26 3 2 1
A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26
B-022
B
A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 F-003 H-005
5 4 3 2 1 I-008
A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 A51 A52 W W
10 9 8 7 6 B
EA13T450010

DIAGNOSIS & TESTING

HINT:

Fuse 55-29
Outside rear view mirror adjustment switch 45-14
Outside rear view mirror cannot operate
Outside rear view mirror assembly 45-9
Outside rear view mirror intermittent Ground 55-44

malfunction Wire harness or connector 55-44
Rear window defroster switch -
Rear view mirror defroster cannot operate
Outside rear view mirror assembly 45-14
(if equipped)
BCM damaged 46-18
Diagnosis Tool
Digital Multimeter
Diagnostic Help
45 1. Only use a digital multimeter to measure voltage of electronic system.
3. Visually check the related wire harness.

 Inspect mounting areas of rear view mirror assembly, wire harness or wire harness connector and so on
for damage, foreign matter, etc. that will cause incorrect signals.
 Check and clean all wire harness connectors and grounding parts related to DTC.
perform a test. If DTC cannot be cleared, Body Control Module (BCM) is malfunctioning. If DTC can be
cleared, reinstall Body Control Module (BCM) to original vehicle. (if equipped)

Ground Inspection
Diagnosis Procedure
HINT:
Use following procedures to troubleshoot the rear view mirror control system.
NEXT
NEXT
3 Customer problem analysis 45

NEXT
4 Check for DTCs
NEXT
NEXT

NEXT
7 End
45

ON-VEHICLE SERVICE
Outside Rear View Mirror Assembly
Removal
HINT:
CAUTION
Be sure to wear necessary safety equipment to prevent accidents, when removing outside rear view mirror
assembly.
Operate carefully to prevent components from being damaged, when removing outside rear view mirror
assembly.
Prevent interior and body paint from being scratched, when removing outside rear view mirror assembly.

3. Remove the clutch switch.
off clips from left outside rear view mirror inner
triangular block, and remove left outside rear view
mirror inner triangular block (1).
1
RA13T450010
5. Remove the left outside rear view mirror assembly.
45
a. Disconnect the left outside rear view mirror assembly
connector (1).
1
RA13T450020

b. Remove 3 fixing bolts (arrow) from left outside rear

view mirror assembly, and remove left outside rear
view mirror assembly.
RA13T450030
Inspection
1. Check the outside rear view mirror assembly.
a. Apply battery voltage to terminals of outside rear view
mirror assembly connector and check operation of
outside rear view mirror assembly according to table
below.
Specified 1
Measurement Condition
Condition
UP
RA13T450060
DOWN
LEFT
RIGHT
2. If result is not as specified, replace outside rear view mirror assembly.
Installation
45 Installation is in the reverse order of removal.
CAUTION
Connect connector in place and tighten fixing bolts to specified torque, when installing outside rear view
mirror assembly.
Make sure outside rear view mirror assembly can move smoothly, flexibly and reliably after installation.

Outside Rear View Mirror Lens Assembly

Removal
HINT:
CAUTION
Avoid breaking claws, when removing outside rear view mirror lens assembly.
Avoid damaging lens due to dropping, when removing outside rear view mirror lens assembly.
Prevent body paint surface from being scratched, when removing outside rear view mirror lens assembly.

3. Remove the left outside rear view mirror lens assembly.
a. Press outside rear view mirror surface to tilt it.
b. Apply protective tape around exterior frame of outside
rear view mirror.
off claws (arrow) from left outside rear view mirror lens
assembly.
RA13T450050
d. Disconnect connectors (arrow) from left outside rear

view mirror lens assembly, and remove left outside
rear view mirror lens assembly (1).(if equipped with
rear mirror heater)
1
45
RA13T450060

Inspection
(if equipped with rear mirror heater)
1. Check the outside rear view mirror lens assembly.
a. Apply battery voltage to terminals of outside rear view
+ -
mirror lens assembly connector, and check operation
of outside rear view mirror lens assembly according to
table below.
Specified
Measurement Condition
Condition
Battery positive Battery negative Outside rear view
(+) (-) mirror lens
becomes warm RA13T450070
2. If result is not as specified, replace outside rear view mirror lens assembly.
Installation
If result is not as specified, replace outside rear view mirror lens assembly.
CAUTION
Make sure outside rear view mirror lens assembly can move smoothly, flexibly and reliably after installation.
45

Inside Rear View Mirror Assembly

Removal
CAUTION
 Appropriate force should be applied, when removing inside rear view mirror assembly. Be careful not to
operate roughly.
 Prevent front windshield from being scratched, when removing inside rear view mirror assembly.
1. Remove the inside rear view mirror assembly.

a. Hold inside rear view mirror assembly base with one hand and turn inside rear view mirror assembly
with the other one.
b. Remove inside rear view mirror assembly (1) in
RA13T450080
Installation
CAUTION
Make sure inside rear view mirror assembly can move smoothly, flexibly and reliably after installation.
45

Outside Rear View Mirror Adjustment Switch

Removal
CAUTION
Be sure to wear safety equipment to prevent accidents, when removing outside rear view mirror adjustment
switch.
Prevent front left door inner protector assembly from being scratched, when removing outside rear view
mirror adjustment switch.

3. Remove the outside rear view mirror adjustment switch.
off outside rear view mirror control master switch
assembly.
RA13T450090
b. Disconnect the headlight leveling switch connector

(1).
c. Disconnect the outside rear view mirror adjustment
1
2
45 RA13T450100

detach claws (arrow) from outside rear view mirror
adjustment switch.
RA13T450110
e. Remove the outside rear view mirror adjustment switch.

Inspection
1. Check the outside rear view mirror adjustment switch.
a. Adjust outside rear view mirror adjustment switch to
"L" position.
+ -
b. Using a digital multimeter, check for continuity 1 2 3 4 5
between terminals of outside rear view mirror 6 7 8 9 10
adjustment switch according to table below.

Terminal 6 -
UP Continuity RA13T450130
Terminal 3
Terminal 7 -
UP Continuity
Terminal 1
Terminal 5 -
DOWN Continuity
Terminal 7
Terminal 1 -
DOWN Continuity
Terminal 3
Terminal 5 -
LEFT Continuity
Terminal 7
Terminal 6 -
LEFT Continuity
Terminal 3
Terminal 6 -
RIGHT Continuity
Terminal 7
Terminal 3 -
RIGHT Continuity
Terminal 5
If result is not as specified, replace outside rear view mirror adjustment switch.
c. Adjust outside rear view mirror adjustment switch to
"R" position.
+ -
d. Using a digital multimeter, check for continuity 1 2 3 4 5
between terminals of outside rear view mirror 6 7 8 9 10
adjustment switch according to table below.
45
Terminal 2 -
UP Continuity RA13T450130
Terminal 3
Terminal 1 -
UP Continuity
Terminal 7
Terminal 4 -
DOWN Continuity
Terminal 7
Terminal 1 -
DOWN Continuity
Terminal 3
Terminal 4 -
LEFT Continuity
Terminal 7
Terminal 2 -
LEFT Continuity
Terminal 3


Terminal 2 -
RIGHT Continuity
Terminal 7
Terminal 3 -
RIGHT Continuity
Terminal 4
If result is not as specified, replace outside rear view mirror adjustment switch.
Installation
CAUTION
Operate carefully to prevent damage to other components, when installing outside rear view mirror
adjustment switch.
Connect connectors in place, when installing outside rear view mirror adjustment switch.
Check that switch can operate normally after installing outside rear view mirror adjustment switch.
45

INSTRUMENT PANEL
Specifications 46-6 Disassembly 46-14
Tool 46-7 Assembly 46-16
Installation 46-16
Instrument Panel Crossmember 
Auxiliary Fascia Console Assembly 46-8 Assembly 46-17
Instrument Panel Assembly 46-11
46

46

46 - INSTRUMENT PANEL
GENERAL INFORMATION
INSTRUMENT PANEL
Description
Auxiliary Fascia Console Assembly
4 2
×2
3
5
×2
46
RA13T460010
1 - Shift Knob and Boot Assembly 2 - Auxiliary Fascia Console Front Left Extension
Panel Assembly
3 - Auxiliary Fascia Console Front Right Extension 4 - shift cover plate assembly
Panel Assembly
5 - shift cover plate assembly

Instrument Panel Assembly
3 18
×4
4
19
5
15
×12
×6
17
×3
14
12
6
×4 11
8 13
7
10
16
×4
RA13T460020
1 - Instrument Panel Assembly 2 - Instrument Panel Left End Cover Assembly

3 - Instrument Panel Left Outlet Assembly 4 - Instrument Cluster
5 - Instrument Cluster Trim Frame Assembly 6 - Headlight Leveling Switch Assembly
46 7 - Instrument Panel Relay Box Cover Assembly 8 - Instrument Panel Lower Left Protector Assembly
9 - Intake Manifold Resonant Cavity Vacuum Hose 10 - A/C Control Panel Assembly
11 - USB port 12 - Cigarette Lighter Retainer
13 - Cigarette Lighter Element 14 - Disc-less DVD
15 - Instrument Panel Center Outlet Assembly 16 - Glove Box Assembly
17 - Instrument Panel Right Outlet Assembly 18 - Instrument Panel Right End Cover Assembly
19 - Instrument Panel Left End Cover Assembly

×2
1
2 ×2
3 ×2
×3
×2
7
4
6
×5
×4
5
×3
8
×7
×3
10
×4
46
RA13T460030
1 - Instrument Panel Crossmember Assembly 2 - Left Defroster Duct Assembly

3 - Center Defroster Duct Assembly 4 - right face air duct
5 - Rotary Valve O-Ring 6 - split seat
7 - left face air duct 8 - face air connecting duct assembly
9 - Instrument Panel Assembly 10 - Front Passenger Airbag Assembly

Specifications

1.3 ± 0.2
and Lower Housing
Air Filter Assembly Fixing Bolt 8 ± 1.5
Air Filter Assembly Fixing Nut 8 ± 1.5
Air Direct Pipe Assembly Fixing Bolt 5±1
Air Filter Bracket Fixing Bolt 5±1
Resonant Cavity Fixing Bolt 8 ± 1.5/5 ± 1
Electronic Throttle Assembly Fixing Bolt 8+3
Engine Trim Cover Bracket 8±3
Intake Manifold Assembly Fixing Nut 20 + 5
Vacuum Actuator Fixing Bolt 8+3
Rotary Valve Fixing Bolt 8+3
Variable Intake Air Control Valve Fixing Bolt 8+3
Electronic Accelerator Pedal Fixing Bolt 8±1
Worm Clamp 3 ± 0.5
46

Tool
Special Tool
RCH0000014
46

ON-VEHICLE SERVICE
Auxiliary Fascia Console Assembly
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing auxiliary fascia console
assembly.
 Appropriate force should be applied, when removing auxiliary fascia console assembly. Be careful not to
operate roughly.
 DO NOT scratch interior and body paint, when removing auxiliary fascia console assembly.

3. Remove shift knob boot assembly and parking brake
protector assembly. 1
3 5
4 R
2
RA13T460040
4. Remove the shift cover plate assembly.
46
RA13T460050
5. Remove the auxiliary fascia console front left extension panel assembly.
a. Remove 1 fixing screw (arrow) from auxiliary fascia
console front left extension panel assembly.
(Tightening torque: 2.5 ± 0.5 N.m)
RA13T460060


off clips from auxiliary fascia console front left
extension panel assembly as shown in illustration.
Remove the auxiliary fascia console front left
extension panel assembly.
RA13T460070
6. Remove the auxiliary fascia console front right extension panel assembly.
a. Remove 1 fixing screw (arrow) from auxiliary fascia
console front right extension panel assembly.
RA13T460080

off clips from auxiliary fascia console front right
extension panel assembly as shown in illustration..
Remove the auxiliary fascia console front right
extension panel assembly (1).
RA13T460090
7. Remove the auxiliary fascia console assembly (take left side as an example).
a. Remove 3 fixing screws (arrow) between auxiliary
fascia console assembly and instrument panel
assembly.
46
RA13T460100

b. Remove 1 fixing screw (1) from left side of auxiliary

fascia console assembly.
RA13T460110
c. Move front seat assembly to foremost position.

d. Remove 1 fixing bolt (arrow) from rear part of auxiliary
fascia console assembly (take left side as an
example).
RA13T460120
Installation
CAUTION
 Be sure to tighten fixing bolts and fixing screws to specified torque, when installing auxiliary fascia
console assembly.
 Check each electrical equipment for proper operation, after installing auxiliary fascia console assembly.
46

Instrument Panel Assembly

Removal
WARNING
restraint system.
 When removing instrument panel assembly, all components related to airbag should be operated with
battery power off. Never operate with power on. Because within 60 seconds after engine stalls or fuse is
removed, there is enough power remaining in the airbag control module for activating airbag, and the
airbag can be accidentally activated, causing personal injury or vehicle damage.
 Never expose airbag components directly to hot air or open flames.
 Removed airbag should be well kept. If triggered accidentally, it may cause personal injury.
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing instrument panel assembly.
 DO NOT scratch interior and body paint, when removing instrument panel assembly.

4. Remove the instrument cluster (See page 38-49).
6. Remove the spiral cable (See page 31-48).
8. Remove the wiper switch assembly (See page 28-13).
9. Remove the combination light switch assembly (See page 28-13).
10.Remove the A-pillar upper protector assembly (See page 50-14).
11. Remove the center control integration panel assembly (See page 30-28).
46
12.Remove the No Disc DVD (See page 39-33).
13.Remove the instrument panel left end cover assembly (take left side as an example).
off clip from instrument panel left end cover assembly,
and remove instrument panel left end cover assembly
(1).
1
RA13T460130
14.Remove the headlight leveling switch assembly (See page 35-82).

15.Remove the instrument panel left lower protector assembly.

a. Remove instrument panel left lower protector cover
plate (1) and remove fixing bolt (arrow) from 2
instrument panel lower protector assembly.
b. Remove fixing screw (2) from instrument panel lower
protector assembly.
RA13T460140
c. Remove 2 fixing screws (arrow) between diagnostic

interface and instrument panel lower protector
assembly, and move away diagnostic interface (1). 1
RA13T460150
d. Using a screwdriver wrapped with protective tape, pry

off clips from instrument panel lower protector
assembly, and remove instrument panel left end cover
assembly (1).
1 RA13T460160
16.Remove the glove box assembly.

a. Open glove box assembly in direction of arrow as
46
RA13T460170

b. Rotate lock knobs in direction of arrow as shown in

illustration, and remove lock knobs.
RA13T460180
c. Disengage claws from lower side of glove box assembly, and remove glove box assembly .
17.Loosen the front passenger airbag assembly.
a. Disconnect the front passenger airbag connector
(arrow).
RA13T460200
b. Remove 2 fixing bolts (arrow) from front passenger

airbag assembly.
RA13T460210
18.Remove the instrument panel assembly.

a. Remove 2 fixing bolts (arrow) from left side of
instrument panel assembly (take left side as an
example).
46
RA13T460220

b. Remove 8 fixing bolts (arrow) from front side of

instrument panel assembly, and remove instrument
panel assembly.
RA13T460230
Installation
Disassembly
CAUTION
 Be sure to wear safety equipment to prevent accidents, when disassembling instrument panel assembly.
 DO NOT scratch instrument panel surface, when disassembling instrument panel assembly.
1. Remove the right face air duct.

a. Remove 4 fixing screws from right face air duct.
RA13T460240
b. Remove the right face air duct.

2. Remove the left face air duct.
46 a. Remove 4 fixing screws from left face air duct.

RA13T460250
b. Remove the left face air duct.

3. Remove the right defroster duct.

a. Remove 3 fixing screws from right defroster duct.
RA13T460260
b. Remove the right defroster duct.

4. Remove the left defroster duct.
a. Remove 3 fixing screws from left defroster duct.
RA13T460270
5. Remove front defroster duct body.

a. Remove 5 fixing screws from front defroster duct
body.
RA13T460280
b. Remove front defroster duct body.

6. Remove split seat. 46
a. Remove 7 fixing screws from split seat.
RA13T460290

7. Remove cigarette lighter (1) and USB port (2).
1 2
RA13T460490
8. Remove the left outlet housing (take left side as an example).

off clips from instrument panel outlet assembly.
RA13T460300
9. Remove the front passenger airbag assembly.

a. Disengage claws (arrow) from front passenger airbag
assembly.
b. Remove front passenger airbag assembly (1) from
instrument panel assembly.
1
RA13T460310
Assembly
46 Installation
CAUTION
 Be sure to tighten fixing bolts and fixing screws to specified torque, when installing instrument panel
assembly.
 Check airbag for proper installation, after installing instrument panel assembly.
 Check each electrical equipment for proper operation, after installing instrument panel assembly.

Instrument Panel Crossmember Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing instrument panel crossmember
assembly.
 DO NOT scratch interior and body paint, when removing instrument panel crossmember assembly.

4. Remove the front windshield lower garnish assembly (See page 49-29).
5. Remove 3 fixing bolts from face air connecting duct
assembly.
RA13T460500
6. Remove the instrument panel fuse box.

a. Remove 2 fixing screws (arrow) from instrument panel
fuse box.
b. Detach instrument panel fuse box from instrument
panel bracket.
RA13T460320 46

7. Remove the Body Control Module (BCM).

a. Remove 3 fixing nuts (arrow) from Body Control
Module (BCM), and remove Body Control Module
(BCM).
RA13T460330
b. Disconnect the Body Control Module (BCM)

connectors (arrow).
RA13T460340
8. Disconnect 4 instrument panel wire harness connectors

(arrow).
46
RA13T460350
9. Disconnect anti-theft module connector (1), ignition

switch connector (2) and ignition illumination switch
connector (3).
1
3
RA13T460360

10.Disconnect the electronic accelerator pedal connector

(arrow).
RA13T460370
11. Disconnect the brake light switch connector (arrow).
RA13T460380
12.Disconnect the airbag module connector.

a. Remove 2 fixing bolts (arrow) from airbag module.
RA13T460390
b. Disconnect the airbag module connector (arrow).
46
RA13T460400
13.Remove 3 instrument panel ground bolts (arrow) and

disconnect connector (1) between instrument panel wire
harness and roof wire harness.
RA13T460410

14.Disconnect connector (arrow) between instrument panel

wire harness and power A/C wire harness.
RA13T460420
15.Disconnect connector (arrow) between instrument panel

wire harness and front right door wire harness.
RA13T460430
16.Detach clips from instrument panel front wire harness.
RA13T460440
17.Remove 2 fixing nuts (arrow) from steering column upper

bracket.
46
RA13T460450
18.Remove 1 fixing bolt (arrow) from steering column lower

bracket.
RA13T460460

19.Remove fixing bolt (arrow) from outer part of instrument

panel crossmember assembly.
RA13T460470
20.Remove 8 fixing bolts (arrow) from upper part of

instrument panel crossmember assembly, and remove
instrument panel crossmember (1) and instrument panel
crossmember assembly.
RA13T460480
Installation
CAUTION
 Be sure to tighten fixing bolts to specified torque, when installing instrument panel crossmember
assembly.
 Check airbag for proper installation, after installing instrument panel crossmember assembly.
 Check each electrical equipment for proper operation, after installing instrument panel crossmember
assembly.
46

- MEMO -

SEAT
Description 47-3 Inspection 47-13
Specifications 47-6 Rear Seat Assembly 47-15
Removal 47-15
Disassembly 47-17
Front Seat Assembly 47-7
Assembly 47-17
Removal 47-7
Installation 47-18
Disassembly 47-9
Inspection 47-18
Assembly 47-13
47

47

47 - SEAT
GENERAL INFORMATION
SEAT
Description
Driver Seat Assembly
2
3
×4
×3
RA13T470001
47
1 - Driver Seat Headrest Assembly 2 - Driver Seat Headrest Guide (w/o Button)
3 - Driver Seat Headrest Guide (w/ Button) 4 - Driver Seat Belt Buckle
5 - Driver Seat Inner Shield Assembly 6 - Driver Seat Reclining Adjuster Handle
7 - Driver Seat Outer Shield Assembly 8 - Driver Seat Reclining Adjuster Handle Cover
9 - Driver Seat Cushion Sub-assembly

47 - SEAT
Front Passenger Seat Assembly
2
3
4
8
×4
×3
×2
RA13T470002
1 - Front Passenger Seat Headrest Assembly 2 - Front Passenger Seat Headrest Guide (w/o Button)
3 - Front Passenger Seat Headrest Guide (w/ Button) 4 - Front Passenger Seatback Assembly
5 - Front Passenger Seat Inner Shield 6 - Front Passenger Seat Belt Buckle
47 7 - Front Passenger Seat Cushion Assembly 8 - Front Passenger Seat Outer Shield
9 - Front Passenger Seat Reclining Adjuster Handle

47 - SEAT
Rear Seat Assembly
3
2
7
6
RA13T470003
47
1 - Rear Right Seat Headrest Assembly 2 - Rear Seat Headrest Guide (w/ Button)
3 - Rear Seat Headrest Guide (w/o Button) 4 - Rear Seatback Assembly
5 - Rear Seat Belt Single Buckle Assembly 6 - Rear Seat Belt Double Buckle Assembly
7 - Rear Seat Cushion Assembly
Front seat assembly can be moved forward and backward by seat track unlock handle, and upward and
downward by seat height adjusting handle (for driver side seat), and seatback reclining can be adjusted by
seat reclining adjuster handle.
Rear seat position is not adjustable; however, rear seatback can be folded forward by pulling seatback unlock
mechanism assembly, to increase storage space of luggage compartment.

47 - SEAT
Specifications

Front Seat Assembly Fixing Bolt 25 ± 4
Seat Track Unlock Handle Fixing Screw 4.8 ± 0.5
Seat Outer Shield Assembly Fixing Screw 4.8 ± 0.5
Seat Belt Buckle Assembly Fixing Bolt 50 ± 5
Seat Inner Shield Assembly Fixing Screw 4.8 ± 0.5
Rear Seatback Hook Assembly Fixing Bolt 25 ± 4
Rear Seatback Rear End Webbing Short-plate Fixing
25 ± 4
Bolt
Rear Seat Protector Assembly Fixing Nut 3 ± 0.5
47

47 - SEAT
ON-VEHICLE SERVICE
Front Seat Assembly
Removal
HINT:
Use same procedures for front passenger seat assembly and driver seat assembly.
Procedures listed below are for driver seat assembly.
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing seat assembly.
 Try to prevent body paint surface and carpet from being scratched or damaged, when removing seat
assembly.

3. Remove the driver seat headrest assembly.
a. As shown in illustration, press release button of seat
headrest guide (w/ button), and remove driver seat
headrest assembly.
RA13T470010
4. Remove the driver seat assembly.

a. As shown in illustration, pull up seat track unlock
handle and move seat assembly to the rearmost
position.
47
RA13T470020

47 - SEAT
b. Remove 2 fixing bolts (arrow) from front side of seat

assembly.
RA13T470030
c. As shown in illustration, pull up seat track unlock

handle and move seat assembly to the foremost
position.
RA13T470021
d. Remove 2 fixing bolts (arrow) from rear side of seat

assembly.
RA13T470040
e. Disconnect wire harness connector (arrow) under

seat assembly.
47
RA13T470031
f. Pull up seat track unlock handle to move seat assembly to mid-position. Also, operate seat reclining
adjuster handle to move seatback to upright position, and remove driver seat assembly.

47 - SEAT
Disassembly
HINT:
Use same procedures for front passenger seat assembly and driver seat assembly.
Procedures listed below are for driver seat assembly.
CAUTION
 Be sure to wear safety equipment to prevent accidents, when disassembling seat assembly.
1. Remove the seat height adjusting handle (for driver side).

Using a screwdriver wrapped with protective tape, pry out
seat height adjusting handle cover (arrow).
RA13T470060
2. Remove the driver seat reclining adjuster handle (for driver side).
Using a screwdriver wrapped with protective tape, pry out
seat reclining adjuster handle cover (arrow).
RA13T470070
3. Remove the seat outer shield assembly (for driver side).

a. Remove 3 fixing screws from seat outer shield
assembly.
47
RA13T470080

47 - SEAT
b. Detach claw and remove seat outer shield assembly.
RA13T470081
4. Remove seat outer shield assembly (for front passenger side).

out seat reclining adjuster handle cover (1).
b. Remove 3 fixing screws from seat outer shield
assembly.
1
RA13T470090

out seat outer shield assembly claw and remove seat
outer shield assembly.
RA13T470091
5. Remove the driver seat belt buckle assembly.

a. Remove 1 fixing nut (arrow) from seat belt buckle
assembly.
b. Remove clip (arrow) from seat belt buckle assembly,
and remove driver seat belt buckle assembly.
47
1
RA13T470100

47 - SEAT
6. Remove the driver seat inner shield assembly.

a. Remove 2 fixing screws (arrow) from seat inner shield
assembly.
off claw (2) from seat inner shield assembly, and
remove driver seat inner shield assembly.
RA13T470101
7. Remove hooks (arrow) connecting driver seatback

assembly and seat cushion assembly.
RA13T470110
8. Remove the driver seat headrest guide.

a. Remove 5 hog rings (arrow) from seatback assembly.
RA13T470120
b. Remove the plastic lining plate of seatback.

c. Press and hold lower part of seat headrest guide in
direction of arrow as shown in illustration, and remove
driver seat headrest guide.
47
RA13T470130

47 - SEAT
9. Remove the seat cushion assembly (for driver side).

a. Remove 3 hog rings (1) from seat cushion assembly.
1
out 3 seat cushion assembly clips (arrow).
2
RA13T470140
c. Remove the driver seat cushion assembly.

10.Remove the seat cushion assembly (for front passenger side).
a. Remove hook (1) connecting seatback assembly and
seat cushion assembly.
b. Remove 8 hog rings (arrow) from seat cushion
assembly.
RA13T470150
c. Remove the front passenger seat cushion assembly.

11. Remove the seat track assembly (for front passenger side).
a. Remove 4 fixing bolts (arrow) from left seat track
assembly.
RA13T470160
b. Remove 4 fixing bolts (arrow) from right seat track

assembly, and remove front passenger seat track
47 assembly.
RA13T470170

47 - SEAT
Assembly
CAUTION
 Be sure to wear safety equipment to prevent accidents, when assembling seat.

