I10 Workshop Manual - A

Monday, November 21, 2011 9:58 AM
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Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning
Air conditioner
Item Specification 1.1 /1.2Engine (Gasoline) Compressor Type Oil type & Capacity Pulley type Displacement Condenser APT(A/C pressure transducer) Expansion valve Refrigerant Heat rejection The method to measure the pressure Type Type Capacity [oz.(g)] HS-09 (Swashplate) FD46XG (PAG), 120 10cc 4PK type 110cc/rev 9200 kcal/hr Voltage = 0.00878835 * Pressure + 0.37081095 [PSIA] Block R-134a 17.6 0.88 (450 25) 5PK type 90cc/rev U1.1 Engine (Diesel)
Blower unit
Item Fresh and recirculation Blower Operating method Type Speed step Speed control Air filter Type Specification Actuator or cable Sirocco 1-4 speed (Manual) Blower resistor Particle filter
Heater and evaporator unit

Item Heater Type Heating capacity PTC heater capacity Mode operating method Temperature operating method Evaporator Temperature control type A/C ON/OFF [C(F)] Specification Pin & Tube type 4100 5% kcal/hr 1000W + 5%/-10% Cable Cable Evaporator temperature sensor ON : 3.0 0.5 (37.4 32.9), OFF: 2.4 0.4 (36.3 32.7)
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Troubleshooting Problem Symptoms Table

Before replacing or repairing air conditioning components, first determine if the malfunction is due to the refrigerant charge, air flow or compressor. Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. After correcting the malfunction, check the complete system to ensure that performance is satisfactory. Standard: Symptom No blower operation Suspect Area 1. Blower fuse 2. Blower relay 3. Blower motor 4. Power mosfet 5. Blower speed control switch 6. Wire harness No air temperature control 1. Engine coolant capacity 2. Heater control assembly No compressor operation 1. Refrigerant capacity 2. A/C Fuse 3. Magnetic clutch 4. Compressor 5. A/C pressure transducer 6. A/C switch 7. Evaporator temperature sensor 8. Wire harness No cool comes out 1. Refrigerant capacity 2. Refrigerant pressure 3. Drive belt 4. Magnetic clutch 5. Compressor 6. A/C pressure transducer 7. Evaporator temperature sensor 8. A/C switch 9. Heater control assembly 10. Wire harness Insufficient cooling 1. Refrigerant capacity 2. Drive belt 3. Magnetic clutch
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4. Compressor 5. Condenser 6. Expansion valve 7. Evaporator 8. Refrigerant lines 9. A/C pressure transducer 10. Heater control assembly No engine idle-up when A/C switch ON 1. Engine ECM 2. Wire harness No air inlet control No mode control 1. Heater control assembly 1. Heater control assembly 2. Control actuator No cooling fan operation 1. Cooling fan 2. Fan motor 3. Engine ECM 4. Wire harness
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Special Service Tools

Tool (Number and name) 09977-29000 Disc & hub assembly bolt remover Illustration Use Removal and installation of the disc & hub assembly bolt
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Instructions When Handling Refrigerant

1. 2. 3. 4. R-134a liquid refrigerant is highly volatile. A drop on the skin of your hand could result in localized frostbite. When handling the refrigerant, be sure to wear gloves. It is standard practice to wear goggles or glasses to protect your eyes, and gloves to protect your hands. If the refrigerant splashes into your eyes, wash them with clean water immediately. The R-134a container is highly pressurized. Never leave it in a hot place, and check that the storage temperature is below 52C (126F) An electronic leak detector should be used to check the system for refrigerant leakage. Bear in mind that the R-134a, upon coming into contact with flame, produces phosgene, a highly toxic gas. Use only recommended the lubricant for R-134a systems. If lubricants other than the recommended one used, system failure may occur. PAG lubricant absorbs moisture from the atmosphere at a rapid rate, therefore the following precautions must be observed: A. When removing refrigerant components from a vehicle, cap immediately the components to prevent from the entry of moisture. B. When installing refrigerant components to a vehicle, do not remove the cap until just before connecting the components. C. Complete the connection of all refrigerant tubes and hoses without delay to prevent the A/C system from taking on moisture. D. Use the recommended lubricant from a sealed container only. 7. If an accidental discharge in the system occurs, ventilate the work area before resuming service.
5. 6.
When Replacing Parts On A/C System

1. 2. 3. 4. Never open or loosen a connection before discharging the system. Seal the open fittings of components with a cap or plug immediately to prevent intrusion of moisture or dust. Do not remove the sealing caps from a replacement component until it is ready to be installed. Before connecting an open fitting, always install a new sealing ring. Coat the fitting and seal with refrigerant oil before making the connection.
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When Installing Connecting Parts

Flange With Guide Pin Check the new O-ring for damage (use only the specified) and lubricate it using compressor oil. Tighten the nut to specified torque.
Size
Tightening torque [ N.m (kg.m, lbf.ft) ] General bolt, nut 4T 7T 9 - 11 (0.9 - 1.1, 6.5 - 7.9) 20 - 26 (2.0 - 2.6, 14 - 18) 45 - 55 (4.5 - 5.5, 32 - 39)
M6 M8 M10 Size
5-6 (0.5 - 0.6, 3.6 - 4.3) 12 - 14 (1.2 - 1.4, 8.7 - 10) 25 - 28 (2.5 - 2.8, 18 - 20) Flange bolt, nut 4T
7T 8 - 12 (0.8 - 1.2, 5.8 - 8.6) 19 - 28 (1.9 - 2.8, 14 - 20) 39 - 60 (3.9 - 6.0, 28 - 43)
M6 M8 M10
5-7 (0.5 - 0.7, 3.6 - 5.0) 10 - 15 (1.0 - 1.5, 7 - 10) 21 - 31 (2.1 - 3.1, 15 - 22)
T means tensile intensity, which is stamped on the head of bolt only numeral. Handling Tubing And Fittings The internal parts of the refrigeration system will remain in a state of chemical stability as long as pure moisture-free refrigerant and refrigerant oil are used. Abnormal amounts of dirt, moisture or air can upset the chemical stability and cause problems or serious damage.
The Following Precautions Must Be Observed

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The Following Precautions Must Be Observed

1. 2. 3. 4. 5. When it is necessary to open the refrigeration system, have everything you will need to service the system ready so the system will not be left open any longer than necessary. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture. All lines and components in parts stock should be capped or sealed until they are ready to be used. Never attempt to rebind formed lines to fit. Use the correct line for the installation you are servicing. All tools, including the refrigerant dispensing manifold, the gauge set manifold and test hoses, should be kept clean and dry.
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Refrigeration Cycle
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Refrigerant System Service Basics Refrigerant Recovery

Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a(R-134a) from the air conditioning system.
- Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect an R-134a refrigerant Recovery/Recycling/Charging System (A) to the high-pressure service port (B) and the lowpressure service port (C) as shown, following the equipment manufacturer's instructions.
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2.
Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to install the same amount of new refrigerant oil back into the A/C system before charging.
System Evacuation
- Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be evacuated using an R-134a refrigerant Recovery/Recycling/Charging System. (If the system has been open for several days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.) Connect an R-134a refrigerant Recovery/Recycling/Charging System (A) to the high-pressure service port (B) and the low-pressure service port (C) as shown, following the equipment manufacturer's instructions.
2.
3.
If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 10 minutes, there is probably a leak in the system. Partially charge the system, and check for leaks (see Leak Test.). Remove the low pressure valve from the low-pressure service port.
4.
System Charging
- Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment.
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- Do not breathe refrigerant or vapor. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect an R-134a refrigerant Recovery/Recycling/Charging System (A) to the high-pressure service port (B) as shown, following the equipment manufacturer's instructions.
2.
Add the same amount of new refrigerant oil to system that was removed during recovery. Use only specified refrigerant oil. Charge the system with 17.6 0.88 (450 25) of R-134a refrigerant. Do not overcharge the system the compressor will be damaged.
Refrigerant Leak Test

Always conduct a leak test with an electronic leak detector whenever leakage or refrigerant is suspected and when conducting service operations which are accompanied by disassembly or loosening or connection fittings. In order to use the leak detector properly, read the manual supplied by the manufacturer. If a gas leak is detected, proceed as follows: 1. 2. Check the torque on the connection fittings and, if too loose, tighten to the proper torque. Check for gas leakage with a leak detector (A). If leakage continues even after the fitting has been tightened, discharge the refrigerant from the system, disconnect the fittings, and check their seating faces for damage. Always replace, even if the damage is slight. Check the compressor oil and add oil if required. Charge the system and recheck for gas leaks. If no leaks are found, evacuate and charge the system again.
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Component Location Index Engine Room
Interior
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Components
1. Bolt 2. Disc & hub assembly 3. Shim (Gap washer) 4. Retainer ring (Pulley) 5. Pulley
6. Retainer ring (Field coil) 7. Field coil 8. Screw 9. Connector bracket 10. Compressor assembly
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1. Bolt 2. Disc & hub assembly 3. Shim (Gap washer) 4. Retainer ring (Pulley) 5. Pulley
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6. Retainer ring (Field coil) 7. Field coil 8. Screw 9. Connector bracket 10. Compressor assembly
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Removal
1. 2. 3. 4. 5. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few minutes, then shut the engine off. Disconnect the negative cable from the battery. Recover the refrigerant with a recovery/charging station. Loosen the drive belt. Remove the bolts, then disconnect the suction line (A) and discharge line (B) from the compressor. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
6.
Disconnect the compressor clutch connector, and then remove 4 mounting bolts and the compressor (A).
Installation
1. Make sure of the length of compressor mounting bolts, and then tighten it ABCD order.
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Tightening torque : 2.04~3.36 kg/f 2. Install in the reverse order of removal, and note these items. A. If you're installing a new compressor, drain all the refrigerant oil from the removed compressor, and measure its volume, Subtract the volume of drained oil from 120cc(4.20 oz.) the result is the amount of oil you should drain from the new compressor (through the suction fitting). B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for R-134a to avoid leakage. C. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. D. Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption. E. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. F. Adjust the drive belt. G. Charge the system and test its performance.
Inspection
1. 2. Check the plated parts of the disc & hub assembly (A) for color changes, peeling or other damage. If there is damage, replace the clutch set. Check the pulley (B) bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag.
3.
Check operation of the magnetic clutch. Connect the compressor side terminals to the battery (+) terminal and the ground battery (-) terminal to the compressor body. Check the magnetic clutch operating noise to determine the condition.
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Disassembly
1. 2. Disconnect the negative(-) battery terminal. Remove the front tire (A).
3.
Remove the side cover (A).
4. 5.
Remove the wheel house. (Refer to BD group - "Body Side Moldings") Remove the center bolt (A) while holding the disc & hub assembly. Tightening torque : 10~15 N.m(1.02~1.53 kgf.m, 7.37~11 lb.ft)
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6.
Remove the disc & hub assembly (A) and shim (gap washer) (B), taking care not to lose the shims.
7. 8.
Disconnect the drive belt. (Refer to EM group - "Drive Belt") If you remove the field coil, remove retainer ring (A) with retainer ring pliers.
- Be careful not to damage the pulley (B) and compressor during removal/installation. - Once retainer ring (A) is removed, replace it with a new one.
9.
Remove the screw (A) from the field coil ground terminal. Remove the retainer ring (B) and then remove the field coil (C) from the shaft with a puller. Be careful not to damage the coil and compressor.
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10.
Reassemble the compressor clutch in the reverse order of disassembly, and note these items : A. Clean the pulley and compressor sliding surfaces with non-petroleum solvent. B. Install new retainer rings, and make sure they are fully seated in the groove. C. Make sure that the pulley turns smoothly after its reassembled.
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Component Location
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Inspection
1. 2. Check the condenser fins for clogging and damage. If clogged, clean them with water, and blow them with compressed air. If bent, gently bend them using a screwdriver or pliers. Check the condenser connections for leakage, and repair or replace it, if required.
Replacement Condenser Assembly

1. 2. 3. 4. Recover the refrigerant with a recovery/ recycling/ charging station. Disconnect the negative (-) battery terminal. Remove the front bumper. (Refer to BD group - "Front Bumper") Remove 2 nuts (A), and then disconnect the discharge line and liquid line from the condenser. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination. Tightening torque : 7.8~11.7 N.m(0.8~1.2 kgf.m, 5.9~8.7 lb.ft)
5.
Remove the condenser side cover (A).
6.
Remove 2 bolts, and then remove the condenser by lifting it up. Be careful not to damage the radiator and condenser fins when removing the condenser (B).
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radiator and condenser fins when removing the condenser (B).
7.
Install in the reverse order of removal, and note these items : A. If you're installing a new condenser, add refrigerant oil ND-OIL8. B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for R-134a to avoid leakage. C. Be careful not to damage the radiator and condenser fins when installing the condenser. D. Charge the system, and test its performance.
Desiccant
1. Remove the condenser, and then remove the bottom cap (B) with L wrench (A) from the condenser. Tightening torque : 20~25 N.m(2.0~2.5 kgf.m, 14.5~18.2 lb.ft)
2.
Remove the desiccant (A) from condenser using a long nose plier. Check for crumbled desiccant and clogged bottom cap filter.
3. 4.
Apply air conditioning compressor oil along the O-rings and threads of the new bottom cap. Insert the new desiccant into the receiver drier tank. The desiccant must be sealed in vacuum
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before it is exposed to air for use. 5. Install the new bottom cap to the condenser.
- Always replace the desiccant and bottom cap at the same time. - Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for R-134a to avoid leakage. - Be careful not to damage the radiator and condenser fins when installing the condenser. - Charge the system, and test its performance.
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Component Location
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Replacement
1. 2. Discharge refrigerant from refrigeration system. Replace faulty tube or hose. Cap the open fittings immediately to keep moisture or dirt out of the system. 3. Tighten joint of bolt or nut to specified torque. Connections should not be torque tighter than the specified torque. Part tightened Condenser - Discharge hose Condenser - Liquid tube Compressor - Discharge hose Compressor - Suction hose Expansion valve - Evaporator 1.2~1.5 0.5~0.6 kg.m (N.m, lbf.ft) 0.5~0.6
4.
Evacuate air in refrigeration system and charge system with refrigerant. Specified amount : 450 25g (17.60.88)
5. 6.
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Inspect for leakage of refrigerant. Using a gas leak detector, check for leakage of refrigerant. Inspect A/C operation.
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Description
A/C pressure transducer convert the pressure value of high pressure line into voltage value after measure it. By converted voltage value, engine ECM controls cooling fan by operating it high speed or low speed. Engine ECM stop the operation of compressor when the temperature of refrigerant line is so high or so low irregularly to optimize air conditioning system.
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Inspection
1. Measure the pressure of high pressure line by measuring voltage output between NO.1 and NO.2 terminals.
2.
Inspect the voltage value whether it is sufficient to be regular value or not. Voltage = 0.00878835 * Pressure + 0.37081095 [PSIA]
3.
If the measured voltage value is not specification, replace the A/C pressure transducer.
Replacement
1. 2. 3. 4. Disconnect the negative (-) battery terminal. Recover the refrigerant with a recovery/charging station. Disconnect A/C pressure transducer connector (3P) (A). Remove the A/C pressure transducer (B).
Take care that liquid & suction pipe are not bent. 5. Installation is the reverse order of removal. Tightening torque : 10~12 N.m(1.0~1.2 kgf.m, 7.4~8.8 lbf.ft)
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Description
The evaporator temperature sensor will detect the evaporator core temperature and interrupt compressor relay power in order to prevent evaporator freezing by excessive cooling. It is a negative type thermistor whose resistance is inversely proportional to temperature.
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Inspection
1. 2. 3. Ignition "OFF" Disconnect evaporator temperature sensor. Using the multi-tester, Measure resistance between terminal "1" and "2" of evaporator temperature sensor.
[Specification] Evaporator core temperature [C(F)] -10(14) 0(32) 10(50) 20 (68) 30(86) 40(104) 50(122) Resistance [k] 43.35 27.62 18.07 12.11 8.30 5.81 4.15
4. 5.
If the measured resistance is not specification, substitute with a known-good evaporator temperature sensor and check for proper operation. If the problem is corrected, replace the evaporator temperature sensor.
Replacement
1. 2. 3. Remove the glove box. (Refer to BD group - "Crash pad") Remove the heater unit. Remove the heater unit lower cover(A).
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4.
Remove the evaporator temperature sensor (B).
5.
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Installation is the reverse order of removal
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Components Location
Components
1. Heater case (L) 7. Lower insulation 13. O-Ring 2. Cowl seal 8. Lower evaporator case 14. Seal
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3. Def door 4. Vent door 5. Floor door 6. Temp door
9. Drain hose 10. Mode cam 11. Temp lever 12. Shipping cap
15. Evaporator pipe braket 16. Evaporator core 17. Upper insulration 18. Evaporator sensor
1. Heater case (R) 4. Heator pipe cover 2. PTC controller 5. Heator pipe cover 3. PTC heator core 6. Heator core
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Replacement
1. 2. 3. 4. Disconnect the negative (-) battery terminal. Recover the refrigerant with a recovery/ recycling/ charging station. When the engine is cool, drain the engine coolant from the radiator. Remove the bolts (A) and the expansion valve (B) from the evaporator core.Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
5.
Disconnect the inlet (A) and outlet (B) heater hoses from the heater unit.
Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on electrical parts or painted surfaces. If any coolant spills, rinse it off immediately. 6. 7. Remove the wiper. (Refer to Be group - "Wiper") Remove the cowl cover (A)
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8.
Loosen the heater unit mount bolts (A).
9. 10. 11.
Remove the crash pad. (Refer to BD group - "Crash pad") Remove the cowl cross bar assembly. (Refer to BD group - "Crash pad") Remove the heater & blower unit after loosening 3 mounting bolts.
12.
Remove the blower unit (B) from heater unit after loosening 3 screws.
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13.
Remove the heater core (B) cover (A).
14.
Be careful that the inlet and outlet pipe are not bent during heater core removal, and pull out the heater core.
15.
Remove the heater unit lower case(A).
16.
Remove the evaporator core(A).
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16.
Remove the evaporator core(A).
17. 18.
Install the heater core in the reverse order of removal. Installation is the reverse order of removal, and note these items : A. If you're installing a new evaporator, add refrigerant oil (ND-OIL8). B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for R-134a to avoid leakage. C. Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. D. Do not spill the refrigerant oil on the vehicle ; it may damage the paint ; if the refrigerant oil contacts the paint, wash it off immediately. E. Apply sealant to the grommets. F. Make sure that there is no air leakage. G. Charge the system and test its performance. H. Do not interchange the inlet and outlet heater hoses and install the hose clamps securely. I. Refill the cooling system with engine coolant.
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Description
1. 2. Heater unit includes mode control actuator and temperature control actuator. Temperature control actuator is located at the heater unit. It regulates the temperature by the procedure as follows. Signal from control unit adjusts position of temperature door by operating temperature switch and then temperature will be regulated by the hot/cold air ratio decided by position of temperature door
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Inspection
1. 2. 3. Ignition "OFF" Disconnect the connector of temperature control actuator. Verify that the temperature control actuator operates to the hot position when connecting 12V to the terminal 3 and grounding terminal 4. Verify that the temperature control actuator operates to the cool position when connecting in the reverse.
1. 4. Cool Position 2. 5. Sensor Ground 3. Hot Position 6. Feedback Signal 7. 5V (Vcc)
4.
Check the voltage between terminals 5 and 6. Specification Door position Max. cooling Max. heating Voltage (5-6) 0.45 0.15V 4.55 0.15V Error detecting Low voltage : 0.1V or less High voltage : 4.9V or more
* It will feedback current position of actuator to controls. 5. 6. If the measured voltage is not specification, substitute with a known-good temperature control actuator and check for proper operation. If the problem is corrected, replace the temperature control actuator.
Replacement
1. 2. 3. 4. Disconnect the negative (-) battery terminal. Remove the glove box. (Refer to BD group - "Crash pad") Remove the glove box housing. (Refer to BD group - "Crash pad") Loosen the mounting screw and then remove the temperature control actuator (B).
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5.
Installation is the reverse order of removal.
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Component Location
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Description
The mode control actuator is located at the heater unit. It adjusts position of mode door by operating mode control actuator based on signal of A/C control unit. Pressing mode select switch makes the mode control actuator shift in order of vent B/L floor mix.
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Inspection
1. 2. 3. 4. Ignition "OFF Disconnect the connector of mode control actuator. Verify that the mode control actuator operates to the defrost mode when connecting 12V to the terminal 3 and grounding terminal 4. Verify that the mode control actuator operates to the vent mode when connecting in the reverse.
1. 4. Vent mode 2. 5. Sensor ground 3. Defrost mode 6. Feedback signal 7. 5V (Vcc)
5.
Check the voltage between terminals 5 and 6. Door position Vent Defrost Voltage (5-6) 0.3 0.15V 4.7 0.15V Error detecting Low voltage :0.1V or less High voltage :4.9V or more
It will feedback current position of actuator to controls. 6. 7. If the measured voltage is not specification, substitute with a known-good console temp control actuator and check for proper operation. If the problem is corrected, replace the console temp control actuator.
Replacement
1. 2. Disconnect the negative (-) battery terminal. Remove the crash pad side cover (A).
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3.
After loosening the crash pad lower panel mounting screws, then remove the lower panel (B).
4.
Remove the extension cover(A).
5.
Loosen the mounting screw and then remove the mode control actuator (B).
6.
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Description
PTC (Positive Temperature Coefficient) heater (A) is an electric heater using a PTC element as an auxiliary heating device that supplements deficiency of interior heat source in highly effective diesel engine (U engine).
An electric heater heats up the interior by directly heating the air that passes through the heater. PTC = positive Temperature Coefficient The name itself implies that the element has a proportional resistance change sensitive to temperature. PTC heater is installed at the exit or the backside of heater core.
Operation Principle
ECM outputs a PTC on signal. Operate PTC from 1st setting to 3rd setting with an interval of 15 seconds. Heat up the air, which passes through a heater core.
Operation Condition
Judge the condition by ambient temperature is below 5C, coolant temperature is below 70C, and battery voltage is above 11V and engine RPM is above 700RPM.
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Inspection
Inspect the PTC operation by confirmation logic as below. 1. Entering method (1) (2) (3) (4) (5) (6) (7) 2. Set the floor mode, maximum heating. Turn off the blower switch Press the intake button more than 5 times. Indicator of entire button is flashed with an interval of 0.5 seconds continuously (Manual). Confirm the PTC operation by operating the blower switchManual: 1~4 step. Each PTC relay is operated with an interval of 3 seconds. Execute the PTC operation by confirmation logic for 30 seconds.
Cancellation method (1) (2) (3) Select the A/C button or intake button. IG "OFF" Cancel the logic after 30 seconds automatically.
3.
If the PTC operation is not operated, substitute with a known-good PTC and check for proper operation. (1) If the problem is corrected, replace the PTC.
Replacement
1. 2. Remove the glove box. (Refer to BD group - "Crash pad") Remove the lower panel (A).
3.
Disconnect the PTC heater connector (A).
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4.
Remove the PTC heater core (A).
5.
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Component Location
Components
1. Cowl seal 6. Filter cover 2. Inlet duct case 7. Blower upper case
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3. Inlet door 8. Blower lower case 4. Intake actuator 9. Blower resistor 5. Filter 10. Blower motor
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Replacement
1. 2. 3. 4. 5. Disconnect the negative (-) battery terminal. Remove the crash pad. (Refer to BD group - "Crash pad") Disconnect the connectors from the intake actuator, the blower motor and power mosfet. Remove the cowl cross bar assembly. (Refer to BD group - "Crash pad") Remove the blower unit (A) from the heater unit after loosening a mounting bolt and 3 screws.
- Make sure that there is no air leaking out of the blower and duct joints. 6.
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Inspection
1. Connect the battery voltage and check the blower motor rotation.
2. 3.
If the blower motor voltage is not operated well, substitute with a known-good blower motor and check for proper operation. If the problem is corrected, replace the blower motor.
Replacement
1. 2. Disconnect the negative (-) battery terminal. Disconnect the connector (A) of the blower motor and then remove the blower motor (B) after loosening the mounting screws.
3.
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Inspection
1. 2. Measure terminal-to-terminal resistance of the blower resistor. If measured resistance is not within specification, the blower resistor must be replaced. (After removing the resistor)
Replacement
1. 2. 3. Disconnect the negative (-) battery terminal. Disconnect the power mosfet connector (A) at the connecting part between heater and blower unit. Remove the power mosfet (B) after loosening the mounting screws.
4.
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Description
This has particle filter which eliminates foreign materials and odor. The particle filter includes filter as well as conventional dust filter to ensure comfortable interior environment.
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Replacement
1. Open the glove box (A). Lower the glove box down completely by removing the glove box stopper (B) to the glove box.
2.
Remove the filter cover (A) with pushing the knob.
3.
Replace the air filter (B), install it after making sure of the direction of air filter.
In case of driving in an air-polluted area or rugged terrain, check and replace the air filter as frequently as possible.
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General Page 74
Global Service Way

Component Location
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General Page 75
Global Service Way

Description
1. 2. 3.
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The intake actuator is located at the blower unit. It regulates the intake door by signal from control unit. Pressing the intake selection switch will shift between recirculation and fresh air modes.
General Page 76
Global Service Way

Inspection
1. 2. 3. 4. Ignition "OFF" Disconnect the intake actuator connector. Verify that the actuator operates to the recirculation position when connecting 12V to the terminal 3 and grounding terminal 3. Verify that the intake actuator operates to the fresh position when connecting in the reverse.
5.
Check the voltage between terminals 5 and 6. Door position Fresh Recirculation Voltage (5-6) 0.3 0.15V 4.7 0.15V Error detecting Low voltage : 0.1V or less High voltage : 4.9V or more
If the intake actuator is not operated well, substitute with a known-good intake actuator and check for proper operation. 6. If the problem is corrected, replace the intake actuator.
Replacement
1. 2. 3. 4. Disconnect the negative (-) battery terminal. Remove the glove box. (Refer to BD group) Disconnect the intake actuator connector. Loosen the mounting screw and then remove the intake actuator (A) from the blower unit.
General Page 77
5.
General Page 78
Global Service Way

Component Location (Cable Type)
Connector PIN Function Connector Connector (A) Blower PIN 1 2 3 4 5 6 7 8 Connector (B) A/C SW 1 2 3 4 5 6 Connector (C) Rear DEF 1 2 3 Function ILL (-) HIGH COMMON GND ILL (+) M/H M/L LOW RHEO (ILL-) BLOWER (+) TAIL (ILL+) A/C OUTPUT GND RHEO (ILL-) HTD TAIL (ILL+)
General Page 79
4 5 6 Connector (D) Intake SW 1 2 3 4 5 6 Connector (E) S/WARM (RH) 1 2 3 4 5 6 Connector (F) S/WARM (LH) 1 2 3 4 5 6
GND IND RHEO (ILL-) IG2 TAIL (ILL+) REC FRESH GND RHEO (ILL-) IG2 TAIL (ILL+) RH S/WARM GND RHEO (ILL-) IG2 TAIL (ILL+) LH S/WARM GND
Component Location (Actuator Type)
Connector PIN Function Connector PIN no Function Connector PIN no Function
General Page 80
Connector(A)
Connector (B)
Tail lamp(ILL+)
2 3 4 5 6 7 8
High Common GND M/High M/Low Low
2 3 4 5 6 7 8 9
IGN1 Mode actuator(Vent) Mode actuator(Def) Temp actuator(Cool) Temp actuator(Warm) Intake actuator(Fre) Intake actuator(Rec) Mode actuator(F/B)
10 11 12 13 14 15 16 17 18 19 20 21 22
Temp actuator(F/B) Intake actuator(F/B) Blower Common Max Blower ON Signal Rheostat (ILL-) Battery IGN2 HTD Rear Defog S/W C_CAN High C_CAN Low S/Warmer LH S/W
General Page 81
23 24 25 26 27 28
S/Warmer RH S/W Sensor REF(+5V) Evaporator Sensor(+) Ambient Sensor (+) Sensor GND GND
General Page 82
Global Service Way

Replacement Cable Type

1. 2. Disconnect the negative (-) battery terminal. Remove the crash pad lower cover (A).
3.
Remove the crash pad lower pannel (A).
4.
Disconnect the cable (A), from heater unit.
5.
Remove the console under garnish (A).
General Page 83
6.
Remove the console under cover (A).
7.
After loosening the mounting screws, then remove the front console (A).
8.
After loosening the heater control mounting screws, remove the heater control unit (A).
9.
Disconnect the connectors (A) from the center facia.
General Page 84
9.
Disconnect the connectors (A) from the center facia.
10.
Disconnect the heater control unit (A) from center facia.
11.
Actuator Type
1. 2. Disconnect the negative (-) battery terminal. Remove the crash pad side cover (A).
3.
After loosening the crash pad lower panel mounting screws, then remove the lower panel (B).
General Page 85
4.
Remove the console under garnish(A).
5.
Remove the console under cover(A)
6.
After loosening the mounting screws, then remove the front console(A).
7.
After loosening the heater control mounting screws, and then remove the heater control unit(A).
General Page 86
8.
Disconnect the connector(A) from the center fascia.
9.
Remove the heater & A/C controller (A) from center fascia panel
10.
General Page 87
Global Service Way

2011 > G 1.1 SOHC > Restraint
General Information
The supplemental restraint system (SRS) is designed to supplement the seat belt to help reduce the risk or severity of injury to the driver and passenger by activating and deploying the driver, passenger, side airbag and belt pretensioner in certain frontal or side collisions. The SRS (Airbag) consists of : a driver side airbag module located in the center of the steering wheel, which contains the folded cushion and an inflator unit ; a passenger side airbag module located in the passenger side crash pad contains the folded cushion assembled with inflator unit ; side airbag modules located in the driver and passenger seat contain the folded cushion and an inflator unit. The impact sensing function of the SRSCM is carried out by electronic accelerometer that continuously measure the vehicle's acceleration and delivers a corresponding signal through amplifying and filtering circuitry to the microprocessor.
SRSCM (SRS Control Module)

SRSCM will detect front impact with front impact sensor, and side impact with side impact sensor, and determine airbag module deployment. 1. DC/DC converter: DC/DC converter in power supply unit includes up/down transformer converter, and provide ignition voltage for 2 front airbag ignition circuits and the internal operation voltage of the SRSCM. If the internal operation voltage is below critical value setting, it will perform resetting. Back up power supply: SRSCM has separate back up power supply, that will supply deployment energy instantly in low voltage condition or upon power failure by front crash. Self diagnosis: SRSCM will constantly monitor current SRS operation status and detect system failure while vehicle power supply is on, system failure may be checked with trouble codes using GDS. Airbag warning lamp on: Upon detecting error, the module will transmit signal to SRSCM indicator lamp located at cluster. MIL lamp will indicate driver SRS error. Upon ignition key on, SRS lamp will turn on for about six seconds. Trouble code registration: Upon error occurrence in system, SRSCM will store DTC corresponding to the error. DTC can be cleared only by GDS. However, if an internal fault code is logged or if a crash is recorded thefault clearing should not happen. Self diagnostic connector: Data stored in SRSCM memory will be output to GDS or other external output devices through connector located below driver side crash pad. Once airbag is deployed, SRSCM should not be used again but replaced. Side airbag deployment will be determined by SRSCM that will detect satellite sensor impact signal upon side crash, irrespective to seat belt condition.
2. 3.
4.
5.
6. 7. 8.
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Restraint Page 1
Global Service Way

Specification
Item Driver Airbag (DAB) Passenger Airbag (PAB) Side Airbag (SAB) Curtain Airbag (CAB) Seat Belt Pretensioner (BPT) Resistance () 1.7 ~ 2.3 1.7 ~ 2.3 1.9 ~ 2.5 1.7 ~ 2.3 1.8 ~ 2.5
Tightening Torques
Item Driver Airbag (DAB) Passenger Airbag (PAB) Side Airbag (SAB) Curtain Airbag (CAB) Seat Belt Anchor Bolt (BPT) SRSCM Mounting Bolt Front Impact Sensor (FIS) Mounting Bolt Side Impact Sensor (SIS) Mounting Bolt Nm 7.9 ~ 10.8 11.8 ~ 17.7 3.7 ~ 4.3 4.9 ~ 6.8 10.8 ~ 14.7 39.2 ~ 53.9 6.8 ~ 9.2 6.8 ~ 9.2 6.8 ~ 9.2 kgfm 0.8 ~ 1.1 Bolt : 1.2 ~ 1.8 Nut : 0.4 ~ 0.6 0.5 ~ 0.7 1.1 ~ 1.5 4.0 ~ 5.5 0.7 ~ 0.9 0.7 ~ 0.9 0.7 ~ 0.9 lb-ft 5.8 ~ 8.0 8.7 ~ 13.0 2.7 ~ 3.2 3.6 ~ 5.0 8.0 ~ 10.8 28.9 ~ 39.8 5.0 ~ 6.8 5.0 ~ 6.8 5.0 ~ 6.8
Restraint Page 2
Global Service Way

Precautions General Precautions

Please read the following precautions carefully before performing the airbag system service. Observe the instructions described in this manual, or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation.
Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector.
Airbag Handling and Storage