 Be careful not to damage seat cover when assembling seat.
 Replace damaged hog rings when assembling seat.
 Keep seat cover clean and tidy, and try to prevent wrinkles when assembling seat.
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents, when installing seat assembly.
 Be careful not to damage body paint surface, when installing seat assembly.
 Try to prevent carpet from being scratched or damaged, when installing seat assembly.
Inspection
After completing installation of seat assembly, check basic functions of seat assembly, and confirm that
following functions operate normally:
1. When sliding seat to the foremost and rearmost positions
by pulling up seat track unlock handle, check if any of the
following seat malfunctions occur: heavy operation, high
sliding resistance, seizure, noise, etc. Repair or replace
seat equipment, if any of these malfunctions occur.
RA13T470180
2. Adjust seat reclining to the maximum and minimum

angles by turning seat reclining adjuster handle, to check
if seatback operation is heavy and stuck, etc. Repair or 47
replace seat equipment, if any of these malfunctions
occur.
RA13T470181

47 - SEAT
3. Adjust seat to the highest and lowest positions by pulling

seat height adjusting handle (for driver side), to check for
heavy operation of seat or if it becomes stuck, etc.
Repair or replace seat equipment, if any of these
malfunctions occur.
RA13T470182
4. Move headrest up and down by pressing release button

of headrest guide (w/ button), to check for heavy
operation of seat headrest or if it becomes stuck, etc.
malfunctions occur.
RA13T470010
5. Check if fixing bolts are set in position. Tighten them to specified torque as necessary.
47

47 - SEAT
Rear Seat Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing rear seat assembly.
 Try to prevent body paint surface and carpet from being scratched or damaged, when removing rear seat
assembly.
1. Remove the rear seat headrest assembly.

a. Press handle release cover, adjust seatback and
press headrest release button to remove rear seat
headrest assembly as shown in illustration.
RA13T470190
2. Remove the rear seat cushion assembly.
CAUTION
 Try to prevent rear seat cushion frame from being deformed, when removing rear seat cushion.
a. Remove 2 bolts under seat cushion.

b. Put hands on both sides of seat cushion respectively,
then raise rear seat cushion assembly to detach "n"
wire from gap under seatback.
47
RA13T470200
c. Remove the rear seat cushion assembly.
RA13T470210

47 - SEAT
3. Remove the rear seatback assembly.

a. Put down rear seatback by pressing buttons on both
sides.
RA13T470220
b. Remove fixing bolt (arrow) between rear seatback

rear end webbing and body floor.
RA13T470230
c. Using a screwdriver wrapped with protective tape,

separate lock plate and set bushing on one side under
the rear seatback to separate trough on body
mounting bracket.
Use the same procedure for the other side.
RA13T470240
d. Remove the rear seatback assembly.
47

47 - SEAT
CAUTION
 Try to prevent body paint surface and carpet from being scratched or damaged, when removing rear seat
assembly.
Disassembly
CAUTION
 Be sure to wear safety equipment to prevent accidents, when disassembling rear seat assembly.
1. Remove the rear seat headrest guide.

a. Pull apart adhesive strips under seatback.
RA13T470250
b. Press and hold lower part of rear seat headrest guide

in direction of arrow as shown in illustration, and
remove rear seat headrest guide from one side.
Use the same procedure for the other side.
RA13T470260
Assembly
47
CAUTION
 Be sure to wear safety equipment to prevent accidents, when assembling rear seat assembly.
 Be careful not to damage seat cover, when assembling rear seat assembly.
 Replace damaged hog rings, when assembling rear seat assembly.
 Keep seat cover clean and tidy, and try to prevent wrinkles, when assembling rear seat assembly.

47 - SEAT
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents, when installing rear seat assembly.
 Be careful not to damage body paint surface, when installing rear seat assembly.
 Try to prevent carpet from being scratched or damaged, when installing rear seat assembly.
 When installing rear seat cushion, make sure that seat belt buckle is not under the seat cushion.
Inspection
After installing rear seat assembly, check basic functions of rear seat assembly, and confirm that following
functions operate normally:
1. Pull up seatback release handle, to check if rear
seatback operation is heavy and stuck, etc. Repair or
replace seat equipment, if any of these malfunctions
occur.
RA13T470270
2. Move headrest up and down by pressing release button

of headrest guide (w/ button), to check for heavy
operation of seat headrest or if it becomes stuck, etc.
malfunctions occur.
RA13T470190
4. Check if side protectors and cushion are installed securely.
47

ENGINE HOOD/DOOR
Description 48-3 Adjustment 48-23
Tool 48-8 Rear Door Inner Protector Assembly 48-26
Removal 48-26
Installation 48-28
Hood Assembly 48-9
Rear Door Assembly 48-29
Removal 48-9
Removal 48-29
Installation 48-10
Installation 48-33
Adjustment 48-11
Adjustment 48-33
Inspection 48-12
Inspection 48-35
Hood Hinge Assembly 48-13
Back Door Assembly 48-36
Removal 48-13
Removal 48-36
Installation 48-13
Installation 48-38
Hood Cable Assembly 48-14
Adjustment 48-38
Removal 48-14
Inspection 48-39
Installation 48-15
Back Door Opener Switch Assembly 48-40
Front Door Inner Protector Assembly 48-16
Removal 48-40
Removal 48-16
Installation 48-40
Installation 48-18
Back Door Hinge Assembly 48-41
Front Door Assembly 48-19
Removal 48-41
Removal 48-19
Installation 48-41
48

48

48 - ENGINE HOOD/DOOR
GENERAL INFORMATION
ENGINE HOOD/DOOR
Description
Hood Assembly
3
2
×2
×2 ×2
5
×2
4 ×2 6
×4
8
7
×15
48
RA13T480010
1 - Hood Assembly 2 - Support Rod Upper Holder

3 - Engine Compartment Front Weatherstrip 4 - Hood Right Hinge Assembly

5 - Holder 6 - Hood Left Hinge Assembly
7 - Adjustable Buffer Block 8 - Support Rod Assembly
9 - Hood Sound Insulator
Front Left Door Assembly
5 2
3
×2 4
6 ×2
19
18
×3 11
7 10
8 ×2
16
17
12 20 21
×2
×4
×2
9
×2
×5
13 ×4
×3 15
14
×4
22
RT21480020
48
1 - Front Door Opening Weatherstrip 2 - Front Door Upper Glass Guide
3 - Front Door Glass Assembly 4 - Front Door Assembly
5 - Front Door Cover 6 - Front Door Outer Weather Bar
7 - Front Door Outside Handle Assembly 8 - Front Door Key Cylinder Assembly
9 - Front Door Lock Latch Assembly 10 - Front Door Inner Weather Bar
11 - Front Door Upper Hinge Assembly 12 - Front Door Outside Handle Base Assembly
13 - Front Door Lower Hinge Assembly 14 - Front Speaker
15 - Front Door Power Glass Regulator Assembly 16 - Front Door Protective Film Assembly

17 - Front Door Inner Protector Assembly 18 - Front Door Glass Regulating Switch Assembly
19 - Outside Rear View Mirror Inner Triangular Block 20 - Front Door Inside Handle Assembly
Assembly
21 - Front Door Inside Handle Screw Block Cover 22 - Front Door Inside Handle Trim Strip
Rear Left Door Assembly
3
4
5
×2
9 18
6 10 11 14 16
7 ×2
15 17
19 20
×2
×2 ×4
×2
×5
×2
12
×3
13 21
8 ×3
RA13T480030
1 - Rear Door Opening Weatherstrip 2 - Rear Door Upper Glass Guide

3 - Rear Door Glass Assembly 4 - Rear Door Assembly 48
5 - Rear Door Outer Weather Bar 6 - Rear Door Outside Handle
7 - Rear Door Key Cylinder Assembly 8 - Rear Door Lock Latch Assembly
9 - Rear Door Inner Weather Bar 10 - Rear Door Upper Hinge Assembly
11 - Rear Door Glass Guide Rail Assembly 12 - Rear Door Outside Handle Base Assembly
13 - Rear Door Lower Hinge Assembly 14 - Rear Door Power glass regulator assembly
15 - Rear Door Protective Film Assembly 16 - Rear Door Inner Triangular Block Assembly
17 - Rear Door Inner Protector Assembly 18 - Power Glass Regulating Switch Assembly
19 - Rear Door Inside Handle Assembly 20 - Rear Door Inside Handle Screw Block Cover

21 - Rear Door Handle Box Trim Panel
Back Door Assembly
1
4
×2
×2 6
2 3
7
×4 8
10
×2
9
×4
×3
14 12
×2 11
×2
13
15
16
48
RA13T480031
1 - Rear Trim Strip Assembly 2 - Spoiler Assembly

3 - Left Air Spring Upper Holder 4 - Back Door Assembly
5 - Back Door Lock Assembly 6 - Back Door Lock Latch Protective Cover
7 - Back Door Handle 8 - Back Door Protector Assembly
9 - Adjustable Buffer Block 10 - Right Air Spring Upper Holder
11 - Rear Wiper Motor Assembly 12 - Back Door Right Hinge Base Assembly

13 - Back Door Wire Harness Mounting Hole Cover 14 - Back Door Left Hinge Base Assembly
Plate
15 - Left Air Spring Assembly 16 - Right Air Spring Assembly
The vehicle is designed as a structure with four doors & two covers (front left door, rear left door, front right
door, rear right door, back door and hood).
Specifications

Fixing Bolt Between Hood Assembly and Hood
25 ± 2
Hinge Assembly
25 ± 2
Body
Hood Lock Assembly Fixing Bolt 9±1
10 ± 1
Wing Assembly
Front Door Inner Protector Assembly Fixing Screw 1.5 ± 0.5
Front Door Inner Protector Assembly Fixing Bolt
Front Door Inside Handle Fixing Screw 1.5 ± 0.5
Front Door Outside Handle Base Assembly Fixing
7±1
Screw
24 ± 2
Front Door Assembly
24 ± 2
Body
Fixing Nut Between Door Check and Front Door
10 ± 2
Assembly
Fixing Bolt Between Door Check and Body 22 ± 3.5
Front Door Lock Striker Fixing Screw 23 ± 2
Rear Door Inner Protector Assembly Fixing Screw 1.5 ± 0.5
Rear Door Inside Handle Fixing Screw 1.5 ± 0.5
Rear Door Metal Bracket Fixing Bolt 5±1
Rear Door Outside Handle Cover Fixing Screw 7±1 48
Rear Door Outside Handle Base Assembly Fixing
7±1
Screw
55 ± 5
Rear Door Assembly
55 ± 5
Body
Rear Door Lock Striker Fixing Screw 23 ± 1
25 ± 2
Back Door Assembly


25 ± 2
Body
Tool
General Tool
Interior Crow Plate
RCH0000025
48

ON-VEHICLE SERVICE
Hood Assembly
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing hood assembly.
 When removing hood assembly, try to prevent hood from dropping, otherwise, body or front windshield
may be damaged.
WARNING
 When removing hood assembly, an assistant is needed to hold hood. Try to prevent hood from dropping
or suddenly closing to cause accidents during operation.
1. Remove the hood sound insulator.

a. Remove clip (arrow) from hood sound insulator, and
remove hood sound insulator (1).
1
RA13T480039
2. Remove the hood adjustable buffer block.

a. Turn hood adjustable buffer block (arrow)
counterclockwise to remove it.
48
RA13T480040

3. Remove the engine weatherstrip.

a. Disengage clips from engine weatherstrip, and
remove engine weatherstrip (1). 1
RA13T480050
4. Remove 2 fixing screws (arrow) from holder, and remove

hood support rod (1).
RA13T480070
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing hood support rod.
 Try to prevent body paint surface from being scratched, when removing hood support rod.
 When removing hood support rod, try to prevent hood from dropping, otherwise, body may be damaged.
WARNING
 When removing hood support rod, an assistant is needed to hold hood. Try to prevent hood from
dropping or suddenly closing to cause accidents during operation.
5. Remove the hood assembly.

a. Remove 4 fixing nuts (arrow) between hood assembly
and hood hinge assembly, and remove hood
48 assembly.
RA13T480080
Installation

Adjustment
1. Adjust the hood assembly.
a. Loosen fixing bolts on hood hinge assembly.
b. Adjust clearance of hood assembly to standard range and pre-tighten fixing bolts on hood hinge
assembly.
Standard ranges of clearance between installation position of hood assembly and each part are as
follows:
4±1.0
RA13T480085
c. After adjustment, tighten fixing bolts between hood hinge assembly and hood assembly to specified
torque.
d. After adjustment, tighten fixing bolts between hood hinge assembly and body to specified torque.
48
2. Adjust height of hood front end with adjustable buffer blocks.
a. Raise or lower hood front end by rotating adjustable
buffer blocks clockwise or counterclockwise.
RA13T480090

b. After adjustment, make sure that alignment between hood assembly and wing assembly is within
standard range.
Standard alignment:4±1.0 mm
3. Adjust the hood lock assembly.
a. Slightly loosen fixing nuts of hood lock assembly, and
adjust hood lock assembly in direction of arrow as
RA13T480100
b. Tighten hood lock assembly fixing nuts to specified torque after adjustment.
Inspection
After hood assembly is adjusted, perform following inspections:
1. Check hood for wear or deformation during installation. Repair as necessary.
3. Check if clearance and alignment between installation position of hood assembly and each part are within
specified range. Adjust as necessary.
48

Hood Hinge Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing hood hinge assembly.
 When removing hood hinge assembly, try to prevent hood from dropping, otherwise, body or front
windshield may be damaged.
WARNING
 When removing hood hinge assembly, an assistant is needed to hold hood. Try to prevent hood from
dropping or suddenly closing to cause accidents during operation.
1. Remove the front hub assembly.

a. Remove 2 fixing nuts (arrow) between hood left hinge
assembly and hood assembly.
RA13T480110
b. Remove 2 fixing bolts (arrow) between hood left hinge

assembly and body, and remove hood left hinge
assembly.
48
RA13T480120
Installation

Hood Cable Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing hood cable assembly.
 Try to prevent interior and body paint surface from being scratched, when removing hood cable
assembly.

4. Remove the hood lock assembly (See page 48-14).
5. Remove the A-pillar lower protector assembly (See page 50-15).
6. Remove the front windshield lower trim board assembly (See page 49-29).
7. Remove the hood cable assembly.
a. Remove 2 fixing screws (arrow) from hood grip drive
block.
RA13T480143
b. Disengage hood cable assembly (1) from hood grip

drive block (2).
1
2
RA13T480140
48 c. Using a screwdriver wrapped with protective tape, pry
up rubber cushion (arrow).
RA13T480150

d. Disengage clips (arrow) from hood cable assembly,

and remove hood cable assembly.
RA13T480160
e. Remove 3 fixing bolts (arrow) from hood lock, and

disengage cable assembly (1).
RA13T480170
Installation
CAUTION
 After installing hood cable assembly, make sure that hood can be opened smoothly without seizuring.
48

Front Door Inner Protector Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing front door inner protector
assembly.
 Try to prevent front door inner protector surface from being damaged, when removing front door inner
protector assembly.

3. Remove the left outside rear view mirror inner triangular block.
up clips on outside rear view mirror inner triangular
block, and remove left outside rear view mirror inner
triangular block (1).
RA13T480173
4. Remove the front left door inside handle trim strip (1).
48 1
RA13T480220

5. Remove the front left door inside handle screw block cover.
up front left door inside handle screw block cover (1).
RA13T480230
6. Remove the power glass regulator control master switch (See page 44-40).
7. Remove the front left door inner protector assembly.
a. Remove 4 fixing screws (arrow) and 2 bolts (1) from
front door inner protector assembly.
(Tightening torque for screw: 1.5 ± 0.5 N·m)
RA13T480250
b. Using an interior crow plate, pry up clips on front door

inner protector assembly, and loosen front door inner
protector assembly in direction of arrow as shown in
illustration.
48
RA13T480260

c. Disengage front door inside handle cable (arrow) from

front door inside handle, and remove front left door
glass regulator switch connector (arrow).
1
d. Remove the front left door inner protector assembly
(1).
RA13T480270
8. Remove the front door inside handle.

a. Remove 4 fixing screws (arrow) from front door inside
handle. 1
up claws (arrow) on front door inside handle, and
remove front door inside handle (1).
RA13T480290
Installation
CAUTION
 Replace damaged clips and install front door inner protector assembly in place, when installing front door
inner protector assembly.
 Install connectors in place, when installing front door inner protector assembly.
 Check that each function can operate properly, after installing front door inner protector assembly.
48

Front Door Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing front door assembly.
 Try to prevent body paint surface from being scratched, when removing front door assembly.
WARNING
 When removing front door assembly, an assistant is needed to hold front door, to prevent front door from
dropping to cause accidents during operation.

4. Remove the front left door protective film assembly.
a. As shown in illustration, remove front left door
protective film assembly (1) by gently peeling it along
edges from one corner of front left door protective film
assembly.
RA13T480310
b. Disconnect the left rear view mirror connector (arrow).
48
RA13T480313

CAUTION
 Try to prevent front door protective film from being damaged, when removing front door protective film
assembly.
 Place front door protective film assembly properly after removal, and avoid adhesive sticker on front door
protective film assembly from sticking to other components.
5. Remove the front left door speaker assembly (See page 39-35).
7. Remove the front left door weather bar (See page 44-43).
8. Remove the front door glass upper run (See page 44-44).
9. Remove the front door glass rear guide rail assembly (See page 44-47).
10.Remove the front door glass assembly (See page 44-46).
11. Remove the front door power glass regulator (See page 44-47).
12.Remove the front left door lock assembly (See page 37-39).
13.Remove the front left door key cylinder assembly (See page 37-41).
14.Remove the front left door outside handle.
up front left door lock block cover (1), loosen door lock
screw and clip (2) and remove key cylinder assembly
(3).
2
1
RA13T480331
b. Slide and pull front door outside handle in direction of

arrow as shown in illustration to remove it.
48
RA13T480340

15.Remove the front left door outside handle base assembly.

a. Remove fixing screw (arrow) from front door outside
handle base assembly.
RA13T480350
b. Disengage clip (arrow) from door lock link, and

remove front left door outside handle base assembly.
RA13T480360
16.Remove the front left door outside handle shim.

a. Disengage claws on front door outside handle front
shim, and remove front left door outside handle front
shim (1).
b. Disengage claws on front door outside handle rear
shim, and remove front left door outside handle rear 1
shim (2).
48
RA13T480370

17.Disconnect the front left door connector.

up front door dust boot.
RA13T480390
b. Disconnect front left door wire harness connector (1)

and remove ground wire fixing nut (arrow).
MODE SET
1 2
0 3
1
A/C
1 3 5
2 4 R
RA13T480391
18.Remove the front left door assembly.

a. Remove 3 fixing bolts (arrow) between front door
hinge assembly and front door assembly.
RA13T480400
b. Remove the front left door assembly.

19.Remove the front left door hinge assembly.
48 a. Remove 2 fixing bolts (arrow) between front door
hinge assembly and body, and 2 fixing bolts on back
of hinge.
b. Remove front door upper hinge assembly (1) and
front door lower hinge assembly (2).
RA13T480411

Installation
CAUTION
 Replace damaged clips and install front door inner protector in place, when installing front door inner
protector.
 Stick protective film in specified position, not in a wrong position or an asymmetric position between left
and right sides or cover the mounting holes of other installation parts.
 DO NOT drag protective film when sticking. It should be installed under its original condition and ensure
sheet metal is clean before installation.
 Finished protective film should have no defects, such as wrinkles, bubbles or turnups.
 Finished protective film should have powerful adherence. Protective film sticking should be finished at
one time. Avoid repeat sticking.
WARNING
 Be sure to wear safety equipment to prevent accidents, when installing front door assembly.
 When installing front door assembly, an assistant is needed to hold front door, to prevent front door from
Adjustment
1. Adjust the front door assembly.
a. Loosen 3 fixing bolts on front door hinge assembly,
and adjust front door assembly position in direction of
RA13T480420
48

b. Tighten fixing bolts on front door hinge assembly to specified torque after adjustment.
Standard ranges of clearance and alignment between installation positions of front door assembly and
each part are as follows:
6.0±1.5//2.0 ±1.0//1.0
RA13T480440
c. After adjustment, make sure alignment between front door assembly and rear door assembly is within
standard range.
Standard alignment: ±1.0 mm
2. Adjust the front door lock striker.
a. Slightly loosen fixing screws on front door lock striker,
and tap it with a plastic hammer in direction of arrow
as shown in illustration, to adjust the lock striker
position.
48
RA13T480450
b. Tighten fixing screws on front door lock striker to specified torque after adjustment.

Inspection
After front door assembly is adjusted, perform following inspections:
1. Check front door assembly for wear or deformation during installation. Repair as necessary.
2. Check if fixing bolts and fixing screws are set in position. Tighten them to specified torque as necessary.
3. Check if clearance and alignment between installation position of front door assembly and each part are
within specified range. Adjust as necessary.
48

Rear Door Inner Protector Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing rear door inner protector
assembly.
 Try to prevent rear door inner protector surface from being damaged, when removing rear door inner
protector assembly

3. Remove the rear left door inside handle screw block cover.
up rear left door inside handle screw block covers (1)
and (2) as well as rear left door inner protector trim
strip (3).
RA13T480480
4. Remove the rear left door inner protector assembly.

a. Remove 5 fixing screws (arrow) from rear left door
48
RA13T480500

b. Using an interior crow plate, pry up clips on rear door

inner protector assembly, and loosen rear door inner
protector assembly in direction of arrow as shown in
illustration.
RA13T480510
c. Disengage handle cable (1) and regulator switch

connector (2) from rear door inside handle, and
remove inner protector assembly (3).
3
1
RA13T480520
5. Remove the rear door inside handle.

a. Remove 4 fixing screws (arrow) from rear door inside
handle.
1
up claws on rear door inside handle, and remove rear
door inside handle (1).
RA13T480523 48

Installation
CAUTION
 Replace damaged clips and install rear door inner protector assembly in place, when installing rear door
 Check that inside handle assembly can be used normally, after installing rear door inner protector
assembly.
48

Rear Door Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing rear door assembly.
 Try to prevent rear door protector surface from being damaged, when removing rear door assembly.
WARNING
 When removing rear door assembly, an assistant is needed to hold rear door, to prevent rear door from

4. Remove the rear left door protective film assembly.
CAUTION
 Try to prevent rear door protective film from being damaged, when removing rear door protective film
assembly.
 Place rear door protective film assembly properly after removal, and avoid adhesive sticker on rear door
protective film assembly from sticking to other components.
a. As shown in illustration, remove rear left door

protective film assembly (1) by gently peeling it along
edges from one corner of rear left door protective film
assembly.
48
1
RA13T480560
5. Remove the rear left door opening weatherstrip (See page 50-12).
6. Remove the rear left door weather bar (See page 44-52).

7. Remove the rear door glass upper run (See page 44-56).
8. Remove the rear door glass guide rail assembly (See page 44-57).
9. Remove the rear door glass assembly (See page 44-54).
10.Remove the rear door power glass regulator (See page 44-58).
11. Remove the rear left door lock assembly (See page 37-44).
12.Remove the B-pillar lower protector assembly (See page 50-17).
13.Remove the rear left door outside handle cover.
a. Remove the rear door outside handle cover plug
(arrow).
RA13T480570
b. Loosen fixing screw (arrow) on rear door outside

handle cover, and remove rear door outside handle
cover (1).
1
RA13T480590
14.Remove the rear left door outside handle.

a. Slide and pull rear door outside handle in direction of
arrow as shown in illustration to remove it.
RA13T480600
48 15.Remove the rear left door outside handle base assembly.

a. Remove 1 fixing screw (arrow) from rear left door
outside handle base assembly, and remove rear left
door outside handle base assembly.
RA13T480610

16.Remove the rear left door outside handle shim.

a. Disengage claws on rear door outside handle front
shim, and remove rear left door outside handle front
shim (1).
b. Disengage claws on rear door outside handle rear
shim, and remove rear left door outside handle rear 1
shim (2).
RA13T480370
17.Disconnect the rear left door connector.

up rear door dust boot.
RA13T480630

up connector wire harness fixing clip (arrow).
48
RA13T480631

c. Disconnect the rear left door connector (arrow).
RA13T480632
18.Remove the rear left door assembly.

a. Remove 2 fixing bolts (arrow) between rear door
hinge assembly and rear door assembly.
RA13T480640
b. Remove 2 fixing bolts (arrow) between rear door

hinge and B-pillar.
RA13T480657
c. Remove the rear left door assembly.
48

Installation
CAUTION
 Replace damaged clips and install rear door inner protector in place, when installing rear door inner
protector.
 Stick protective film in specified position, not in a wrong position or an asymmetric position between left
and right sides or cover the mounting holes of other installation parts.
 DO NOT drag protective film when sticking. It should be installed under its original condition and ensure
sheet metal is clean before installation.
 Finished protective film should have no defects, such as wrinkles, bubbles or turnups.
 Finished protective film should have powerful adherence. Protective film sticking should be finished at
one time. Avoid repeat sticking.
WARNING
 Be sure to wear safety equipment to prevent accidents, when installing rear door assembly.
 When installing rear door assembly, an assistant is needed to hold rear door, to prevent rear door from
Adjustment
1. Adjust the rear door assembly.
a. Loosen fixing bolts on rear door hinge assembly and
adjust rear door assembly position in direction of
RA13T480671
48

b. Tighten fixing bolts on rear door hinge assembly to specified torque after adjustment.
Standard ranges of clearance between installation position of rear door assembly and each part are as
follows:
6.0±1.5//2.0 6.0±1.5//2.0
RA13T480680
c. After adjustment, make sure alignment between rear door assembly and front door assembly is within
standard range.
Standard alignment:±1.0mm
d. After adjustment, make sure alignment between rear door assembly and body outer panel is within
standard range.
Standard alignment: 4.0±1.0mm
2. Adjust the rear left door lock striker assembly.
a. Slightly loosen fixing screws on rear door lock striker,
and tap it with a plastic hammer in direction of arrow
as shown in illustration, to adjust the lock striker
48 position.
RA13T480690
b. Tighten fixing screws on rear door lock striker assembly to specified torque after adjustment.

Inspection
After rear left door assembly is adjusted, perform following inspections:
1. Check rear door assembly for wear or deformation during installation. Repair as necessary.
2. Check if fixing bolts and fixing screws are set in position. Tighten them to specified torque as necessary.
3. Check if clearance and alignment between installation position of rear door assembly and each part are
48

Back Door Assembly

Removal
CAUTION
 Be sure to wear safety equipment, when removing back door assembly.