Do not disassemble the airbags; it has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the air bag during service, please observe the following precautions. Store the removed airbag with the pad surface up. Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly.
Restraint Page 3
Store the removed airbag on secure, flat surface away from any high heat source (exceeding 85 C/185F). Never perform electrical inspections to the airbags, such as measuring resistance. Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Refer to the scrapping procedures for disposal of the damaged airbag. Be careful not to bump or impact the SRS unit or the side impact sensors whenever the ignition switch is ON, wait at least three minutes after the ignition switch is turned OFF before begin work. During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the SRS unit and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. After a collision in which the airbags were deployed, replace the front airbags and the SRS unit. After a collision in which the side airbag was deployed, replace the side airbag, the front impact sensor and side impact sensor on the side where the side airbag deployed and the SRS unit. After a collision in which the airbags or the side air bags did not deploy, inspect for any damage or any deformation on the SRS unit and the side impact sensors. If there is any damage, replace the SRS unit, the front impact sensor and/or the side impact sensors. Do not disassemble the SRS unit, the front impact sensor or the side impact sensors Turn the ignition switch OFF, disconnect the battery negative cable and wait at least three minutes before beginning installation or replacement of the SRS unit. Be sure the SRS unit, the front impact sensor and side impact sensors are installed securely with the mounting bolts. Do not spill water or oil on the SRS unit,or the front impact sensor or the side impact sensors and keep them away from dust. Store the SRS unit, the front impact sensor and the side impact sensors in a cool (15 ~ 25C/59 ~ 77F) and dry (30% ~ 80% relative humidity, no moisture) area.
Wiring Precautions
SRS wiring can be identified by special yellow outer covering. Observe the instructions described in this section. Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness.
Restraint Page 4
Be sure to install the harness wires so that they are not pinched, or interfere with other parts.
Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose.
Precautions for Electrical Inspections

When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector.
Use a u-shaped probe. Do not insert the probe forcibly. Use specificed service connectors for troubleshooting. Using improper tools could cause an error in inspection due to poor metal contact.
Spring-loaded Lock Connector Airbag Connector

Restraint Page 5
Connecting
Hold both connector halves and press firmly until the projection (C) of the sleeve-side connector clicks to lock.
Restraint Page 6
Global Service Way

Warning Lamp Activation Warning Lamp Behavior After Ignition On

As soon as the operating voltage is applied to the SRSCM ignition input, the SRSCM activates the warning lamp for a bulb check. The lamp shall turn on for 6 seconds during the initialization phase and be turned off afterward. However, in order to indicate the driver, the warning lamp shall turn on for 6 seconds and off for one second then on continuously after the operating voltage is applied if any active fault exists. 1. Active fault or historical fault counter is greater or equal to 10
2.
Normal or historical fault counter is less than 10
SRSCM Independent Warning Lamp Activation

There are certain fault conditions in which the SRSCM cannot function and thus cannot control the operation of the standard warning lamp. In these cases, the standard warning lamp is directly activated by appropriate circuitry that operates independently of the SRSCM. These cases are: 1. 2. 3. 4. Loss of battery supply to the SRSCM : warning lamp turned on continuously. Loss of internal operating voltage : warning lamp turned on continuously. Loss of Microprocessor operation : warning lamp turned on continuously. SRSCM not connected : warning lamp turned on continuously through the shorting bar.
Passenger Airbag Deactivation (PAD) Lamp Operation

The SRSCM is designed with circuitry and software to drive a PAD lamp, which is used for depowered airbag system. For the PAD indicator circuitry to function properly, both the SRSCM and PAD indicator are sourced from the same ignition line. After ignition on, the PAD indicator will be turned on for 4 seconds and off for 3 seconds during the initialization phase. Thereafter the lamp will be turned on as long as the PAD switch is in the disabled position.
Passenger Restraints Activation With Pad Switch

Restraint Page 7
The PAD switch affects the activation of the front passenger airbag only and the switch is controlled manually. The PAD switch will be functioned as follows: PAD Switch status Phase-up Enabled position Disabled position Fault PAD Lamp ON OFF OFF ON Based on PAB PAB Default Enable Disable Default
Restraint Page 8
Global Service Way

Component Replacement After Deployment

Before doing any SRS repairs, use the Hi-Scan Pro to check for DTCs. Refer to the Diagnostic Trouble Code list for repairing of the related DTCs. When the front airbag(s) deployed after a collision, replace the following items. - SRSCM - Deployed airbag(s) - Seat belt pretensioner(s) - Front impact sensors - SRS wiring harnesses - Inspect the clock spring for heat damage. If any damage found, replace the clock spring. When the seat belt pretensioner(s) deployed after a collision, replace the following items. - Seat belt pretensioner(s) - SRSCM (if B1658 detected) - Front impact sensors - SRS wiring harnesses When the side/curtain airbag(s) deployed after a collision, replace the following items. - SRSCM - Deployed airbag(s) - Side impact sensor(s) for the deployed side(s) - SRS wiring harnesses After the vehicle is completely repaired, confirm the SRS airbag system is OK. - Turn the ignition switch ON, the SRS indicator should come on for about 6 seconds and then go off.
Restraint Page 9
Global Service Way

Components
1. Driver Airbag (DAB) 2. Steering Wheel 3. Clock Spring 4. Seat Belt Pretensioner (BPT) 5. Side Impact Sensor (SIS) 6. Side Airbag (SAB)
7. Passenger Airbag (PAB) 8. Front Impact Sensor (FIS) 9. Passenger Airbag Deactivation (PAD) Switch 10. Supplemental Restraint System Control Module (SRSCM) 11. Airbag Warning Lamp 12. Curtain Airbag (CAB)
Restraint Page 10
1. Driver Airbag (DAB) 2. Steering Wheel 3. Clock Spring 4. Seat Belt Pretensioner (BPT) 5. Side Impact Sensor (SIS) 6. Side Airbag (SAB)
7. Passenger Airbag (PAB) 8. Front Impact Sensor (FIS) 9. Passenger Airbag Deactivation (PAD) Switch 10. Supplemental Restraint System Control Module (SRSCM) 11. Airbag Warning Lamp
Component Locations Supplemental Restrain System Control Module (SRSCM)
Driver Airbag (DAB) / Passenger Airbag (PAB)
Side Airbag (SAB)

Restraint Page 11
Side Airbag (SAB)
Front Impact Sensor (FIS)
Seat Belt Pretensioner (BPT) / Side Impact Sensor (SIS)
Restraint Page 12
Seat Belt Pretensioner (BPT) / Side Impact Sensor (SIS)
Restraint Page 13
Global Service Way

Description
The primary purpose of the SRSCM (Supplemental Restraints System Control Module) is to discriminate between an event that warrants restraint system deployment and an event that does not. The SRSCM must decide whether to deploy the restrain system or not. After determining that pretensioners and/or airbag deployment is required, the SRSCM must supply sufficient power to the pretensioners and airbag igniters to initiate deployment. The SRSCM determines that an impact may require deployment of the pretensioners and airbags from data obtained from impact sensors and other components in conjunction with a safing function. The SRSCM will not be ready to detect a crash or to activate the restraint system devices until the signals in the SRSCM circuitry stabilize. It is possible that the SRSCM could activate the safety restraint devices in approximately 2 seconds but is guaranteed to fully function after prove-out is completed. The SRSCM must perform a diagnostic routine and light a system readiness indicator at key-on. The system must perform a continuous diagnostic routine and provide fault annunciation through a warning lamp indicator in the event of fault detection. A serial diagnostic communication interface will be used to facilitate servicing of the restraint control system.
Restraint Page 14
Global Service Way

Components
Restraint Page 15
Global Service Way

Removal
1. 2. 3. 4. 5. Remove ignition key from the vehicle. Disconnect the negative (-) cable from battery and wait for at least three minutes. Disconnect the DAB, PAB, SAB, CAB and BPT connectors. Remove the floor console. (Refer to the Body group - "Console") Press the lock(1), then pull back the connector lever (2) until it clicks.
6. 7.
Disconnect the SRSCM harness connector (A) and (B) from the SRSCM. Remove the SRSCM mounting bolts (3EA) from the SRSCM, then remove the SRSCM.
Installation
1. 2. 3. Remove ignition key from the vehicle. Disconnect the negative (-) cable from battery and wait for at least three minutes. Install the SRSCM with the SRSCM mounting bolts. Tightening Torque: 6.8 ~ 9.2 N.m (0.7 ~ 0.9 kgf.m , 5.0 ~ 6.8 lb-ft)
Restraint Page 16
4.
Connect the SRSCM harness connector (A, B).
5. 6. 7. 8.
Install the floor console. (Refer to the Body group - "Console") Connect the DAB, PAB, SAB, CAB and BPT connectors. Reconnect the battery negative cable. After installing the SRSCM, confirm proper system operation: A. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.
Restraint Page 17
Global Service Way

Description
The front impact sensors (FIS) are installed on the upper of the side panel in Front End Module(FEM). They are remote sensors that detect acceleration due to a collision at their mounting locations. The primary purpose of the Front Impact Sensor (FIS) is to provide an indication of a collition. The Front Impact Sensor(FIS) sends acceleration data to the SRSCM.
Restraint Page 18
Global Service Way

Removal
Removal of the airbag must be performed according to the precautions/ procedures described previously. Before disconnecting the front impact sensor connector, disconnect the front airbag connector(s). Do not turn the ignition switch ON and do not connect the battery cable while replacing the front impact sensor. 1. 2. 3. 4. Disconnect the battery negative cable, and wait for at least three minutes before beginning work. Remove the head lamp assembly. (Refer to the Body Electrical System group - "Head lamps") Disconnect the front impact sensor connector. Remove the front impact sensor mounting bolt.
5.
Remove the front impact sensor.
Installation
Be sure to install the harness wire not to be pinched or interfere with other parts. Do not turn the ignition switch ON and do not contact the battery cable while replacing the front impact sensor. 1. Install the new Front Impact Sensor with bolt then connect the SRS harness connector to the Front Impact Sensor. Tightening torque: 6.8 ~ 9.2 N.m (0.7 ~ 0.9 kgf.m , 5.0 ~ 6.8 lb-ft) 2. 3. Install the head lamp assembly. Reconnect the negative battery cable.
Restraint Page 19
4.
After installing the Front Impact Sensor, confirm proper system operation: Turn the ignition switch ON the SRS indicator light should be turned on for about six seconds and then go off.
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Restraint Page 20
Global Service Way

Description
The Side Impact Sensor (SIS) system consists of two front SIS which are installed inside the Center Pillar (LH and RH). They are remote sensors that detect acceleration due to collision at their mounting locations. The primary purpose of the Side Impact Sensor (SIS) is to provide an indication of a collision. The Side Impact Sensor (SIS) sends acceleration data to the SRSCM.
Inserted from <http://service.hyundai-motor.com/Main/Viewer/index.asp?IsClickMenu=true&group=SHOP>
Restraint Page 21
Global Service Way

Components
Restraint Page 22
Global Service Way

Removal
Removal of the airbag must be performed according to the precautions/procedures described previously. Before disconnecting the side impact sensor connector(s), disconnect the side airbag connector(s). Do not turn the ignition switch ON and do not connect the battery cable while replacing the side impact sensor. 1. 2. Disconnect the battery negative cable, and wait for at least three minutes before beginning work. Remove the following parts. (Refer to the Body group - "Interior trim") A. Center pillar trim, Door scuff trim 3. 4. Disconnect the Side Impact Sensor connector. Remove the SIS mounting bolt then remove the Side Impact Sensor.
Installation
Be sure to install the harness wires not to be pinched or interfered with other parts. Do not turn the ignition switch ON and do not connect the battery cable while replacing the side impact sensor. 1. Install the new Side Impact Sensor with the bolt then connect the SRS harness connector to the Side Impact Sensor. Tightening torque: 6.8 ~ 9.2 N.m (0.7 ~ 0.9 kgf.m , 5.0 ~ 6.8 lb-ft) 2. Install the following parts. (Refer to the Body group - "Interior trim")
Restraint Page 23
A. Door scuff trim, Center pillar trim 3. 4. Reconnect the negative battery cable. After installing the Side Impact Sensor, confirm proper system operation: Turn the ignition switch ON, the SRS indicator light should be turned on for about six seconds and then go off.
Restraint Page 24
Global Service Way

Description
Driver can control the passenger airbag operating Condition (Enable or Disable) by using this PAB ON/OFF switch. Passenger Airbag (PAB) ON/OFF Switch is installed in the crash pad side cover.
Restraint Page 25
Global Service Way

Components
Restraint Page 26
Global Service Way

Removal
1. 2. 3. 4. Remove the ignition key from the vehicle. Disconnect the battery negative cable and wait for at least three minutes before beginning work. Remove the crash pad side cover. (Refer to the Body group - "Crash pad") Disconnect the PAB ON/OFF switch connector (A).
5.
Remove the PAB ON/OFF switch.
Installation
1. 2. 3. 4. 5. 6. Remove the ignition key from the vehicle. Disconnect the battery negative cable and wait for at least three minutes before beginning work. Install the PAB ON/OFF switch to the crash pad side cover. Connect the PAB ON/OFF switch connector to the crash pad side cover. Install the crash pad side cover. (Refer to the Body group "Crash pad") After installing the SRSCM, confirm proper system operation: A. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.
Restraint Page 27
Global Service Way

Circuit Diagram (1)
Circuit Diagram (2)
Restraint Page 28
SRSCM Connector Terminal SRSCM Harness Connector
For short circuit check, shorting bar must be opened. Use a plastic clip as a shorting bar opener for disconnecting shorting bar. Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 Function (Connector A) Passenger Airbag Low Passenger Airbag High Driver Airbag High Driver Airbag Low PAB ON-OFF Switch Return Line Ground Crash Output Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 Function (Connector B) Seat Belt Pretensioner [Front-Driver] High Seat Belt Pretensioner [Front-Driver] Low Seat Belt Pretensioner [Front-Passenger] Low Seat Belt Pretensioner [Front-Passenger] High Side Airbag [Front-Driver] High Side Airbag [Front-Driver] Low Side Airbag [Front-Passenger] Low Side Airbag [Front-Passenger] High Curtain Airbag [Driver] High
Restraint Page 29
14 15 16 17 18 19 20 21 22 23 24
PAB ON-OFF Switch Front Impact Sensor [Driver] High Front Impact Sensor [Driver] Low K-Line Diagnostic Airbag Warning Lamp PAD Lamp Front Impact Sensor [Passenger] Low Front Impact Sensor [Passenger] High Ignition
14 15 16 17 18 19 20 21 22 23 24
Curtain Airbag [Driver] Low Curtain Airbag [Passenger] Low Curtain Airbag [Passenger] High Side Impact Sensor [Driver] High Side Impact Sensor [Driver] Low
25 Side Impact Sensor [Passenger] Low 26 Side Impact Sensor [Passenger] High 27 28 29 30 31 32
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Restraint Page 30
Global Service Way

Components
Restraint Page 31
Global Service Way

2011 > G 1.1 SOHC > Body (Interior and Exterior)
Specifications
Hood Front Door Type Construction Regulator system Locking system Rear Door Construction Regulator system Locking system Tailgate Type Front door glass Rear door glass Rear hinged, gas lifter type Front hinged, full door construction Wire drum type Pin-fork system Front hinged, full door construction Wire drum type Pin-fork system Inner hinged, gas lifter 5mm 4mm 4mm
Glass Thicknes Windshield glass
Rear window glass 3.5mm Seat Belts Front Rear 3 point type with Emergency Locking Retractor (E.L.R) 3 point type with Emergency Locking Retractor (E.L.R)2 point type
Tightening Torque
Items Foont and rear doors Door hinge to body Door hinge to door Door Striker Checker to body Checker to door Hood Hood hinge to body Hoodl hinge to hood Hood latch to body Seat Front seat mounting bolts Front seat mounting nut Rear seat mounting bolts Rear seat frame mounting bolts Seat belt Front seat belt height adjuster Front seat belt buckle mounting bolt Front seat belt anchor mounting bolt Front seat belt lower anchor Front seat belt upper anchor Nm 21.6~26.5 21.6~26.5 16.7~21.6 16.7~21.6 6.9~10.8 21.6~26.5 21.6~26.5 6.9~10.8 34.3 ~ 53.9 23.5~35.3 16.7~25.5 16.7~25.5 39.2~53.9 39.2~53.9 39.2~53.9 39.2~53.9 39.2~53.9 kgfm 2.2~2.7 2.2~2.7 1.7~2.2 1.7~2.2 0.7~1.1 2.2~2.7 2.2~2.7 0.7~1.1 3.5~5.5 2.4~3.6 1.7~2.6 1.7~2.6 4.0 ~ 5.5 4.0 ~ 5.5 4.0 ~ 5.5 4.0 ~ 5.5 4.0 ~ 5.5 Lbfft 15.9~19.5 15.9~19.5 12.3~15.9 12.3~15.9 5.1~8.0 15.9~19.5 15.9~19.5 5.1~8.0 25.3~39.8 17.4~26.0 12.3~18.8 12.3~18.8 28.9 ~ 39.8 28.9 ~ 39.8 28.9 ~ 39.8 28.9 ~ 39.8 28.9 ~ 39.8
Body (Interior and Exterior) Page 1.1
Rear seat belt anchor attaching bolt Rear seat belt retractor mounting bolt
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39.2~53.9 39.2~53.9
4.0 ~ 5.5 4.0 ~ 5.5
28.9 ~ 39.8 28.9 ~ 39.8
Global Service Way