 Try to prevent body paint surface from being scratched, when removing back door assembly.
WARNING
 When removing back door assembly, an assistant is needed to hold back door, so as to prevent back
door from dropping or suddenly closing to cause accidents during operation.

3. Remove the back door adjustable buffer block.
4. Remove the C-pillar upper protector.
5. Remove the left speaker cover assembly.
6. Remove the tonneau cover assembly.
a. Turn 4 back door adjustable buffer blocks (1)
counterclockwise to remove them.
RA13T480700
7. Remove the back door trim board assembly.

a. Remove plastic clips (arrow) from back door trim
board assembly, and remove back door trim board 1
assembly (1).
48
RA13T480710

8. Remove the back door lock latch assembly.

a. Remove 2 fixing bolts (arrow) from back door lock
latch, and pry up lock latch protective cover (1) with a
screwdriver wrapped with protective tape.
1
RA13T480713
b. Disconnect the back door lock latch wire harness

connector (arrow).
RA13T480715
c. Remove the back door lock latch assembly.

9. Remove the back door assembly.
up back door dust boot (arrow).
RA13T480714
b. Remove back door wire harness fixing clip (arrow),

and disconnect back door lock wire harness
connector (1).
48
RA13T480730

c. Disconnect the back door hydraulic support rod (1).
RA13T480731
d. Remove 4 fixing bolts (arrow) between back door

hinge assembly and back door assembly, and remove
back door assembly.
RA13T480733
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents, when installing back door assembly.
 Try to prevent body paint surface from being scratched, when installing back door assembly.
WARNING
 When installing back door assembly, an assistant is needed to hold back door, so as to prevent back
door from dropping or suddenly closing to cause accidents during operation.
Adjustment
1. Adjust the back door assembly.
48 a. Loosen fixing bolts on back door assembly, and adjust
back door assembly position in direction of arrow as
RA13T480771
b. Tighten fixing bolts on back door assembly to specified torque after adjustment.

c. Standard ranges of clearance between installation position of back door assembly (See page 52-13).
2. Adjust height of back door with back door adjustable buffer blocks.
a. Raise or lower back door by rotating back door
adjustable buffer blocks clockwise or counterclockwise.
RA13T480800
3. Adjust the back door lock striker assembly.

a. Slightly loosen fixing screws on back door lock striker
assembly, and adjust back door lock striker assembly
position by tapping with a plastic hammer in direction
of arrow as shown in illustration.
RA13T480810
b. Tighten fixing screws on back door lock striker assembly to specified torque after adjustment.
Inspection
After back door assembly is adjusted, perform following inspections:
1. Check back door for wear or deformation during installation. Repair as necessary.
3. Check if clearance and alignment between installation position of back door assembly and each part are
48

Back Door Opener Switch Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing back door opener switch
assembly.
 Try to prevent body paint surface from being scratched, when removing back door opener switch
assembly.

3. Remove the back door opener switch assembly.
a. Remove 2 fixing bolts (arrow) from back door opener
switch assembly, and disconnect back door opener
1
RA13T480820
b. Remove the back door opener switch assembly (1).
RA13T480830
Installation
48 CAUTION
 Install connector in place, after installing back door opener switch assembly.
 Check that back door opener switch assembly functions properly after installation.

Back Door Hinge Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing back door hinge assembly.
 When removing back door hinge assembly, try to prevent back door from dropping, otherwise, body or
rear windshield may be damaged.
WARNING
 When removing back door hinge assembly, an assistant is needed to hold back door, so as to prevent
back door from dropping or suddenly closing to cause accidents during operation.
1. Remove the back door hinge assembly.

a. Remove 2 connecting bolts (arrow) between back
door left hinge assembly and body, and remove back
door hinge assembly.
RA13T480831
Installation
CAUTION
 After installing back door hinge assembly, it is necessary to adjust back door.
48

- MEMO -

EXTERIOR
GENERAL INFORMATION 49-3 Disassembly 49-22
Specifications 49-5 Rear Bumper Mounting Bracket 49-24
Tool 49-6 Removal 49-24
Installation 49-24
Rear Bumper Crossmember 
Front Bumper Assembly 49-7 Assembly 49-25
Disassembly 49-9 Installation 49-25
Assembly 49-11 Rear Left Wheel Trims 49-26
Front Bumper Mounting Bracket 49-12 Installation 49-26
Removal 49-12 Rear Wheel House Protector 49-27
Front Bumper Crossmember  Installation 49-27
Assembly 49-13
Rear Trim Strip Assembly 49-28
Removal 49-13
Removal 49-28
Installation 49-13
Installation 49-28
Front Wheel House Protector 49-14
Front Windshield Lower Support 
Removal 49-14 Assembly 49-29
Wing Assembly 49-15 Installation 49-29
Removal 49-15 Fuel Filler Cap Assembly 49-30
Side Skirt Protector Assembly 49-17 Installation 49-30
Removal 49-17 Roof Rack Assembly 49-31
Front Left Door Trim Board 49-19 Installation 49-31
Removal 49-19 Rear Spoiler Assembly 49-32
Rear Left Door Trim Board 49-20 Installation 49-33
Removal 49-20 Name Plate 49-34
Rear Bumper Assembly 49-21 Installation 49-34
Removal 49-21
49

49

49 - EXTERIOR
GENERAL INFORMATION
EXTERIOR
Description
2
1
3
×5
4 6
5
×7
×4 2
×3
7
20
18
8 19
21
×2
×14
×4
9 ×7
17
×4 16
×4
×9 10
11 ×2
×4
15 ×3
14
13 ×14
×4
12
RA13T490010
1 - Front Windshield Lower Support Assembly 2 - Right Skirt Protector Assembly

3 - Front Right Door Trim Board 4 - Front Right Wheel Trims 49
5 - Right Wing Assembly 6 - Front Windshield Lower Support Right Sealing
Plate
7 - Front Right Wheel House Protector 8 - Front Bumper Right Mounting Bracket
9 - Front Right Wing Spacer 10 - Front Bumper Crossmember Assembly
11 - Front Bumper Grille Assembly 12 - Front Bumper Assembly
13 - Front Left Wing Spacer 14 - Front Bumper Left Mounting Bracket
15 - Front Left Wheel House Protector 16 - Front Left Wheel Trims

49 - EXTERIOR
17 - Left Wing Assembly 18 - Left Skirt Protector Assembly

19 - Front Left Door Trim Board 20 - Front Windshield Lower Support Left Sealing
Plate
21 - Front Left Triangular Plate Assembly 22 - Front Right Triangular Plate Assembly
1
2
×4
×4
5
18
4
×5 16
15
17
×2
×4
×4
6
14 ×2
7 12
13
×5
×2 ×6
×2 ×4
11
×4
×4
10
8
9
RA13T490020
1 - Right Roof Rack Assembly 2 - Front Right Side Outer Trim Board
3 - Left Roof Rack Assembly 4 - Left C-pillar Trim Board Assembly
49
5 - Right C-pillar Trim Board Assembly 6 - Rear Left Door Trim Board
7 - Rear Left Wheel Trims 8 - Rear Bumper Left Mounting Bracket
9 - Rear Left Wheel Trims Mounting Bracket 10 - Rear Left Wheel House
11 - Rear Bumper Assembly 12 - Rear Bumper Crossmember Assembly
13 - Rear Trim Strip Assembly 14 - Rear Right Door Trim Board
15 - Rear Right Wheel House 16 - Rear Right Wheel Trims Mounting Bracket
17 - Rear Bumper Right Mounting Bracket 18 - Rear Right Wheel Trims

49 - EXTERIOR
Bumper assembly and bumper crossmember assembly are the safety devices of body protection, to mainly
absorb and reduce shock from the outside. The exterior mainly consists of front bumper assembly, front
bumper mounting bracket, front bumper crossmember assembly, front bumper center bracket, front wheel
house wind deflector, front wheel house protector, front wheel trims, wing assembly, side skirt protector
assembly, door protector assembly, front bumper lower protector, rear bumper assembly, rear bumper
mounting bracket, rear bumper bracket, rear bumper crossmember assembly, rear wheel house protector,
front windshield lower support assembly, fuel filler cap assembly, roof rack assembly and spoiler, etc.
Specifications

Front Bumper Assembly Fixing Screw 1.5 ± 0.5
Front Bumper Assembly Fixing Bolt 5±1
Name Plate "CAC" Bracket Fixing Screw 1.5 ± 0.5
Front Daytime Running Light Assembly Fixing Screw 1.5 ± 0.5
Front Bumper Mounting Bracket Fixing Bolt 4.5 ± 1
Front Bumper Center Bracket Fixing Bolt 4.5 ± 1
Front Bumper Crossmember Assembly Fixing Bolt 47 ± 3
Front Wheel House Wind Deflector Fixing Screw 3±1
Front Wheel House Protector Fixing Screw 3±1
Wing Cover Plate Fixing Screw 3±1
Wing Assembly Fixing Bolt 10 ± 1
Front Bumper Lower Protector Fixing Screw 1.5 ± 0.5
Rear Bumper Assembly Fixing Screw 1.5 ± 0.5
Rear Bumper Assembly Fixing Bolt 5±1
Fixing Screw Between Rear Bumper Assembly and
3±1
Rear Wheel House
Rear Bumper Mounting Bracket Fixing Screw 1.5 ± 0.5
Rear Bumper Crossmember Assembly Fixing Nut 25 ± 2
Rear Wheel House Protector Fixing Screw 3±1
Front Windshield Lower Support Assembly Fixing
3.0 ± 0.5
Screw
Fuel Filler Cap Assembly Fixing Bolt 10 ± 1
49

49 - EXTERIOR
Tool
General Tool
Interior Crow Plate
RCH0000025
49

49 - EXTERIOR
ON-VEHICLE SERVICE
Front Bumper Assembly
Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing front bumper
assembly.
 Appropriate force should be applied, when removing front bumper assembly. Be careful not to operate
roughly.
 Try to prevent body paint surface from being scratched, when removing front bumper assembly.

3. Remove the front bumper assembly.
a. Remove 3 fixing screws (arrow) and clips from front
left wheel trims, and then remove front wheel trims.
RA13T490030
b. Remove 1 screw (arrow) from the side of front bumper

assembly.
RA13T490031
c. Raise vehicle to a proper position, and remove 4 fixing

screws (arrow) from lower part of front bumper
assembly.
49
RA13T490040

49 - EXTERIOR
d. Lower vehicle to a proper position, and remove 4

fixing bolts (arrow) from upper part of front bumper
assembly.
RA13T490050
e. Disengage claws from front bumper assembly (take

left side as an example).
RA13T490060
f. Disconnect front daytime running light connectors

(arrow), and remove front bumper assembly (1).
RA13T490070
49

49 - EXTERIOR
Disassembly
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when disassembling front bumper
assembly.
 Appropriate force should be applied, when disassembling front bumper assembly. Be careful not to
operate roughly.
 Avoid breaking claws, when disassembling front bumper assembly.
1. Remove the front bumper towing hook cover.

off front bumper towing hook cover.
b. Remove front bumper towing hook cover (1) from 1
front bumper assembly.
RA13T490080
2. Remove the name plate "CAC".

off dowel pins of name plate "CAC".
b. Remove name plate "CAC" (1) from front bumper
assembly.
RA13T490090
3. Remove the name plate "CAC" bracket.

a. Remove 4 fixing screws (arrow) from name plate
"CAC" bracket, and remove name plate "CAC"
bracket (1). 1
49
RA13T490100

49 - EXTERIOR
4. Remove the front grille assembly.

a. Remove 9 fixing screws (arrow) from inner side of
grille.
b. Remove the intake grille.
RA13T490110
5. Remove the center intake grille.

off claws from center intake grille.
b. Remove center intake grille (1) from front bumper
assembly.
RA13T490120
6. Remove the front daytime running light assembly (take

left side as an example).
a. Remove 3 fixing screws (arrow) from front daytime
running light assembly.
b. Remove daytime running light assembly from front
bumper assembly.
RA13T490130
7. Remove the front bumper daytime running light grille

(take left side as an example).
off claws from front bumper daytime running light
grille.
Remove 4 fixing screws (arrow) and clips from
daytime running light grille.
b. Remove front bumper daytime running light grille from
front bumper assembly.
49 RA13T490140

49 - EXTERIOR
Assembly
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when assembling front bumper
assembly.
 Try to prevent paint surface of front bumper assembly from being scratched, when assembling front
bumper assembly.
Installation
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when installing front bumper
assembly.
 Try to prevent body paint surface from being scratched, when installing front bumper assembly.
 Make sure that front bumper is installed correctly and fitting clearance between front bumper and body is
appropriate, when installing front bumper assembly.
49

49 - EXTERIOR
Front Bumper Mounting Bracket

Removal
HINT:
CAUTION
mounting bracket.
 Try to prevent body paint surface from being scratched, when removing front bumper mounting bracket.

4. Remove the front bumper left mounting bracket.
a. Remove 2 fixing bolts (arrow) from front bumper left
mounting bracket, and remove front bumper left
mounting bracket (1). 1
RA13T490150
Installation
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when installing front bumper mounting
bracket.
 Try to prevent body paint surface from being scratched, when installing front bumper mounting bracket.
49

49 - EXTERIOR
Front Bumper Crossmember Assembly

Removal
CAUTION
 Try to prevent body paint surface from being scratched, when removing front bumper crossmember
assembly.

4. Remove the horn (See page 42-8).
5. Remove the front bumper crossmember assembly.
a. Pry off the horn wire harness fixing clips (1).
b. Remove 8 fixing bolts (arrow) from front bumper 1
crossmember assembly, and remove front bumper
RA13T490170
Installation
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when installing front bumper
 Try to prevent body paint surface from being scratched, when installing front bumper crossmember
assembly.
 There should be no looseness, shaking and deformation, after installing front bumper crossmember
assembly.
49

49 - EXTERIOR
Front Wheel House Protector

Removal
HINT:
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing front wheel house
protector.
 Try to prevent body paint surface from being scratched, when removing front wheel house protector.
1. Remove the front wheel trims (See page 49-7).

2. Remove the front left wheel house protector.
a. Remove 14 fixing screws (arrow) from front left wheel
house protector, and remove front left wheel house
protector assembly.
RA13T490190
Installation
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when installing front wheel house
protector assembly.
 Try to prevent body paint surface from being scratched, when installing front wheel house protector
assembly.
49

49 - EXTERIOR
Wing Assembly
Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing wing assembly.
 Try to prevent body paint surface from being scratched, when removing wing assembly.

3. Remove the front left wheel trims (See page 49-7).
4. Remove the front wheel house protector (See page 49-14).
5. Remove the left skirt protector assembly (See page 49-17).
7. Remove the front bumper left mounting bracket (See page 49-12).
8. Remove the left headlight assembly (See page 35-89).
9. Remove the left wing assembly.
a. Remove the front left wing spacer (1).
RA13T490210

off claw on front windshield lower support left sealing
plate, and remove front windshield lower support left
sealing plate (1).
1
49
RA13T490213

49 - EXTERIOR
c. Remove fixing bolt (arrow) between front part of wing

assembly and body.
RA13T490211
d. Remove 4 fixing screws (arrow) from upper part of

wing assembly.
RA13T490220
e. Remove fixing bolt (arrow) between lower part of wing

assembly and body.
RA13T490240
f. Remove 2 fixing bolts (arrow) between inner part of

wing assembly and body, and remove wing assembly.
RA13T490250
49 Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents, when installing front wing.
 Try to prevent body paint surface from being scratched, when removing front wing.
 Make sure that front wing is installed correctly and fitting clearance between front wing and body is
appropriate, when installing front wing.

49 - EXTERIOR
Side Skirt Protector Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing side skirt protector assembly.
 Try to prevent body paint surface from being scratched, when removing side skirt protector assembly.

3. Remove the front wheel house protector (See page 49-14).
4. Remove the rear left wheel trims mounting bracket (See page 49-27).
5. Remove the side skirt protector assembly.
a. Remove 4 fixing screws (arrow) on both ends of left
skirt protector.
RA13T490203
b. Raise vehicle to a proper position, and remove fixing

screws (arrow) from left skirt protector.
RA13T490205
c. Using an interior crow plate, pry up left skirt protector.

49
RA13T490207

49 - EXTERIOR
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents, when installing left skirt protector.
 Try to prevent body paint surface from being scratched, when installing left skirt protector.
49

49 - EXTERIOR
Front Left Door Trim Board

Removal
HINT:
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing front left door trim
board.
 Try to prevent body paint surface from being scratched, when removing front left door trim board.
1. Using an interior crow plate, pry off fixing clips from front
left door trim board.
RA13T490208
2. Remove the front left door trim board.
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents, when installing front left door trim board.
 Try to prevent body paint surface from being scratched, when installing front left door trim board.
49

49 - EXTERIOR
Rear Left Door Trim Board

Removal
HINT:
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing rear left door trim
board.
 Try to prevent body paint surface from being scratched, when removing rear left door trim board.
1. Using an interior crow plate, pry off fixing clips from rear
left door trim board.
RA13T490221
2. Remove the rear left door trim board.
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents, when installing rear left door trim board.
 Try to prevent body paint surface from being scratched, when installing rear left door trim board.
49

49 - EXTERIOR
Rear Bumper Assembly

Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing rear bumper
assembly.
 Appropriate force should be applied, when removing rear bumper assembly. Be careful not to operate
roughly.
 Try to prevent body paint surface from being scratched, when removing rear bumper assembly.

3. Remove the rear left and right combination lights (See page 35-93).
4. Remove the rear bumper assembly.
a. Remove 5 fixing screws (arrow) between rear bumper
assembly and rear wheel house protector (take left
side as an example).
RA13T490270
b. Raise vehicle to a proper height, and remove 2 fixing

screws (arrow) from lower part of rear bumper
assembly.
RA13T490280
c. Lower vehicle and remove 6 fixing screws (arrow)

from upper part of rear bumper assembly.
49
RA13T490290

49 - EXTERIOR
d. Disengage claws from the side of rear bumper

assembly (take left side as an example).
RA13T490310
e. Disengage claws from front part of rear bumper

assembly.
RA13T490320
f. Disconnect connector (arrow) from rear bumper

assembly, and remove rear bumper assembly.
RA13T490330
Disassembly
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when disassembling rear bumper
assembly.
 Appropriate force should be applied, when disassembling rear bumper assembly. Be careful not to
operate roughly.
 Avoid breaking claws, when disassembling rear bumper assembly.
49
1. Remove the reversing radar sensor (See page 40-8).

49 - EXTERIOR
2. Remove the rear bumper towing hook cover.

off claw on rear bumper towing hook cover.
b. Remove rear bumper towing hook cover (1) from rear
bumper assembly.
1
RA13T490340
3. Remove the rear fog light assembly (take left side as an

example).
a. Remove 4 screws (arrow) from rear bumper inner fog
light, and remove rear fog light assembly.
RA13T490350
4. Remove the rear bumper spoiler.

a. Remove 4 fixing screws (arrow) and clips from rear
bumper spoiler, and remove rear bumper spoiler.
RA13T490360
Installation
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when installing rear bumper
assembly.
 Try to prevent body paint surface from being scratched, when installing rear bumper assembly.
 Make sure that rear bumper is installed correctly and fitting clearance between rear bumper and body is
appropriate, when installing rear bumper assembly. 49

49 - EXTERIOR
Rear Bumper Mounting Bracket

Removal
HINT:
CAUTION
mounting bracket.
 Try to prevent body paint surface from being scratched, when removing rear bumper mounting bracket.

3. Remove the rear left and right combination light assemblies (See page 35-93).
5. Remove the rear bumper left mounting bracket
a. Remove 2 fixing bolts (arrow) from rear bumper left
mounting bracket, and remove rear bumper left
mounting bracket (1).
1
RA13T490370
Installation
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when installing rear bumper mounting
bracket.
 Try to prevent body paint surface from being scratched, when installing rear bumper mounting bracket.
49

49 - EXTERIOR
Rear Bumper Crossmember Assembly

Removal
CAUTION
 Try to prevent body paint surface from being scratched, when removing rear bumper crossmember
assembly.

4. Remove the rear bumper crossmember assembly.
a. Remove 6 fixing nuts (arrow) from rear bumper
crossmember assembly, and remove rear bumper
RA13T490380
Installation
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when installing rear bumper
 Try to prevent body paint surface from being scratched, when installing rear bumper crossmember
assembly.
 There should be no looseness, shaking and deformation after installing rear bumper crossmember
assembly.
49

49 - EXTERIOR
Rear Left Wheel Trims

Removal
HINT:
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing rear left wheel trims.
 Try to prevent body paint surface from being scratched, when removing rear left wheel trims.
1. Remove 5 fixing screws (arrow) from rear left wheel

trims.
RA13T490385

clips from rear left wheel trims.
RA13T490387
3. Remove the rear left wheel trims.
Installation
CAUTION
49  Be sure to wear safety equipment to prevent accidents, when installing rear left wheel trims.
 Try to prevent body paint surface from being scratched, when installing rear left wheel trims.

49 - EXTERIOR
Rear Wheel House Protector

Removal
HINT:
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing rear wheel house
protector.
 Try to prevent body paint surface from being scratched, when removing rear wheel house protector.
1. Remove the rear left wheel trims (See page 49-26).

2. Remove 4 fixing screws (arrow) from rear left wheel trims
mounting bracket.
RA13T490225
3. Remove the rear left wheel trims mounting bracket.

4. Remove 4 fixing screws (arrow) and 2 fixing plastic clips
from rear left wheel house protector.
2
RA13T490229
5. Remove the rear left wheel house protector (2).
Installation
CAUTION
49
 Be sure to wear necessary safety equipment to prevent accidents, when removing rear left wheel house
protector.
 Try to prevent body paint surface from being scratched, when removing rear left wheel house protector.

49 - EXTERIOR
Rear Trim Strip Assembly

Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing rear trim strip
assembly.
 Appropriate force should be applied when removing rear trim strip assembly. Be careful not to operate
roughly.
 Try to prevent body paint surface from being scratched, when removing rear trim strip assembly.
1. Remove the back door panel (See page 48-36).

2. Remove the rear trim strip assembly.
a. Remove 2 fixing bolts (arrow) from rear trim strip.
RA13T490233
b. Using an interior crow plate, pry up clips from rear trim

strip assembly.
RA13T490235
c. Remove the rear trim strip assembly.
Installation
49 CAUTION
 Be sure to wear safety equipment to prevent accidents, when installing rear trim strip assembly.
 Try to prevent body paint surface from being scratched, when installing rear trim strip assembly.

49 - EXTERIOR
Front Windshield Lower Support Assembly

Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing front windshield lower
support assembly.
 Try to prevent body paint surface from being scratched, when removing front windshield lower support
assembly.
1. Remove the wiper arm assembly (See page 36-29).

2. Remove the front windshield lower support sealing plate (See page 49-15).
3. Remove the front windshield lower support weatherstrip.
a. Remove clips from front windshield lower support
weatherstrip, and remove front windshield lower
support weatherstrip (1).
RA13T490430
4. Remove the front windshield lower support assembly.

a. Remove 5 fixing screws (arrow) from front windshield
lower support assembly, and remove front windshield
lower support assembly.
RA13T490440
Installation
CAUTION 49
 Be sure to wear necessary safety equipment to prevent accidents, when installing front windshield lower
support assembly.
 Try to prevent body paint surface from being scratched, when installing front windshield lower support
assembly.

49 - EXTERIOR
Fuel Filler Cap Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing fuel filler cap assembly.
 Try to prevent body paint surface from being scratched, when removing fuel filler cap assembly.
1. Open fuel filler cap assembly as shown in illustration.
RA13T490450
2. Remove the fuel filler cap assembly.

a. Disconnect connecting wire (1) from fuel filler cap
assembly.
b. Remove 2 fixing bolts (arrow) from fuel filler cap
assembly, and remove fuel filler cap assembly (2).
2
1
RA13T490460
49
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents, when installing fuel filler cap assembly.
 Try to prevent body paint surface from being scratched, when installing fuel filler cap assembly.

49 - EXTERIOR
Roof Rack Assembly

Removal
HINT:
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing roof rack.
 Try to prevent body paint surface from being scratched, when removing roof rack.

roof rack outer trim board on front left end (2) and roof
rack outer trim board on rear left end (1). 2
RA13T490465
2. Remove 4 fixing bolts (arrow) from front and rear ends of

roof rack outer trim board.
RA13T490469
3. Remove the roof rack assembly.
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents, when installing roof rack assembly. 49
 Try to prevent body paint surface from being scratched, when installing roof rack assembly.

49 - EXTERIOR
Rear Spoiler Assembly

Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents, when removing rear spoiler assembly.
 Try to prevent body paint surface from being scratched, when removing rear spoiler assembly.

caps (arrow) from rear spoiler assembly fixing nut.
RA13T490473
2. Remove 6 fixing nuts (arrow) from rear spoiler.
RA13T490475
3. Remove the high mounted stop light wire harness cover

plate (1).
RA13T490477
4. Disconnect the high mounted stop light wire harness

49 connector (arrow).
RA13T490478

49 - EXTERIOR
5. Remove the spoiler assembly (1).

1
RA13T490479
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents, when installing rear spoiler assembly.
 Try to prevent body paint surface from being scratched, when installing rear spoiler assembly.
49

49 - EXTERIOR
Name Plate
Removal
HINT:
 Use same procedures for front name plate "CAC", rear name plate "CAC", name plate "TIGGO3x" and
name plate "CHERY".
 Procedures listed below are for name plate "CHERY".
CAUTION
 If planning to reuse name plate "CHERY", be careful not to damage it.

 Try to prevent body paint surface from being scratched, when removing name plate "CHERY".
1. Remove the name plate "CHERY".

a. Attach protective tape around the name plate
"CHERY".
b. Insert a piano wire between body and name plate
"CHERY".
CHERY
c. Tie both ends of piano wire with objects (such as
wooden blocks) that can serve as handles.
d. Pull piano wire to remove double-sided tape that
holds name plate on body. RA13T490470
e. Remove the name plate "CHERY".
Installation
1. Clean the body surface.
a. Using a heat light, heat body surface, and remove double-sided tape from body.
b. Wipe off all tape adhesive residues with cleaner.
2. Clean the name plate "CHERY" (if planning to reuse name plate "CHERY")
a. Using a heat light, heat name plate, and remove double-sided tape from name plate "CHERY".
b. Wipe off all tape adhesive residues with cleaner.
c. Apply new double-sided tape to name plate "CHERY".
3. Install the name plate "CHERY".
a. Using a heat light, heat body and name plate "CHERY".
b. Remove release paper from name plate "CHERY", and install name plate "CHERY" in place.
CAUTION
49
 DO NOT overheat body and name plate.
 DO NOT remove release paper from name plate in advance.
 DO NOT touch name plate adhesive surface with hands.
 After removing release paper, prevent foreign matter from attaching to the outside adhesive.

49 - EXTERIOR
4. Installation distance ranges for name plate "CHERY" are as follows:

a. When attaching name plate "CHERY", keep it
horizontal and centered.
b. Vertical distance "a" between right side of name plate
"CHERY" and right side of back door is 80 ± 2 mm.
c. Vertical distance "b" between lower side of name plate a
CHERY
"CHERY" and the lower side of back door is 46 ± 2 b
mm.
RA13T490480
5. Install the rear name plate "CAC".

a. Position rear name plate "CAC" directly into the fixed
box of rear trim strip.
3X CHERY
RA13T490490
6. Installation distance ranges for name plate "TIGGO3x" are as follows:

a. When attaching name plate "TIGGO3x", keep it
horizontal and centered.
b. Vertical distance "a" between lower side of name plate
"TIGGO3x" and lower side of back door is 48 ± 2 mm.
c. Vertical distance "b" between left side of name plate b
"TIGGO3x" and left side of back door is 78 ± 2 mm. 3X
a
RA13T490500
49

- MEMO -

INTERIOR
GENERAL INFORMATION 50-3 C-pillar Lower Protector Assembly 50-20
Tool 50-6 C-pillar Upper Protector Assembly 50-21
Removal 50-21
Installation 50-22
Front Doorsill Pressure Plate 
Sun Visor Assembly 50-23
Assembly 50-7
Removal 50-23
Removal 50-7
Installation 50-23
Installation 50-7
Passenger Grip Assembly 50-24
Rear Doorsill Pressure Plate 
Assembly 50-8 Removal 50-24
Installation 50-9 Roof Assembly 50-25
Luggage Compartment Doorsill  Removal 50-25
Pressure Plate Assembly 50-10 Installation 50-26
Removal 50-10 Front Floor Carpet Assembly 50-27
Front Door Opening Weatherstrip 50-11 Installation 50-28
Removal 50-11 Driver Side Foot Rest Bracket 50-29
Rear Door Opening Weatherstrip 50-12 Installation 50-29
Removal 50-12 Luggage Compartment Carpet 
Luggage Compartment Weatherstrip 50-13 Removal 50-30
Installation 50-13 Tonneau Cover Assembly 50-31
A-pillar Upper Protector Assembly 50-14 Removal 50-31
Installation 50-14 Luggage Compartment Wheel 
House Assembly 50-32
A-pillar Lower Protector Assembly 50-15
Removal 50-32
Removal 50-15
Installation 50-32
Installation 50-16
Fuel Filler Door Cable Assembly 50-33
B-pillar Lower Protector Assembly 50-17
Removal 50-33
Removal 50-17
Installation 50-34
Installation 50-17
B-pillar Upper Protector Assembly 50-18
Removal 50-18
Installation 50-19
50

50

50 - INTERIOR
GENERAL INFORMATION
INTERIOR
Description
3
6 20
9 4 ×4
×3
×2
7 ×3
19
17
10
×3
15
×2 ×4
18
16 ×3
12
14
13 ×3
×3
11
50
RA13T500001
1 - Roof Assembly 2 - Right C-pillar Upper Protector Assembly

3 - Rear Right Speaker Cover Assembly 4 - Right C-pillar Lower Protector Assembly

50 - INTERIOR
5 - Rear Right Doorsill Pressure Plate Assembly 6 - Right B-pillar Upper Protector Assembly
7 - Right B-pillar Lower Protector Assembly 8 - Front Right Doorsill Pressure Plate Assembly
9 - Right A-pillar Upper Protector Assembly 10 - Right A-pillar Lower Protector Assembly
11 - Left A-pillar Lower Protector Assembly 12 - Left A-pillar Upper Protector Assembly
13 - Front Left Doorsill Pressure Plate Assembly 14 - Left B-pillar Lower Protector Assembly
15 - Left B-pillar Upper Protector Assembly 16 - Rear Left Doorsill Pressure Plate Assembly
17 - Rear Left Speaker Cover Assembly 18 - Left C-pillar Lower Protector Assembly
19 - Left C-pillar Upper Protector Assembly 20 - Luggage Compartment Rear Trim Board
Assembly
2
1
3
×2
8
50 10
×2 ×2
RA13T500002

50 - INTERIOR
1 - Roof Assembly 2 - Rear Right Passenger Grip Assembly

3 - Front Right Passenger Grip Assembly 4 - Rear Left Passenger Grip Assembly
5 - Right Sun Visor Holder 6 - Left Sun Visor Holder
7 - Right Sun Visor Assembly 8 - Left Sun Visor Assembly
9 - Interior Front Dome Light Cover 10 - Interior Front Dome Light Assembly
4
2
5
6
3
11
7 10
9
RA13T500003
1 - Luggage Compartment Weatherstrip 2 - Tonneau Cover Assembly

3 - Luggage Compartment Carpet Assembly 4 - Right Luggage Compartment Wheel House
Assembly
50
5 - Rear Right Door Opening Weatherstrip 6 - Front Right Door Opening Weatherstrip
7 - Front Floor Carpet Assembly 8 - Driver Side Foot Rest Bracket
9 - Front Left Door Opening Weatherstrip 10 - Rear Left Door Opening Weatherstrip
11 - Left Luggage Compartment Wheel House
Assembly

50 - INTERIOR
The interior consists of following parts: roof assembly, doorsill pressure plate assembly, sun visor assembly,
door opening weatherstrip, passenger grip assembly, pillar protector assembly, luggage compartment wheel
house assembly, tonneau cover assembly and carpet assembly, etc.
Specifications

Rear Doorsill Pressure Plate Assembly Fixing Screw 1.5 ± 0.5
Rear Doorsill Pressure Plate Assembly Fixing Nut 1.5 ± 0.5
Luggage Compartment Doorsill Pressure Plate
1.5 ± 0.5
Assembly Fixing Screw
A-pillar Upper Protector Assembly Fixing Screw 3 ± 0.5
Hood Grip Fixing Screw 1.5 ± 1
A-pillar Lower Protector Assembly Fixing Screw 1.5 ± 0.5
B-pillar Lower Protector Assembly Fixing Screw 1.5 ± 0.5
Front Seat Belt Assembly Lower Fixing Bolt 50 ± 5
B-pillar Upper Protector Assembly Fixing Screw 1.5 ± 0.5
C-pillar Upper Protector Assembly Fixing Screw 3 ± 0.5
Sun Visor Assembly Fixing Screw 9±1
Sun Visor Holder B Fixing Screw 5±1
Passenger Grip Assembly Fixing Screw 4±1
Interior Front Dome Light Assembly Fixing Screw 2.5 ± 0.5
Front Floor Carpet Assembly Fixing Nut 5±1
Driver Side Foot Rest Bracket Fixing Nut 5±1
High Mounted Stop Light Assembly Fixing Screw 1.5 ± 0.5
Fuel Tank Cap Opener Assembly Fixing Screw 4±1
Tool
Special Tool
Interior Crow Plate

50
RCH0000025

50 - INTERIOR
ON-VEHICLE SERVICE
Front Doorsill Pressure Plate Assembly
Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing front doorsill pressure plate
assembly.
 Appropriate force should be applied, when removing front doorsill pressure plate assembly. Be careful
 Prevent interior and body paint from being scratched, when removing front doorsill pressure plate
assembly.
1. Remove the front left doorsill pressure plate assembly.

a. Remove 3 fixing screws (arrow) from front left doorsill
pressure plate assembly.
b. Using an interior crow plate, pry off 3 clips from front
left doorsill pressure plate assembly and remove the
1
front left doorsill pressure plate assembly (1).
RA13T500010
Installation
CAUTION
 Replace damaged clips and install front doorsill pressure plate assembly in place, when installing front
doorsill pressure plate assembly.
 Make sure that front doorsill pressure plate assembly is well fitted with B-pillar lower protector assembly
and A-pillar lower protector assembly, after installing front doorsill pressure plate assembly.
50

50 - INTERIOR
Rear Doorsill Pressure Plate Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing rear doorsill pressure plate
assembly.
 Appropriate force should be applied, when removing rear doorsill pressure plate assembly. Be careful
 Prevent interior and body paint from being scratched, when removing rear doorsill pressure plate
assembly.

3. Remove the rear left doorsill pressure plate assembly.
a. Remove the fixing screw (arrow) from rear doorsill
RA13T500020
b. Using an interior crow plate, pry off 3 clips from rear

left doorsill pressure plate assembly and remove the
rear left doorsill pressure plate assembly (1).
1
RA13T500021
50

50 - INTERIOR
Installation
CAUTION
 Replace damaged clips and install rear doorsill pressure plate assembly in place, when installing rear
 Make sure that rear doorsill pressure plate assembly is well fitted with B-pillar lower protector assembly
and C-pillar lower protector assembly, after installing rear doorsill pressure plate assembly.
50

50 - INTERIOR
Luggage Compartment Doorsill Pressure Plate Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing luggage compartment doorsill
 Appropriate force should be applied, when removing luggage compartment doorsill pressure plate
assembly. Be careful not to operate roughly.
 Try to prevent interior and body paint from being scratched, when removing luggage compartment
1. Remove the luggage compartment weatherstrip (See page 50-13).

2. Remove the luggage compartment carpet assembly (See page 50-30).
3. Remove the luggage compartment doorsill pressure plate assembly.
a. Remove 3 fixing screws (arrow) from luggage
compartment doorsill pressure plate assembly.
RA13T500030
b. Using an interior crow plate, pry off the clips from

luggage compartment doorsill pressure plate 1
assembly and remove the luggage compartment
doorsill pressure plate assembly (1).
RA13T500031
Installation
CAUTION
50
 Replace damaged clips and install luggage compartment doorsill pressure plate assembly in place, when
installing luggage compartment doorsill pressure plate assembly.

50 - INTERIOR
Front Door Opening Weatherstrip

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing front door opening weatherstrip.
 Appropriate force should be applied when removing front door opening weatherstrip. Be careful not to
operate roughly.
 Try to prevent front door opening weatherstrip from being damaged, when removing front door opening
weatherstrip.
1. Remove the front left door opening weatherstrip.

a. Remove the front left doorsill pressure plate assembly
(See page 50-7).
b. Remove the front left door opening weatherstrip (1) by
gently pulling it along edges from one corner of front
door opening weatherstrip. 1
RA13T500040
Installation
CAUTION
 Front door opening weatherstrip and body should be fitted with a certain amount of clamping force and
the weatherstrip should not fall off easily, when installing front door opening weatherstrip.
 When installing front door opening weatherstrip, tap all around uniformly with a rubber hammer to install
it in place. The surface of weatherstrip should have no defects, such as tapped dents, deformation and
warpage after installation. 50
 After installing front door opening weatherstrip, do not remove or install it unless it is necessary.
Otherwise the weatherstrip holding force of installation may be reduced.

50 - INTERIOR
Rear Door Opening Weatherstrip

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing rear door opening weatherstrip.
 Appropriate force should be applied when removing rear door opening weatherstrip. Be careful not to
operate roughly.
 Try to prevent rear door opening weatherstrip from being damaged, when removing rear door opening
weatherstrip.
1. Remove the rear left door opening weatherstrip.

a. Remove the rear left doorsill pressure plate assembly
(See page 50-8).
b. Remove the rear left door opening weatherstrip (1) by
1
gently pulling it along edges from one corner of rear
door opening weatherstrip.
RA13T500050
Installation
CAUTION
 Rear door opening weatherstrip and body should be fitted with a certain amount of clamping force and
the weatherstrip should not fall off easily, when installing rear door opening weatherstrip.
 When installing rear door opening weatherstrip, tap all around uniformly with a rubber hammer to install it
in place. The surface of weatherstrip should have no defects, such as tapped dents, deformation and
50 warpage after installation.
 After installing rear door opening weatherstrip, do not remove or install it unless it is necessary.

50 - INTERIOR
Luggage Compartment Weatherstrip

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing luggage compartment
weatherstrip.
 Appropriate force should be applied when removing luggage compartment weatherstrip. Be careful not to
operate roughly.
 Try to prevent luggage compartment weatherstrip from being damaged, when removing it.
1. Remove the luggage compartment weatherstrip.

a. Remove the luggage compartment weatherstrip (1) by
gently pulling it along edges from one corner of
luggage compartment weatherstrip.
RA13T500060
Installation
CAUTION
 Luggage compartment weatherstrip and body should be fitted with a certain amount of clamping force
and the weatherstrip should not fall off easily, when installing luggage compartment weatherstrip.
 When installing luggage compartment weatherstrip, tap all around uniformly with a rubber hammer to
install it in place. The surface of weatherstrip should have no defects, such as tapped dents, deformation
and warpage after installation.
 After installing luggage compartment weatherstrip, do not remove or install it unless it is necessary.
50

50 - INTERIOR
A-pillar Upper Protector Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing A-pillar upper protector
assembly.
 Appropriate force should be applied, when removing A-pillar upper protector assembly. Be careful not to
operate roughly.
 Prevent interior and body paint from being scratched, when removing A-pillar upper protector assembly.
1. Remove the front left door opening weatherstrip (See page 50-12).
2. Remove the left A-pillar upper protector assembly.
a. Using an interior crow plate, pry off 3 clips from left A-
pillar upper protector assembly and remove the left A-
pillar upper protector assembly.
RA13T500070
Installation
CAUTION
 Make sure that damaged clips are replaced and A-pillar upper protector assembly is installed in place,
when installing A-pillar upper protector assembly.
 A-pillar upper protector assembly should be well fitted with instrument panel and roof headlining, after
installing A-pillar upper protector assembly.
 A-pillar upper protector assembly and front door opening weatherstrip should be fitted closely, after
installing A-pillar upper protector assembly.
50

50 - INTERIOR
A-pillar Lower Protector Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing A-pillar lower protector
assembly.
 Appropriate force should be applied, when removing A-pillar lower protector assembly. Be careful not to
operate roughly.
 Prevent interior and body paint from being scratched, when removing A-pillar lower protector assembly.
1. Remove the front door opening weatherstrip (See page 50-12).

2. Remove the front doorsill pressure plate assembly (See page 50-7).
3. Remove the left A-pillar lower protector assembly.
a. Remove 2 fixing screws (arrow) and hood grip.
RA13T500080
b. Remove the bolt (arrow) from A-pillar lower protector

assembly and remove the left A-pillar lower protector
assembly (1).
RA13T500090
4. Remove the right A-pillar lower protector assembly.

a. Remove the fixing bolt (arrow) from A-pillar lower
protector assembly.
50
RA13T500100

50 - INTERIOR
b. Using an interior crow plate, pry off the clip from A-

pillar lower protector assembly and remove the right
A-pillar lower protector assembly (1).
RA13T500101
Installation
CAUTION
 Make sure that damaged clips are replaced and A-pillar lower protector assembly is installed in place,
when installing A-pillar lower protector assembly.
 A-pillar lower protector assembly and front door opening weatherstrip should be fitted closely, after
installing A-pillar lower protector assembly.
50

50 - INTERIOR
B-pillar Lower Protector Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing B-pillar lower protector
assembly.
 Appropriate force should be applied, when removing B-pillar lower protector assembly. Be careful not to
operate roughly.
 Prevent interior and body paint from being scratched, when removing B-pillar lower protector assembly.
2. Remove the front left doorsill pressure plate assembly (See page 50-7).
4. Remove the rear left doorsill pressure plate assembly (See page 50-8).
5. Remove the left B-pillar lower protector assembly.
a. Using an interior crow plate, pry off the clip from B-
pillar lower protector assembly and remove the left B-
pillar lower protector assembly (1).
1
RA13T500111
Installation
CAUTION
 Make sure that damaged clips are replaced and B-pillar lower protector assembly is installed in place,
when installing B-pillar lower protector assembly.
 B-pillar lower protector assembly should be well fitted with front and rear doorsill pressure plate
assemblies, after installing B-pillar lower protector assembly.
 B-pillar lower protector assembly and front and rear door opening weatherstrips should be fitted closely, 50
after installing B-pillar lower protector assembly.

50 - INTERIOR
B-pillar Upper Protector Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing B-pillar upper protector
assembly.
 Appropriate force should be applied, when removing B-pillar upper protector assembly. Be careful not to
operate roughly.
 Prevent interior and body paint from being scratched, when removing B-pillar upper protector assembly.
6. Remove the left B-pillar upper protector assembly.
off the front seat belt assembly lower bolt cover
(arrow).
RA13T500120
b. Remove the fixing bolt (arrow) from the lower part of

front seat belt assembly.
50 RA13T500130

50 - INTERIOR

off the front seat belt assembly upper bolt cover
(arrow).
RA13T500150
d. Remove the front seat belt assembly upper bolt

(arrow) and B-pillar upper protector assembly.
RA13T500160
e. Using a screwdriver wrapped with protective tape, pry off fixing clip from B-pillar upper protector and
remove B-pillar upper protector.
Installation
CAUTION
 B-pillar upper protector assembly should be well fitted with B-pillar lower protector assembly and roof
headlining, after installing B-pillar upper protector assembly.
 B-pillar upper protector assembly and front and rear door opening weatherstrips should be fitted closely,
after installing B-pillar upper protector assembly.
50

50 - INTERIOR
C-pillar Lower Protector Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing C-pillar lower protector
assembly.
 Appropriate force should be applied, when removing C-pillar lower protector assembly. Be careful not to
operate roughly.
 Prevent interior and body paint from being scratched, when removing C-pillar lower protector assembly.

2. Remove the rear seatback assembly (See page 47-15).
5. Remove the left C-pillar lower protector assembly.
a. Remove 3 fixing screws (arrow) from left C-pillar lower
protector assembly.
off 2 circular clips from left C-pillar lower protector
assembly and remove left C-pillar lower protector
assembly (1).
1
RA13T500170
Installation
CAUTION
 Make sure that damaged clips are replaced and C-pillar lower protector assembly is installed in place,
when installing C-pillar lower protector assembly.
 C-pillar lower protector assembly should be well fitted with C-pillar upper protector assembly and rear
doorsill pressure plate assembly, after installing C-pillar lower protector assembly.
50  C-pillar lower protector assembly and rear door opening weatherstrip should be fitted closely, after
installing C-pillar lower protector assembly.

50 - INTERIOR
C-pillar Upper Protector Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing C-pillar upper protector
assembly.
 Appropriate force should be applied, when removing C-pillar upper protector assembly. Be careful not to
operate roughly.
 Prevent interior and body paint from being scratched, when removing C-pillar upper protector assembly.

3. Remove the left C-pillar lower protector assembly (See page 50-20).
4. Remove the rear left seat belt upper fixing bracket.
RA13T500181
5. Remove the rear left speaker cover assembly.

a. Remove 4 fixing screws from rear left speaker cover
assembly.
RA13T500182
b. Disconnect horn connector 5.

c. Remove the horn bracket assembly. 50

50 - INTERIOR
6. Remove the left C-pillar upper protector assembly.

a. Using an interior crow plate, pry off the clips from C-
pillar upper protector assembly.
b. Remove the left C-pillar upper protector assembly
RA13T500200
Installation
CAUTION
 Make sure that damaged clips are replaced and C-pillar upper protector assembly is installed in place,
when installing C-pillar upper protector assembly.
 C-pillar upper protector assembly should be well fitted with tonneau cover assembly and roof headlining,
after installing C-pillar upper protector assembly.
 C-pillar upper protector assembly and rear door opening weatherstrip should be fitted closely, after
installing C-pillar upper protector assembly.
50

50 - INTERIOR
Sun Visor Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing the sun visor assembly.
 Appropriate force should be applied, when removing sun visor assembly. Be careful not to operate
roughly.
 Try to prevent interior and roof from being damaged, when removing sun visor assembly.
1. Remove the left sun visor assembly.

a. Disengage one side of the sun visor assembly from
holder (1).
1
b. Remove 2 fixing screws (arrow) from sun visor 2
assembly and remove the left sun visor assembly (2).
RA13T500220
2. Remove the left sun visor holder.

a. Remove the fixing screw (arrow) from sun visor
holder.

off the left sun visor holder (1).
RA13T500230
Installation
50

50 - INTERIOR
Passenger Grip Assembly

Removal
HINT:
Use same procedures for rear left/rear right and front right sides.
Procedures listed below are for front right side.
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing passenger grip assembly.
 Appropriate force should be applied, when removing the passenger grip assembly. Be careful not to
operate roughly.
 Try to prevent interior and roof from being damaged, when removing passenger grip assembly.
1. Remove the front right passenger grip assembly.

loosen the passenger grip covers (arrow).
RA13T500240
b. Remove 2 fixing screws (arrow) from passenger grip

assembly, and remove the front right passenger grip
assembly (1).
RA13T500250
Installation
50

50 - INTERIOR
Roof Assembly
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing roof assembly.
 Appropriate force should be applied, when removing roof assembly. Be careful not to operate roughly.
 Try to prevent interior and body paint from being scratched, when removing roof assembly.

3. Remove the interior front dome light assembly.
remove the interior front dome light cover (1), (2) and
(3).
1
3 2
RA13T500260
b. Remove 3 fixing screws (arrow) from interior front

dome light assembly.
RA13T500270
c. Disconnect the interior front dome light connector

(arrow), and remove the interior front dome light
assembly (1).
50
RA13T500280
4. Remove the sun visor assembly (See page 50-23).

5. Remove the passenger grip assembly (See page 50-24).
7. Remove the rear door opening weatherstrip (See page 50-12).
8. Remove the A-pillar upper protector assembly (See page 50-14).

50 - INTERIOR
9. Remove the B-pillar upper protector assembly (See page 50-18).

10.Remove the C-pillar upper protector assembly (See page 50-21).
11. Remove the roof assembly.
a. Remove 6 clips (arrow) and roof asssembly.
RA13T500290
Installation
CAUTION
 Make sure that damaged clips are replaced and roof assembly is installed in place, when installing roof
assembly.
 Roof assembly and pillar upper protectors should be fitted closely, when installing roof assembly.
 Roof assembly and door opening weatherstrips should be fitted closely, after installing roof assembly.
50

50 - INTERIOR
Front Floor Carpet Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing front floor carpet assembly.
 Appropriate force should be applied, when removing front floor carpet assembly. Be careful not to
operate roughly.
 Try to prevent interior and body paint from being scratched, when removing front floor carpet assembly.

4. Remove the front seat assembly (See page 47-7).
8. Remove the rear door opening weatherstrip (See page 50-12).
9. Remove the rear doorsill pressure plate assembly (See page 50-8).
10.Remove the A-pillar lower protector assembly (See page 50-15).
11. Remove the B-pillar lower protector assembly (See page 50-17).
12.Loosen the lower part of front seat belt assembly (take left side as an example).
off the front seat belt assembly lower bolt cover
(arrow).
RA13T500120
b. Remove the fixing bolt (arrow) from the lower part of

front seat belt assembly and loosen the lower part of
front seat belt assembly.
50
RA13T500130

50 - INTERIOR
13.Remove the front floor carpet assembly.

a. Remove the fixing nut (arrow) from front left side of
front floor carpet assembly.
RA13T500300
b. Remove the fixing nut (arrow) from the front right side
of front floor carpet assembly and remove the front
floor carpet assembly.
RA13T500310
Installation
CAUTION
 Always pay attention to the flatness around front floor carpet assembly and the routing of relative body
wire harness, when installing front floor carpet assembly.
 Spread front floor carpet assembly along the bottom shape, with no obvious bumps and unevenness
found. Expose installation holes, and front floor carpet should be firmly abutted against the bottom.
50

50 - INTERIOR
Driver Side Foot Rest Bracket

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing driver side foot rest bracket.
 Appropriate force should be applied when removing driver side foot rest bracket. Be careful not to
operate roughly.
 Try to prevent interior and body paint from being scratched, when removing driver side foot rest bracket.

3. Remove the fixing nut from front left side of front floor carpet assembly (See page 50-28).
4. Remove the driver side foot rest bracket.
a. Lift a left corner of carpet assembly in the direction of
arrow.
RA13T500301
b. Remove the driver side foot rest bracket (arrow).
RA13T500303
Installation
50

50 - INTERIOR
Luggage Compartment Carpet Assembly

Removal
1. Remove the luggage compartment carpet assembly.
a. Pull down the rear seat in the direction of arrow as
RA13T500330
b. Fold the both side corners of luggage compartment

carpet in half.
RA13T500340
c. Lift up the band in center of the rear part of luggage

compartment carpet and remove the luggage
compartment carpet assembly by pulling it outward.
RA13T500341
Installation
CAUTION
 Make sure that the left and right sides of luggage compartment carpet are fitted in place, when installing
luggage compartment carpet assembly.
50  Adhesive strip and rear seat should be fitted closely, after installing luggage compartment carpet
assembly.

50 - INTERIOR
Tonneau Cover Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing tonneau cover assembly.
 Appropriate force should be applied, when removing tonneau cover assembly. Be careful not to operate
roughly.
 Try to prevent interior and body paint from being scratched, when removing tonneau cover assembly.
1. Remove the tonneau cover assembly.

a. Remove the adjuster rope (arrow) from two ends of
tonneau cover assembly.
b. Remove the fixing clips (1) from tonneau cover
assembly.
RA13T500360
c. Remove the tonneau cover assembly.
Installation
CAUTION
 Make sure that damaged clips are replaced and tonneau cover assembly is installed in place, when
installing tonneau cover assembly.
50

50 - INTERIOR
Luggage Compartment Wheel House Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing luggage compartment wheel
house assembly.
 Appropriate force should be applied, when removing luggage compartment wheel house assembly. Be
careful not to operate roughly.
 Try to prevent interior and body paint from being scratched, when removing luggage compartment wheel
house assembly.