Tool (Number and name) 09793-2100 Door hinge adjusting wrench Illustration Use Adjustment, removal and installation of the door hinge
09800-21000 Ornament remover
Trim removal
09853-31000 Headliner clip remover
Removal of the headliner clips
09861-31100 Sealant cut-out tool
Cutting the sealant of the windshield (Use with 09861-31200)
09861-31200 Sealant cutting blade
Cutting the sealant of the windshield (Use with 09861-31100)
09861-31000 Windshield molding remover
Removal of the windshield molding
09880-4F000 Hog ring clip installer
Installation of the hog ring clip
09840-1E100 Center fascia remover
Center fascia removal
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Global Service Way

Troubleshooting
Symptom Water leaks from sunroof Suspect Area Dirt accumulated in drain tube Clogged drain tube Broken or dislocated drain tube, defective or cracked clip Remedy Clear dirt inside of drain Blow air into drain to remove dirt Check tube installation and flange contact
Deteriorated roof lid weatherstrip Replace Excessive roof lid-to-body clearance and improperly fitted weatherstrip Wind noise around sunroof Sunroof lid makes a noise when move Loose or deformed deflector, gaps in body work Adjust
Retighten adjust or replace
Foreign particles lodged in guide Check drive cable rail and guide rails for foreign particles Loose guide rails and lid Retighten
Motor runs but sunroof does not move or moves Foreign particles lodged in guide Adjust or replace only partially rail Incorrect engagement of motor pinion with drive cable Decrease in motor`s clutch slipping force Increased sunroof sliding resistance or interference of sunroof with drive cables, weatherstrip, etc. due to mal adjustment of sunroof Noise in motor (clutch slipping noise from motor when sunroof Is fully opened or closed is not an unusual noise Incorrect engagement of motor pinion with drive cable Worn out or damaged motor pinion bearing Worn out or deformed drive cable Door glass fails to operate up and down Incorrect window glass installation Check pinion installation and retighten motor Replace motor assembly Replace Adjust position
Damaged or faulty regulator arm Correct or replace orregulator Door does not open or close completely Incorrect door installation Defective door check assembly Adjust position Correct or replace
Door hinge requires grease Hood does not open or close completely Striker and latch not properly aligned Incorrectly installed hood Incorrect hood bumper height Water leak through windshield end rear window Defective seal Defective flange
Apply grease Adjust Adjust Adjust Fill with sealant Correct
Global Service Way

Replacement
Take care not to damage the hood and body. When removing the clips, use a clip remover. 1. Remove the windshield side molding (A).
2.
After loosening the mounting screws, remove the mud guide (A).
3.
After loosening the mounting screws and bolt, then remove the front bumper side mounting bracket (A).
4.
After loosening the mounting bolts, then remove the fender (A).
5.
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Installation is the reverse of removal.
Global Service Way

Replacements Hood Assembly Replacement

When removing and installing the hood, an assistant is necessary. Take care not to damage the hood and body. When removing the clips, use a clip remover. 1. After loosening the hood hinge (A) mounting bolts,remove the hood (B).
Make sure the hood opens properly and locks securely. Adjust the hood alignment.
2.
Hood Insulator Replacement

1. Using a clip remover, detach the clips, and remove the hood insulator (A).
Take care not to scratch the hood panel.
2.
Replace any damaged clips.
Hood Seal Weatherstrip Replacement

1. Detach the clips, then remove the hood weatherstrip(A). Take care not to scratch the hood.
2.
Hood Latch Replacement

1. After loosening the mounting bolts, then remove the hood latch cover (A).
2.
After loosening the mounting bolts, then remove the hood latch (B).
3.
Disconnect the hood latch cable (C) and remove the latch (D).
3.
Disconnect the hood latch cable (C) and remove the latch (D).
4.
Make sure the hood latch cable is connected properly. Make sure the hood locks securely.
Adjustment Adjust Hood

1. 2. 3. After loosening the hinge (A) mounting bolt, adjust the hood (D) by moving it up or down, or right or left. Adjust the hood height by turning the hood overslam bumpers (B). After loosening the hood latch (C) mounting bolts,adjust the latch by moving it up or down, or right or left.
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Global Service Way

Replacements Tailgate Trim Replacement

When prying with a flat-tipped screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage. Put on gloves to protect your hands. 1. Remove the tailgate trim (A).
Replace damaged clips.
2.
Latch Assembly Replacement

1. 2. 3. Remove the tailgate trim. Disconnect the tailgate handle rod (A) and latch rod (B). Disconnect the connector (C).
4.
After loosening the mounting bolts, then remove the latch assembly (C).
5.
Make sure the connector is connected properly and the connecting rod is connected properly. Make sure the tailgate opens properly and locks securely.
Key Clinder Replacement

1. 2. Remove the latch assembly. Remove the key clinder (A).
3.
Outside Handle Replacement

1. 2. 3. Remove the tailgate trim. Remove the wiper motor. Disconnect the outside handle rod (A).
4.
After loosening the mounting nuts, then remove the outside handle (B).
5.
Make sure the tailgate opens properly and locks securely.
Lifter Replacement
1. Using a screwdriver (A), lift up slightly the socket clips (B) of both ends on the lifer (D), and then remove the lifter from the bracket (C).
2.
Push the socket of the lifter into the bracket for installation.
Tailgate Weatherstrip Replacement

Do not apply sealant to the body. 1. Remove the tailgate weather strip (A).
2.
Fuel Fill Door Replacement

Fuel Fill Door Replacement

1. 2. Open the fuel door. Loosen the bolts, then remove the fuel filler door (A).
3.
Make sure the fuel fill door opens properly and locks securely. 4. Check that the fuel fill door (A) fit flush against the body. If necessary, adjust it.
Adjustment
1. 2. 3. After loosening the tailgate hinge (A) mounting bolt,adjust the tailgate by moving it up or down, or right or left. Adjust the tailgate fit by turning the tailgate over slam bumper and side bumper (B). Adjust the striker (C) by moving it up or down, or right or left.
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Global Service Way

Replacements Door Trim Replacement

Take care not to scratch the door trim and other parts. Put on gloves to protect your hands. 1. Remove the quadrant inner cover (A).
2.
After loosening the mounting screw, then remove the inside handle cover (B).
3.
Loosen the door trim (C) mounting screws. Release the clips that hold the door trim, then remove the door trim by pulling it upward. Disconnect the power window switch connector, power mirror connector.
4.
Make sure of connectors is plugged in properly and each rod is connected securely. Make sure the door lock and opens properly.
Inside Handle Replacement

1. 2. Remove the door trim. Loosen the door inside handle mounting screws, remove the door inside handle (A).
3.
Disconnect the lock cable (B) and door latch cable (C).
4.
Glass Replacement
1. 2. 3. Remove the front door trim. Remove the inside handle. Remove the door screen (A) and door trim mounting bracket (B).
Using the door switch to align the mounting hole with the hole on the door glass. If it is impossible, align the hole with hands after removing the motor.
Take care not to drop to glass and scratch the glass surface. 4. Carefully move the glass (C) until you can see the bolts, then loosen them. Separate the glass from the glass run and carefully pull the glass out through the window slot.
5.
Roll the glass up down to see if it move freely without binding. Adjust the position of the glass as necessary.
Speaker Replacement
1. 2. 3. Remove the door trim. Disconnect the speaker connector (A). After loosening the mounting screws, then remove the speaker (B).
4.
Use sheet metal screws to secure the speaker.
Door Regulator Assembly and Power Window Motor Replacement

1. Remove the following parts. A. Door trim. B. Door screen. C. Glass. 2. Disconnect the power window motor connector (A).
2.
Disconnect the power window motor connector (A).
3.
Loosen the door module mounting bolts, then remove the door module (B).
4.
The area of whole parts should be applied with sufficient grease. Make sure the connector is plugged in properly and each rod is connected securely. Make sure the door lock and open properly.
Out Side Handle Replacement

1. 2. Disconnect the outside rod (A) and lock rod (B). After loosening the outside handle mounting bolt, then remove the key holder (C).
3.
Remove the outside handle lever (D).
4.
Make sure the door lock and open properly.
Door Weatherstrip Replacement

1. 2. Loosen the checker mounting bolts. Detach the clips, then remove the weatherstrip (A).
3.
Adjustment Glass Adjustment

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

After installing the door, check for a flush fit with the Body, then check for equal gaps between the front,Rear, and bottom, door edges and the body. Check That the door and body edges are parallel. Before Adjusting, replace the mounting bolts. 1. 2. Place the vehicle on a firm, level surface when adjusting the doors. Adjust at the hinges (A): A. Loosen the door mounting bolts slightly, and move the door IN or OUT until it aligns flush with the body. B. Loosen the hinge mounting bolts slightly, andmove the door BACKWARD or FORWARD, UP or DOWN as necessary to equalize the gaps. C. Place a shop towel on the jack to prevent damage to the door when adjusting the door.
3.
Check that the door and body edges are parallel.
4.
Grease the pivot portions of the hinges indicated by the arrows.
5.
Check for water leaks.
Door Striker Adjustment

Make sure the door latches securely without slamming it. If necessary adjust the striker (A): The striker nuts are fixed. The striker can be fine adjusted up or down, and in or out. 1. Loosen the screws (B), then insert a shop towel between the body and striker.
2. 3. 4. 5. 6.
Lightly tighten the screws. Wrap the striker with a shop towel, then adjust the striker by tapping it with a plastic hammer. Do not tap the striker too hard. Loosen the screws and remove the shop towel. Lightly tighten the screws. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches properly, tighten the screws and recheck.
Global Service Way


Take care not to scratch the door trim and other parts. Put on gloves to protect your hands. 1. Remove the quadrant inner cover (A).
2.
After loosening the mounting screw, then remove the inside handle cover (B).
3.
Loosen the door trim (C) mounting screws. Release the clips that hold the door trim, then remove the door trim by pulling it upward. Disconnect the power window switch connector, power mirror connector.
4.
Inside Handle Replacement

3.
Disconnect the lock cable (B) and door latch cable (C).
4.
Glass Replacement
1. 2. 3. Remove the front door trim. Remove the inside handle. Remove the door screen (A) and door trim mounting bracket (B).
Using the door switch to align the mounting hole with the hole on the door glass. If it is impossible, align the hole with hands after removing the motor.
Take care not to drop to glass and scratch the glass surface. 4. Carefully move the glass (C) until you can see the bolts, then loosen them. Separate the glass from the glass run and carefully pull the glass out through the window slot.
5.
Roll the glass up down to see if it move freely without binding. Adjust the position of the glass as necessary.
Speaker Replacement
4.
Use sheet metal screws to secure the speaker.
Door Regulator Assembly and Power Window Motor Replacement

1. Remove the following parts. A. Door trim. B. Door screen. C. Glass. 2. Disconnect the power window motor connector (A).
2.
Disconnect the power window motor connector (A).
3.
Loosen the door module mounting bolts, then remove the door module (B).
4.
Out Side Handle Replacement

1. 2. Disconnect the outside rod (A) and lock rod (B). After loosening the outside handle mounting bolt, then remove the key holder (C).
3.
Remove the outside handle lever (D).
4.

3.
Adjustment Glass Adjustment

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

After installing the door, check for a flush fit with the Body, then check for equal gaps between the front,Rear, and bottom, door edges and the body. Check That the door and body edges are parallel. Before Adjusting, replace the mounting bolts. 1. 2. Place the vehicle on a firm, level surface when adjusting the doors. Adjust at the hinges (A): A. Loosen the door mounting bolts slightly, and move the door IN or OUT until it aligns flush with the body. B. Loosen the hinge mounting bolts slightly, andmove the door BACKWARD or FORWARD, UP or DOWN as necessary to equalize the gaps. C. Place a shop towel on the jack to prevent damage to the door when adjusting the door.
3.
4.
5.

Make sure the door latches securely without slamming it. If necessary adjust the striker (A): The striker nuts are fixed. The striker can be fine adjusted up or down, and in or out. 1. Loosen the screws (B), then insert a shop towel between the body and striker.
2. 3. 4. 5. 6.
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Global Service Way


Take care not to scratch the door trim and other parts. Put on gloves to protect your hands. 1. After loosening the mounting screw, then remove the inside handle cover (A).
2.
Loosen the door trim (B) mounting screws. release the clips that hold the door trim, then remove the door trim by pulling it upward. disconnect the power window switch connector.
3.
Door Window Regulator Handle Replacement

1. Push the clip (C) using a piece of cloth (B), and then remove the door window regulator handle (A). [ Manual type only]
2.
Inside Handel Replacement

3.
Disconnect the lock cable (B) and latch cable (C).
4.
Speaker Replacement
3.
After loosening the mounting screws, then remove the speaker (B).
4.
Outside Handle Replacement

1. Disconnect the outside handle rod (A).
2.
After loosening the mounting bolt, then remove the outside handle lever (B).
3.
Regulator Assembly and Power Window Motor Replacement

1. Remove the following parts. A. Door trim. B. Door screen. C. Window glass. 2. 3. Disconnect the power window connector (A). After loosening the mounting nuts, then remove the door regulator assembly (B).
4.
Door Belt Weatherstrip Replacement

1. Loosen the mounting screw, then remove the door belt weatherstrip (A).
2.

3.
Installation is the reverse the removal.
Adjustment Door Position Adjustment
After installing the door, check for a flush fit with the Body, then check for equal gaps between the front,Rear, and bottom, door edges and the body. Check that the door and body edges are parallel. before Adjusting, replace the mounting bolts. 1. 2. Place the vehicle on a firm, level surface when adjusting the doors. Adjust at the hinges (A): A. Loosen the door mounting bolts slightly, and move the door IN or OUT until it aligns flush with the body. B. Loosen the hinge mounting bolts slightly, and move the door BACKWARD or FORWARD, UP or DOWN as necessary to equalize the gaps. C. Place a shop towel on the jack to prevent damage to the door when adjusting the door.
3.
4.
5.

Make sure the door latches securely without slamming it.If necessary adjust the striker (A): The
striker nuts are fixed. The striker can be fine adjusted up or down, and in or out. 1. Loosen the screws (B), then insert a shop towel between the body and striker.
2. 3. 4. 5. 6.
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Global Service Way

Replacements Spolier Replacement

1. Loosening the mounting nuts (A).
2.
Remove the spoiler (B).
3.
Global Service Way

Replacements Outside Rear View Mirror Relplacement

When prying with a flat-up screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage. Put on gloves to protect your hands. 1. Remove the quadrant inner cover (A).
2.
After disconnecting the connector (A), remove the outside rear view mirror (B).
3.
Inside Rear View Mirror Replacement

1. Push the inside rear view mirror base (A) down to remove to inside rear view mirror assembly (B).
2.
Global Service Way

Replacement
1. Remove the wiper (A).
2. 3.
Remove side cover (A). Detach the clips, then remove the cowl top cover (B).
4.
Global Service Way

Components
1. Floor console 3. Floor console pad 2. Floor console mat
Front Console
1. Console side cover 4. Console under cover (A/T) 2. Front console 5. Console under cover (M/T) 3. Console side cover
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Global Service Way

Replacements Floor Console Replacement

When prying with a flat-up screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage. Put on gloves to protect your hands. 1. 2. Remove the front seat. (Refer to the BD group - "Front Seat") Remove the mat (A).
3.
Remove the pad (A).
4.
After loosening the console mounting screws, remove the floor console assembly (A).
5.
Make sure the connector is plugged in properly. Replace any damaged clips.
Front Console Replacement

1. Remove the console under garnish (A).
2.
Remove the console under cover (A).
3.
Remove the console side cover (A).
4.
After loosening the mounting screws, then front console (A).
4.
After loosening the mounting screws, then front console (A).
5.
Console Side Cover Replacement

1. Remove the console side cover (A).
[Driver's]
[Passenger's]
2.
Global Service Way

Components
1. Crash pad main panel 2. Air vent 3. Crash pad side granish 4. Glove box 5. Audio assembly 6. Center fascia panel 7. Cluster facia
8. Center facia lower panel 9. Cluster 10. Heater control assey 11. Crash pad side granish 12. Air vent 13. Crash pad side switch 14. Main wiring harness
15. Cowl cross bar 16. Airvent duct 17. Defroster nozzle 18. Passenger air bag 19. Center facia lower tray
1. Crash pad 2. Side cover 3. Air bag on/off switch 4. Fuse box cover
5. Lower cover 6. Side cover 7. Shroud upper 8. Shroud lower
Global Service Way

Replacements Cluster Replacement

When prying with a flat-up screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage. Put on gloves to protect your hands. 1. 2. Tilt the steering column down. Remove the airvent (A).
3.
After loosening the mounting screws, then remove the cluster fascia panel (B).
4.
After loosening the mounting screws, then remove the cluster assembly (C).
5.
Disconnect the connectors (D).
6.
Installation is the reverse the removal.
Make sure the connector is plugged in properly.
Center Fascia Panel Replacement

When prying with a flat-up screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage. Put on gloves to protect your hands. 1. Put the SST (09840-1E100) into the space between the center fascia and crash pad.
Be care not to damage the center fascia and crash pad. 2. Separate the center fascia panel (B) from the crash pad pulling the SST (09840-1E100) as shown on the photo.
Pull the SST slowly not to damage the center fascia panel.
3.
Pull the other side of center fascia panel with the SST (09840-1E100) in the way of "step 2)".
Lower Panel Replacement

1. Remove fules box cover (A).
2.
After loosening the crash pad lower panel mounting screws and bolts, then remove the lower panel (B).
3.
Heater Control Unit Replacement

1. Remove the side cover (A).
2.
After loosening the mounting screws and bolts, then remove the lower panel (A).
2.
After loosening the mounting screws and bolts, then remove the lower panel (A).
3.
Remove the cable (A) and (B).
4.
After loosening the heater control mounting screws, then remove the heater control unit (A).
5.
Disconnect the connectors (A).
6.
Make sure the connector is plugged in properly
Audio Assembly Replacement

1. 2. Remove the center fascia panel. After loosening the audio mounting screws, then remove the audio (A).
3.
Disconnect the connector (B).
4.
Disconnect the connector (C).
5.
Make sure the connector is plugged in properly.
Glove Box Replacement

1. Disconnect the damper (B) from the glove box (A).
2.
Remove the glove box (C).
3.
Shroud Replacement
1. 2. Loosen the screws. Remove the shroud assembly (A).
3.
Cover Replacement
When prying with a flat-up screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage. Put on gloves to protect your hands.
1.
Remove the crash pad side cover (A).
2.
Crash Pad Replacement

When prying with a flat-up screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage. Put on gloves to protect your hands. 1. Remove the following items. A. Front seat. B. Cluster fascia panel, cluster. C. Audio assembly. D. Glove box. E. Crash pad side cover. 2. Remove the photo sensor (A).
3.
Disconnect the passenger's air bag connector (B).
4.
Remove the air vent (C).
5.
Remove the front pillar trim (D).
6. 7.
Remove door scuff trim. Remove the cowl side trim (E).
8.
Loosen the bolts and nuts, then remove the crash pad (F).
Make sure the crash pad fits onto the guide pins correctly. Before tightening the bolts, make sure the crash pad wire harnesses are not pinched. Make sure the connectors are plugged in properly, and the antenna lead is connected properly. Enter the anti- theft code for the radio, then enter the customer`s radio station presets.
9.
Global Service Way

Components
1. Room lamp mounting bracket 2. Room lamp 3. Sunvisor 4. Holder 5. Sunvisor

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6. Assist handle 7. Room lamp mounting bracket (s/roof) 8. Room lamp (s/roof) 9. Assist handle monuting bracket 10. Roof trim
Global Service Way

Replacements Sunvisor Replacement

When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Put on gloves to protect your hands. 1. Remove the sunvisor (A) and holder (B) from each side.
2.
Assist Handle Replacement

When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Put on gloves to protect your hands. 1. Remove the covers (B), and remove the screws, then remove the assist handle (A).
2.
Room Lamp Replacement

When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Put on gloves to protect your hands.
1.
Remove the overhead console A. Pull out the lens of lamp (A). B. Remove the bolts. C. Pull out the roof console (B).
2.
Disconnect the connector (C).
3.
Headliner Replacement
Put on gloves to protect your hands. When prying with a flat-tip screwdriver, wrap itwith protective tape to prevent damage. Take care not to bend or scratch the trim and panels. 1. Remove the following items. A. Front seat, rear seat assembly. B. Door scuff trim. C. Front pillar trim. D. Center pillar trim. E. Rear pillar trim. F. Room lamp. G. Sunvisor. H. Assist handle. 2. Remove the headliner (A).
3.
Replace any damage clips.

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Global Service Way

Components
1. Front pillar trim 5. Center pillar upper trim 2. Cowl side trim 6. Rear door scuff trim 3. Center pillar lower trim 7. Rear pillar trim 4. Front door scuff trim
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Global Service Way

Replacements Door Scuff Trim Replacement

Put on gloves to protect your hands. Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface. Take care not to bend or scratch the trim and panels. 1. Using a screwdriver or remover, remove the front door scuff tirm (A).
[Front]
2. 3.
Remove the rear seat cushion. (Refer to the BD group - "Rear Seat") After loosening the mounting screws, then remove rear door scuff trim (A).
[Rear]
4.
Front Pillar Trim Replacement
Put on gloves to protect your hands. Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface. Take care not to bend or scratch the trim and panels. 1. Using a screwdriver or remover, remove the front pillar trim (A).
2.
Cowl Side Trim Replacement

Put on gloves to protect your hands. Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface. Take care not to bend or scratch the trim and panels. 1. 2. Remove the front door scuff trim. Detach the clips, then remove the cowl side trim (A).
3.
Center Pillar Trim Replacement

Put on gloves to protect your hands. Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
Take care not to bend or scratch the trim and panels. 1. 2. Remove the front door scuff trim and rear door scuff trim. Remove the center pillar lower trim (A).
3.
Using a screwdriver or remover (B), remove the front seat belt upper anchor cover (A).
4.
After loosening the mounting bolt, then remove the front seat belt upper anchor (A). Tightening torque : 39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)
5.
After loosening the mounting bolts, then remove the center pillar upper trim (A).
5.
After loosening the mounting bolts, then remove the center pillar upper trim (A).
6.
Rear Pillar Trim Replacement

Put on gloves to protect your hands. Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface. Take care not to bend or scratch the trim and panels. 1. 2. 3. Remove the rear seat. (Refer to the BD group Rear Seat) Remove the rear door scuff trim. Detach the mounting clips, remove the transverse trim (A).
4.
After loosening the mounting bolt, then remove the rear seat belt lower anchor (A). Tightening torque : 39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)
5.
After loosening the mounting bolts, then remove the rear seat bracket (A).
6. 7.
Using a screwdriver or remover, remove the luggage side trim cover (B). After loosening the mounting screws, then remove the luggage side trim (A).
8.
Disconnect the lamp connector (A).
9.
After loosening the mounting bolt, then remove the rear pillar trim (A).
10.
Luggage Side Trim Replacement

Put on gloves to protect your hands. Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface. Take care not to bend or scratch the trim and panels. 1. 2. 3. 4. 5. 6. 7. 8. Remove the rear seat assembly. Remove covering shelf trim (7). Remove the transverse trim (3). Remove the luggage cover mat (4). Remove the luggage floor side cover (6). Remove the luggage side branking cover (8). Remove the luggage side trim (1) (2). Installation is the reverse of removal.
1. Luggage side trim 4. Luggage cover mat 7. Covering shelf trim 2. Luggage side trim 5. Luggage floor box 8. Luggage side branking cove 3. Transverse trim 6. Luggage floor side cover
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Global Service Way

Components
1. Windshield molding 2. Windshield glass

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Global Service Way

Components-1
1. Front bumper cover 3. Front bumper side bracket 2. Lower stiffner bracket
Components-2
1. Front bumper ensrgy absorber

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Global Service Way

Replacement
Put on gloves to protect your hands. Use a plastic panel removal tool to remove interior trip pieces to without marring the surface. Take care not bend or scratch the cover and other parts. 1. Loosen the radiator upper cover mounting clips and bolts.
2.
After loosening the front bumper sides mounting screw, then disconnect the sides.
3.
Remove the mounting clips.
4.
Disconnect the fog lamp connector (A).
5.
Global Service Way

Monday, November 21, 2011 12:01 PM
Components
1. Rear bumper cover 3. Rear bumper side bracket [LH] 2. Rear bumper side bracket [RH]
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Global Service Way

Replacement
Put on gloves to protect your hands. Use a plastic panel removal tool to remove interior trip pieces to without marring the surface. Take care not bend or scratch the cover and other parts. 1. 2. After loosening the mounting screws, then remove the rear combination lamp (A). Push the lock pin, disconnect the connector (B).
3.
After loosening the rear bumper sides mounting screws and clip, then disconnect the sides.
4.
Remove the mounting clips.
5. 6.
Remove the main muffler. (Refer to the EM group - " Muffler") After loosening the mounting nuts, then remove the heat protector (A).
7.
Loosen the mounting bolts.
8.
After loosening the mounting screws and clip, then remove the rear bumper (A).
9.
Disconnect the rear bumper main connector (A) and wiring harness (B).
10.
Global Service Way

Components
1. Headrest 2. Headrest guide 3. Seat back frame 4. Seat back cushion pad
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5. Seat back cover 9. Seat cushion cover 6. Recliner lever 10. Seat cushion pad 7. Recliner cover 11. Seat track assembly 8. Recliner cover
Global Service Way

Replacements Seat Assembly Replacement

1. After loosening the seat assembly mounting bolts, remove the seat assembly (A).
2.
Disconnect the connectors (B), and remove the seat assembly.
3.
Installation is the reverse of removal. SEAT MOUNTING BOLT INSTALLATION PROCE-DURE (manual seat only) Set the into the most rearward position. Check then each slide is locked, and then Tighten the front mounting bolt temporarily. Set the seat into most forward position. Check that each slide is locked, and then Tighten the rear mounting bolt completely. Set the seat into the most rearward position. Check the front mounting bolt completely. Check that the seat operates to and fro smoothyand the locking portion locks properly.
Recliner Cover Replacement

1. 2. Remove the front seat assembly. After loosening the recliner mounting screw, then remove the recliner lever (B).
3.
After loosening the recliner mounting screw, then remove the recliner cover (C).
4.
After loosening the mounting screws, then remove the recliner cover (D).
5.
Seat Back Cover Replacement

1. 2. 3. Remove the front seat assembly. Remove the recliner cover. Remove the hog ring clip (A).
4.
Disconnect the protector (B) from the back frame.
5.
Disconnect the protector (C).
6.
Remove the hog ring clip (D).
7.
Pull out the headrest guides (E) while pinching the end of the guides, and remove them.
8.
After removing the hogring clip on the front of seat cushion and remove the seat cushion cover (G).
9.
Seat Cushion Cover Replacement

1. Remove front seat assembly.
2. 3.
Remove the recliner cover. After loosening the mounting bolt, then disconnect the seat back (A) and seat cushion (B).
4. 5.
Disconnect the seat buckle connector (C). After loosening the mounting nuts, then remove the seat cushion (D).
6.
Disconnect the protector (E).
7.
After removing the hogring clip on the front of seat cushion and remove the seat cushion cover (G).
8.
Seat Frame Replacement

Seat Frame Replacement

1. Remove the following items. A. Recliner cover. B. Headrest guide. C. Seat back cover. D. Seat cushion cover. 2. After loosening the mounting bolts, then disconnect the seat back frame (A) and seat cushion frame (B).
Remove the side air bag for replacing side air bag installation seat. Be fore service, be fully aware of precautions and service procedure relevant to air bag (Refer to page RT-Airbag)
3.
Global Service Way

Components
1. Rear seat cushion 3. Side rear seat bracket 2. Rear seat back
Global Service Way

Replacement Seat Assembly Replacement

1. After loosening the mounting bolts, then remove the seat cushion (A).
2.
After loosening the mounting bolts, then remove the rear center seat buckle (B).
3.
After loosening the mounting bolts, then remove the rear seat back (A).
4.
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Global Service Way

Components
1. Front seat belt 5. Rear center seat buckle 2. Rear seat belt 6. Rear center seat belt 3. Rear center seat belt 7. Hight adjuster 4. Rear center seat buckle
Global Service Way

Replacements Front Seat Belt Replacement

When installing the belt, make sure not to damage the pretensioner. 1. 2. Disconnect the battery negative cable, and wait for at least three minutes before beginning work. Remove the following items fist. A. Front seat assembly. B. Door scuff trim. 3. Loosen the lower anchor mounting bolt (A). Tightening torque : 39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)
4.
Remove the center pillar lower trim (A).
5.
Using a screwdriver or remover (B), remove the front seat belt upper anchor cover (A).
6.
After loosening the mounting bolt, then remove the front seat belt upper anchor (A). Tightening torque : 39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)
7.
After loosening the mounting bolt, then remove the center pillar upper trim (A).
8.
After loosening the pretensioner mounting bolt, then remove the pretensioner (A). Tightening torque : 39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)
9.
Disconnect the SIS connector (A).
10.
Height Adjust Replacement

1. Remove the following items first : A. Front seat assembly (Refer to the BD group Front Seat) B. Front door scuff trim & Rear door scuff trim (Refer to the BD group - "Interior Trim") C. Front seat belt lower anchor D. Center pillar lower trim (Refer to the BD group - "Interior Trim") E. Front seat belt upper anchor cover F. Front seat belt upper anchor G. Center pillar upper trim (Refer to the BD group - "Interior Trim") 2. After loosening the bolts, then remove the height adjustor (A). Tightening torque : 39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)
3.
Replace ant damaged clips. Make sure the height adjust properly.
Front Seat Belt Buckle Replacement

1. Remove the following items first : A. Front seat assembly (Refer to the BD group - "Front Seat") 2. After loosening the mounting bolt, then remove the front seat belt buckle (A). Tightening torque : 39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)
3.
Global Service Way

Replacements Rear Seat Belt Replacement

When installing the belt, make sure not to damage the pretensioner. 1. Remove the following items first. A. Rear seat assembly B. Rear door scuff trim 2. Detach the mounting clips, remove the transverse trim (A).
3.
After loosening the mounting bolt, then remove the rear seat belt lower anchor (A). Tightening torque : 39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)
4.
After loosening the mounting bolts, then remove the rear seat bracket (A).
5. 6.
Using a screwdriver or remover, remove the luggage side trim cover (B). After loosening the mounting screws, then remove the luggage side trim (A).
7.
Disconnect the lamp connector (A).
8.
After loosening the mounting bolt, then remove the rear pillar trim (A).
9.
After loosening the retractor (B) mounting bolt, remove the rear seat belt (A). Tightening torque : 39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)
10.
Center Rear Seat Belt Replacement

1. 2. Remove the seat cushion. Remove the center seat belt lower anchor (A).
3.
Remove the seat back (B).
4.
Remove the center seat belt cover (C).
5.
Remove the recliner knob (D).
5.
Remove the recliner knob (D).
6.
Disconnect the protector (E).
7.
Disconnect the clip (F).
8.
Remove the headrest guide (G).
9.
Remove the headrest guide (H).
10.
After loosening the mounting bolt, then remove the rear center seat belt (I).
11.
Rear Seat Latch Replacement

1. 2. 3. Remove the rear seat. Remove the rear seat cover. After loosening the latch mounting bolt, then remove the latch (A).
4.
Rear Seat Belt Buckle Replacement

1. 2. Remove the rear seat cushion Remove the seat belt buckle (A).
3.
Global Service Way