4. Remove the luggage compartment weatherstrip (See page 50-13).
5. Remove the luggage compartment doorsill pressure plate assembly (See page 50-10).
6. Remove the rear left C-pillar lower protector assembly (See page 50-20).
7. Remove the rear left speaker cover assembly (See page 39-37).
8. Remove the luggage compartment wheel house assembly.
a. Remove the fixing screws (arrow) from luggage
compartment wheel house assembly.
RA13T500390
b. Remove 6 clips (arrow) from luggage compartment wheel house assembly and remove the luggage
compartment wheel house assembly (1).
Installation
50

50 - INTERIOR
Fuel Filler Door Cable Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing fuel filler door cable assembly.
 Appropriate force should be applied, when removing fuel filler door cable assembly. Be careful not to
operate roughly.
 Try to prevent interior and body paint from being scratched, when removing fuel filler door cable
assembly.

5. Remove the left A-pillar lower protector assembly (See page 50-13).
7. Remove the rear doorsill pressure plate assembly (See page 50-8).
10.Remove the luggage compartment wheel house assembly (See page 50-32).
11. Remove the fuel filler door cable assembly.
a. Remove 2 fixing screws (arrow) from fuel tank cap
opener assembly.
RA13T500400
b. Disengage the fuel tank cap cable from slot (arrow) to

separate the fuel tank cap cable from fuel tank cap
opener assembly.
50
RA13T500401

50 - INTERIOR
c. Cut off the wire harness band.
RA13T500410
d. Press the claws in the direction of arrow as shown in

the illustration, and remove the fuel filler door cable
assembly.
RA13T500419
Installation
CAUTION
 Check that fuel filler door can open normally, after installing fuel filler door cable.
50

SLIDING ROOF
Description 51-3 Sliding Roof Glass 51-10
Tool 51-4 Sliding Roof Bracket 51-11
Circuit Diagram 51-5 Removal 51-11
Installation 51-12
Sliding Roof Visor Assembly 51-13
Initialization 51-6
Removal 51-13
Problem Symptoms Repair 
Installation 51-13
Procedures 51-7
Sliding Roof Motor and Control Unit 
ON-VEHICLE SERVICE 51-9 Assembly 51-14
Sliding Roof Switch Assembly 51-9 Removal 51-14
51

51

51 - SLIDING ROOF
GENERAL INFORMATION
SLIDING ROOF
Description
3
×10
4
6
5
×4 8
RA13T510010
1 - Sliding Roof Glass 2 - Sliding Roof Visor

3 - Sliding Roof Bracket 4 - Sliding Roof Control Unit Assembly
5 - Sliding Roof Seat 6 - Sliding Roof Motor
51
7 - Sliding Roof Front Drain Hose 8 - Sliding Roof Rear Drain Hose

51 - SLIDING ROOF
Operation
By using principle of hydromechanics, sliding roof unit draws out turbid gas from vehicle to fully exchange air.
In hydromechanics research filed, experiments showed that pressure acting on tube wall from fluid is low at
high flow velocity, and pressure is high at low flow velocity. As roof cover has a certain radian, during high
speed driving, the speed of outside airflow is high when it passes through roof cover. Pressure from outside
airflow to roof cover is lower than pressure from inside airflow to roof cover. Inside air flows out to outside of
vehicle, pressure becomes lower, then outside fresh air supplements into vehicle. Thus, inside air is circulated
and fresh air is kept inside the vehicle.
Function
It has functions of enhancing aesthetics, broadening horizon, increasing lighting, economy and practicability,
beautifying car image, and it functions as movable window.
Specifications

Sliding Roof Switch Assembly Fixing Screw 1.5 ± 0.5
Sliding Roof Glass Fixing Bolt 5±1
Sliding Roof Bracket Fixing Bolt 14 ± 0.5
Tool
General Tool
Digital Multimeter
RCH0000002
51

51 - SLIDING ROOF
Circuit Diagram
IGNITION SEITCH
BATTERY
ON OR ACC
ENGINE
IP FUSE
COMPARTMENT
EF17 RF26 AND RELAY
FUSE AND
BOX
25A RELAY BOX 10A
I-032
E-067
66 55
RL
P
I-003
8
E-030 C-001
1
GW
I-036
5
P
FRONT
ROOM
I-003 LIGHT
1 C-001 C-003
3 4
P
OB
Gr
1 6 5
SUNROOF
MODULE
C-002
3 4 2
Br
B
W
C-001
3 4 2 I-003
Br
7 B18
INSTRUMENT
BCM (B)
CLUSTER I-005
I-034
I-011
9 8 7 6 5 4 3 2 1
1 2 3 4 5 1 2 3
18 17 16 15 14 13 12 11 10 1 2 3 4 5 6
6 7 8 9 10 4 5 6
I-036 C-002 C-003

B I-003 W W
W
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
51
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24
I-034
W
I-011
L EA13T510010

51 - SLIDING ROOF
DIAGNOSIS & TESTING

Initialization
Sliding roof initial position losing
Definition: A situation that sliding roof cannot be opened, closed normally or closed to a normal position, and
initial movement for sliding roof cannot be performed. When there is such problem in sliding roof, movement
process for sliding roof will be disordered.
Problem Symptom
1. Sliding roof cannot be closed and opened completely or tilted. Shuddering may occur during the process
from tilt to close.
2. When opening, tilting or closing sliding roof, it cannot reach to initial set position.
3. A function that short pressing the button to open and close sliding roof cannot be performed.
4. Sliding roof operation cannot be controlled by sliding roof module.
Solution Method
Perform repair according to following procedures with sliding roof mechanical fault repaired, and make sure
that power supply shall not be shut off and battery voltage is higher than 10 V during operation. Make sure
that there is no hard matter (all obstacles) which blocks operation of sliding mechanism before repairing.
Make sure that problem symptom occurred in sliding roof is among four problem symptoms listed above.
1. Module initial memory position recovering method (pay attention that pressing way and pressed button)
1st step: Open sliding roof visor to the maximum position.
2nd step: Press and hold sliding roof ON/OFF button (be sure button is correct) for 10 seconds with sliding
roof fully closed, and sliding roof initialization is complete when a "click" sound is heard from sliding roof
motor.
3rd step: Adjust sliding roof after completing above procedures, and replace module or motor if symptom
still cannot be solved.
CAUTION
 After replacing sliding roof motor, sliding roof module, sliding roof assembly or if entire vehicle power is
cut off, perform sliding roof initialization procedures.
51

51 - SLIDING ROOF
Problem Symptoms Repair Procedures

Problem Cause Repair Operation Method
Water leakage Drain hose is clogged or Check condition of drain hose.
folded
Weatherstrip is damaged with Replace sliding roof glass assembly
poor seals to ensure sealing performance.
Abnormal noise Dust enters during sliding roof Clean sliding roof rail during vehicle
operation, causing a large maintenance to reduce movement
movement resistance of resistance of sliding roof, ensuring
sliding roof normal operation.
Apply grease to movement
Grease in sliding roof rail is
mechanism of sliding roof during
reduced, causing insufficient
vehicle maintenance to soften
lubrication
sliding roof effectively.
Jam protection function fault When Slide/Tilt button is •Check if P5 or P6 voltage on ECU
pressed, sliding roof cannot side is high (battery voltage), if not,
return automatically if it check Tilt/Slide operation signal
encounters an obstacle circuit; Check the operation button.
Ignition key function fault •Check if P4 voltage on ECU side is
low (0 V), if not, check if igniter is in
an effective position; Check state
signal circuit and wire harness of
igniter.
Sliding roof does not close
automatically after removing •Check if P4 voltage on ECU side is
ignition key for a certain low (0 V), if it is, the ECU or sliding
amount of time roof mechanism is malfunctioning if
relay operation sound is heard after
a period of time; if relay operation
sound is not heard after a period of
time, the ECU is malfunctioning,
replace it.
•Sliding roof opens automatically
during operation, and repeats for
Sliding roof does not close
several times. Sliding roof resistance
automatically in place after
is large, please remove dust or apply
removing ignition key for a
lubricant; Sliding roof mechanism is
certain amount of time
deformed, replace sliding roof fixing
bracket.
•Check if P4 voltage on ECU side is
Sliding roof can be operated
low (0 V), if not, check state signal
without ignition key in effective
circuit and wire harness of ignition
position
key.
51

51 - SLIDING ROOF
Problem Cause Repair Operation Method

•If sliding roof moves slightly or relay
operation sound can be heard
without any sliding roof movement
when Slide or Tilt button is pressed
Mechanical fault with ignition key in effective position,
replace sliding roof fixing bracket.
(Regardless of sliding roof fixing
bracket, perform initialization of the
sliding roof)
•Power supply circuit is fault. Check
drive circuit fuse; Check sliding roof
No drive power is applied
power supply circuit and wire
harness.
•Check if P4 voltage on ECU side is
high (battery voltage), if not, check if
ignition key is in an effective
position; Check state signal circuit
and wire harness of ignition key.
•With ignition key in effective
position, long press Tilt button to
check if P5 voltage on ECU side is
No control signals high (battery voltage), if not, check
Tilt state signal circuit; Check the
operation button.
Sliding roof does not operate position, long press Slide button to
check if P6 voltage on ECU side is
high (battery voltage), if not, check
Slide state signal circuit; Check the
operation button.
position, long press Tilt and Slide
buttons respectively, to check if P5
ECU failure
and P6 voltage on ECU side is high
(battery voltage), if not, replace
ECU.
•Check if sliding roof is in full-tilted/
fully open position, and if full-tilted/
fully open does not response to
operation.
•Long press Tilt button to check if
P5/P6 voltage on ECU side is high
Tilt/Slide button operation has (battery voltage), if not, check Tilt/
no response or acts partially Slide status signal circuit; Check the
with no response operation button.
•Briefly press Tilt/Slide button to
51 check if P1 voltage is in effective
range of 9~16 V immediately after
sliding roof moves, if not, replace or
recharge battery; check voltage drop
of wire harness and connector.

51 - SLIDING ROOF
ON-VEHICLE SERVICE
Sliding Roof Switch Assembly
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing sliding roof switch assembly.
 Appropriate force should be applied when removing sliding roof switch assembly. Be careful not to
operate roughly.

3. Remove the sliding roof switch assembly (See page 50-25).
Installation
51

51 - SLIDING ROOF
Sliding Roof Glass

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing sliding roof glass.
 Appropriate force should be applied when removing sliding roof glass. Be careful not to operate roughly
to prevent sliding roof from being damage.
HINT:
Before removing sliding roof glass, press sliding roof switch to open the roof to full-tilted position.
1. 1.Turn off all electrical equipment and the ignition switch.
3. Remove the sliding roof glass.
a. Remove 2 fixing bolts (arrow) from left side of sliding
roof glass.
RA13T510020
b. Remove 2 fixing bolts (arrow) from right side of sliding

roof glass.
RA13T510030
c. Remove the sliding roof glass.
Installation
CAUTION
51  The flatness tolerance between front part of roof glass and top roof is 1 ~ -2 mm.
 The flatness tolerance between rear part of roof glass and top roof is -1 ~ 2 mm.
 The flatness tolerance between side part of roof glass and top roof is -1.5 ~ 1.5 mm.
 Check the open and close operations of roof after installation to ensure that there is no abnormality.

51 - SLIDING ROOF
Sliding Roof Bracket

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing sliding roof bracket.
 Appropriate force should be applied when removing sliding roof bracket. Be careful not to operate
roughly.

3. Remove the sliding roof glass (See page 51-10).
4. Remove the sliding roof bracket.
a. Remove 2 clamps (1) from sliding roof left drain hose
and sliding roof drain hose joint, and then remove 3
fixing bolts (arrow).
1
RA13T510050
b. Remove 2 clamps (1) from sliding roof right drain hose

and sliding roof drain hose joint, and then remove 3
fixing bolts (arrow).
1
RA13T510060
c. Remove 3 fixing bolts (arrow) from front part of sliding

roof bracket.
RA13T510070
51
d. Remove the sliding roof bracket.

51 - SLIDING ROOF
Installation
CAUTION
 Make sure that the open and close operations of sliding roof have no any abnormal noise and resistance,
after installing sliding roof bracket.
 Make sure sliding roof drain joint is installed in place and there is no any water leakage, after installing
sliding roof bracket.
51

51 - SLIDING ROOF
Sliding Roof Visor Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing sliding roof visor assembly.
 Try to prevent sliding roof visor assembly from being scratched or damaged, when removing sliding roof
visor assembly.

4. Remove the sliding roof visor assembly.
a. Remove 2 fixing bolts (arrow) from right end of sliding
roof visor assembly.
RA13T510080
5. Move sliding roof visor assembly in direction of arrow to

remove it.
RA13T510090
Installation
CAUTION
 Sliding roof visor should be wrapped firmly without any looseness and wrapping force of spring should be
adjusted properly, when installing sliding roof visor assembly.
 After installing sliding roof visor assembly, sliding roof visor should return automatically once opened and 51
be wrapped and pulled freely.

51 - SLIDING ROOF
Sliding Roof Motor and Control Unit Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents, when removing sliding roof motor and control
unit assembly.
 Try to prevent sliding roof motor and control unit assembly from being damaged during removal.

3. Remove the sliding roof bracket (See page 51-11).
4. Remove the sliding roof motor assembly.
a. Remove 4 fixing bolts (arrow) from sliding roof motor.
RA13T510091
b. Remove the sliding roof motor assembly.

5. Remove the sliding roof control unit assembly.
a. Cut off 2 fixing bands (arrow) from control unit, and
unplug connector (1).
1
RA13T510093
b. Remove the sliding roof control unit assembly.
Installation
CAUTION
51
 Tighten fixing bolts in place and fix band securely to avoid looseness, when installing sliding roof motor
and control unit assembly.
 Make sure no abnormal noise occurs between motor tooth and steel wire, after installing sliding roof
motor.

BODY DIMENSIONS
GENERAL INFORMATION 52-3 Body Frame Dimensions 52-9
Description 52-3 Body Assembly Dimensions 52-12
Body Opening Dimensions  Body Movable Part Dimensions 52-13
(Front View) 52-4 Clearance between body A-pillar 
Body Opening Dimensions  hinges 52-14
(Side View) 52-6 Clearance between body B-pillar 
Body Opening Dimensions  hinges 52-15
(Rear View) 52-7
52

52

52 - BODY DIMENSIONS
GENERAL INFORMATION
BODY DIMENSIONS
Description
 All measurements should be made from the bare metal. Remove the trim and bumper covers as
necessary.
 Repair the badly damaged areas before taking measurements for underbody alignment.
 Monitor the upper body structure for excessive stress or movement while making any corrections to the
underbody structure.
 Remove all the necessary glasses to prevent breakage.
 All dimensions are shown in millimeters (mm).
52

Body Opening Dimensions (Front View)
B D
A C
RA13T520010
Dimension Number Standard Value (mm)

A 1089.39 ± 2
B 1409.2 ± 2
C 179.1 ± 2
D 682.77 ± 2
E 737.70 ± 2
52

A1 A1
B1
B2
RA13T520013

A1 1346.2
A2 1346.2
B1 1291.5
B2 1277
52

Body Opening Dimensions (Side View)
F E D
A B
RA13T520020

A 827.4 ± 1
B 896 ± 1
C 1009.8 ± 2
D 1416 ± 2
E 1093.5 ± 2
F 1264 ± 2
52

Body Opening Dimensions (Rear View)
RA13T520030

A 882 ± 2
B 2408 ± 2
52

A1 A2
RA13T520033

A1 1195 ± 2
A2 1195 ± 2
52

Body Frame Dimensions
RA13T520035

A 1363 ± 2
B 1337 ± 2
52

RA13T520037

C 1101 ± 2
D 998 ± 2
52

A B C
a b c
RA13T520040
Description:
Point A — a: Front suspension set position;
Point C — c: Rear towing arm set position;
Point D — d: Rear damper spring set position
Measurement Area Standard Value (mm)

Between A and a 913.25 ± 1
Between B and b 1200 ± 1
Between A and B 703 ± 1
Between B and C 2124 ± 1.5
Between B and c 2261 ± 2
Between C and c 880 ± 1.5
Between C and D 875 ± 1.5
Between C and d 1306 ± 1.5
Between D and d 1047 ± 1.5
52

Body Assembly Dimensions

1. Gap is indicated by the standard distance measurement symbol .
2. Flush measurement method and instructional symbol description:
a. Reference surface is indicated by .
b. Pointed surface is indicated by .
c. If the level is higher than the reference surface, the number is positive, whereas negative.
52

Body Movable Part Dimensions
A B C D E F
RA13T520070
Dimension Number Standard Value (mm) Note

A 4 ± 1.0 //1.0
B 6.0 ± 1.5//2.0 Including side slirt protector
C ± 1.0//1.0
D 6.0 ± 1.5//2.0 Including side slirt protector
E 4.0 ± 1.0//1.0
F 7.0 ± 1.5//1.5 Including back door spoiler
52

Clearance between body A-pillar hinges
RA13T520071

A 323.4 ± 0.5
52

Clearance between body B-pillar hinges
RA13T520073

B 285.2 ± 0.5
52

- MEMO -

CAN COMMUNICATION
GENERAL INFORMATION 53-3 Diagnosis Tools 53-8
Description 53-3 Diagnostic Help 53-8
Operation 53-3 Intermittent DTC Troubleshooting 53-8
Tools 53-3 Ground Inspection 53-9
Circuit Diagram 53-5 Diagnosis Procedure 53-9
Diagnostic Interface cannot 
DIAGNOSIS & TESTING 53-7 Connect to System 53-10
53

53

53 - CAN COMMUNICATION
GENERAL INFORMATION
CAN COMMUNICATION
Description
This vehicle is equipped with CAN bus. CAN bus is a kind of fieldbus, and a serial communication network
which supports distributed control system effectively. It mainly consists of CAN controller, CAN transceiver,
data transmission line and data transmission terminating resistor. BCM, diagnostic interfaces, audio, radar
control module, IC, TCU, ECM, ABS/ESP, SAS, SRS are connected via CAN bus, CAN controller and CAN
transceiver are integrated into electronic control unit. Terminating resistors are respectively integrated into IC,
BCM and ECM, forming CAN bus with the IC and BCM as terminating resistors, the ECM and BCM drive CAN
bus as terminating resistors.
Operation
CAN bus is also called vehicle bus, and full name is "Controller Area Network" which means local area
network, it connects all control units together in some way to form a complete system. Each control unit
collects different signals by each sensor, and transmits data between modules under the same rules. Network
information can be priority to meet different real-time requirements. Data transmitted via CAN bus control unit
is level model of binary format, and data transmission line transmits the voltage signal.
Tools
Special Tools
ཽ⪔⊳䖜
RCH0000001
ESC
NO
1 2 3 4 5
6 7 8 9 0
RCH0000061
53

General Tool
Digital Multimeter
RCH0000002
53

Circuit Diagram
CAN Bus
BATTERY
R
ENGINE
COMPARTMENT
MF05 FUSE AND IP FUSE
RELAY BOX AND
40A RF15
E-067 RELAY BOX
E-063 7.5A I-032
E-028
R 40
R
16
DIAGNOSTIC
INTERFACE BCM (B)
I-033 I-034
CAN2-L CAN2-H
CAN2-H CAN2-L B2 B15
3 11 4 5
B
G
Y
B
G
CAN2-L CAN2-H
I-004
Y C7
AUDIO (C)
G C1 I-016
G
Y
CAN2-L CAN2-H
CAN2-H CAN2-L
RADAR 5 G G G 30 INSTRUMENT
CONTROL 6
CLUSTER
MODULE 13 Y Y Y 29
5 I-011
B-004
B-019 I-002
16 15 14 13 12 11 10 9 C6 C5 C4 C3 C2 C1
I-033 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034 I-016
8 7 6 5 4 3 2 1 B B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W C12 C11 C10 C9 C8 C7 L
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I-011
1 2 3 4 5 6 7 8 B-004 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 L
9 10 11 12 13 14 15 16 W
53
EA13T530010

ECM(A) E-041
CAN1-L CAN1-H
CAN1-L CAN1-H
CAN1-H CAN1-L
A23 A11
32 G G 14
TCU ESP
E-069 31 Y Y 2 E-051
G
Y
E-054
6 5
I-018
CAN1-H CAN1-L
CAN1-L CAN1-H
STEERING 1 Y Y 2
SRS CONTROL
ANGLE
MODULE
SENSOR 2 G G 17
I-020
I-028
G
Y
CAN1-L CAN1-H
CAN1-H CAN1-L
INTERFACE BCM (B)
I-033 G G B16 I-034
6
1 2 3 4 5 6 7 8 9 10 41 42
11 12 13 14 15 16 17 18 19 20 43 44 E-069
21 22 23 24 25 26 27 28 29 30 45 46 B
31 32 33 34 35 36 37 38 39 40 47 48
A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37 E-041
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
B
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I-020

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 Gr
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 I-034

B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24 W
E-051 16 15 14 13 12 11 10 9
12 11 10 9 8 7 6 5 4 3 2 I-033
13 1
B 8 7 6 5 4 3 2 1 B
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
4 3 E-054 6 5 4 3 2 1 I-028
2 1
W B
10 9 8 7 6 5
EA13T530020
53

DIAGNOSIS & TESTING

CAN bus 53-5
Diagnostic interface cannot BCM failure 46-18

connect to system Instrument cluster failure 38-49
ECM failure 55-35
CAN bus 53-5
Battery voltage 55-41
Engine control system failure
Module damage -
Ground cable 55-44
Wheel speed 25-95
Brake control system failure Wire harness or connector 55-44
Airbag system failure
Airbag module failure 31-45
46-18
failure
Body electrical failure
Turn signal light switch (steering
35-79
switch)
Immobilizer system failure
Immobilizer control module failure 33-24
Transmission Control Unit (TCU)
18-89
failure
Transmission failure Wire harness or connector 55-44

Sensor failure -
53

Diagnosis Tools
with vehicle.
 DLC is located at driver side instrument panel crossmember.
Digital Multimeter
Oscilloscope
 Measure the CAN network output waveform.
Diagnostic Help
1. Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC), and make it
3. If DTC cannot be deleted, malfunction is current.
7. Check and clean all DVD system grounds related to the latest DTC.

 Inspect the mounting areas of instrument cluster, wire harness or wire harness connector and so on for
 Check and clean all wire harness connectors and grounds related to DTC.
 Remove instrument cluster from malfunctioning vehicle, and install it to a new vehicle and perform a test. If
DTC cannot be cleared, instrument cluster is malfunctioning. If DTC can be cleared, reinstall instrument
cluster to original vehicle.
53  If multiple trouble codes were set, refer to circuit diagrams to look for any common ground circuit or power

Ground Inspection
(rust) and oxidation may increase load resistance. This situation will seriously affect normal operation of
circuit. Check ground points as follows:
Diagnosis Procedure
HINT:
Use following procedures to troubleshoot the power door lock control system.
NEXT
If voltage is below 11 V, recharge or replace battery
NEXT
NEXT
DTC
occurs
NO
DTC

53
NEXT

NEXT
NEXT
NEXT
10 End
Diagnostic Interface cannot Connect to System

CAN-H Open to Ground
CAN-L Open to Ground
ECU Internal Open
BCM Internal Open
Instrument Cluster Internal Open
a. Using a digital multimeter, measure voltage between

positive battery terminal and negative battery terminal.
b. Battery voltage should be between 11 and 14 V.
OK Check battery terminal
NEXT
OK Check fuse
53

NEXT
3 Check fuse
a. Check if engine compartment fuse box RF15 10A fuse is

blown.
NG Replace fuse
OK Check BCM
NEXT
4 Check BCM
a. Disconnect the Body Control Module (BCM) connector I-

034.
b. Using ohm band of multimeter, measure resistance
between connectors I-034 (B2) and I-034 (B15) (standard
resistance is 120 Ω).
Normal Condition
+ -
Digital Specified
Condition
EI-034 (B2) - Ignition switch
120 Ω
I-034 (B15) OFF
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
I-034
RA13T530010
RM1A370500
c. Using ohm band of multimeter, measure resistance

between connectors I-034 (B3) and I-034 (B16) (standard
Normal Condition
+ -
Digital Specified
Condition
EI-034 (B3) - Ignition switch
120 Ω
I-034 (B16) OFF
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
NG Replace BCM I-034
OK Check instrument cluster

53
RA13T530020
RM1A370500

NEXT
5 Check instrument cluster
a. Disconnect the instrument cluster connector I-001.

between connectors I-011 (29) and I-011 (30) (standard
Normal Condition
+ -
Digital Specified
Condition
I-011 (29) - I-011 Ignition switch
120 Ω
(30) OFF 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
NG Replace instrument cluster assembly

I-011
OK Check ECM
RA13T530030
RM1A370500
NEXT
6 Check ECM
a. Disconnect the Engine Control Module (ECM) connector

E-041.
between connectors E-041 (A23) and E-041 (A11)
(standard resistance is 120 Ω).
Normal Condition
+ -
Digital Specified
Condition
Multimeter Condition A56 A55 A54 A53 A52 A51 A50 A49
E-041 (A23) - Ignition switch A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
120 Ω A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
E-041 (A11) OFF A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
NG Replace ECM
OK Check CAN network resistance

E-041
RA13T530040
RM1A370500
NEXT
53

7 Check CAN network resistance
a. Using an ohmmeter, measure resistance between

connectors I-033 (3) and I-033 (11) (standard resistance
is 60 Ω).
b. Using an ohmmeter, measure resistance between
connectors I-033 (6) and I-033 (14) (standard resistance + -
is 60 Ω).
Normal Condition
16 15 14 13 12 11 10 9
Digital Specified 8 7 6 5 4 3 2 1
Condition
Multimeter Condition I-033

60 Ω
(11) OFF
60 Ω
(14) OFF
RA13T530050
RM1A370500
OK Check connector
NEXT
8 Check BCM and connector

c. Disconnect the Body Control Module (BCM) connector I-
034. + -
d. Check for continuity between connectors I-034 (B2) and
I-033 (11), and connectors I-034 (B15) and I-033 (3).
Normal Condition B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
Digital Specified I-034

Condition
I-034 (B2) - I-033 Ignition switch
Continuity 16 15 14 13 12 11 10 9
(11) OFF 8 7 6 5 4 3 2 1
I-034 (B15) - Ignition switch I-033

Continuity
I-033 (3) OFF
I-034 (B3) - I-033 Ignition switch RA13T530060
RM1A370500
Continuity
(14) OFF
I-034 (B16) - Ignition switch
Continuity
I-033 (6) OFF
NG Replace instrument panel wire harness 53

OK Check connector and instrument cluster

NEXT
9 Check connector and instrument cluster
a. Disconnect the instrument cluster connector I -011.

b. Check for continuity between connectors I-033 (3) and I-
011 (30), and connectors I-033 (11) and I-011 (29).
Normal Condition
+ -
Digital Specified
Condition
Multimeter Condition 16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
I-033 (3) - I- Ignition switch
Continuity
011(30) OFF I-033
I-033 (11) - I- Ignition switch

Continuity
011(29) OFF
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
OK Check audio and connector

I-011
RA13T530070
RM1A370500
NEXT
10 Check audio and connector
a. Disconnect the audio system connector I-016.