2011 > G 1.1 SOHC > Brake System
Specifications
Item Master cylinder Type I.D. Piston stroke Fluid level warning sensor Brake booster Type Boosting ratio Front brake(Disc) Type Disc O.D. Disc I.D. Disc thickness Pad thickness Cylinder type Cylinder I.D. Rear brake (Disc) Type Disc O.D. Disc I.D. Disc thickness Pad thickness Cylinder type Cylinder I.D. Rear brake (Drum) Type Drum I.D. Brake lining thickness Clearance adjustment Parking brake Actuation Type DISC O.D. DISC I.D. Specification Tandem type 20.64 mm (0.81 in) CBS/ESP :31 mm (1.22 in), ABS : 30.7 mm (1.21 in) Provided Vacuum 4.5 : 1 Floating type with ventilated disc 241 mm (9.49 in) 150 mm (5.91 in) 18 mm (0.71 in) 10 mm (0.39 in) Single piston 51.1 mm(2.01 in) Floating type with solid disc 234 mm (9.21 in) 158 mm (6.22 in) 10 mm (0.39 in) 9 mm (0.35 in) Single piston 33.96 mm (1.34 in) Leading trailing 180 mm (7.09 in) 4.3 mm (0.17 in) Automatic PIC (Porking Integrated Caliper) Lever 234mm (9.21 in) 158 mm (6.22 in)
ABS : Anti-lock Brake System CBS : Conventional Brake System
Service Standard
Item Standard value Brake pedal height Brake pedal stroke Standard value 205 mm (6.86 in) 120 mm (5.31 in)
Brake System Page 1
Stop lamp switch outer case to pedal stopper clearance Brake pedal free play Booster push rod to master cylinder piston clearance Parking brake lever stroke when lever assembly is pulled with 196N (20Kg, 44lb force) Front disc brake pad thickness Front disc thickness Rear disc brake pad thickness Rear disc brake disc thickness Rear brake lining thickness
120 mm (5.31 in) 1.0 ~ 2.0 mm (0.04 ~ 0.08 in) 3 ~ 8 mm (0.11 ~ 0.31 in) 0mm (at 500 mmHg vacuum) 7 clicks 10 mm (0.39 in.) 18 mm (0.71 in) 9 mm (0.35 in) 10 mm (0.39 in) 4.3 mm (0.17 in)
Tightening Torques
Item Master cylinder to booster mounting nut Brake booster mounting nut Bleeder screw Brake tube to flare nuts Caliper guide rod bolt Caliper mounting bolt (Front) Caliper mounting bolt (Rear) Brake hose to caliper Brake pedal member assembly bracket mounting nut (cowl side upper mounting) Brake pedal member bracket to booster mounting nut Stop lamp switch mounting nut Wheel speed sensor mounting bolt (Front) HECU mounting bracket bolt HECU mounting bracket nut HECU bracket mounting bolt Yaw rate & Lateral G sensor mounting bolt Nm 12.7 ~ 16.7 12.7 ~ 15.7 6.9 ~ 12.7 12.7 ~ 16.7 21.6 ~ 31.4 78.5 ~ 98.1 38.5 ~ 52.3 24.5 ~ 29.4 19.6 ~ 29.4 12.7 ~ 15.7 7.9 ~ 9.8 7.9 ~ 9.8 16.7 ~ 25.5 17.7 ~ 21.6 11 ~ 14 7.9 ~ 10.8 kgf.m 1.3 ~ 1.7 1.3 ~ 1.6 0.7 ~ 1.3 1.3 ~ 1.7 2.2 ~ 3.2 8.0 ~ 10.0 3.9 ~ 5.3 2.5 ~ 3.0 2.0 ~ 3.0 1.3 ~ 1.6 0.8 ~ 1.0 0.8 ~ 1.0 1.7 ~ 2.6 1.8 ~ 2.2 1.1 ~ 1.4 0.8 ~ 1.1 lb-ft 7.2 ~ 12.3 9.4 ~ 11.6 5.1 ~ 9.4 9.4 ~ 12.3 15.9 ~ 23.1 57.9 ~ 72.3 28.5 ~ 38.5 18.1 ~ 21.7 14.5 ~ 21.7 9.4 ~ 11.6 5.8 ~ 7.2 5.8 ~ 7.2 12.3 ~ 18.8 13.0 ~ 15.9 8.1 ~ 10.3 5.8 ~ 8.0
Specification (ABS)
Part Item Standard value 4 channel 4 sensor (Solenoid) Remark HECU(Hydraulic and System Electronic Control Unit)
ABS system:ABS & EBD control
Type Operating
Motor, valve relay intergrated type 10 V ~ 16 V(DC)
Brake System Page 2
Current consumption Supply voltage Acitve wheel speed sensor Operating temperature Output current low Output current High Frequency range Front Air gap Rear Tone wheel Output duty (Front)
80 mA DC 4.5 ~ 20 V
-40 ~ 150 C (-40 ~ 302 F) 5.9 ~ 8.4 mA Typ.7 mA
11.8 ~ 16.8 mA 1 ~ 2500 HZ 0.5 ~ 1.5 mm 0.2 ~ 0.7 mm 48 teeth 40~60 %
Typ.14 mA
Typ.0.7 mm(0.03 in) Typ.0.5 mm(0.02 in)
Specification (ESP)
Part Item Standard Value 4 channel 4 sensor(Solenoid) Remark HECU(Hydraulic and System Electronic Control Unit)
Total control(ABS, EBD, TCS, ESP)
Type Operating voltage Operating temperature Warning lamp Operating voltage
Motor, valve relay intergrated type 10 V ~ 16 V(DC) -40 ~ 120 C (-40 ~ 248 F) 12 V ESP Operating Lamp ESP Warning Lamp
Current consumption Active wheel speed sensor Supply voltage
80 mA DC 4.5 ~ 20V -40 ~ 150 C (-40 ~ 302 F) 5.9 ~ 8.4 mA
Operating temperature Output current low
11.8 ~ 16.8 mA
Brake System Page 3
11.8 ~ 16.8 mA Output current high 48 teeth Tone wheel 1 ~ 2500 HZ Frequency range Front Airgap Rear Steering Wheel Angle Sensor Operating Voltage Current Consumption Max 780 /sec Operating Angular velocity Yaw-rate & Lateral G sensor Operating Voltage 10 V ~ 16 V 0.2 ~ 0.7 mm 8V ~ 16 V Max 150 mA Typ.0.5 mm (0.02 in) 0.5 ~ 1.5 mm Typ.0.7 mm (0.03 in)
Max. 140 mA Current Consumption 75 /s Yaw Sensor Operating Range -128 ~ 127.938 /s Digital range 1.8 G G Sensor Operating Range -32 ~ 31.98 m/s Digital range
Lubricant
Item Brake fluid Brake pedal bushing and brake pedal bolt Parking brake shoe and backing plate contact surfaces Front caliper guide rod bolt and boot Rear caliper guide rod and boot Recommended lubricant DOT 3 or DOT 4 Chassis grease Bearing grease AI-11P grease AI-11P grease Quantity As required As required As required 0.3 ~ 0.8g, 1.0 ~ 1.5g 0.8 ~ 1.3g
Brake System Page 4
Global Service Way


Tool (Number and Name) 09581 - 11000 Piston expander Illustration Use Pushing back of the front disc and rear disc brake piston
Brake System Page 5
Global Service Way

Troubleshooting
Problem Symptoms Table Use the table below to help you find the cause of the problem. The numbers indicate the priority of the like cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Lower pedal or spongy pedal Suspect Area Remedy Repair Air bleeding Replace Replace
1. Brake system (Fluid leaks) 2. Brake system (Air in) 3. Piston seals (Worn or damaged) 4. Master cylinder (Faulty)
Brake drag 1. Brake pedal free play (Minimum) 2. Parking brake lever travel (Out of adjustment) 3. Parking brake wire (Sticking) 4. Pad or lining (Cracked or distorted) 5. Piston (Stuck) 6. Piston (Frozen) 7. Return spring (Faulty) 8. Booster system (Vacuum leaks) 9. Master cylinder (Faulty) Brake pull 1. Piston (sticking) 2. Pad or lining (Oily) 3. Piston (Frozen) 4. Disc (Scored) 5. Pad or lining (Cracked or distorted) Hard pedal but brake inefficient
Adjust Adjust Repair Replace Replace Replace Replace Replace Replace
Replace Replace Replace Replace Replace
1. Brake system (Fluid leaks) 2. Brake system (Air in) 3. Pad or lining (Worn) 4. Pad or lining (Cracked or distorted) 5. Pad or lining (Oily) 6. Pad or lining (Glazed) 7. Disc (Scored)
Repair Air bleeding Replace Replace Replace Replace Replace Replace
Brake System Page 6
8. Booster system (Vacuum leaks) Noise from brake Replace Retighte n Replace Replace Clean Replace Replace Replace Replace
1. Pad or lining (Cracked or distorted) 2. Installation bolt (Loosen) 3. Disc (Scored) 4. Sliding pin (Worn) 5. Pad or lining (Dirty) 6. Pad or lining (Glazed) 7. Return spring (Faulty) 8. Brake pad shim (Damage) 9. Shoe hold-down spring (Damage)
Brake fades 1. Master cylinder Brake vibration, pulsation
Replace
1. Disc (Excessive thickness variation) 2. Disc (Faulty run-out) 3. Disc (Uneven worn or crack) 4. Pad or lining (Uneven worn and contact) 5. Caliper (Faulty pad sliding)
Replace Replace Replace Replace Replace
Brake chatter Brake chatter is usually caused by loose or worn components, or glazed or burnt linings. Rotors with hard spots can also contribute to brake chatter. Additional causes of chatter are out-of-tolerance rotors, brake lining not securely attached to the shoes, loose wheel bearings and contaminated brake lining.
Brake System Page 7
Global Service Way

Operation and Leakage Check

Check all of the following items: Component Brake Booster (A) Procedure Check brake operation by applying the brakes during a test drive. If the brakes do not work properly, check the brake booster. Replace the brake booster as an assembly if it does not work properly or if there are signs of leakage. Check brake operation by applying the brakes. Look for damage or signs of fluid leakage. Replace the master cylinder as an assembly if the pedal does not work properly or if there is damage or signs of fluid leakage. Check for a difference in brake pedal stroke between quick and slow brake applications. Replace the master cylinder if there is a difference in pedal stroke Brake hoses (C ) Look for damage or signs of fluid leakage. Replace the brake hose with a new one if it is damaged or leaking.
Piston cup and pressure cup inspection (B)
Caliper piston seal Check brake operation by applying the brakes. and piston boots Look for damage or signs of fluid leakage. If the pedal does not work properly, the (D) brakes drag, or there is damage or signs of fluid leakage, disassemble and inspect the brake caliper. Replace the boots and seals with new ones whenever the brake caliper is disassembled.
Brake Booster Operating Test

For simple checking of the brake booster operation, carry out the following tests : 1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains unchanged, the booster is defective.
Brake System Page 8
2.
With the engine stopped, step on the brake pedal several times. Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good condition. If there is no change, the booster is defective.
3.
With the engine running, step on the brake pedal and then stop the engine. Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition, if the pedal rises, the booster is defective. If the above three tests are okay, the booster performance can be determined as good. Even if one of the above three tests is not okay, check the check valve, vacuum hose and booster for defect.
Vacuum Hose (Check Valve)

Inspection 1. 2. Disconnect the brake booster vacuum hose (check valve built in) (A) at the booster . Start the engine and let it idle. There should be vacuum available. If no vacuum is available, the check valve is not working properly. Replace the brake booster vacuum hose and check valve and retest.
Brake System Page 9
Brake Pedal & Brake Switch Adjustment

Pedal Height 1. 2. Disconnect the brake switch connector, loosen the brake switch locknut (A), and brake off the brake switch (B) until it is no longer touching the brake pedal. Measure the pedal height (C) from the middle of the left-side center of the pedal pad. Standard pedal height (on the carpet) : 205 mm (8.07 in)
3.
Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod depressed.
Stop Lamp Switch Clearance

Screw in the stop lamp switch until its switch rod is fully depressed (threded end (A) touching the pad (B) on the pedal arm) then brake off the switch 3/4 turn to make 1.0~2.0 mm(0.04~0.08 in.) of clearance between the stop lamp switch pad. Make sure that the brake lights go off when the pedal is released.
Brake System Page 10
Pedal Free Play

1. With the engine stopped, depress the brake pedal two or three times. After eliminating the vacuum in the power brake booster, press the pedal(B) down by hand, and confirm that the amount of movement(A) before resistance is met (the free play) is within the standard value. Standard value : 3 ~ 8 mm (0.117 - 0.312 in.)
2.
If free play does not reach the standard value, check that clearance between the outer case of stop lamp switch(C) and brake pedal is within the standard value. If free play exceeds the standard value, it is probably due to excessive clearance between the clevis pin and brake pedal arm. Check for excessive clearance and replace faulty parts as required. Start the engine, depress the brake pedal with approximately 120kg(1176.8N, 264.5 lb) of force, and check for oil leakage in the master cylinder, brake line and each connecting part. Repair the faulty parts as required.
3.
Inspection Of Front Disc Brake Pad

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

1. Check the brake pad thickness through the caliper body inspection hole. Pad thickness Standard value : 9.0 mm (0.35 in.) Service limit : 2.0 mm (0.0787 in.)
- If the pad thickness is out of specification, left and right pads must be replaced as a complete set. - When the thickness difference between the left pad and right pad is large, check the sliding condition of the piston and the guide rod.
Global Service Way

Components
1. Brake Booster 3. Vaccum Hose 2. Master Cylinder 4. Check Valve
Global Service Way

Removal
1. Disconnect the vacuum hose (B) from the brake booster.
2. 3.
Remove the master cylinder. (Refer to "Master cylinder - Removal") Remove the clevis pin (A) and snap pin (B).
4. 5.
Remove the four booster mounting nuts (C). Remove the brake booster (A) from the engine compartment.
Installation
1. Adjust push rod length of the booster, and then install the seal on the booster assembly. Standard length (A) : 107.8 0.5 mm (4.24 0.02 in)
2.
Insert the booster and tighten the nuts (C).
3.
Connect the booster push rod and brake pedal with a clevis pin (A) and install a snap pin (B) to the clevis pin (A). Grease the pin before installing the snap pin. Always use a new snap pin.
4. 5. 6. 7. 8.
Install the master cylinder, then install the brake tubes to the master cylinder. Connect the vacuum hose to the brake booster. After filling the brake reservoir with brake fluid, bleed the system. Check for fluid leakage. Check and adjust the brake pedal for proper operation.
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Components
1. Reservoir cap 2. Reservoir 3. Grommet 4. Cylinder pin
5. Retainer 6. Primary piston assembly 7. Secondary piston assembly 8. Master cylinder body
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Removal
1. Remove air cleaner assembly and battery. (Refer to EM Gr.)
2.
Disconnect the brake fluid level switch connector (A), and remove the reservoir cap (B).
3.
Remove the brake fluid from the master cylinder reservoir with a syringe. Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.
4.
Disconnect the brake lines (A) from the master cylinder. To prevent spills, cover the hose joints with rags or shop towels.
5.
Remove the master cylinder mounting nuts (A) and washers.
6.
Remove the master cylinder (B) from the brake booster. Be careful not to bend or damage the brake lines when removing the master cylinder.
Installation
1. Install the master cylinder (B) to the brake booster.
2.
Install the master cylinder mounting nuts (A) and washers. Tightening torque : 12.7 ~ 16.7 N.m (1.3 ~ 1.7 kgf.m, 9.4 ~ 12.3 lb-ft)
3.
Connect the brake lines (A) to the master cylinder. Tightening torque : 12.7 ~ 16.7 N.m (1.3 ~ 1.7 kgf.m, 9.4 ~ 12.3 lb-ft)
4.
Connect the brake fluid level switch connector (A).
5. 6.
Refill the master cylinder reservoir to the MAX line. Bleed the brake system. (Refer to "Bleeding of brake system")
Disassembly
1. 2. Remove the reservoir cap and drain the brake fluid into a suitable container. Remove the reservoir (C) from the master cylinder (B) after remove the mounting screw (A).
3. 4. 5.
Remove the retainer ring (A) by using the snap ring pliers. Remove the primary piston assembly (B). Remove the pin (D) with the secondary piston (C) pushed completely using a screwdriver. Remove the secondary piston assembly (C).
Do not disassemble the primary and secondary piston assembly.
Inspection
1. 2. Check the master cylinder bore for rust or scratch. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.
1. If the cylinder bore is damaged, replace the master cylinder assembly. 2. Wash the contaminated parts in alcohol.
Reassembly
1. 2. 3. Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets. Carefully insert the springs and pistons in the proper direction. Press the secondary piston (C) with a screwdriver and install the cylinder pin (D).
4. 5. 6.
Install the primary piston assembly (B) and the retainer ring (A). Mount two grommets (D). Install the reservoir (C) to the master cylinder (B) and tighten the screw (A).
Global Service Way

Components
Global Service Way

Components
Global Service Way

Removal
1. Disconnect the brake hose (A) from the brake line (C) using a flare-nut wrench (B).
2.
Remove the brake hose clip (B), and then remove the brake hose (A).
3.
Remove the connector bolt (A) from the caliper, and disconnect the brake hose (B) from the caliper.
Installation
1. Install a brake hose (B) on the caliper with tightening brake hose bolt (A) and washer. Tightening torque : 24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft)
2.
Connect the brake hose (A) to the brake line (C) using a flare-nut wrench (B).
3.
Install the brake hose clip (B) to the brake hose bracket.
4.
After installing the brake hose, bleed the brake system.
- Check the brake hoses for interference and twisting. - Check the brake hose and line joint for leaks, and tighten if necessary.
Inspection
1. 2. 3. Check the brake tubes for cracks, crimps and corrosion. Check the brake hoses for cracks, damaged and oil leakage. Check the brake tube flare nuts for damage and oil leakage.
Brake System Bleeding

- Do not reuse the drained fluid. - Always use Genuine DOT3/DOT4 or Brake Fluid. Using a non-Genuine DOT3/DOT4 or brake fluid can cause corrosion and decrease the life of the system.
- Make sure no dirt of other foreign matter is allowed to contaminate the brake fluid. - Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. - The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. 1. 2. 3. 4. 5. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line. Have someone slowly pump the brake pedal several times, and then apply steady pressure. Loosen the right-rear brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely. Repeat the procedure for each wheel in the sequence shown below until air bubbles no longer appear in the fluid. Refill the master cylinder reservoir to the MAX (upper) level line.
Front Disc Brake :
Rear Disc Brake :
Global Service Way

Components
1. Member assembly bracket 4. Bolt 2. Stop lamp switch 5. Brake pedal 3. Return spring
Global Service Way

Components (1)
1. Brake caliper 4. Guide rod bolt 2. Brake disc 5. Brake pad 3. Pad spring 6. Brake pad shim
Components (2)
1. Guide rod bolt 2. Bleeder screw 3. Caliper housing 4. Caliper carrier
5. Caliper mounting bolt 6. Washer 7. Piston 8. Piston seal
9. Piston boot 10. Shim 11. Brake pad 12. Pad spring
Global Service Way

Removal
1. Remove the brake hose bolt (B) and the guide rod bolts (C) from the caliper assembly (A).
2.
Remove the caliper assembly (A).
3.
Remove the pads (B), the pad shims (C) and the pad springs (D) from the caliper carrier (A).
4.
Remove the caliper carrier (B) and the caliper mounting bolts (A).
5.
Remove the brake disc (A) and the screw (B).
Remove the brake disc from hub using M8 bolt (A) if the brake disc has been seized with the hub due to corrosion or overheat. Be careful not to use the hammer. The disc can be damaged if you remove the disc from the hub by hammer.
Replacement
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your
health. Avoid breathing dust particles. Never use on air hose or brush to clean brake assemblies. 1. Remove guide rod bolt (B) and raise the caliper assembly (A).
2.
Inspection Front Brake Disc Thickness Check

1. Remove all rust and contamination from the disc surface, and then measure the disc thickness at 8 positions at least. Front brake disc thickness Standard value : 18.0 mm (0.71 in) Limit : 16.0 mm ( 0.63 in)
2. 3.
Thickness variation should not exceed 0.005 mm (0.0002in) (circumference) and 0.01 mm(0.0004 in) (radius) at any directions. If wear exceeds the limit, replace the discs and pad assemblies for left and right of the vehicle.
Front Brake Pad Check

1.
Check the pad wear. Measure the pad thickness. replace it if it is less than the specified value. Pad thickness Standard value : 10.0 mm (0.39 in) Service limit : 2.0 mm (0.0787 in)
2.
Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
Front Brake Disc Run Out Check

1. Place a dial gauge about 5mm (0.2 in) from the outer circumference of the brake disc, and measure the run out of the disc. Brake disc run out Limit : 0.04 mm (0.0020 in) or less
2. 3. 4.
If the run out of the brake disc exceeds the limit specification, replace the disc, and then measure the run out again. If the run out does not exceed the limit specification, install the brake disc after turning it and then check the run out of the brake disc again. If the run out cannot be corrected by changing the position of the brake disc, replace the brake disc.
Installation
1. Install the brake disc (A) and tighten the screw (B). Tightening torque : 4.9 ~ 5.9 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)
2.
Install the caliper carrier (B) and tighten the caliper mounting bolts (A). Tightening torque : 78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)
3. 4.
Install the pad springs (D) to the caliper carrier (A). Install the brake pads (B) and pad shims (C) on the pad springs correctly. Install the pad with the wear indicator on the inside. If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. Check the foreign material at the pad shims (A) and the back of the pads (B). Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
5.
Push in the piston using the SST(09581-11000) so that the caliper will fit over the pads. Make sure that the piston boot is in position to prevent damaging it when installing the caliper.
6.
Install the caliper assembly (A). Be careful not to damage the piston pin boot.
7.
Install the brake hose bolt (B) and the guide rod bolts (C) to the caliper assembly (A). Tightening torque : Bolt (B) : 24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft) Bolt (C) : 21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
8. 9. 10.
Refill the master cylinder reservoir to the MAX line. Bleed the brake system. (Refer to "Bleeding of brake system") Depress the brake pedal several times to make sure the brakes work, then test-drive. Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake will restore the normal pedal stroke.
11.
After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
Global Service Way

Component Location
1. Brake caliper 3. Pad spring 2. Brake disc 4. Brake pad
Components
1. Bleeder screw 2. Caliper housing 3. Guide rod 4. Boot 5. Caliper carrier
6. Caliper mounting bolt 7. Washer 8. Guide rod bolt 9. Brake Pad 10. Pad spring
Global Service Way

Removal
1. Remove the brake hose bolt (B) and the guide rod bolts (C) from the caliper assembly (A).
2.
Remove the caliper assembly (A).
3.
Remove the pads (B), the pad springs (D) from the caliper carrier (A).
4.
Remove the caliper carrier (B) and the caliper mounting bolts (A).
5.
Remove the brake disc (A) and the screw (B).
Remove the brake disc from hub using M8 bolt (A) if the brake disc has been seized with the hub due to corrosion or overheat. Be careful not to use the hammer. The disc can be damaged if you remove the disc from the hub by hammer.
Replacement
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your
health. Avoid breathing dust particles. Never use on air hose or brush to clean brake assemblies. 1. Remove guide rod bolt (B) and raise the caliper assembly (A).
2.
Inspection Rear Brake Disc Thickness Check

1. Remove all rust and contamination from the disc surface, and then measure the disc thickness at 8 positions at least. Rear brake disc thickness Standard value : 10.0 mm (0.39 in) Limit : 8.4 mm ( 0.33 in)
2. 3.
Thickness variation should not exceed 0.01 mm (0.0004in) (circumference) and 0.01 mm(0.0004 in) (radius) at any directions. If wear exceeds the limit, replace the discs and pad assemblies for left and right of the vehicle.
Rear Brake Pad Check

1.
Check the pad wear. Measure the pad thickness. replace it if it is less than the specified value. Pad thickness Standard value : 9.0 mm (0.39 in) Service limit : 2.0 mm (0.0787 in)
2.
Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
Rear Brake Disc Run Out Check

1. Place a dial gauge about 5mm (0.2 in) from the outer circumference of the brake disc, and measure the run out of the disc. Brake disc run out Limit : 0.05 mm (0.0020 in) or less
2. 3. 4.
If the run out of the brake disc exceeds the limit specification, replace the disc, and then measure the run out again. If the run out does not exceed the limit specification, install the brake disc after turning it and then check the run out of the brake disc again. If the run out cannot be corrected by changing the position of the brake disc, replace the brake disc.
Installation
1. Install the brake disc (A) and tighten the screw (B). Tightening torque : 4.9 ~ 5.9 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)
2.
Install the caliper carrier (B) and tighten the caliper mounting bolts (A). Tightening torque : 38.5 ~ 52.3 N.m (3.9 ~ 5.3 kgf.m, 28.5 ~ 38.5 lb-ft)
3. 4.
Install the pad springs (C) to the caliper carrier (A). Install the brake pads (B) on the pad springs correctly. Install the pad with the wear indicator on the inside. If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. Check the foreign material at the pad shims (A) and the back of the pads (B). Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
5.
Push in the piston using the SST(09581-11000) so that the caliper will fit over the pads. Make sure that the piston boot is in position to prevent damaging it when installing the caliper.
6.
Install the caliper assembly (A). Be careful not to damage the piston pin boot.
7.
Install the brake hose bolt (B) and the guide rod bolts (C) to the caliper assembly (A). Tightening torque : Bolt (B) : 24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft) Bolt (C) : 21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
8. 9. 10.
Refill the master cylinder reservoir to the MAX line. Bleed the brake system. (Refer to "Bleeding of brake system") Depress the brake pedal several times to make sure the brakes work, then test-drive. Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake will restore the normal pedal stroke.
11.
After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
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Components
1. Shoe hold down pin 2. Bleed screw 3. Wheel cylinder 4. Upper return spring 5. Strut assembly
6. Antirattle spring 7. Shoe 8. Lower return spring 9. Shoe hold pin
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Removal
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles. Never use an air hose or brush to clean brake assemblies. 1. 2. Remove the shoe hole down pins (B) by pushing the shoe hold pin (C) and turning them. Disengage the upper return spring (A).
3. 4. 5. 6.
Lower the brake shoe assembly (A), and remove the lower return spring (B). Make sure not to damage the dust cover on the wheel cylinder. Disconnect the parking brake cable from the parking brake lever. Remove the brake shoe assembly. Remove the upper return spring (C), self-adjuster lever (D) and self-adjuster spring (E), and separate the brake shoes.
7. 8.
Disconnect the brake line (A) from the wheel cylinder (B). Remove the bolt (C) and the wheel cylinder from the backing plate.
Inspection
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles. Never use an air hose or brush to clean brake assemblies.
Contaminated brake linings or drums reduce stopping ability. Block the front wheels before jacking up the rear of the vehicle. 1. 2. 3. Raise the rear of the vehicle, and make sure it is securely supported. Release the parking brake, and remove the rear brake drum. Check the wheel cylinder (A) for leakage.
4. 5.
Check the brake linings (B) for cracking, glazing, wear, and contamination. Measure the brake lining thickness (C). Measurement does not include brake shoe thickness. Brake lining thickness Standard : 4.5 mm (0.18 in.) Service limit : 1.0 mm (0.039 in.)
6. 7. 8.
If the brake lining thickness is less than the service limit, replace the brake shoes as a set. Check the bearings in the hub unit for smooth operation. If it requires servicing, replace it. Measure the inside diameter of the brake drum with inside vernier calipers. Drum inside diameter: Standard : 180 mm (7.09 in.) Service limit : 182 mm (7.165 in.)
9. 10.
If the inside diameter of the brake drum is more than the service limit, replace the brake drum. Check the brake drum for scoring, grooves, and cracks.
Installation
Do not spill brake fluid on the vehicle: it may damage the paint; if brake fluid does contact the paint. Wash it off immediately with water. To prevent spills, cover the hose joints with rags or shop towels. Use only a genuine wheel cylinder special bolt. 1. Apply sealant (C) between the wheel cylinder (A) and backing plate (B), and install the wheel cylinder.
2. 3. 4.
Connect the brake tubes (D) to the wheel cylinder. Connect the parking brake cable to the parking brake lever. Clean the threaded portions of adjuster sleeve (A) and push rod female (B).
5.
Hook the self-adjuster spring (D) to the strut assembly, then to the brake shoe.
6. 7. 8.
Install the strut assembly and upper return spring (E), noting the installation direction. Be careful not to damage the wheel cylinder dust covers. Install the lower return spring (F). Apply brake cylinder grease or equivalent rubber grease to the sliding surfaces shown. Wipe off any excess. Don't get grease on the brake linings.
9.
Apply brake cylinder grease or equivalent rubber grease to the brake shoe ends and opposite edges of the shoes shown. Wipe off any excess. Don't get grease on the brake linings.
10. 11.
Install the brake shoes (A) onto the backing plate. Be careful not to damage the wheel cylinder dust covers. Install the shoe hole down pins (B) and the shoe hold pin (C).
12. 13. 14. 15. 16.

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Hook the upper return spring (D). Install the brake drum. If the wheel cylinder has been removed, bleed the brake system. Depress the brake pedal several times to set the self-adjusting brake. Adjust the parking brake.
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Component Location
1. Rear parking brake 3. Parking brake switch 2. Parking brake lever 4. Parking brake cable
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Removal
The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature failure.
Rear drum brake

1. 2. Remove the console. Loosen the adjusting nut (A) and the parking brake cables.
3.
Disconnect the connector (A) of parking brake switch.
4.
Remove the parking brake lever assembly (A).
5. 6.
Remove the wheel and tire. Remove the brake drum and the brake shoe.
(Refer to the rear drum brake) 7. 8. Remove the parking brake cable from the brake shoe. Remove the parking brake cable retaining (B), from the parking brake cable (A).
9.
Remove the parking brake cable (A) from the backing plate (B).
10.
Remove the clamps of parking brake cables and then remove the parking brake cables.
Rear disc brake

1. 2. Remove the console. Loosen the adjusting nut (A) and the parking brake cables.
3.
3.
4.
Remove the parking brake lever assembly (A).
5. 6.
Remove the parking cable clip (A) from the parking brake cable (B). Disconnect the parking brake cable (B) from the lever (C).
7.
Remove the clamps of parking brake cables and then remove the parking brake cables.
Installation
1. Check the parking brake cables for an identification mark paint and install as appropriate on the left and right sides. DT LHD RR Type COLOR DRUM Left Orange
Right DISC Left Right RHD DRUM Left Right DISC Left Right
Gray Blue Red Pink Purple White Green
2. 3.
Install the removed parts in the reverse order of removal. Apply a coating of the specified grease to each sliding parts of the ratchet plate or the ratchet pawl. Specified grease : Multi purpose grease SAE J310, NLGI No.2
4.
After installing the cable adjuster, adjust the parking brake lever stroke (Refer to the parking brake check and adjustment).
Parking brake check and adjustment

Inspection 1. Pull the parking brake lever (A) with 196 N (20 kg, 44lbf) force to fully apply the parking brake. The parking brake lever should be locked within the specified number of clicks (B). Lever locked clicks: Vehicle with rear disc brakes: 7~8 Vehicle with rear drum brakes: 7
2.
Adjust the parking brake if the lever clicks are out of specification.
Adjustment
After rear brake caliper servicing, loosen the parking brake adjusting nut, start the engine and depress the brake pedal several times to set the self-adjusting brake before adjusting the parking brake. 1. 2. Block the front wheels, then raise the rear of the vehicle and make sure it is securely supported. Make sure the parking brake arm (A) on the rear brake caliper contacts the brake caliper pin (B).
3. 4. 5.
Pull the parking brake lever up one click. Remove the floor console. (Refer to Body group-Floor console) Tighten the adjusting nut (A) until the parking brakes drag slightly when the rear wheels are turned.
6. 7. 8.
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Release the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are turned. Readjust if necessary. Make sure that the parking brakes are fully applied when the parking brake lever is pulled up fully. Reinstall the console.
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Components
1. Front left wheel speed sensor 2. ABS control module(HECU) 3. Front right wheel speed sensor
4. Hydrauric line 5. Rear right wheel speed sensor 6. Rear left wheel speed sensor
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Description
This specification applies to HCU(Hydraulic Control Unit) and ECU(Electronic Control Unit) of the HECU.(Hydraulic and Electronic Control Unit) This specification is for the wiring design and installation of ABS/ESP ECU. This unit has the functions as follows. - Input of signal from Pressure sensor, Steering angle sensor, Yaw & Lateral G sensor,the wheel speed sensors attached to each wheel. - Control of braking force / traction force / yaw moment. - Failsafe function. - Self diagnosis function. - Interface with the external diagnosis tester. Installation position : engine compartment - Brake tube length from Master cylinder port to HECU inlet port should be max. 1m - The position should not be close to the engine block and not lower than the wheel.
Operation
The ECU shall be put into operation by switching on the operating voltage (IGN). On completion of the initialization phase, the ECU shall be ready for operation. In the operating condition, the ECU shall be ready, within the specified limits (voltage and temperature), to process the signals offered by the various sensors and switches in accordance with the control algorithm defined by the software and to control the hydraulic and electrical actuators.
Wheel sensor signal processing

The ECU shall receive wheel speed signal from the four active wheel sensors. The wheel signals are converted to voltage signal by the signal conditioning circuit after receiving current signal from active wheel sensors and given as input to the ECU.
Solenoid valve control

When one side of the valve coil is connected to the positive voltage that is provided through the valve relay and the other side is connected to the ground by the semiconductor circuit, the solenoid valve goes into operation. The electrical function of the coils are always monitored by the valve test pulse under normal operation conditions.
Voltage limits
- Overvoltage When overvoltage is detected(above 17 0.5 V), the ECU switches off the valve relay and shuts down the system. When voltage is returned to operating range, the system goes back to the normal condition after the initialization phase. - Undervoltage In the event of undervoltage(below 9.5 0.5V), ABS control shall be inhibited and the warning lamp shall be turned on. When voltage is returned to operating range, the warning lamp is switched off and ECU returns to normal operating mode.
Pump motor checking