016 (C1), and connectors I-033 (11) and I-016 (C7).
Normal Condition + -
Condition
I-033
Continuity
(C1) OFF
Continuity
(C7) OFF C6 C5 C4 C3 C2 C1
C12 C11 C10 C9 C8 C7
NG Replace instrument panel wire harness I-016
OK Check radar module and connector

RA13T530080
RM1A370500
NEXT
53

11 Check radar module and connector
a. Disconnect the reversing radar module connector B-004.

b. Check for continuity between connectors I-033 (3) and B-
004 (5), and connectors I-033 (11) and B-004 (13).
Condition
I-033
I-033 (3) - B-004 Ignition switch
Continuity
(5) OFF
I-033 (11) - B-004 Ignition switch
Continuity
(13) OFF 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
NG Replace instrument panel wire harness B-004
OK Check airbag module

RA13T530090
RM1A370500
NEXT
12 Check airbag module
a. Disconnect the SRS control module connector I-020.

16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
Digital Specified
Condition

Continuity
(2) OFF
I-033 (6) - I-020 Ignition switch 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Continuity
(17) OFF 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17

I-020
OK Check ESP control module

RA13T530100
RM1A370500
NEXT
53

13 Check ESP control module
a. Disconnect the ABS/ESP control module connector E-

051.
b. Check for continuity between connectors I-033 (14) and
E-051 (2), and connectors I-033 (6) and E-051 (14).
+ -
Normal Condition 16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
Digital Specified I-033

Condition
I-033 (14) - E-051 Ignition switch
Continuity
(2) OFF 13
12 11 10 9 8 7 6 5 4 3 2
1
24 23 22 21 20 19 18 17 16 15 14
I-033 (6) - E-051 Ignition switch 25

Continuity
38 37 36 35 34 33 32 31 30 29 28 27 26
(14) OFF
NG Replace instrument panel wire harness E-051
RA13T530110
RM1A370500
OK Check TCU module and connector
NEXT
14 Check TCU module connector E-069
a. Disconnect the TCU connector E-069.

b. Check for continuity between connectors I-033 (14) and
E-069 (31), and connectors I-033 (6) and E-069 (32).
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
Digital Specified
Condition
I-033 (14) - E-069 Ignition switch

Continuity
(31) OFF 1 2 3 4 5 6 7 8 9 10 41 42
I-033 (6) - E-069 Ignition switch 11 12 13 14 15 16 17 18 19 20 43 44

Continuity 21 22 23 24 25 26 27 28 29 30
(32) OFF 45 46
31 32 33 34 35 36 37 38 39 40 47 48
NG Replace body wire harness E-069
OK Check steering angle sensor

RA13T530120
RM1A370500
NEXT
53

15 Check steering angle sensor and connector
a. Disconnect the steering angle sensor connector I-028.

9
Digital Specified 16 15 14 13 12 11 10
Condition
I-033
Continuity
(1) OFF
Continuity 6 5 4 3 2 1
(2) OFF
I-028
NG Replace body wire harness
RA13T530130
RM1A370500
OK
End
53

CAN Network Short

 CAN-H Short to Ground
 CAN-L Short to Ground
 CAN-H Short to Power Supply
 CAN-L Short to Power Supply
 Short Between CAN-H and CAN-L
Problem causes:
 BCM internal short circuit
 Instrument cluster internal short circuit
 ECM internal short circuit
 Short circuit between CAN-H and CAN-L
1 Check connector
a. Connect oscilloscope to terminals 3, 11 of diagnostic

interface connector I-033, and observe waveform of
oscilloscope (standard for CAN-H: 2.5 V to 3.5 V,
standard for CAN-L: 1.5 V to 2.5 V).
NG Check BCM
YES ENTER
ESC
NO
1 2 3 4 5
6 7 8 9 0
OK Check instrument panel wire harness

16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
I-033
RA13T530140
NEXT
53

2 Check BCM
a. Connect the Body Control Module connector I-034.

b. Connect oscilloscope to terminals B3, B16 of body
control module connector I-034, and observe waveform
(standard for CAN-H: 2.5 V to 3.5 V, standard for CAN-L:
1.5 V to 2.5 V). YES
NO
1 2 3 4
ENTER
ESC
5
6 7 8 9 0
NG Check instrument cluster
OK Replace BCM B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12

B13 B14 B15 B16 B17 B18 B19 B20 B21B22 B23 B24
I-034
RA13T530150
NEXT
3 Check instrument cluster
a. Connect the instrument cluster connector I-011.

b. Connect oscilloscope to terminals 29, 30 of instrument
cluster connector I-011, and observe waveform (standard
for CAN-H: 2.5 V to 3.5 V, standard for CAN-L: 1.5 V to
2.5 V).
NG Check ECM
YES ENTER
ESC
NO
1 2 3 4 5
6 7 8 9 0
OK Replace instrument cluster
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-011
RA13T530160
NEXT
53

4 Check ECM
a. Connect the ECM connector E-041.

b. Connect oscilloscope to terminals A23, A11 of ECM
connector E-041, and observe waveform (standard for
CAN-H: 2.5 V to 3.5 V, standard for CAN-L: 1.5 V to 2.5
V).
NG Check audio module

YES ENTER
ESC
NO
1 2 3 4 5
6 7 8 9 0
OK Replace ECM A56 A55 A54 A53 A52 A51 A50 A49
A48A47 A46 A45 A44 A43 A42 A41A40 A39 A38A37
A36 A35A34 A33 A32 A31A30 A29 A28A27 A26 A25
A24 A23 A22 A21 A20 A19 A18 A17A16A15 A14 A13
A12 A11A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
E-041
RA13T530170
NEXT
5 Check audio module
a. Disconnect the audio module connector.
OK Replace audio module
NG Check steering angle sensor
NEXT
6 Check steering angle sensor
a. Disconnect the steering angle sensor connector.
OK Replace steering angle sensor
NG Check TCU
NEXT
7 Check TCU
a. Disconnect the TCU connector.
53 OK Replace TCU module
NG Check ESP module

NEXT
8 Check ESP module
a. Disconnect the ESP module connector.
OK Replace ESP module
NG Check reversing radar module connector
NEXT
9 Check reversing radar module connector
a. Disconnect the reversing radar module connector.
OK Replace reversing radar module
NG Check airbag module
NEXT
10 Check airbag module
a. Disconnect the airbag module connector.
OK Replace airbag module
NG Check steering angle sensor
NEXT
11 Check steering angle sensor
a. Disconnect the steering angle sensor connector.
OK Replace steering angle sensor
NEXT
End
53

- MEMO -

MATCHING
ENGINE IMMOBILIZER SYSTEM 54-3 Throttle Self-learning 54-20
Matching Engine Immobilizer 
STEERING ANGLE SENSOR 
System After ECM Replacement 54-3
MATCHING AND YAW RATE 
Matching Engine Immobilizer 
SENSOR MATCHING 54-21
System After BCM Replacement 54-5
Calibration 54-21
WIRELESS KEY MATCHING 54-9
STALL TEST 54-25
TIRE PRESSURE SELF-LEARNING 54-11
LANGUAGE SWITCHING (DVD) 54-26
Configuration & Learning for Tire 
Pressure Monitoring System 54-11 CONFIGURATION CODE READING 54-27
FLYWHEEL SELF-LEARNING 54-18 BCM Configuration Code Reading 54-27
Flywheel Self-learning 54-18 ICM Configuration Code Reading 54-28
A13T Configuration Code Reading 54-29
SUNROOF INITIALIZATION 
LEARNING 54-19 MAINTENANCE MILEAGE RESET 54-31
Initialization 54-19 Maintenance Mileage Reset 
(Manual) 54-31
Sliding Roof Initial Position Losing 54-19
Maintenance Mileage Reset 
ELECTRONIC THROTTLE  (Diagnostic Tester) 54-31
SELF-LEARNING 54-20
54

54

54 - MATCHING
ENGINE IMMOBILIZER SYSTEM

MATCHING
Matching Engine Immobilizer System After ECM Replacement

to Data Link Connector (DLC), and make it communicate Menu
Then select corresponding model (A13T) on X-431 3G ABS
and select IMMO system. BCM
ICM
PEPS
IMMO
AT
RA13T540300
2. Please select [After sale function] on SELECT

Read fault code
Erase fault code
Read data stream
Write data
After sale function
RA13T540310
3. Please select [Programming ECM] on screen.

After sale function
Programming ECM
Reprogramming ECM
Reprogramming IMMO
Key match
Erase keys
RA13T540320
4. Enter VIN code with 17 digits.

Input
XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RA13T540330
54

54 - MATCHING
5. When "Write VIN succeeded!!" is displayed on Write VIN

screen, and click "OK". Write VIN
Write VIN Succeeded !!
OK
RA13T540340
6. When "Please enter a PIN with 8 digits" is displayed on

Input screen, enter PIN code and click "OK". Input
XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RA13T540350
7. When "Please enter again" is displayed on Input screen,

enter PIN code and click "OK". Input
Please enter again.
XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RA13T540360
8. When "Succeeded to program ECM" is displayed on

Programming ECM screen, click "OK". Programming ECM
Succeeded to program ECM!
OK
RA13T540370
9. Programming ECM is completed.

After matching is completed, turn ignition switch to OFF, disconnect diagnostic tester and wait for
approximately 10 seconds, then turn ignition switch to ON and wait for approximately 10 seconds so that
system certification is successful.
54

54 - MATCHING
Matching Engine Immobilizer System After BCM Replacement

ICM
PEPS
IMMO
AT
RA13T540380

Read fault code
Erase fault code
Read data stream
Write data
After sale function
RA13T540390
3. Please select [Programming IMMO(learn SK from EMS)]

on screen. After sale function
Programming ECM
Reprogramming ECM
Reprogramming IMMO
Key match
Erase keys
RA13T540400
4. Enter VIN code with 17 digits.

Input
XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RA13T540330
54

54 - MATCHING

XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RA13T540350

enter PIN code again and click "OK". Input
Please enter again.
XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RA13T540360
7. When "Succeeded to program IMMO!" is displayed on

Programming IMMO(learn SK from EMS) screen, click Programming IMMO(learn SK from EMS)
"OK".
Succeeded to program IMMO!
OK
RA13T540410
8. Programming IMMO is completed.
CAUTION
 After matching is completed, turn ignition switch to OFF, disconnect diagnostic tester and wait for
approximately 10 seconds, then turn ignition switch to ON and wait for approximately 10 seconds so that
system certification is successful. Perform operations of "Add the old keys" and "match wireless key" for
original key after replacing BCM.

ICM
PEPS
IMMO
54 AT
RA13T540420

54 - MATCHING

Read fault code
Erase fault code
Read data stream
Write data
After sale function
RA13T540430
3. Please select [Key match] on After sale function screen.

After sale function
Programming ECM
Reprogramming ECM
Reprogramming IMMO
Key match
Erase keys
RA13T540440
4. Please select [Add the old keys] on Perform routine

program screen. Perform routine program
Add new keys.
Add the old keys.
RA13T540450

XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RA13T540460
54

54 - MATCHING

enter PIN code again and click "OK". Input
Please enter again.
XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RA13T540470
7. When "Succeeded to add old key!" is displayed on Key match screen, click "OK".
54

54 - MATCHING
WIRELESS KEY MATCHING

BCM
and select BCM system. ICM
TPMS
APM
RA13T540480
2. Please select [Special function] on SELECT FUNCTION

screen. SELECT FUNCTION
Read fault code
Erase fault code
Read data stream
System information
Action Test
write data
special function
RA13T540490
3. Please select [Remote Key Learning (only for vehicles

without PEPS)] on special function screen. special function
Write software configuration information
Remote Key Learning(Only for vehicles without PEPS)
Anti-pinch Learning(Only for vehicles with APM)
RA13T540500
4. Remove key from ignition switch.

Please pull out the Key for remote Key learning
OK Cancel
RA13T540510
54

54 - MATCHING
5. Remove key and then click "OK".

This function can be matched up to two remote control keys!

1)Please press eiger a button on the remote control key from 1 to 2 seconds.
2)If match two remote control keys,please intervals of 1 to 2secondes to
press any of button on another remote control key and keep 1 to 2 seconds.
OK Cancel
RA13T540520
6. Click "OK" after operation is finished.

Match completed
The number of keys have been learning:1
Please Make sure all matched keys are available
OK
RA13T540530
7. Wireless key match is completed.
54

54 - MATCHING
TIRE PRESSURE SELF-LEARNING

Configuration & Learning for Tire Pressure Monitoring System
CAUTION
 Perform tire pressure sensor learning when rotating tire and replacing tire pressure sensor.
1. Flowchart
HINT:
For configuration and learning of tire pressure monitoring system, refer to the configuration of tire pressure
receiver and meter and the learning of tire pressure sensor.
NEXT
2 Check if meter can enter tire pressure information screen
NG Reconfigure body controller and meter
OK
3 Perform tire pressure sensor learning
NEXT
4 Perform running test and vehicle speed is more than 30 km/h for 45 seconds
NEXT
5 Check if tire pressure information is displayed correctly
NG Reconfigure body controller and meter
OK
54

54 - MATCHING
6 End
2. Configuration of body controller and meter

a. Use diagnostic tester to enter write data menu, and
click "Vehicle TPMS Configuration". Remote Key Learning(Only for vehicles without PEPS)
Match completed
The number of keys have been learning:1
Please Make sure all matched keys are available
OK
RA13T540530
b. If tire pressure display function of meter is turned off

currently, click "Vehicle TPMS Configuration" to turn datastream
on the function. Datestream name Value Unit
BCM Configuration Code 03 40 00 00 00

08 02 00 01 01
00 00 00 00 00
00
RA13T540540
c. Click Test Mode menu to detect if tire pressure display

function of meter is turned on. Diagnostic program
ENG
ABS
SRS
BCM
ICM
PEPS
IMMO
AT
RA13T540550
d. When clicking "Routine Start" on meter, tire pressure

malfunction indicator flashes and "Routine Start
Successfully By The Tester" is displayed on
diagnostic tester, which indicates that tire pressure
display function of meter has been turned on 160
180 200 220
00:04
0.0 km
8 7
successfully. Click "Routine Stop" to exit current test 140 6

+ - H F
EPC 5
120
mode and tire pressure malfunction indicator on meter 100

C E
4
goes off. "Routine Stopped" is displayed on diagnostic

80 240km
3
60
40 20 0 km/h x1000rpm 0 1 2
tester, then return to previous menu.
RA13T540560
54

54 - MATCHING
3. Tire pressure monitoring system enters sensor learning status by operating diagnostic tester
a. Turn ignition switch to ON, select write data menu and
click TPMS Self-Learning. Read data stream
data stream
Soft Configuration
Soft configuration Code
RA13T540570
b. Learning screen is shown in illustration, click tire

menu that needs to learn (take front left tire as an datastream
example). Datestream name Value Unit
Soft Configuration Code 03 88 13 88 03

b6 03 ac 54 0f
0a 32 44 00 00
00
RA13T540580
c. During learning, hint will be displayed on diagnostic

tester. Diagnostic program
ENG
ABS
SRS
BCM
ICM
PEPS
IMMO
AT
RA13T540590
CAUTION
 There are two methods for tire pressure sensor learning. One is air bleeding, another is low-frequency
trigger learning. If low-frequency trigger is used, air bleeding will not be performed.
54

54 - MATCHING
d. When clicking "OK" button on diagnostic tester, tire

pressure screen is displayed on meter and tire
pressure warning light flashes. Perform tire pressure
sensor learning when tire pressure monitoring system 160
180 200 220
00:04 8 7
enters sensor learning status.

0.0 km
140 6
+ - H F
EPC 5
120 bar bar
100
C
bar bar 4
E
80 240km
3
60
40 20 0 km/h x1000rpm 0 1 2
bar bar
bar bar
RA13T540600
e. After front left tire pressure sensor learning is successful, tire pressure malfunction indicator on meter
goes off, front left tire pressure value is displayed and "Procedure is finished" is displayed on diagnostic
tester which indicates that front left tire pressure sensor learning has been finished.
4. Tire pressure sensor learning methods
a. Precautions
No. Precautions Details

Tire learned on diagnostic tester menu must be matched
with bleeding tire
Only operate one tire every time, and do not bleed (inflate)
for other tires at this time
Keep away from vehicle with tire pressure sensor, avoiding
error learning or interference.
If only one tire shall be replaced, other tires should not be replaced and positions should not be
changed, only learn one tire separately.
b. Correction methods for tire pressure monitoring system are as follows:
 Keep vehicle speed more than 30 km/h for about 45 seconds;
 If tire pressure monitoring system can be operated normally, pressure information of four tires is
displayed;
 If certain tire pressure information is still not displayed, tire configuration may error and needs to be
relearned.
c. Tire pressure learning method for inflating/bleeding
 After entering learning status with ignition key in IGN-ON, bleed the wheel to be learned quickly
(bleeding for about 20 seconds). At this time, check pressure value of learned tire through meter,
and learning is successful. If multiple wheels should be learned, one minute interval is required
among each wheel learning.
HINT:
1 Start
NEXT
54

54 - MATCHING
2 There is enough pressure in tire (full loaded with pressure recommended)
NEXT
3 Tire pressure monitoring system enters learning status by operating diagnostic tester
NEXT
4 Perform tire pressure bleeding (for about 20 seconds)
NEXT
5 Learned tire pressure value can be displayed on meter
NEXT
NEXT
7 End
CAUTION
d. Tire pressure learning method for low-frequency trigger

After entering learning status with key in IGN-ON, tire pressure wireless signal will be generated from
sensor directly using low-frequency trigger (inflating/bleeding for tire is not needed). After triggering is
finished, pressure value of learned wheel will be displayed on meter, and learning is successful.
HINT:
1 Start
NEXT
54

54 - MATCHING
2 Key is in IGN-ON
NEXT
3 Tire pressure monitoring system enters learning status by operating diagnostic tester
NEXT
4 Trigger tire pressure sensor to be learned using low-frequency trigger
NEXT
5 Sensor ID, temperature value and pressure value are displayed on low-frequency trigger
NEXT
NEXT
7 End
 Distance between low-frequency trigger and tire pressure

sensor is less than 10 cm, make antenna of low-
frequency trigger close to tire around tire pressure sensor
on wheel, then press trigger button on low-frequency
trigger. After low-frequency trigger is triggered 160
180 200 220
00:04
0.0 km
8 7
6
successfully, related information such as learned tire ID,

140 + - H F
EPC 5
120 bar bar
pressure value and temperature value will be displayed. 100
80
C
bar bar
240km
E
4
3
60
40 20 0 km/h x1000rpm 0 1 2
RA13T540620
CAUTION
54

54 - MATCHING
Meter display image with tire pressure sensor learning successfully

1. After inflating/bleeding learning or low-frequency trigger
learning is successful, tire pressure value and
temperature value will be displayed on meter.
180 200 220

00:04 8 7
160
0.0 km
140 6
+ - H F
EPC 5
120 bar bar
100
C
bar bar 4
E
80 240km
3
60
40 20 0 km/h x1000rpm 0 1 2
RA13T540620
2. If turn light stops flashing, front left wheel pressure value is 2.3bar and temperature value is 11°C, front left
wheel learning is successful.
3. If tire pressure monitoring system is learning front left
wheel, left and right turn lights will stop flashing after datastream
bleeding. At this time, one tire pressure sensor is learned Datestream name Value Unit
successfully by tire pressure monitoring system, please ABS Configuration CODE9(ESP Only) 00
click "OK" to finish front left wheel learning.
ABS Configuration CODE9(ESP Only)

0019070314000000
RA13T540630
4. Learning methods for front right, rear right and rear left tire pressure sensors are the same as that for front
left tire pressure sensor. If only one tire shall be replaced, other tires should not be replaced and positions
should not be changed, only learn one tire separately.
5. Inspection of tire pressure monitoring system learning status
a. After reconfiguring tire pressure monitoring system,
use reading function of datastream to perform
inspection for each tire pressure sensor learning
status in tire pressure monitoring system (take front
left wheel as an example).
 Read following datastreams: front left sensor ID,
front left sensor learning status. Diagnostic program
 Front left wheel sensor ID can be read using ENG
diagnostic tester, if learning status is successful, it ABS
indicates that body controller is matched with front

SRS
BCM
left sensor successfully. If not, it indicates that the ICM
match is not successful and front left wheel sensor PEPS
should be relearned. IMMO
AT
RA13T540640
b. Use diagnostic tester to read following datastreams with vehicle speed higher than 30 km for 45
seconds or more.
 Front left wheel sensor pressure: Bar
 Front left wheel sensor temperature: °C
 Temperature is not default and tire pressure is close to the value displayed on meter, it indicates that
body controller can receive wireless signals from front left tire pressure sensor. Or it indicates that 54
learning is not successful or tire pressure sensor is fault.

54 - MATCHING
FLYWHEEL SELF-LEARNING
Flywheel Self-learning
Perform self-learning in the following conditions:
1. Battery is removed and negative battery cable is disconnected.
2. ECM is replaced.
3. ECM is disconnected and reconnected.
Flywheel self-learning conditions:
1. 100.5°C > coolant temperature > 80°C
2. Vehicle Speed = 0 km/h
3. battery voltage 9 V - 15.2 V
Flywheel self-learning procedures:
Depress accelerator pedal continuously and rapidly to 4500 rpm for 3 times.
54

54 - MATCHING
SUNROOF INITIALIZATION LEARNING

Initialization
Sliding Roof Initial Position Losing
Definition
A situation that sliding roof cannot be opened and closed normally, or closed to normal position, and initial
movement for sliding roof cannot be performed. When there is such problem in sliding roof, movement
process for sliding roof will be disordered.
Problem Symptom
1. Sliding roof cannot be closed and opened completely or tilted. Shuddering may occur during the process
from tilt to close.
2. When opening, tilting or closing sliding roof, it cannot reach to initial set position.
3. A function that short pressing the button to open and close sliding roof cannot be performed.
4. Sliding roof operation cannot be controlled by sliding roof module.
Solution Method
Perform repair according to following procedures with sliding roof mechanical fault repaired, and make sure
that power supply shall not be shut off and battery voltage is higher than 10 V during operation. Make sure
that there is no hard matter (all obstacles) which blocks operation of sliding mechanism before repairing.
Make sure that problem symptom occurred in sliding roof is in four point listed above.
1. Module initial memory position recovering method (pay attention that pressing way and pressed button)
1st step: Open sliding roof visor to the maximum position.
2nd step: Press and hold sliding roof ON/OFF button (be sure button is correct) for 10 seconds with sliding
roof fully closed, and sliding roof initialization is complete when a "click" sound is heard from sliding roof
motor.
3rd step: Adjust sliding roof after completing above procedures, and replace module or motor if symptom
still cannot be solved.
Note: After replacing sliding roof motor, sliding roof module, sliding roof assembly or if entire vehicle power
is cut off, perform sliding roof initialization procedures.
54

54 - MATCHING
ELECTRONIC THROTTLE SELF-LEARNING

Throttle Self-learning
 Throttle is replaced or cleaned.
Throttle self-learning conditions:
Throttle self-learning procedures:
Start engine for 3 times to finish self-learning. Then start vehicle and observe if it operates normally.
54

54 - MATCHING
STEERING ANGLE SENSOR MATCHING AND YAW RATE

SENSOR MATCHING
Calibration
Calibration of Steering Angle Sensor
1. Preconditions for Sensor Calibration
a. Perform zero calibration after steering sensor is installed.
b. Calibration should be finished on front wheels (four-wheel) alignment station (confirm that four-wheel
alignment parameters are correct).
c. Before calibration, make the vehicle face ahead. Wheels must be in line along driving direction, error of
both angles should be met toe-in value in four-wheel alignment parameters (for details of data, refer to
related content in Repair Manual), and steering wheel must be centered.
d. Before performing calibration again for calibrated sensor, perform recalibration for sensor, that is, make
the sensor back to calibration status.
CAUTION
 The most important is that pay special attention to center of steering wheel during actual calibration. If
not centered, it may cause error calibration data even the data is correct when performing four-wheel
alignment. It may cause error due to long-term accumulation during driving, or it may cause outrange
when turning steering wheel fully, thus ESC light will come on. So steering wheel must be centered
during four-wheel alignment.
2. Operation Procedures:
a. Connect the diagnostic tester.
b. Turn ignition switch ON.
c. Confirm that steering wheel in centered (vehicle faces
ahead, and wheels must be in line along driving
direction. Adjust steering wheel with centered).
d. Enter "SAM (Steering Angle Module)" menu, and click
"Initial Calibration". Function selection
Read CODE
Read datastream
Re-calibration
Initial Calibration
RA13T540810
54

54 - MATCHING
 If sensor is fault, exit Calibration.