The ECU performs a pump motor test at a speed of 30 km/h(18 MPH) once after IGN is switched on.
Diagnostic interface
Diagnostic interface
Failures detected by the ECU are encoded on the ECU, stored in a EEPROM and read out by diagnostic equipment when the ignition switch is turned on. The diagnosis interface can also be used for testing the ECU during production of the ECU and for actuating the HCU in the test line of manufactories (Air-bleeding line or Roll and Brake Test line).
Warning lamp module
1.
ABS Warning Lamp module The active ABS warning lamp module indicates the self-test and failure status of the ABS. The ABS warning lamp shall be on: A. During the initialization phase after IGN ON. (continuously 3 seconds). B. In the event of inhibition of ABS functions by failure. C. During diagnostic mode. D. When the ECU Connector is separated from ECU. E. Cluster lamp is ON when communication is impossible with CAN module.
2.
PARKING/EBD warning lamp module The active EBD warning lamp module indicates the self-test and failure status of the EBD. However, in case the Parking Brake Switch is turned on, the EBD warning lamp is always turned on regardless of EBD functions. The EBD warning lamp shall be on: A. During the initialization phase after IGN ON. (continuously 3 seconds). B. When the Parking Brake Switch is ON or brake fluid level is low. C. When the EBD function is out of order. D. During diagnostic mode. E. When the ECU Connector is separated from ECU. F. Cluster lamp is ON when communication is impossible with CAN module.
ABS Control
1. NORMAL BRAKING without ABS Under the normal braking, voltage is not supplied to solenoid valve, inlet valve is opened and outlet valve is closed.When the brake is depressed, brake fluid is supplied to the wheel cylinder via solenoid valve to activate the brake.When the brake is released, brake fluid is back to the master cylinder via inlet valve and check valve. Solenoid valve Inlet valve (NO) Outlet valve (NC) State OFF OFF Valve Open Close Master cylinder Wheel cylinder Wheel cylinder Reservoir Passage Pump motor OFF
2.
Dump Mode Under the emergency braking, if the wheels start to lock up, HECU sends a signal to the solenoid valve to decrease the brake fluid, then voltage is supplied to each solenoid. At this time inlet valve is closed and brake fluid is blocked from the master cylinder. Conversely outlet valve is opened and brake fluid passes through wheel cylinder to reservoir, resulting in pressure decrease. Solenoid Inlet valve (NO) Outlet valve (NC) State ON ON Valve Close Open Master cylinder Wheel cylinder Wheel cylinder Reservoir Passage Pump motor ON
3.
Hold Mode When the brake fluid pressure is maximally decreased in wheel cylinder, HECU sends a signal to solenoid valve to keep the fluid pressure, voltage is supplied to inlet valve but it is not supplied to outlet valve. At this time inlet and outlet valves are closed and brake fluid is kept in
wheel cylinder. Solenoid Inlet valve (NO) Outlet valve (NC) State ON OFF Valve Close Close Master cylinder Wheel cylinder Wheel cylinder Reservoir Passage Pump motor OFF
4.
Increase Mode If HECU determines there's no lock-up in the wheel, HECU cuts voltage to solenoid valve. So voltage is not supplied to each solenoid valve, brake fluid passes through the inlet valve to wheel cylinder, resulting in pressure increase. Solenoid Inlet valve (NO) Outlet valve (NC) State OFF OFF Valve Open Close Master cylinder Wheel cylinder Wheel cylinder Reservoir Passage Pump motor ON
ABS HECU External Diagram
Hydraulic System Diagram
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Circuit Diagram - ABS (1)
Circuit Diagram - ABS (2)
ABS Connector Input / Output

Connector Terminal No 29 Description IGNITION1(+)
Specification
High level of wake up voltage : 4.5V < V < 16.0V Low level of wake up voltage : V < 2.4V Nominal current : I < 50mA Over voltage range : 17.0 0.5V Operating voltage range : 10.0 0.5V < V < 16.0 0.5V Low voltage range : 7.0 0.5V < V < 9.5 0.5V Nominal current : I < 25A Max. leakage current : I < 0.25mA Operating voltage range: 10.0 0.5V < V < 16.0 0.5V Peak current : I < 110A Nominal current : I < 40A Max. leakage current : I < 0.25mA Rated current : I <550mA Nominal current: I < 25A Peak current : I < 110A Nominal current : I < 40A Output voltage : V_BAT1-0.6V ~ V_BAT1-1.1V Output current : Max. 30mA
25
POS. BATTERY 1. (SOLENOID)
POS. BATTERY 2. (MOTOR)
38 13 18 34 19 33 31
GROUND PUMP MOTOR GROUND SENSOR FRONT LEFT POWER SENSOR FRONT RIGHT POWER SENSOR REAR LEFT POWER SENSOR REAR RIGHT POWER SENSOR FRONT LEFT SIGNAL
Input current LOW : 5.9 ~ 8.4mA Input current HIGH :11.8 ~ 16.8mA Frequency range :1 ~ 2,500Hz Input duty : 50 10%
21 32 20 23
SENSOR FRONT RIGHT SIGNAL SENSOR REAR LEFT SIGNAL SENSOR REAR RIGHT SIGNAL BRAKE LIGHT SWITCH Input voltage (Low) : V < 2V Input voltage (High) : V > 6V Max. Input current : I < 3mA (12.8V) External pull up resistance :1 K < R Output duty :50 20% Max. Input current : I < 10mA
28 14 26
SENSOR FRONT RIGHT OUTPUT CAN BUS LINE(LOW) CAN BUS LINE(HIGH)
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Standard flow of diagnostic troubleshooting
Notes with regard to diagnosis

The phenomena listed in the following table are not abnormal. Phenomenon System check sound Explanation When starting the engine, a thudding sound can sometimes be heard coming from inside the engine compartment. This is because the system operation check is being performed.
ABS operation sound 1. Sound of the motor inside the ABS hydraulic unit operation (whine). 2. Sound is generated along with vibration of the brake pedal (scraping). 3. When ABS operates, sound is generated from the vehicle chassis due to repeated brake application and release (Thump : suspension; squeak: tires) ABS operation (Long braking distance) For road surfaces such as snow-covered and gravel roads, the braking distance for vehicles with ABS can sometimes be longer than that for other vehicles. Accordingly, advise the customer to drive safely on such roads by lowering the vehicle speed.
Diagnosis detection conditions can vary depending on the diagnosis code. When checking the trouble symptom after the diagnosis code has been
erased, ensure that the requirements listed in "Comment" are met.
ABS Check sheet
Problem symptoms table

Symptom ABS does not operate. Suspect Area Only when 1.~4. are all normal and the problem is still occurring, replace the HECU. 1. Check the DTC reconfirming that the normal code is output. 2. Power source circuit. 3. Speed sensor circuit. 4. Check the hydraulic circuit for leakage. ABS does not operate intermittently. Only when 1.~4. are all normal and the problem is still occurring, replace the ABS actuator assembly. 1. Check the DTC reconfirming that the normal code is output. 2. Wheel speed sensor circuit. 3. Stop lamp switch circuit. 4. Check the hydraulic circuit for leakage. Communication with GDS is not possible. (Communication with any system is not possible) Communication with GDS is not possible. (Communication with ABS
1. Power source circuit 2. CAN line
1. Power source circuit
only is not possible) When ignition key is turned ON (engine OFF), the ABS warning lamp does not light up. Even after the engine is started, the ABS warning lamp remains ON.
2. CAN line 3. HECU
1. ABS warning lamp circuit 2. HECU
1. ABS warning lamp circuit 2. HECU
During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is not an abnormality. Detecting condition Trouble Symptoms Brake operation varies depending on driving conditions and road surface conditions, so diagnosis can be difficult. However if a DTC is displayed, check the following probable cause. When the problem is still occurring, replace the ABS control module. Possible Cause
- Faulty power source circuit - Faulty wheel speed sensor circuit - Faulty hydraulic circuit for leakage - Faulty HECU
Inspection procedures
DTC Inspection 1. 2. 3. Connect the GDS with the data link connector and turn the ignition switch ON. Verify that the normal code is output. Is the normal code output? Check the power source circuit. Erase the DTC and recheck using GDS.
Check the power source circuit

1. 2. Disconnect the connector from the ABS control module. Turn the ignition switch ON, measure the voltage between terminal 29 of the ABS control module harness side connector and body ground. Specification: approximately B+ 3. Is the voltage within specification? Check the ground circuit.
Check the harness or connector between the fuse (10A) in the engine compartment junction block and the ABS control module. Repair if necessary.
Check the ground circuit

1. 2. 3. Disconnect the connector from the ABS control module. Check for continuity between terminals 13, 28 of the ABS control module harness side connector and ground point. Is there continuity? Check the wheel speed sensor circuit. Repair an open in the wire and ground point.
Check the wheel speed sensor circuit

1. 2. Refer to the DTC troubleshooting procedures. Is it normal? Check the hydraulic circuit for leakage. Repair or replace the wheel speed sensor.
Check the hydraulic circuit for leakage

1. 2. 3. Refer to the hydraulic lines. Inspect leakage of the hydraulic lines. Is it normal? The problem is still occurring, replace the ABS control module. Repair the hydraulic lines for leakage.
Detecting condition Trouble Symptoms Possible Cause
Brake operation varies depending on driving conditions and road surface conditions, so diagnosis can be difficult. However if a DTC is displayed, check the following probable cause. When the problem is still occurring, replace the ABS control module.
- Faulty power source circuit - Faulty wheel speed sensor circuit - Faulty hydraulic circuit for leakage - Faulty HECU
DTC Inspection 1. 2. 3. Connect the GDS with the data link connector and turn the ignition switch ON. Verify that the normal code is output. Is the normal code output? Check the wheel speed sensor circuit. Erase the DTC and recheck using GDS.
Check the wheel speed sensor circuit

1. 2. Refer to the DTC troubleshooting procedures. Is it normal? Check the stop lamp switch circuit. Repair or replace the wheel speed sensor.
Check the stop lamp switch circuit

1. 2. Check that stop lamp lights up when brake pedal is depressed and turns off when brake pedal is released. Measure the voltage between terminal 23 of the ABS control module harness side connector and body ground when brake pedal is depressed. Specification : approximately B+ 3. Is the voltage within specification? Check the hydraulic circuit for leakage. Repair the stop lamp switch. Repair an open in the wire between the ABS control module and the stop lamp switch.
Check the hydraulic circuit for leakage

1. 2. 3. Refer to the hydraulic lines. Inspection leakage of the hydraulic lines. Is it normal? The problem is still occurring, replace the ABS control module. Repair the hydraulic lines for leakage.
Detecting condition Trouble Symptoms Possible defect in the power supply system (including ground) for the diagnosis line. Possible Cause
- An open in the wire - Poor ground - Faulty power source circuit
Check The Power Supply Circuit For The Diagnosis 1. Measure the voltage between terminal 16 of the data link connector and body ground. Specification : approximately B+ 2. Is voltage within specification? Check the ground circuit for the diagnosis. Repair an open in the wire. Check and replace fuse (15A) from the engine compartment junction block.
Check the ground circuit for the diagnosis

1. 2. Check for continuity between terminal 4 of the data link connector and body ground. Is there continuity? Repair an open in the wire between terminal 4 of the data link connector and ground point.
Detecting condition Trouble Symptoms When communication with GDS is not possible, the cause may be probably an open in the HECU power circuit or an open in the diagnosis output circuit. Possible Cause
- An open in the wire - Faulty HECU - Faulty power source circuit
Check for Continuity in the Diagnosis Line 1. 2. 3. Disconnect the connector from the ABS control module. Check for continuity between terminals 30 of the ABS control module connector and 8 of the data link connector. Is there continuity? Check the power source of ABS control module. Repair an open in the wire.
Check the power source of ABS control module

1. 2. Disconnect the connector from the ABS control module. Turn the ignition switch ON, measure the voltage between terminal 29 of the ABS control module harness side connector and body ground. Specification : approximately B+ 3. Is voltage within specification? Check for poor ground. Check the harness or connector between the fuse (10A) in the engine compartment junction block and the ABS control module. Repair if necessary.
Check for poor ground

1. Check for continuity between terminal 4 of the data link connector and ground point. Replace the ABS control module and recheck. Repair an open in the wire or poor ground.
Detecting condition Trouble Symptoms When current flows in the HECU the ABS warning lamp turns from ON to OFF as the initial check. Therefore if the lamp does not light up, the cause may be an open in the lamp power supply circuit, a blown bulb, an open in the both circuits between the ABS warning lamp and the HECU, and the faulty HECU. Possible Cause
- Faulty ABS warning lamp bulb - Blown fuse is related to ABS in the engine compartment junction block - Faulty ABS warning lamp module - Faulty HECU
Problem verification 1. 2. Disconnect the connector from the ABS control module and turn the ignition switch ON. Does the ABS warning lamp light up? Inspect again after replacing the ABS HECU. Check the power source for the ABS warning lamp.
Check the power source for the ABS warning lamp

1. 2. Disconnect the instrument cluster connector (M07-B) and turn the ignition switch ON. Measure the voltage between terminal (M07-B) 15 of the cluster harness side connector and body ground. Specification : approximately B+
3.
Is voltage within specification? Check the CAN circuit resistance for ABS warning lamp. Check for blown fuse.
Check the CAN circuit resistance for ABS warning lamp

1. 2. Turn the ignition switch OFF. Disconnect the instrument cluster connector (M07-B). Measure the resistance between terminal (M07-B) 2 and 3 of the cluster harness side connector. Specification : 60
3.
Is resistance within specification? Repair ABS warning lamp bulb or instrument cluster assembly. Check the CAN circuit wiring for ABS warning lamp.
Check the CAN circuit wiring for ABS warning lamp

1. 2. Turn the ignition switch OFF. Disconnect the instrument cluster connector (M07-B) and ABS HECU connector. Check for continuity between terminal (M07-B) 2 of the cluster harness side connector and terminal 26 of ABS HECU harness side. Check for continuity between terminal (M07-B) 3 of the cluster harness side connector and terminal 14 of ABS HECU harness side. Specification : Below 1
3.
Is resistance within specification?
Repair short circuit wiring between terminal 26, 14 of ABS HECU harness connector and ABS warning lamp module. Repair open circuit wiring between terminal 26, 14 of ABS HECU harness connector and ABS warning lamp module.
Detecting condition Trouble Symptoms If the HECU detects trouble, it lights the ABS warning lamp and at the same time prohibits ABS control. The HECU then records a DTC in memory. If the ABS warning lamp remains ON, even after the problem with the DTC is repaired and cleared, then the cause may be an open or short in the ABS warning lamp circuit. Possible Cause
- An open in the wire - Faulty instrument cluster assembly - Faulty ABS warning lamp module - Faulty HECU
Check DTC Output 1. 2. 3. Connect the GDS to the 16P data link connector located behind the driver's side kick panel. Check the DTC output using GDS. Is DTC output? Perform the DTC troubleshooting procedure (Refer to DTC troubleshooting). Check the CAN circuit resistance for ABS warning lamp.
Check the CAN circuit resistance for ABS warning lamp

1. 2. Turn the ignition OFF. Disconnect the instrument cluster connector (M07-B). Measure the resistance between terminal (M07-B) 2 and 3 of the cluster harness side connector. Specification : 60
3.
Is resistance within specification? Repair ABS warning lamp bulb or instrument cluster assembly. Check the CAN circuit wiring for ABS warning lamp.


1. 2. Turn the ignition switch OFF. Disconnect the instrument cluster connector (M07-B) and ABS HECU connector. Check for continuity between terminal (M07-B) 2 of the cluster harness side connector and terminal 26 of ABS HECU harness side. Check for continuity between terminal (M07-B) 3 of the cluster harness side connector and terminal 14 of ABS HECU harness side. Specification : Below 1 3. Is there continuity? Repair short circuit wiring between terminal 26, 14 of ABS HECU harness connector and ABS warning lamp module. Repair open circuit wiring between terminal 26, 14 of ABS HECU harness connector and ABS warning lamp module.
Bleeding of Brake System

This procedure should be followed to ensure adequate bleeding of air and filling of the ABS unit, brake lines and master cylinder with brake fluid. 1. Remove the reservoir cap and fill the brake reservoir with brake fluid. If there is any brake fluid on any painted surface, wash it off immediately. When pressure bleeding, do not depress the brake pedal. Recommended fluid........ DOT3 or DOT4 2. 3. 4. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half filled clear plastic bottle. Connect the GDS to the data link connector located underneath the dash panel. Select and operate according to the instructions on the GDS screen. You must obey the maximum operating time of the ABS motor with the GDS to prevent the motor pump from burning. (1) (2) (3) Select vehicle name. Select Anti-Lock Brake system. Select HCU air bleeding mode.
(3)
Select HCU air bleeding mode.
(4)
Press "OK" to operate motor pump and solenoid valve.
(5)
Wait 60 sec. before operating the air bleeding. (If not, you may damage the motor.)
(6)
Perform the air bleeding.
5.
Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without bubbles. Then close the bleeder screw(A).
Front
Rear
6.
Repeat step 5 until there are no more bubbles in the fluid for each wheel.
7.
Tighten the bleeder screw. Bleed screw tightening torque: 6.9 ~ 12.7 N.m (0.7 ~ 1.3 kgf.m, 5.1 ~ 9.4 lb-ft)
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I10 Workshop Manual - A

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Monday, November 21, 2011 9:58 AM

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

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2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

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2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

Special Service Tools

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2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

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The Following Precautions Must Be Observed

The Following Precautions Must Be Observed

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

Refrigerant System Service Basics Refrigerant Recovery

Refrigerant Leak Test

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

Component Location Index Engine Room

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

Remove the side cover (A).

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

Replacement Condenser Assembly

Remove the condenser side cover (A).

radiator and condenser fins when removing the condenser (B).

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

Remove the evaporator temperature sensor (B).

Installation is the reverse order of removal

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

3. Def door 4. Vent door 5. Floor door 6. Temp door

Global Service Way

2011 > G 1.1 SOHC > Heating,Ventilation, Air Conditioning

Loosen the heater unit mount bolts (A).

Remove the heater core (B) cover (A).

Remove the heater unit lower case(A).

Remove the evaporator core(A).

Remove the evaporator core(A).