 If sensor has not been calibrated, perform Communication Information
calibration automatically.
Now the sensor is being calibrated!
OK
RA13T540820
 If sensor has been calibrated, it reminds that "Re-

calibration" is needed. Click "Recalibration" Communication Information
according to display on diagnostic tester, then click

"Initial Calibration" again. If there is no response,
exit Calibration.
SAM is calibrated,Re-calibration!
OK
RA13T540830
Function selection
Read CODE
Read datastream
Re-calibration
Initial Calibration
RA13T540840
e. There is a reminder whether calibration is successful or not on diagnostic tester.
WARNING
 Never cut off the power during calibration.
CAUTION
 Calibration the steering angle sensor again when performing four-wheel alignment for vehicle.
54

54 - MATCHING
Calibration of Yaw Rate Sensor

1. Initial conditions before sensor calibration:
a. Perform calibration after four-wheel alignment and suspension setting.
b. Test must be performed under front wheel facing front of tested vehicle.
c. Test must be performed on a level work bench (axis angle between front wheel and rear wheel is within
2%).
d. If air suspension is installed on vehicle, test must be performed under conventional setting condition of
air suspension.
CAUTION
 EEPROM of ESP in delivery state has already equipped with predefined offset amount. ECU will write
the newly measured data into EEPROM and it will be used by ESC cannot confirm some preconditions
mentioned above, so the customer must make sure that calibration conditions above are established. If
offset amount is too large, system will refuse to perform calibration, at this time, it is necessary to bring
the vehicle to factory. When replacing ESP, be sure to perform IIS calibration.
2. Operation steps:
a. Connect the diagnostic tester.
b. Turn ignition switch ON.
c. Make sure that maximum inclination angle of vehicle
must be within permissible range, that is both
alignment directions must be satisfied within 2%.
±0.57°
RA13T540850
±0.57°
RA13T540860
54

54 - MATCHING
d. Enter "ESC" system menu, click "Special Operation".

SELECT FUNCTION
Read fault code
Erase fault code
Read data stream
System information
freeze frame data
Special operation
RA13T540870
e. Click "Acceleration Sensor Calibration"

Special operation
Repair Bleed
ABS Configuration Information
Acceleration sensor calibration
RA13T540880
WARNING
 Never cut off the power during calibration.
54

54 - MATCHING
STALL TEST
Purpose
The purpose of stall test is analyze and judge performance and operation condition of engine and automatic
transmission by measuring maximum speed of engine when transmission is in D and R.
Method
1. Check oil amount, add oil as necessary.
2. Warm up engine by driving vehicle for approximately 10 minutes so that CVT fluid temperature reaches 50
to 80°C, and check CVT fluid level. Add fluid if necessary.
3. Apply parking brake securely, so that wheels cannot rotate.
4. Start engine, depress brake pedal and shift lever is in D position.
5. While depressing brake pedal, gently depress the accelerator pedal.
6. Read stall speed quickly, and then move away the foot quickly from accelerator pedal.
CAUTION
 During test, do not depress the accelerator pedal for more than 5 seconds.
7. Move shift lever to N position.

8. Cool the CVT fluid, and run engine at least 1 minute.
9. Move shift lever to R position, and repeat steps from 4 to 7.
54

54 - MATCHING
LANGUAGE SWITCHING (DVD)

1. Open the DVD switch button.
2. Click home button on DVD display.
3. Click Setting on DVD display.
4. Click Language Switch on audio language screen.
54

54 - MATCHING
CONFIGURATION CODE READING

BCM Configuration Code Reading
to Data Link Connector (DLC), and make it communicate Diagnostic program
and select BCM system. BCM
ICM
PEPS
IMMO
AT
RA13T540531
2. Please select [Read data stream] on SELECT

Read fault code
Erase fault code
Read data stream
System information
Action Test
Write data
ECU reset
Special function
RA13T540532
3. Please select [Software Configuration information

(COOE)] on Read data stream screen. Read data stream
Input status (Cruise)
Input status (Tamper In)
Input status (Defrost)
Input status (Reverse shift)
Input status (Washer)
Input status (Wiper Intermission)
Software Configuration information
Software Configuration information (CODE)
RA13T540533
4. Read BCM configuration code.

datastream
Datestream name Value Unit
BCM Configuration Code 03 40 00 00 00

08 02 00 01 01
00 00 00 00 00
00
RA13T540540
54

54 - MATCHING
ICM Configuration Code Reading

and select ICM system. BCM
ICM
PEPS
IMMO
AT
RA13T540550

FUNCTION screen.
180 200 220

00:04 8 7
160
0.0 km
140 6
+ - H F
EPC 5
120
100
C
4
E
80 240km
3
60
40 20 0 km/h x1000rpm 0 1 2
RA13T540560
3. Please select [Soft Configuration Code] on Read data

stream screen. Read data stream
data stream
Soft Configuration
Soft configuration Code
RA13T540570
4. Read ICM configuration code.

datastream
Soft Configuration Code 03 88 13 88 03

b6 03 ac 54 0f
0a 32 44 00 00
00
RA13T540580
54

54 - MATCHING
A13T Configuration Code Reading

and select ABS system. BCM
ICM
PEPS
IMMO
AT
RA13T540590

FUNCTION screen.
180 200 220

00:04 8 7
160
0.0 km
140 6
+ - H F
EPC 5
120 bar bar
100
C
bar bar 4
E
80 240km
3
60
40 20 0 km/h x1000rpm 0 1 2
bar bar
bar bar
RA13T540600
3. Please select [ABS Configuration Information (ESP

Only)] on Read data stream screen. Select datastream
ABS Configuration CODE(ESP Only)
Select all
RA13T540610
4. Please select [ABS Configuration CODE (ESP Only)] on

Select datastream screen.
180 200 220

00:04 8 7
160
0.0 km
140 6
+ - H F
EPC 5
120 bar bar
100
C
bar bar 4
E
80 240km
3
60
40 20 0 km/h x1000rpm 0 1 2
RA13T540620
54

54 - MATCHING
5. Read ESP configuration code.

datastream
ABS Configuration CODE9(ESP Only) 00
ABS Configuration CODE9(ESP Only)

0019070314000000
RA13T540630
54

54 - MATCHING
MAINTENANCE MILEAGE RESET

Maintenance Mileage Reset (Manual)
2. Press set button on steering wheel.
3. Turn ignition switch to ON.
4. Press and hold set button on steering wheel for more than 5 seconds.
Maintenance Mileage Reset (Diagnostic Tester)

and select ICM system.

BCM
ICM
PEPS
IMMO
AT
RA13T540740
2. Please select [write data] on SELECT FUNCTION

screen. SELECT FUNCTION
Read fault code
Erase fault code
Read data stream
System information
Action Test
Write data
RA13T540750
3. Please select [Vehicle service function reset] on special

function screen. special function
write Soft Configuration information Code
Vehicle service function reset
RA13T540760
54

54 - MATCHING
4. Please select [Start Routine] on Reset Vehicle

Maintenance screen. Reset Vehicle Maintenance
Start Routine
RA13T540770
5. Please select [Routine Start Successfully by The Tester]

on Routine screen, and click "OK". Routine
Routine Start Successfully by The Tester
OK
RA13T540780
Maintenance mileage is reset successfully by using diagnostic tester.
54

WIRE HARNESS
WIRE HARNESS INFORMATION 55-3 VEHICLE GROUND 
General Information 55-3 DISTRIBUTION 55-23
Electrical Troubleshooting 55-7 General Information 55-23
Electrical Troubleshooting Tools 55-8 Circuit Diagram 55-24
55
Electrical Repair 55-9
VEHICLE FUSE & RELAY 55-29
Electrical Components 55-10
General Information 55-29
VEHICLE POWER DISTRIBUTION 55-12 Fuse & Relay 55-30
VEHICLE WIRE HARNESS 
Circuit Diagram 55-13 LAYOUT 55-32
Vehicle Wire Harness Layout 55-33

55

55 - WIRE HARNESS
WIRE HARNESS INFORMATION

WIRE HARNESS
General Information
Description
Wire harness information contains basic introduction of circuit diagrams, inspection methods of cables and 55
connectors, as well as layout of connector positions and wire harness positions, etc.
Circuit Diagram Information

Circuit diagrams are classified into each chapter in Service Manual. If a component appears in a specific
system, its related information (such as wire harness, connector, terminal, etc.) will appear in circuit diagram
and be introduced in detail. For example, information of Engine Control Module (ECM) is mainly introduced in
chapter 6. If component wire harnesses involve other systems, the component information will also appear in
corresponding systems.
Chery automobile offers related circuit diagram information of vehicle electrical equipment to help technicians
determine and detect vehicle malfunctions effectively.
Functions and features of circuit diagram:
• Power supply circuit is on the top of page, while ground circuit is at the bottom.
• Components (such as switches and fuses) are shown in circuit diagram in form of simple icon.

55 - WIRE HARNESS
Circuit Diagram Instruction
EXAMPLE
[1] BATTERY
55
IGNITION SWITCH
ON OR START [14]
ENGINE
EF05 COMPARTMENT [15]
[2] FUSE AND RELAY BOX
30A E-049
D3
[3] A
A11 A13
2(86) 3(30) INSTRUMENT

PANEL FUSE
[4] MAIN
RELAY EF14 AND RELAY BOX [16]
10A I-004
1(85) 5(87)
I-005
RF19
15A
A4 A3 B3 B1 B2 [13]
VR
MT AT [12] SENSOR
I-003
RW
1 2
BW
G
[5]
B
I-013
[11] 2 3 E-010
[10] [17]
10 13 15 3 4
1 CONTROL
MODULE
CAN-L CAN-H I-001
MOTOR 5 7 19 20
[6] M E-011 ILLUMINATION
GR
O
[18]
OB
V
[19]
O
2 1 6
SWITCH
[9]
B
[21] I-009
5 TO CAN
[20]
[7] LIGHT
SYSTEM
E-014 [8]
I-025 3 5
4
B-002 I-006
D1 D2 D3 D4 D5
1 2 3 4 5 6 7 8 9 10 11 12 13 A16 A15 A14 A9 A8 A7
14 15 16 17 18 19 20 21 22 23 24 25 26
A6 A5 A4
A13 A12 A11 A10
A3 A2 A1
[22] D6 D7 D8 D9 D10 D11 D12
E-049
I-001 I-004 [23] W
W W
1 2 3 4 5 6 7 8 4 5 6 1 2
1 2 1 2 3
9 10 11 12 13 14 15 16
I-009 I-003
I-013
E-011 W W
W
Gr
EA13T550000

55 - WIRE HARNESS
The following is a list of symbols defined in circuit diagram.

[1] Battery It indicates power supply from battery positive to electrical equipment.
This symbol indicates a fuse; "EF05" indicates fuse number; "30A" indicates
[2] Fuse
rated amperage of this fuse. 55
[3] Splice Point The solid circle indicates that each intersecting wire is interconnected.
This symbol indicates a relay; "MAIN RELAY" indicates relay name; "1", "2",
[4] Relay
"3" and "5", or "85", "86", "87" and "30" indicate terminal numbers of relay.
It indicates color of this wire. Color codes are as follows:
B = Black;
W = White;
R = Red;
G = Green;
L = Blue;
Y = Yellow;
[5] Color Br = Brown;
O = Orange;
Gr = Gray;
P = Pink;
V = Violet;
Lg = Light Green.
For example: "BrR" indicates the main color is brown in wire color and
second color is red.
[6] Motor This symbol indicates a motor.
[7] Ground Point It indicates ground connection.
[8] Light Bulb This symbol indicates a light bulb.
"E-011" indicates connector code of this component. The letter "E" indicates
wire harness code in which the connector is located. Connector codes are as
follows:
E = Engine Wire Harness and Engine Compartment Wire Harness;
I = Instrument Panel Wire Harness;
B = Body Wire Harness;
F = Front Left Door Wire Harness;
H = Front Right Door Wire Harness;
[9] Connector No. L = Rear Left Door Wire Harness;
R = Rear Right Door Wire Harness;
C = Roof Wire Harness;
J = Rear Bumper Wire Harness;
K = A/C Wire Harness;
A = Airbag Wire Harness;
P = Battery Positive Wire Harness;
N = Battery Negative Wire Harness;
[10] Component Name It indicates name of component.

55 - WIRE HARNESS

It indicates junction connectors. "Λ" is female connector and "I-013" is
applicable number; "◊" is male connector and "E-010" is applicable number.
[11] Connector Number "2" and "3" inside male connector indicates the used terminal
number. "----" indicates different terminals come from the same junction
connectors.
55
[12] Vehicle Model "AT" indicates it is for AT model, "MT" indicates it is for MT model.
[13] Terminal No. It indicates terminal number in connector of this component.
[14] Ignition Switch It indicates power supply from ignition switch to electrical equipment.
It indicates that wire harness is connected to the circuit diagram on next
[15] Connected to …
page. Letter "A" is connected with "A" in the circuit diagram on next page.
Fuse and Relay
[16] It indicates the name of fuse and relay box.
Box Name
[17] Twisted-pair It indicates that two wires are twisted.
It indicates CAN wire is used to communicate. It is connected to CAN
[18] CAN
system.
Backlight Power
[19] It indicates illumination power supply outputs from BCM.
Supply
It is used for indicators, warning lights or illuminations in switches or
[20] LED
instrument cluster.
[21] Switch This symbol indicates a switch.
It indicates the cross section of connector and description of terminal
[22] Connector View
number.
Letter "W" indicates the color of connector. Color codes are the same as
[23] Connector Color
above.

55 - WIRE HARNESS
Electrical Troubleshooting
Wire Harness Troubleshooting
Following 6 steps is helpful to troubleshoot the wire harness. Be sure to check non-original components
added to vehicle before performing any diagnosis. If vehicle is equipped with these components, disconnect
them to verify these added components are not the cause of problem.
Perform following steps when troubleshooting wire harness: 55
1. Verify problem.
2. Look for any related symptom (by inspecting components in the same circuit).
3. Analyze symptom (use wire harness diagram to determine current flowing direction, areas where problems
most likely occur and area where diagnosis will continue).
4. Isolate problem area.
5. Repair problem area.
6. Check for proper operation (in this step, check all items in repaired circuit for proper operation).
Voltage Test
1. Ground the negative probe (black) of voltmeter.
2. Connect positive probe (red) of voltmeter to selected measuring point (turn ignition switch to ON as
necessary). Check voltage value displayed on voltmeter.
Circuit Continuity Test

1. Turn off all electrical equipment and the ignition switch, and disconnect the negative battery cable.
2. Remove the circuit to be tested.
3. Connect two probes of ohmmeter to two ends of circuit to be tested respectively, and check for circuit
continuity (low resistance means there is good continuity in circuit).
Short Circuit Test

1. Measure and record battery voltage.
2. Pull out fuse of circuit to be tested or disconnect power supply end of test circuit.
3. Connect positive probe (red) of voltmeter to positive battery terminal and negative probe (black) to power
supply end of circuit.
4. Check voltage value displayed on the voltmeter. If voltage value of battery is displayed, it indicates that test
circuit is short to ground.

55 - WIRE HARNESS
Electrical Troubleshooting Tools

1. Jumper Wire
Jumper wire is used to create a temporary circuit.
Connect jumper wire between terminals of a circuit to
bypass a switch.
55
RA13T550010
CAUTION
 DO NOT connect a jumper wire from power supply end to body ground, as this may damage wire
harnesses or electrical components.
2. Voltmeter
Power circuit
Voltmeter is used to measure circuit voltage. Voltmeter
Measurement range should be higher than 15 V.
Measure voltage by connecting positive probe (red) of Black
V
- +
voltmeter to positive lead of test component and negative
probe (black) to negative lead or body ground.
Ground Red
RA13T550020
3. Ohmmeter
Ohmmeter is used to measure resistance between two
points in a circuit, or to check circuit for open or short. Power Supply
Line
Ground Line
- +
Ohmmeter
RA13T550030
CAUTION
 DO NOT connect ohmmeter to a circuit when applying voltage to circuit, as this may result in inaccurate
measured data or even damaging ohmmeter.

55 - WIRE HARNESS
Electrical Repair
Wire Harness Repair
CAUTION
 Measure length of lead to be repaired and select a proper substitute lead before servicing. 55
 If there are several leads to be repaired, please stagger the repaired parts.
1. Peel off 0.5 inch insulating layer from lead to be repaired and substitute lead.
2. Connect original lead to substitute lead with heat shrink tube and compress metal core of heat shrink tube
with a tool, so that the original lead and substitute lead can be connected firmly.
3. Heat the heat shrink tube to shrink its outer rubber layer and ensure that sealing of repaired area is in good
condition.
4. Wrap the repaired lead with insulating tape.
Fuse Replacement
CAUTION
 Energizing test should be performed after replacing fuse. If the fuse is blown again, check corresponding
circuit for short. If any electrical equipment or additional device which exceeds rated current is installed,
replace it with a fuse with higher amperes.
1. Turn off all electrical equipment and the ignition switch before servicing.
2. Remove the blown fuse with a fuse puller.
Pull
Puller
Fuse
RM1A520040
3. Replace fuse with a new one which has the same specification.

55 - WIRE HARNESS
Electrical Components
1. Battery Cable
Disconnect the negative battery cable (arrow) before
servicing electrical components.
55
RA13T550050
2. Sensor, Switch and Relay

Do not drop or tap sensor, switch or relay to avoid
damaging components during servicing.
RA13T550060
CAUTION
 Use relay of same specification with original one during replacement.
3. Connector
a. Disconnect the connector.
Hold connector by hand and press connector clip to
disconnect it.
RA13T550070
CAUTION
 DO NOT pull wire harness forcibly to avoid damaging components when disconnecting connectors.

55 - WIRE HARNESS
There are a variety of ways to fix connector clip, and

common disconnection methods are shown in illustration.
55
RA13T550080
b. Install the connector.

A "click" sound can be heard when a connector is
installed in place.
ick
Cl
RA13T550090
c. Replace the connector terminal.

As shown in illustration (1), insert a suitable tool into 1
terminal to lift up fixing clip, and then pull out terminal
from behind.
During installation, push terminal from back of
connector to ensure that fixing clip is fitted in place as 2
shown in illustration (2).
RA13T550100
d. Check the connector terminal.

Pull a single terminal wire gently to check if it is
installed in place.
RA13T550110

55 - WIRE HARNESS
VEHICLE POWER DISTRIBUTION

General Information
Description
55 Power distribution system provides secure, reliable and efficient power for all electrical equipment on entire
vehicle.
Power distribution system consists of following components:
 Battery
 Engine compartment fuse and relay box
 Instrument panel fuse and relay box
 Ignition switch
 Fuse
 Relay

55 - WIRE HARNESS
Circuit Diagram
Power Distribution
Circuit Diagram (Page 1 of 10)
55
BATTERY
A
- +
GROUND
SB07
30A ENGINE
COMPARTMENT
MF01 MF04 MF05
FUSE AND
150A 80A 40A RELAY BOX
30 86
E-067
STARTER P-005
RELAY
E-063
ERLY16
87 85
128 129 130
B
E-066
STARTER ECM(A) SPARE
ALTERNATOR
EA13T550010

55 - WIRE HARNESS
55
B B
A A
86 30 86 30 ENGINE
LOW HIGH
BEAM BEAM COMPARTMENT
RELAY RELAY FUSE AND
ERLY04 ERLY02 RELAY BOX
EF22 85 87 85 87 E-067
10A
EF33 EF34 EF03 EF04

15A 15A 10A 10A
16 87 88 8 35 36
BCM(A)
LEFT COMBINATION RIGHT HEADLIGHT

HEADLIGHT ADJUSTMENT MOTOR
LEFT HEADLIGHT RIGHT COMBINATION

ADJUSTMENT MOTOR HEADLIGHT
EA13T060020

55 - WIRE HARNESS
55
B B
A A
EF25 86 30 ENGINE
ECM
15A MAIN COMPARTMENT
RELAY FUSE AND
ERLY05 RELAY BOX
86 30 85 87 E-067
HORN D
RELAY
ERLY11 EF37 EF38 EF13
85 87
10A 15A 15A
90 91 20 115 116 45
HORN SWITCH
INJECTOR 1
INJECTOR 2
INJECTOR 3
BCM(A) INJECTOR 4
ECM(A)
UPSTREAM
OXYGEN SENSOR
DOWNSTREAM
OXYGEN SENSOR
HIGH-PITCHED HORN
LOW-PITCHED HORN
EA13T550030

55 - WIRE HARNESS
55
B B
A A
D D
EF30 EF31 ENGINE

10A 15A COMPARTMENT
FUSE AND
EF14 RELAY BOX
EF35
86 30 86 30 E-067
15A 15A A/C FUEL
CLUTCH PUMP
RELAY RELAY
ERLY12 ERLY13
85 87 85 87
46 93 98 99 102 103
A/C COMPRESSOR
CLUTCH
IGNITION COIL 1
IGNITION COIL 2
IGNITION COIL 3
IGNITION COIL 4
ECM(A)
FUEL PUMP MOTOR

VARIABLE CAMSHAFT TIMING
CANISTER SOLENOID VALVE
EXHAUST GAS RECIRCULATION VALVE
THERMOSTAT
EA13T550040

55 - WIRE HARNESS
55
B B
A A
MF02 MF03 EF28 ENGINE

40A 50A 10A COMPARTMENT
FUSE AND
RELAY BOX
86 30 86 30 86 30 E-067
FAN FAN REVERSE
LOW HIGH LAMP E-064
RELAY 2 RELAY 1 RELAY E-065
ERLY18 ERLY14 ERLY07
85 87 85 87 85 87
138 135 121 120 28 26
REAR LEFT TAIL LIGHT

REAR RIGHT TAIL LIGHT
COOLING
FAN MOTOR
ECM(A) BCM(A)
EA13T550050

55 - WIRE HARNESS
55
B B
A A
EF21 EF16 EF18 EF23 EF29 ENGINE

15A 15A 15A 15A 25A COMPARTMENT
FUSE AND
RELAY BOX
86 30 LOW 86 30 HIGH E-067
WIPER WIPER
RELAY RELAY
ERLY08 ERLY09
85 87a 87b 85 87a 87b
70 65 67 72 3 140 62 63 141
E-066
BCM
WIPER MOTOR
EA13T550060

55 - WIRE HARNESS
55
B B
A A
86 30 EF02 SB06 ENGINE

ACC 7.5A 30A COMPARTMENT
RELAY FUSE AND
EF26 EF24 EF17 EF15
ERLY01 RELAY BOX
86 30 10A 15A 25A 15A E-067
85 87
BLOWER
RELAY
SB09 EF01 ERLY15
85 87
20A 20A
3 4 113 47 123 124 75 73 66 139
E-066
BLOWER
MOTOR
A/C CONTROL ECM(A)

PANEL TCU
SPARE SUNROOF
MODULE
BRAKE SWITCH
EA13T550070

55 - WIRE HARNESS
G G
55 F F
E E
B B
ENGINE
COMPARTMENT
FUSE AND
RELAY BOX
SB01 SB08 SB04 SB02 EF06 EF07 EF08 EF09 E-067
30A 40A 30A 30A 7.5A 15A 10A 7.5A
105 112 108 106 38 39 40 41
BCM RADAR CONTROL MODULE

A/C CONTROL PANEL
ESP
ECM(A)
TCU
BRAKE SWITCH
ALTERNATOR SIGNAL
EA13T550080

55 - WIRE HARNESS
55
F F
RF24
RF15 IP FUSE
30A AND RELAY BOX
7.5A
I-032
RF22 RF21 RF18 RF09 RF10 E-028
86 30
15A 20A 10A 10A 10A
DEFROSTER
RELAY
85 87
51 50 25 47 32 33
BCM
DEFROSTER
DIAGNOSIS
KEY SWITCH
1 5 REAR VIEW
MIRROR
AM1 IG1 ACC AM2 IG2 ST HEATER
DEFROSTER
LOCK
IGNITION SWITCH
ACC SWITCH INDICATION
ON
ST INSTRUMENT
2 3 6 4 CLUSTER
G
AUDIO (B)
H A/C CONTROL PANEL
ECM(A)
GEAR RANGE SWITCH
EA13T550090

55 - WIRE HARNESS
55
IP FUSE
AND RELAY BOX
I-032
RF26 RF28 RF01 RF03 RF05 RF07 RF02 RF04 RF06 RF08
10A 10A 10A 10A 10A 10A 10A 10A 10A 10A
55 57 7 11 15 19 9 13 17 21
SPARE
BACKUP
POWER
SUPPLY
SRS CONTROL
MODULE
STEERING
ANGLE
SENSOR
BCM (B) HEADLIGHT ADJUSTMENT SWITCH

INSTRUMENT CLUSTER AUDIO (C)
IMMOBILIZER COIL A/C CONTROL PANEL
BCM
AUDIO (B)
REAR VIEW MIRROR
ADJUSTMENT SWITCH
FRONT ROOM LIGHT
EA13T550100

55 - WIRE HARNESS
VEHICLE GROUND DISTRIBUTION

General Information
Description
Ground distribution system provides centralized and convenient information about ground positions for 55
electrical equipment on entire vehicle. Technicians can find relevant electrical equipment quickly through
ground points and solve problem accurately and efficiently.

55 - WIRE HARNESS
Circuit Diagram
Ground Distribution
55
1 BRAKE FLUID LEVEL SENSOR
E-004
E-005 2 A/C COMPRESSOR CLUTCH

E-018
3 IGNITION COIL 1
E-023
E-022 3 IGNITION COIL 2

E-014
3 IGNITION COIL 3
E-013
3 IGNITION COIL 4
E-012
A52
ECM(A)
A53 E-041
E-043
13
ESP
38 E-051
E-056
2 HIGH-PITCHED HORN
E-047
E-059 2 LOW-PITCHED HORN

E-048
RIGHT HEADLIGHT
3
ADJUSTMENT MOTOR
E-050
1 RIGHT DAYTIME RUNNING LIGHT

E-058
2
RIGHT COMBINATION
HEADLIGHT
5
E-049
EA13T550110

55 - WIRE HARNESS
1 WIPER MOTOR
E-031 55
E-066 2 SIREN
E-044
1 COOLING FAN MOTOR

E-045
1 HOOD CONTACT SWITCH

E-046
LEFT HEADLIGHT
3
ADJUSTMENT MOTOR
E-060
LEFT DAYTIME
1 RUNNING LIGHT
E-062
2
LEFT COMBINATION
HEADLIGHT
5
E-061
4
ENGINE COMPARTMENT
129 FUSE AND RELAY BOX
E-067
140
5
TCU
42 E-069
E-068
SOLENOID VALVE AND

1 TEMPERATURE SENSOR
E-072
E-070 3 GEAR RANGE SWITCH

E-073
FUEL PUMP MOTOR &

4 FUEL LEVEL SENSOR
B-008
B-009
EA13T550120

55 - WIRE HARNESS
1 REAR LEFT TAIL LIGHT

55 B-003
B-006 14
RADAR CONTROL
MODULE
16
B-004
2 HIGH MOUNTED STOP LIGHT

1
T-002
B-001 T-001
3 REAR WIPER MOTOR

T-004
2 BACK DOOR SWITCH

T-005
1 BACK DOOR LOCK MOTOR

T-006
1 REAR LEFT FOG LIGHT

6
J-002
B-007 J-001
2 LEFT LICENSE PLATE LIGHT

J-004
2 RIGHT LICENSE PLATE LIGHT

J-006
1 REAR RIGHT FOG LIGHT

J-008
2 DRIVER SEAT BELT SWITCH

B-013
B-012 C3
BCM (C)
C4 B-020
REAR LEFT DOOR

2 CONTACT SWITCH
1
L-001
B-011 L-005
REAR LEFT POWER
3
WINDOW SWITCH
L-004
1 REAR RIGHT TAIL LIGHT

B-031
B-032
EA13T550130

55 - WIRE HARNESS
2 PASSENGER DETECTION SENSOR

B-026 55
FRONT PASSENGER
B-025 2
SEAT BELT SWITCH
B-027
REAR RIGHT DOOR

2 CONTACT SWITCH
1
R-001
B-028 R-005
REAR RIGHT POWER
3
WINDOW SWITCH
R-004
11 COMMAND GEAR SHIFT

I-022
I-004 1 BACKUP POWER SUPPLY

I-024
4
DIAGNOSTIC INTERFACE
5 I-033
3 HEADLIGHT ADJUSTMENT SWITCH

I-007
I-005 2 CLUTCH SWITCH

I-009
5 ECO SWITCH
I-010
3 INSTRUMENT CLUSTER
I-011
13 CLOCK SPRING
I-031
2 SUNROOF MODULE
2
C-002
I-003 C-001
1 FRONT ROOM LIGHT

C-003
EA13T550140

55 - WIRE HARNESS
REAR VIEW MIRROR

3 ADJUSTMENT SWITCH
55 I-008
I-006 B12 AUDIO (B)

I-015
2 IMMOBILIZER COIL
I-026
4 STEERING ANGLE SENSOR

I-028
A16 MANUAL A/C PANEL (A)

9
K-012
I-019 K-006
A13 ELECTRICAL A/C PANEL

K-004
16 SRS CONTROL MODULE

I-020
I-021
FRONT LEFT POWER

12 WINDOW SWITCH
F-001
POWER REAR VIEW

F-004 5
MIRROR MOTOR
F-003
2 CENTER CONTROL LOCK

F-007
FRONT LEFT DOOR

2
CONTACT SWITCH
F-009
FRONT RIGHT DOOR

2 CONTACT SWITCH
H-002
FRONT RIGHT POWER

H-007 3
WINDOW SWITCH
H-003
POWER REAR VIEW

5
MIRROR MOTOR
H-005
B6 MANUAL A/C PANEL (B)

K-013
K-010
EA13T550150

55 - WIRE HARNESS
VEHICLE FUSE & RELAY

General Information
Description
Each system should be equipped with fuses and relays to ensure normal operation of vehicle electrical 55
system. Fuses and relays are integrated into fuse and relay boxs which are installed in the following specific
positions of vehicle:
Engine compartment fuse and relay box: located at left side of engine compartment and rear side of front left
combination light.
Instrument panel fuse and relay box: located at lower left side of instrument panel.

55 - WIRE HARNESS
Fuse & Relay

Engine Compartment Fuse and Relay Box
ERLY01 ERLY02 ERLY04 ERLY05 ERLY07 ERLY08
55
Wiper
ACC High beam ERLY03 Low beam Main ERLY06 Back-up
low-speed
relay relay relay relay light relay
relay
ERLY09
MF01 150A
EF06 7.5A
EF09 7.5A
EF01 20A
EF03 10A
EF04 10A
EF07 15A
EF08 10A
EF10 15A
EF11 15A
EF13 15A
EF14 15A
Wiper
EF02
EF05
EF12
high-speed
relay
MF02 40A
EF30 10A
EF31 15A
EF16 15A
EF17 25A
EF21 15A
EF22 10A
EF24 10A
EF25 15A
EF26 10A
EF28 10A
EF29 25A
EF32
EF18
EF19
EF20
EF23
EF27
Memory fuse
EF15 15A
MF03 50A

EF33 15A
EF34 15A
EF35 15A
A/C
EF36
ERLY10 Horn Fuel pump
compressor
relay relay
clutch relay
MF04
SB01 30A
SB02 30A
SB04 30A
SB06 30A
SB07 30A
SB08 40A
SB09 20A
EF37 10A
EF38 15A
SB03
SB05
MF05 40A
EF40 7.5A
EF39

ERLY16 ERLY17
High-speed Low-speed
Blower Starter
cooling fan cooling fan
relay relay
relay relay
EA13T550170
No. Description No. Description No. Description

EF01 Spare EF19 - EF37 ECM
EF02 - EF20 - EF38 Fuel Injector
EF03 Left High Beam EF21 BCM EF39 -
EF04 Right High Beam EF22 Coil Power Supply EF40 Blower Relay
EF05 - EF23 - SB01 ESP/ABS
EF06 ESP/ABS EF24 Brake Switch SB02 BCM
EF07 ECM/TCU (AT EF25 Horn SB03 -
Model)/Brake Switch
EF08 A/C Switch/ EF26 ECM/TCU (AT Model) SB04 BCM
Reversing Radar
EF09 Alternator Excitation EF27 - SB05 -
EF10 BCM EF28 Back-up Light SB06 Blower
EF11 BCM EF29 Wiper SB07 Starter
EF12 - EF30 A/C Compressor SB08 ESP/ABS
EF13 Oxygen Sensor EF31 Fuel Pump SB09 ACC
EF14 Ignition Coil EF32 - MF01 Alternator
EF15 Shipping Fuse EF33 Left Low Beam MF02 Low-speed Fan
EF16 BCM EF34 Right Low Beam MF03 High-speed Fan
EF17 Sunroof EF35 Control Valve MF04 -

55 - WIRE HARNESS
EF18 - EF36 - MF05 Instrument Panel Relay

and Fuse Box (B+)
55

55 - WIRE HARNESS
Instrument Panel Fuse and Relay box
RF01 10A RF02
55 RF03 10A RF04

Rear
defroster
RF05 10A RF06
relay
RF07 10A RF08

RF09 10A
RF10 10A
RF15 15A
RF18 10A
RF12
RF13
RF14
RF16
RF17
RF19
RF11
RF21 20A
RF22 10A
RF24 30A
RF26 10A
RF28 15A
RF23
RF27
RF25
RF20
EA13T550190
No. Description No. Description No. Description

RF01 BCM/Instrument RF11 - RF21 AM2
Cluster/Engine
Immobilizer
RF02 - RF12 - RF22 AM1
RF03 SAS RF13 - RF23 -
RF04 - RF14 - RF24 Rear Window
Defroster Relay
RF05 Airbag RF15 Diagnosis/Key Switch/Rear RF25 -
Window Defroster Relay
RF06 - RF16 - RF26 Audio/Rear View
Mirror Adjustment/
BCM/Sunroof
RF07 Audio/A/C RF17 - RF27 -
Panel/Headlight
Leveling Motor
RF08 - RF18 Rear View Mirror Heater/Rear RF28 Backup Power
Window Defroster Switch Supply
Indicator
RF09 Audio/A/C Panel RF19 -
RF10 Instrument RF20 -
Cluster

55 - WIRE HARNESS
VEHICLE WIRE HARNESS LAYOUT

General Information
Description
Wire harness layout introduces location information of vehicle wire harness and electrical components in the 55
form of graphic.
The entire vehicle wire harnesses are divided into the following parts:
 Engine wire harness
 Engine compartment wire harness (AT model)
 Engine compartment wire harness (MT model)
 Battery positive/negative wire harness
 Instrument panel wire harness
 Body wire harness
 Front left door wire harness
 Front right door wire harness
 Rear left door wire harness
 Rear right door wire harness
 Luggage compartment door wire harness
 Roof wire harness
 Manual/Power A/C wire harness
 Rear bumper wire harness

55 - WIRE HARNESS
Vehicle Wire Harness Layout

Entire Vehicle Wire Harness Layout
Engine Wire Harness Instrument Panel Roof Wire Harness Rear Bumper
55 Front Right Door

Wire Harness
Rear Right Door
Wire Harness
Back Door Wire Harness
Wire Harness Wire Harness
Battery Positive Battery Negative Front Left Door

Wire Harness Wire Harness Wire Harness
Engine Compartment A/C Wire Harness Body Wire Rear Left Door
Wire Harness Harness Wire Harness
EA13T550200

55 - WIRE HARNESS
Engine Wire Harness
E-022 E-020 E-023 E-015 E-025 E-014 E-013 E-012 E-004 E-008 E-002 E-007 E-001
55
E-021 E-024 E-017 E-019 E-018 E-016 E-011 E-010 E-009 E-005 E-003 E-006 E-035
EA13T550210
No. Color/Terminal Name

E-001 B/56 ECU Connector B
E-002 B/6 Exhaust Gas Recirculation Valve
E-003 B/3 Phase Sensor
Brake Fluid Level Sensor* (Positions may be different
E-004 B/2
depending on models)
E-005 - Ground 3
E-006 B/2 Coolant Temperature Sensor
E-007 B/12 Engine Compartment Wire Harness Interface
E-008 B/6 Throttle Position Sensor
E-009 B/2 Injector 4
E-012 B/3 Ignition Coil 4

55 - WIRE HARNESS

E-015 B/2 Canister Solenoid Valve
E-016 B/1 Oil Pressure Switch
55 E-017 B/3 Alternator Signal

E-018 B/2 A/C Compressor Clutch
E-019 B/1 Power Steering
E-020 B/2 VVT Solenoid Valve
E-021 B/3 Knock Sensor
E-022 - Ground 2
E-025 B/4 Air Pressure Sensor

55 - WIRE HARNESS
Engine Compartment Wire Harness (AT model)
E-054 I-018 E-052 E-055 E-051 E-007 E-004 E-035 E-041 E-069 E-031 E-028 E-033 E-068 E-029 I-035 I-036 E-030
55
B-015
E-053
E-026
E-057
B-014
E-056
E-034
E-050 E-032
E-060
B-024
E-066
E-049
E-063
E-059 E-062
E-058 E-061
E-067
E-048 E-039 E-070 E-071 E-073 E-072 E-042 E-036 E-037 E-038 E-047 E-045 E-046 E-044 E-043 E-065 E-064
EA13T550230

E-004 B/2 Brake Fluid Level Sensor* (Positions may be different
depending on models)
E-026 W/16 Interior Wire Harness Interface A
E-028 - Instrument Panel Relay and Fuse Box Power Supply
E-029 W/16 Instrument Panel Wire Harness Interface B
E-030 B/18 Instrument Panel Wire Harness Interface A
E-031 B/5 Wiper Motor
E-032 W/18 Interior Wire Harness Interface E
E-033 W/12 Body Controller D
E-034 B/2 Front Left ABS Wheel Speed Sensor
E-035 B/12 Engine Wire Harness Interface
E-036 Gr/2 Thermostat Assembly
E-037 B/4 Upstream Oxygen Sensor
E-038 B/4 Downstream Oxygen Sensor

55 - WIRE HARNESS

E-039 B/3 Speed Sensor
E-041 B/56 ECU Connector A
E-042 B/1 Starter Control Wire
55 E-043 - Ground 4
E-044 B/2 Anti-theft Horn
E-045 B/3 Cooling Fan
E-046 B/3 Engine Compartment Contact Switch
E-047 Gr/2 High Pitched Horn
E-048 Gr/2 Low Pitched Horn
E-049 B/10 Right Combination Light
E-050 B/3 Right Headlight Leveling Motor
E-051 B/38 ESP Controller
E-052 B/2 Front Right ABS Wheel Speed Sensor
E-053 W/16 Interior Wire Harness Interface B
E-054 W/10 Interior Wire Harness Interface C
E-055 Gr/4 Pressure Switch
E-064 - High-speed Fan Power Supply
E-065 - Low-speed Fan Power Supply
E-066 - Ground 9
E-067 - Engine Compartment Fuse and Relay Box
E-068 - Ground 7
E-069 B/48 TCU Interface
E-070 - Ground 5
E-071 B/3 Turbine Speed Sensor
E-072 Gr/10 Solenoid Valve and Temperature Sensor
E-073 B/10 Gear Switch

55 - WIRE HARNESS
Engine Compartment Wire Harness (MT model)
E-054 I-018 E-052 E-055 E-051 E-007 E-035 E-042 E-031 E-028 E-033 E-029 I-035 I-036 E-030
55
B-015
E-053
E-026
E-057
B-014
E-056
E-034
E-050 E-032
E-060
B-024
E-066
E-049
E-063
E-059 E-062
E-058 E-061
E-067
E-048
E-037 E-039 E-036 E-038 E-041 E-040 E-047 E-045 E-046 E-044 E-043 E-065 E-064
EA13T550220

E-026 W/16 Interior Wire Harness Interface A
E-029 W/16 Instrument Panel Wire Harness Interface B
E-030 B/18 Instrument Panel Wire Harness Interface A
E-031 B/5 Wiper Motor
E-032 W/18 Interior Wire Harness Interface E
E-033 W/12 Body Controller D
E-034 B/2 Front Left ABS Wheel Speed Sensor
E-035 B/12 Engine Wire Harness Interface
E-036 Gr/2 Thermostat Assembly
E-037 B/4 Upstream Oxygen Sensor
E-038 B/4 Downstream Oxygen Sensor
E-039 B/3 Speed Sensor

55 - WIRE HARNESS

E-040 B/2 Back-up Light Switch
E-041 B/56 ECU Connector A
E-042 B/1 Starter Control Wire
55 E-043 - Ground 4
E-044 B/2 Anti-theft Horn
E-045 B/3 Cooling Fan
E-046 B/3 Engine Compartment Contact Switch
E-047 Gr/2 High Pitched Horn
E-048 Gr/2 Low Pitched Horn
E-049 B/10 Right Combination Light
E-050 B/3 Right Headlight Leveling Motor
E-051 B/38 ESP Controller
E-052 B/2 Front Right ABS Wheel Speed Sensor
E-053 W/16 Interior Wire Harness Interface B
E-054 W/10 Interior Wire Harness Interface C
E-055 Gr/4 Pressure Switch
E-064 - High-speed Fan Power Supply
E-065 - Low-speed Fan Power Supply
E-066 - Ground 9
E-067 - Engine Compartment Fuse and Relay Box

55 - WIRE HARNESS
Battery Positive/Negative Wire Harness
P-001 N-003 P-002 P-003 N-001 N-002 P-004 P-005
55
EA13T550340

P-001 - Alternator
P-002 - Starter
P-003 - Battery Positive Pole
P-004 - Center Relay and Fuse Box Pole
P-005 - Center Relay and Fuse Box Interface - Alternator
N-001 - Battery Negative
N-002 - Body Negative
N-003 - Transmission Negative

55 - WIRE HARNESS
Instrument Panel Wire Harness
I-003 C-001 I-004 I-006 I-005 I-009 I-028 I-031 I-029 I-013 I-026 I-012 I-015 I-014 I-019 I-017 E-054 I-018
55
I-030
I-010
I-008
I-007
MODE SET
I-001
I-002 1 2
0 3
I-035 A/C
B-019 1 3 5
2 4 R
B-017 E-029 E-030 I-036 I-032 I-033 I-034 I-011 I-025 I-027 I-021 I-020 I-022 I-024 I-023 I-016 K-006
EA13T550240

I-001 W/18 Interior Wire Harness Interface A
I-002 W/20 Interior Wire Harness Interface B
I-003 W/10 Interior Wire Harness Interface B
I-004 - Ground 1
I-005 - Ground 2
I-006 - Ground 3
I-007 W/6 Headlight Leveling Switch
I-008 B/10 Electric Rear View Mirror Adjustment
I-009 B/2 Clutch Switch Connector
I-010 W/8 ECO Switch
I-011 L/32 Instrument Cluster
I-012 B/6 Accelerator Pedal Position Sensor
I-013 B/4 Brake Switch

55 - WIRE HARNESS

I-014 Y/8 Radio A
I-015 B/8 Radio B
I-016 L/12 Radio C
I-017 BYG/2 to Front Passenger Airbag Connector 55
I-018 W/10 Engine Compartment Wire Harness Interface C
I-019 W/15 to A/C Wire Harness
I-020 Gr/32 Airbag
I-021 - Ground 4
I-022 B/11 Gear Shift Mechanism
I-023 B/16 Integration Switch
I-024 W/2 Backup Power Supply
I-025 W/6 Ignition Switch
I-026 W/3 Anti-theft Module (Coil)
I-027 W/4 Jiggle Switch
I-028 B/6 Steering Angle Sensor
I-029 B/10 Wiper Switch
I-030 B/10 Combination Light Switch
I-031 W/16 Clock Spring
I-032 - Instrument Panel Relay and Fuse Box
I-033 B/16 Diagnosis Module
I-034 W/24 Body Controller B
I-035 W/16 Engine Compartment Wire Harness Interface B
I-036 B/18 Engine Compartment Wire Harness Interface A

55 - WIRE HARNESS
Body Wire Harness
H-008 E-053 B-023 B-024 B-026 B-028 R-005 B-025 B-027 B-029 B-030 B-031 B-032 I-001 I-002
T-001
55 B-001
B-002
B-003
B-004
B-005
J-001
B-006
B-007
B-009
B-010
L-005
B-011
B-008
B-012
B-033
B-016
B-015
B-014
B-018 B-013 B-022 B-020 B-021 B-017 B-019 F-005 E-026 E-032
EA13T550250

B-001 W/10 to Luggage Compartment Door Wire Harness
B-002 B/2 Rear Left Speaker
B-003 W/6 Rear Left Combination Light
B-004 W/16 Radar Module
B-005 B/2 Luggage Compartment Light
B-006 - Ground 15
B-007 W/14 Rear Bumper Wire Harness Interface
B-008 B/4 Fuel Pump/Level Sensor
B-009 - Ground 14
B-010 W/2 Rear Left ABS Wheel Speed Sensor
B-011 W/10 Rear Left Door Wire Harness Interface
B-012 - Ground 16
B-013 B/2 Driver Seat Belt Switch

55 - WIRE HARNESS

B-014 W/18 Engine Compartment Wire Harness Interface E
B-015 W/16 Engine Compartment Wire Harness Interface A
B-016 W/26 Front Left Door Wire Harness Interface
B-017 W/18 Instrument Panel Wire Harness Interface A 55
B-018 W/1 Parking Brake Switch
B-019 W/20 Instrument Panel Wire Harness Interface B
B-020 B/14 Body Controller C
B-021 W/20 Body Controller E
B-022 B/52 Body Controller A
B-023 W/18 Front Right Door Wire Harness Interface
B-024 W/16 Engine Compartment Wire Harness Interface B
B-025 - Ground 17
B-026 W/2 Occupant Detection Cushion
B-027 B/2 Front Passenger Seat Belt Switch
B-028 W/10 Rear Right Door Wire Harness Interface
B-029 W/2 Rear Right ABS Wheel Speed Sensor
B-030 B/2 Rear Right Speaker
B-031 W/6 Rear Right Combination Light
B-032 - Ground 18
B-033 - Ground 19

55 - WIRE HARNESS
Front Left Door Wire Harness
55
F-009 F-007 F-008 F-001 F-002 F-003 F-006 F-004 B-016 F-005
EA13T550270

F-001 Y/16 Glass Regulating Switch
F-002 Gr/2 Left Glass Regulator Motor
F-003 W/6 Left Rear View Mirror Connector
F-004 - Ground 1
F-005 W/26 Interior Wire Harness Interface
F-006 B/2 Front Left Speaker
F-007 B/3 Central Lock
F-008 B/3 Front Left Door Lock Motor
F-009 B/2 Front Left Door Contact Switch

55 - WIRE HARNESS
Front Right Door Wire Harness
55
H-008 B-023 H-007 H-006 H-005 H-004 H-003 H-001 H-002
EA13T550280

H-001 B/3 Front Right Door Lock Motor
H-002 B/2 Front Right Door Contact Switch
H-003 L/4 Front Right Door Glass Regulating Switch
H-004 Gr/2 Right Glass Regulator Motor
H-005 W/6 Right Rear View Mirror Connector
H-006 B/2 Front Right Speaker
H-007 - Ground 1
H-008 W/18 Interior Wire Harness Interface

55 - WIRE HARNESS
Rear Left Door Wire Harness
55
L-002 L-001 L-003 L-004 L-005 B-011
EA13T550290

L-001 B/2 Rear Left Door Contact Switch
L-002 B/3 Rear Left Door Lock Motor Connector
L-003 Gr/2 Left Glass Regulator Motor Connector
L-004 L/4 Glass Regulating Switch
L-005 W/10 Interior Wire Harness Connector

55 - WIRE HARNESS
Rear Right Door Wire Harness
55
B-028 R-005 R-004 R-003 R-001 R-002
EA13T550300

R-001 B/2 Rear Right Door Contact Switch Connector
R-002 B/3 Rear Right Door Lock Motor Connector
R-003 Gr/2 Right Glass Regulator Motor Connector
R-004 L/4 Glass Regulating Switch
R-005 W/10 Interior Wire Harness Connector

55 - WIRE HARNESS
Luggage Compartment Door Wire Harness
T-007 T-008 T-001 B-001 T-003 T-002 T-004 T-006 T-005 T-009 T-010
55
EA13T550310

T-001 W/10 Interior Wire Harness Connector
T-002 W/2 High Mounted Stop Light
T-003 W/1 to Rear Window Defroster Positive Wire Harness
T-004 W/3 Rear Wiper Motor
T-005 B/2 Luggage Compartment Door Opener Switch
T-006 B/4 Luggage Compartment Door Lock Motor
T-007 W/1 to Luggage Compartment Door Wire Harness
T-008 B/1 Rear Window Defroster Positive
T-009 B/1 Rear Window Defroster Negative
T-010 - Rear Window Defroster Ground

55 - WIRE HARNESS
Roof Wire Harness
C-004 C-003 C-002 C-001 I-003
55
EA13T550260

C-001 W/10 Instrument Panel Wire Harness Interface
C-002 W/6 Sunroof Module
C-003 W/6 Front Dome Light
C-004 W/1 Antenna Amplifier

55 - WIRE HARNESS
Manual/Power A/C Wire Harness
K-001 K-002 K-003 K-004 K-005 K-011 K-007 I-019 K-008 K-009 K-010
55
MODE SET
1 2
0 3
A/C
1 3 5
2 4 R
K-013 K-012 K-006
EA13T550320

K-001 W/7 Defrost Damper Motor
K-002 W/2 Evaporator Temperature Sensor
K-003 W/7 Face Damper Motor
K-004 L/32 Power A/C Panel
K-005 W/6 Mix Damper Motor
K-006 W/15 to Instrument Panel Wire Harness
K-007 B/3 Speed Regulator Module
K-008 W/2 Blower
K-009 W/7 Inner/Outer Circulation Motor
K-010 - Ground
K-011 W/5 Speed Resistor
K-012 W/16 Manual A/C Panel A
K-013 W/6 Manual A/C Panel B

55 - WIRE HARNESS
Rear Bumper Wire Harness
55
J-002 B-007 J-001 J-003 J-004 J-005 J-009 J-006 J-007 J-008
EA13T080130

J-001 W/14 to Interior Wire Harness Interface
J-002 Gr/2 Rear Left Fog Light
J-003 B/3 Left Reversing Radar Sensor
J-004 B/2 Left License Plate Light
J-005 B/3 Center Reversing Radar Sensor
J-006 B/2 Right License Plate Light
J-007 B/3 Right Reversing Radar Sensor
J-008 Gr/2 Rear Right Fog Light
J-009 B/4 Backup Camera

- MEMO -

CHERY Service Manual - A13T

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CHERY A13T  CAUTION:

This manual is only for specialized

2016 manual or without proper equipment and

All Rights Reserved © 2016

VEHICLE INFORMATION 02-10

Chery Automobile Co., Ltd. 02–1

02–2 Chery Automobile Co., Ltd.

How to Use This Manual

Chery Automobile Co., Ltd. 02–3

02–4 Chery Automobile Co., Ltd.

 Always wear a clean uniform.

Chery Automobile Co., Ltd. 02–5

2. Jacking up and supporting vehicle

02–6 Chery Automobile Co., Ltd.

b. Precautions for using a plate type lifter

Chery Automobile Co., Ltd. 02–7

8. Lubrication and seal

02–8 Chery Automobile Co., Ltd.

Seal Lock Adhesive 02

11. Rubber parts and rubber hoses

- Cool the exhaust pipe with a fan.

Chery Automobile Co., Ltd. 02–9

VIN is also located on right drip channel of engine

Vehicle Identification Number (VIN)

WMI VDS VIS

ƶƶƶ ƶƶƶƶƶƶ ƶƶƻƻƻƻƻƻ

□: represents a letter or a number (letters I, O and Q cannot be used); ○: represents a number.

02–10 Chery Automobile Co., Ltd.

 The first three digits of VIN represent world manufacturer identifier.

No. WMI Code Vehicle Category

 The fourth digit of VIN represents vehicle type.

Chery Automobile Co., Ltd. 02–11

5. The transmission number (for AT model) is stamped on

02–12 Chery Automobile Co., Ltd.

1 - Seat Belt Reminder Light 2 - ABS Warning Light

Chery Automobile Co., Ltd. 02–13

CIRCUIT DIAGNOSIS INFORMATION

ECM Control System Troubleshooting

Diagnosis and Troubleshooting

Procedure Types Details Troubleshooting Methods

2. Detailed troubleshooting steps

02–14 Chery Automobile Co., Ltd.

Circuit Simulation Test

Chery Automobile Co., Ltd. 02–15

 DO NOT heat the components to a temperature higher than 60°C (140°F).

02–16 Chery Automobile Co., Ltd.

6. Cold/hot start test

Chery Automobile Co., Ltd. 02–17

Precautions for Control Module and Electrical Components Inspection

02–18 Chery Automobile Co., Ltd.

How to Check Connector

by the bonding of components or relays. Before determining

1. Check connector with a digital multimeter

Chery Automobile Co., Ltd. 02–19

02–20 Chery Automobile Co., Ltd.

 The terminal side view in the circuit diagram is shown

Connector Symbol Connector

MANUAL TRANSMISSION AUTO TRANSMISSION

Chery Automobile Co., Ltd. 02–21

3. Circuit diagram example

ENGINE COMPARTMENT [15]

2 (86) 3 (30) INSTRUMENT